JD220 Dieselengine

John Deere Series 220
Diesel Engines
COMPONENT
TECHNICAL
MANUAL
John Deere
Lawn & Grounds Care Division
CTM3 (10AUG93)
Replaces CTM3 (28NOV89)
Litho in U.S.A.
FOREWORD
This manual is written for an experienced This manual is part of a total product support
technician. Essential tools required in performing program.
certain service work are identified in this manual
and are recommended for use. FOS MANUALS—REFERENCE
Live with safety: Read the safety messages in the TECHNICAL MANUALS—MACHINE SERVICE
introduction of this manual and the cautions
presented throughout the text of the manual. COMPONENT MANUALS—COMPONENT
SERVICE
Use this component technical manual in conjunction
with the machine technical manual. An application Fundamentals of Service (FOS) Manuals cover basic
listing in the Specifications and General Information theory of operation, fundamentals of
section identifies product-model/component type- troubleshooting, general maintenance, and basic
model relationship. See the machine technical type of failures and their causes. FOS Manuals are
manual for information on component removal and for training new personnel and for reference by
installation, and gaining access to the components. experienced technicians.
This manual is organized so that all the information
on a particular engine is kept together in a single Technical Manuals are concise guides for specific
section. machines. Technical manuals are on-the-job guides
containing only the vital information needed for
Information in each section is organized in groups diagnosis, analysis, testing and repair.
for the various components requiring service
instruction. At the beginning of each group are Component Technical Manuals are concise service
summary listings of all applicable essential tools, guides for specific components. Component
other materials needed to do the job and service technical manuals are written as stand-alone
parts kits. All specifications, wear tolerances, and manuals covering multiple machine applications.
torque values appear at the beginning of each
section.
JOHN DEERE DEALERS
IMPORTANT: The changes listed below make • Turbocharger analysis, inspection and repair
your current CTM obsolete. Discard CTM3, information has been added. See Accessories -
dated 28 NOV 89. Please remove this page and Series 220 Power Unit Engines.
route through your service department. • Information/model designation for Series 220
• The format or “style” of the book has been engines (3009, 3011, 3014 and 4019) have been
changed. The familiar “modular” layout has added wherever applicable.
been replaced by a two-column “floating text” • Engine application charts have been updated to
format. Also, a heavy emphasis on the use of include the latest product models. See
“exploded” line art, to illustrate specific yet Specifications and General Information section.
“simple” procedures, is used. • The book’s title. The title was changed from
• The layout of the book also changed. It has been “3TN and 4TN Series Yanmar Diesel Engines”
completely reorganized to cover a different to “John Deere 220 Series Diesel Engines”, to
engine “family” in its own section, similar to include information pertaining to the OEM
how a Technical manual is layed out, using Stand-alone power packs.
sections and groups. • A safety section, fuels, lubricants and coolant
- Sections 1 through 4 cover engine service. information and an alphabetical index have also
This includes; engine teardown, diagnosis, been added.
checks, tests, adjustments and operational • A nominal or “standard” specification has been
tests. added and listed with the “wear limit” 3
specification.
- Section 10 covers removal/installation and
repair of accessories, primarily on Series 220
OEM Power Unit engines.
- Section 20 covers Theory of Operation of the
various engine systems.
- Section 21 covers Electrical System
component location and schematics for Series
220 OEM Power Unit engines.
ABOUT THIS MANUAL
This Component Technical Manual (CTM3) covers Direction of engine crankshaft rotation in this
the recommended repair and adjustment procedures manual is referenced facing the flywheel looking
for the following engines: toward the water pump. Front of engine is water
• 3 and 4TN Series Diesel Engines used in John pump end.
Deere Lawn and Grounds Care and small Some components of this engine may be serviced
Industrial products. without removing the engine from the machine.
• Series 220 Diesel Engines offered as OEM units. Refer to the specific machine technical manuals for
Three different configurations are available: information on components that can be serviced
Base industrial engine, industrial power unit or a without removing the engine from the machine and
generator drive unit. for engine removal and installation procedures.
Before beginning repair of an engine, clean the Read each story completely before performing
engine and mount on a repair stand. service to check engine model differences in
procedure or specifications.
This manual contains SI Metric units of measure,
followed immediately by the U.S. customary units
of measure.
Introduction
Each section will be identified with a symbol, letter

or a number. Safety S
All information, illustrations and specifications in
this manual are based on the latest information
available at the time of publication. The right is Specifications and
reserved to make changes at any time without notice. General Information G
3TN66, 3TNA72 (3009) 1
3TN75, 3TN78, 3TNC78 (3011),

3TN82, 3TNA82, 3TN84 (3014) 2
4TN78T, 4TN82, 4TN84(T) (4019) 3
4TN100 4
Accessories - Series 220

Power Unit Engines 10
Engine, Air Intake and

Fuel System 20
Electrical System - Series 220

Power Unit Engines 21
COPYRIGHT© 1993
JOHN DEERE HORICON WORKS
Horicon, Wisconsin
All rights reserved
Introduction
Safety
RECOGNIZE SAFETY INFORMATION HANDLE FLUIDS SAFELY-AVOID

FIRES S
Be Prepared For Emergencies
T81389
This is the safety-alert symbol. When you see this

symbol on your engine or in this manual, be alert to TS291
the potential for personal injury.
Follow recommended precautions and safe servicing
practices.
Understand Signal Words

A signal word—DANGER, WARNING, or
CAUTION—is used with the safety-alert symbol.
DANGER identifies the most serious hazards.
DANGER or WARNING safety signs are located
near specific hazards. General precautions are listed TS227
on CAUTION safety signs. CAUTION also calls
attention to safety messages in this manual. When you work around fuel, do not smoke or work
near heaters or other fire hazards.
REPLACE SAFETY SIGNS Store flammable fluids away from fire hazards. Do
not incinerate or puncture pressurized containers.
Make sure engine is clean of trash, grease, and
debris.
Do not store oily rags; they can ignite and burn
spontaneously.
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance
service, hospital, and fire department near your
telephone.
TS201
Replace missing or damaged safety signs. See the

machine operator’s manual for correct safety sign
placement.
4/7/95 S-1
Safety
USE CARE IN HANDLING AND • If acid is swallowed:

S SERVICING BATTERIES 1. Do not induce vomiting.
2. Drink large amounts of water or milk, but do not
exceed 1.9 L (2 quarts).
3. Get medical attention immediately.
SERVICE COOLING SYSTEM SAFELY
TS204 TS203
Prevent Battery Explosions

• Keep sparks, lighted matches, and open flame
away from the top of battery. Battery gas can
explode. TS281
• Never check battery charge by placing a metal
object across the posts. Use a volt-meter or Explosive release of fluids from pressurized cooling
hydrometer. system can cause serious burns.
• Do not charge a frozen battery; it may explode. Shut off engine. Only remove filler cap when cool
Warm battery to 16°C (60°F). enough to touch with bare hands. Slowly loosen cap
to first stop to relieve pressure before removing
Prevent Acid Burns completely.
• Sulfuric acid in battery electrolyte is poisonous.
It is strong enough to burn skin, eat holes in USE SAFE SERVICE PROCEDURES
clothing, and cause blindness if splashed into
eyes. Wear Protective Clothing
• Avoid acid burns by: Wear close fitting clothing and safety equipment
appropriate to the job.
1. Filling batteries in a well-ventilated area.
Prolonged exposure to loud noise can cause
2. Wearing eye protection and rubber gloves.
impairment or loss of hearing. Wear a suitable
3. Avoiding breathing fumes when electrolyte is hearing protective device such as earmuffs or
added. earplugs to protect against objectionable or
4. Avoiding spilling or dripping electrolyte. uncomfortable loud noises.
5. Use proper jump start procedure. Operating equipment safely requires the full
attention of the operator. Do not wear radio or music
• If you spill acid on yourself: headphones while operating engine.
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize the
acid.
3. Flush your eyes with water for 15-30 minutes.
4. Get medical attention immediately.
TS206
S-2 4/7/95
Safety
Service Engines Safely Support Engine Properly and Use

Tie long hair behind your head. Do not wear a Proper Lifting Equipment S
necktie, scarf, loose clothing, or necklace when you
work near machine tools or moving parts. If these
items were to get caught, severe injury could result.
Remove rings and other jewelry to prevent electrical
shorts and entanglement in moving parts.
TS229
If you must work on a lifted engine, securely support

TS228
the engine.
Do not support the engine on cinder blocks, hollow
Use Proper Tools tiles, or props that may crumble under continuous
load. Do not work under an engine that is supported
Use tools appropriate to the work. Makeshift tools solely by a jack. Follow recommended procedures in
can create safety hazards. Use power tools only to this manual.
loosen threaded parts and fasteners. For loosening
and tightening hardware, use the correct size tools. Lifting heavy components incorrectly can cause
DO NOT use U.S. measurement tools on metric severe injury or engine damage. Follow
fasteners. Use only service parts meeting John Deere recommended procedure for removal and
specifications. installation of components in the manual.
Shut Down Engine Work In A Clean Area
• Before starting a job:

1. Clean work area and engine.
2. Make sure you have all necessary tools to do your
job.
3. Have the right parts on hand.
4. Read all instructions thoroughly; do not attempt
TS230 shortcuts.
Illuminate Your Work Area Safely

• Before working on the engine:
Illuminate your work area adequately but safely. Use
1. Stop the engine and remove the key.
a portable safety light for working inside or under
2. Disconnect the battery ground strap. the engine. Make sure the bulb is enclosed by a wire
cage. The hot filament of an accidentally broken
3. Hang a “DO NOT OPERATE” tag on the
bulb can ignite spilled fuel or oil.
instrument panel.
4/7/95 S-3
Safety
Work In A Ventilated Area Escaping fluid under pressure can penetrate the skin
S causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
Search for leaks with a piece of cardboard. Protect
hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any
fluid injected into the skin must be surgically
TS220
removed within a few hours or gangrene may result.
Engine exhaust fumes can cause sickness or death. If Doctors unfamiliar with this type of injury should
it is necessary to run an engine in an enclosed area, reference a knowledgeable medical source. Such
remove the exhaust fumes from the area with an information is available from Deere & Company
exhaust pipe extension. Medical Department in Moline, Illinois, U.S.A.
If you do not have an exhaust pipe extension, open Avoid Heating Near Pressurized Fluid
the doors and get outside air into the area. Lines
Remove Paint Before Welding Or
Heating
Avoid potentially toxic fumes and dust. Hazardous
fumes can be generated when paint is heated by
welding, soldering, or using a torch. Do all work
outside or in a well ventilated area. Dispose of paint
and solvent properly. Remove paint before welding
or heating: If you sand or grind paint, avoid
breathing the dust. Wear an approved respirator. If
you use solvent or paint stripper, remove stripper TS953
with soap and water before welding. Remove Flammable spray can be generated by heating near
solvent or paint stripper containers and other pressurized fluid lines, resulting in severe burns to
flammable material from area. Allow fumes to yourself and bystanders. Do not heat by welding,
disperse at least 15 minutes before welding or soldering, or using a torch near pressurized fluid
heating. lines or other flammable materials. Pressurized lines
can be accidentally cut when heat goes beyond the
USE CARE AROUND HIGH- immediate flame area.
PRESSURE FLUID LINES
HANDLE CHEMICAL PRODUCTS
Avoid High-Pressure Fluids SAFELY
X9811 TS1132 TS1133
S-4 4/7/95
Safety
Direct exposure to hazardous chemicals can cause LIVE WITH SAFETY

serious injury. Potentially hazardous chemicals used S
with John Deere equipment include such items as
lubricants, coolants, paints, and adhesives.
A Material Safety Data Sheet (MSDS) provides
specific details on chemical products: physical and
health hazards, safety procedures, and emergency
response techniques. Check the MSDS before you
start any job using a hazardous chemical. That way
you will know exactly what the risks are and how to
do the job safely. Then follow procedures and TS231
recommended equipment.
Before returning machine to customer, make sure
Dispose of Waste Properly engine is functioning properly, especially the safety
Improperly disposing of waste can threaten the systems. Install all guards and shields.
environment and ecology. Potentially harmful waste
used with John Deere equipment include such items
as oil, fuel, coolant, brake fluid, filters, and batteries.
Use leakproof containers when draining fluids. Do
not use food or beverage containers that may
mislead someone into drinking from them. Do not
pour waste onto the ground, down a drain, or into
any water source. Inquire on the proper way to
recycle or dispose of waste from your local
environmental or recycling center, or from your John
Deere dealer.
4/7/95 S-5
Safety
S-6 4/7/95
G
SPECIFICATIONS AND
GENERAL INFORMATION
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuels, Lubricants and Coolant . . . . . . . . . . . . . . . . . . . . . . . 8
Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
G
General Information
ENGINE SERIAL NUMBER PLATE Factory Code
NOTE: The engine serial number plate can be CH. . . . . . . . . . . . . . . . . . Yanmar

easily destroyed. Before “hot tank”
cleaning the block, remove the plate or Engine Model Designation
record the information elsewhere. 3009D . . . . . . . . . . . . . . . Definition explained G
following. (See
Location “Engine Model
All except 4TN100: The engine serial number plate Designation”.)
is located on the rocker arm cover.
4TN100: The engine serial number plate is located Sequential Number
on the side of the engine, under exhaust manifold. 000000 . . . . . . . . . . . . . . 6-digit sequential
Refer to the engine model designation on your serial number
engine's serial number plate to identify as to which Engine Model Designation -
section to use for repair information.
3TN and 4TN Series Engines
John Deere engine model designation includes
number of cylinders, usage, engine type, bore
diameter, fuel injection (type) and application. For
example:
3TNA72UJK Engine
3 . . . . . . . . . . . . . . . . . . . . . . . .Number of cylinders
T . . . . . . . . . . . . . . . . . . . . . . . . . . . Usage (tractor)
NA . . . . . . . . . . . . . . . . . . . . . . . . . . Engine type
M37502 72 . . . . . . . . . . . . . . . . . . . . . . .Bore diameter
U . . . . . . . . . . . . . . . Fuel Injection (Type)
Engine Serial Number Information
JK. . . . . . . . . . . . . . . . . . . . .Application
Each engine has a 13-digit John Deere engine serial
number identifying the producing factory, engine Engine Type
model designation, and a 6-digit sequential number.
The following are examples: NA. . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel
G . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline
3TN and 4TN Series Engines
CH3029D000000 Fuel Injection (Type)
CH . . . . . . . . . . Factory producing engine (Yanmar) U . . . . . . . . . . . . . . . . . . . . Indirect injection
3029D . . . . . . . . . . . . Engine model designation R . . . . . . . . . . . . . . . . . . . . . .Direct injection
000000 . . . . . . Sequential serial number
Application
Series 220 OEM Engines JK . . . . . . . . . . . . . . . . . . . . . . . . John Deere
CH3009D000000 E-SP . . . . . . . . . . Export - Sperry Company
CH . . . . . . . . . . . . . . . . . . .Factory producing engine
3009D . . . . . . . . . . . . Engine model designation
000000 . . . . . . Sequential serial number
4/7/95 G-1
General Information
Engine Model Designation -Series 220 Aspiration Code

OEM Engines D . . . . . . . . . . . . . . . . . . . Naturally aspirated
John Deere engine model designation includes T . . . . . . . . . . . . . . . . . . . . . . . Turbocharged
number of cylinders, displacement in liters,
aspiration, user code and application code. For
G example:
User Code
F0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OEM
3009DF001 Engine
3 . . . . . . . . . . . . . . . . . . . . . . . .Number of cylinders Application Code
0.9 . . . . . . . . . . . . . . . . . . . . . . . . Liter designation 01 . . . . . . . . . . . . . . . Bare industrial engine
D . . . . . . . . . . . . . . . . . . . . . . . Aspiration code 05 . . . . . . . . . . . . . . . Industrial power pack
F0 . . . . . . . . . . . . . . . . . . . . . . . . . . User code 06 . . . . . . . . . . . . . . . Gen set power pack
01 . . . . . . . . . . . . . . . . . Application code
ENGINE APPLICATION CHART - LAWN AND GROUNDS CARE EQUIPMENT

Machine Model No. Engine Model
LAWN AND GARDEN TRACTORS
330 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3TN66UJ
332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3TN66UJ
430 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNA72UJ*
455 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNA72UJ3
FRONT MOWERS
F915 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3TN66UJ
F925 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNA72UJ
F935 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNA72UJ
F1145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3TN75RJ
COMPACT UTILITY TRACTORS
655 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3TN66UJ
670 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNA72UJK
755 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNA72UJ
770 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNA82RJK
855 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3TN75RJ
870 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TN84RJK
955 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3TN84UJ
970 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4TN82RJK
1070 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4TN84RJK
SKID STEER LOADERS
375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3TN66E-SP
575 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3TN82E-SP
675 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4TN82E-SP
GOLF AND TURF
756 Compact Utility Tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNA72UJ
856 Compact Utility Tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3TN75RJ
3325 Professional Turf Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4TN82RJE
3365 Professional Turf Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4TN82RJE
* 430 Lawn and Garden Tractors were built with two slightly different versions of 3TNA72UJ engines. In
this manual, 3TNA72UJ engines, Serial Numbers ( - 5000), are referred to as “Early 3TNA72”. Engines
with Serial Numbers (5001 - ) are referred to as “Later 3TNA72”.
G-2 4/7/95
General Information
ENGINE APPLICATION CHART - INDUSTRIAL EQUIPMENT

EXCAVATORS
15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNA72UJB G
25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TN78RJB
30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TN82RJB
50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4TN78TRJB
LOADERS
84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4TN100RJF
244E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4TN100LFB
ENGINE APPLICATION CHART - OEM APPLICATION

3009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNA72
3011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNC78
3014 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TN84
4019D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4TN84
4019T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4TN84T
4/7/95 G-3
General Engine Specifications
BASIC ENGINE SPECIFICATIONS
UNIT OF
GENERAL MEASURE 3TN66 3TNA72 (3009) 3TN75 3TN78
G Number of ---- 3 3 3 3
Cylinders
Bore mm 66 72 75 78
(in.) (2.60) (2.83) (2.95) (3.07)
Stroke mm 64.2 72 75 86
(in.) (2.53) (2.83) (2.95) (3.39)
Displacement L 0.658 0.879 0.994 1.232
(cu in.) (40.15) (53.64) (60.70) (75.20)
Compression Ratio ---- 23:1 22.3:1 17.8:1 17.75:1
Horsepower* kW 10.4 - 12.7 12.7 - 16.4 17.9 17
(hp) (14 - 17) (17 - 22) (24) (23)
Firing Order ---- 1-3-2 1-3-2 1-3-2 1-3-2
Combustion System ---- Indirect Indirect Direct Direct
Injection Injection Injection Injection
Aspiration ---- Natural Natural Natural Natural
Weight (dry) kg 85 118 160 123
(lbs) (187) (260) (353) (271)
Starter ---- Hitachi 0.8 kW Nippondenso Nippondenso Hitachi 2.0 kW
1.0 kW 1.0 kW
(Hitachi 0.8 kW
on 3009)
Alternator ---- Kokosan 20A, Kokosan 20A, Nippondenso Hitachi 25A
Nippondenso Nippondenso 35 or 40A
35 or 40A 35 or 40A
* Engine horsepower will vary by application. Refer to machine technical manual or operator's manual for
specific engine horsepower.
G-4 4/7/95
UNIT OF
GENERAL MEASURE 3TNC78 (3011) 3TN82 3TNA82 3TN84 (3014)
Number of ---- 3 3 3 3
Cylinders
G
Bore mm 78 82 82 84
(in.) (3.07) (3.23) (3.23) (3.31)
Stroke mm 80 86 86 86
(in.) (3.15) (3.39) (3.39) (3.39)
Displacement L 1.146 1.362 1.362 1.429
(cu in.) (69.90) (83) (83) (87.2)
Compression Ratio ---- 18:1 18.06:1 18.1:1 17.8:1
Horsepower* kW 16.9 - 20.2 18 - 24.6 17.2 20.9 - 24.9
(hp) (22.7 - 27.1) (24 - 33) (24) (28 - 33.5)
Firing Order ---- 1-3-2 1-3-2 1-3-2 1-3-2
Combustion System ---- Direct Direct Direct Direct
Aspiration ---- Natural Natural Natural Natural
Weight (dry) kg 160 190 190 153
(lbs) (353) (419) (419) (337)
Starter ---- Nippondenso Hitachi 2.0 kW, Nippondenso Nippondenso
1.0 kW Nippondenso 1.0 or 1.2 kW 1.0 or 1.2 kW
1.4 kW
Alternator ---- Nippondenso Hitachi 25A, Kokosan 20A, Kokosan 20A,
40A Nippondenso Nippondenso Nippondenso
35 or 40A 35A 35 or 40A
4/7/95 G-5
UNIT OF
GENERAL MEASURE 4TN78T 4TN82 4TN84 (4019D) 4TN84T (4019T)
Number of ---- 4 4 4 4
Cylinders
G
Bore mm 78 82 84 84
(in.) (3.07) (3.23) (3.31) (3.31)
Stroke mm 86 86 86 86
(in.) (3.39) (3.39) (3.39) (3.39)
Displacement L 1.643 1.816 1.906 1.906
(cu in.) (100) (110.8) (116.3) (116.3)
Compression Ratio ---- 17.75:1 18.1:1 17.8:1 17.8:1
Horsepower* kW 29 24.6 - 28 28.1 - 33.4 34.4 - 40.3
(hp) (39) (33 - 38) (37.7 - 44.8) (46.1 - 54)
Firing Order ---- 1-3-4-2-1 1-3-4-2-1 1-3-4-2-1 1-3-4-2-1
Combustion System ---- Direct Direct Direct Direct
Aspiration ---- Turbocharged Natural Natural Turbocharged
Weight (dry) kg 230 220 194 199
(lbs) (507) (485) (428) (439)
Starter ---- Hitachi 0.8 kW Nippondenso Nippondenso Nippondenso
1.0 or 1.4 kW, 1.0 or 1.4 kW 1.4 kW
Hitachi 2.0 kW
Alternator ---- Hitachi 25A Kokosan 20A, Kokosan 20A, Nippondenso
Nippondenso Nippondenso 40A
35 or 40A 40A
G-6 4/7/95
UNIT OF
GENERAL MEASURE 4TN100
Number of ---- 4
Cylinders
G
Bore mm 100
(in.) (3.90)
Stroke mm 110
(in.) (4.30)
Displacement L 3.5
(cu in.) (211)
Compression Ratio ---- N/A
Horsepower* kW 38.8 - 44
(hp) (52 - 59)
Firing Order ---- 1-3-4-2-1
Combustion System ---- Direct
Injection
Aspiration ---- Natural or
Turbocharged
Weight (dry) kg 332
(lbs) (731)
Starter ---- Nippondenso
1.4 kW
Alternator ---- Hitachi 25A
4/7/95 G-7
Fuels, Lubricants and Coolant
DIESEL FUEL performance; these properties may result in longer

engine life.
Use either Grade No. 1-D or Grade No. 2-D fuel as
defined by ASTM Designation D975 for diesel NOTE: When John Deere TORQ-GARD SUPREME
fuels. In European countries, use ISO 1585 PLUS-50™ engine oil and a John Deere oil
commercial diesel fuel. filter are used, the change interval may be
G extended by 50 hours. ALWAYS follow
NOTE: At altitudes above 1500 m (5000 ft) use recommendations in the operator’s manual.
Grade 1-D for all temperatures. If engine is
operated under “stand-by” conditions, use John Deere TORQ-GARD SUPREME® engine oil
grade 1-D for all temperatures. is also recommended but standard operator’s manual
oil change intervals must be maintained. Other oils
If engine is operated at temperatures of -40° to - may be used if they meet one or more of the
57°C (-40° to -70°F), Grade DF-A arctic fuel is following specifications:
recommended.
• API Service Classification CE or CD
Fuel sulfur content of less than 0.5 percent is
preferred, to prevent higher wear from corrosive • Military Specification MIL-L-2104E or MIL-L-
combustion products. 2104D or MIL-L-2104C
IMPORTANT: If fuel sulfur content exceeds 0.5 In European countries, oils meeting CCMC
percent, the engine oil drain interval must be Specification D4 or D5 may be used.
reduced by 50 percent. SAE 5W20, SAE 5W30, and arctic oil viscosity
Cetane number should be no less than 40 to assure grades meeting API Service Classification CC may
satisfactory starting and overall performance. At low be used, but oil and filter must be changed at one-
temperatures and/or high altitude, a cetane number half the normal interval.
of more than 45 is recommended. Oils meeting Military Specification MIL-L-46167B
may be used as arctic oils.
NOTE: Excessive white smoke at start-up could be
the result of low cetane fuel. NOTE: Some increase in oil consumption may be
Cloud point should be at least 6°C (10°F) below expected when low viscosity oils are used.
lowest expected air temperature at time of starting. Check oil levels more frequently.
Wax can separate from fuel when temperature
decreases to cloud point and may plug filter.
DIESEL ENGINE OIL

Use oil viscosity based on the expected air
temperature range during the period between oil
changes.
IMPORTANT: John Deere TORQ-GARD
SUPREME PLUS-50™ engine oil is not
recommended during engine break-in (first
100 hours on a new or overhauled engine). The
superior lubricating properties of this oil will
not allow the engine to properly wear during
break-in period. Use SAE 10W 30.
John Deere TORQ-GARD SUPREME PLUS-50™
engine oil is recommended at all other times. This
oil is specially formulated to provide superior
protection against high temperature thickening and TS238
wear as well as exceptional cold weather starting
G-8 4/7/95
OILSCAN® AND COOLSCAN™

OILSCAN and COOLSCAN are John Deere
sampling programs to help you monitor machine
performance and identify potential problems before
they cause serious damage.
G
Oil and coolant samples should be taken from each
system prior to its recommended change interval.
Check with your John Deere dealer for the
availability of OILSCAN and COOLSCAN kits.
TS1417
T6828AB
ENGINE COOLANT
GREASE RECOMMENDATIONS
Use grease based on the expected air temperature
range during the service interval.
The following greases are preferred:
CAUTION
• John Deere MOLY HIGH TEMPERATURE EP Explosive release of fluids from pressurized
GREASE cooling system can cause serious burns.
• John Deere HIGH TEMPERATURE EP
GREASE Shut off engine. Remove the radiator filler
cap only when the cap is cool enough to touch
• John Deere GREASE-GARD™ with bare hands. Slowly loosen cap to first
Other greases may be used if they meet one of the stop to relieve pressure before removing
following: completely.
• SAE Multipurpose EP Grease with a maximum
of 5% molybdenum disulfide • Always maintain engine coolant at correct level.
• SAE Multipurpose EP Grease • Coolant make-up should be mixed at same

concentrations as original coolant, including
Grease meeting Military Specification MIL-G- inhibitors.
10294F may be used as arctic grease.
4/7/95 G-9
• In tropical areas where antifreeze of John Deere Water Quality Specifications

Cooling Fluid is not available, use water
meeting quality specifications outlined in this Parts Grains
group and John Deere RE23182 Liquid Coolant Per Per
Conditioner. The liquid coolant conditioner Item Million Gallon
G should be added in the amount recommended on
the label for your cooling system capacity. Chlorides (maximum) . . . . . . . . . 40 2.5
Sulfates (maximum) . . . . . . . . . . 100 5.9
IMPORTANT: John Deere Liquid Coolant
Conditioner does not protect against freezing. Total Dissolved
Solids (maximum). . . . . . . . . . . . 340 20
In certain geographical areas where water quality is
unacceptable, John Deere Engine Cooling Fluid is Total Hardness (maximum). . . . . 170 10
marketed for use in the engine cooling system. It
protects the engine from corrosion and freezing pH Level . . . . . . . . . . . . . . . . . . . . . . 5.5 - 9.0
down to -37°C (-35°F).
John Deere Engine Cooling Fluid or John Deere If Chlorides, Sulfates, or Total Dissolved Solids are
Low Silicate Antifreeze are recommended for all higher than the above given specifications, the water
John Deere Diesel Engines. John Deere Cooling must be distilled, de-mineralized, or de-ionized
Fluid is ready to use as it is without dilution or before using in cooling system.
mixing. John Deere Low Silicate Antifreeze is If Total Hardness is higher than the above given
concentrated and should be mixed minimum 40% - specification, and all other parameters are within the
maximum 60% antifreeze and distilled to deionized given specifications, the water must be softened
water. Consult your John Deere Parts Network for before using in cooling system.
local availability.
Ethylene Glycol Concentrate

(Antifreeze)
IMPORTANT: DO NOT use methyl alcohol or
methoxy propanol base concentrate. This
concentrate is not compatible with additives
used in supplemental coolant additives.
Damage can occur to rubber seals on cylinder
liners which are in contact with coolant.
TS281 DO NOT use ethylene glycol concentrate

sealer or stop-leak additives.
DO NOT use concentrate containing less than

ENGINE COOLANT SPECIFICATIONS 10% ethylene glycol.
Water Quality
DO NOT use concentrate containing more
Distilled, de-ioned, or soft water is preferred for use than 0.1% anhydrous metasilicate. This type
in cooling systems. Mineral (hard/tap) water should of concentrate, which is intended for use in
NEVER be put in a cooling system unless first aluminum engines, may cause a gel-like
tested. However, water that meets the following deposit to form that reduces heat transfer and
water quality specifications is acceptable. coolant flow. Check container label or consult
with supplier before using.
G-10 4/7/95
John Deere Low Silicate Antifreeze is the ethylene

glycol concentrate recommended for all John Deere
Diesel Engines. This product is concentrated and
should be mixed 50/50 with quality water. Add to
the mixture 3% (by volume) supplemental coolant
CAUTION
additives (SCA’s). John Deere Liquid Coolant Conditioner G
John Deere Low Silicate Antifreeze is available in contains alkali. Avoid contact with eyes.
the following sizes: Avoid prolonged or repeated contact with
skin. Do not take internally. In case of
- TY6377 - 208 L (55 U.S. Gal) container contact, immediately wash skin with soap
- TY15886 - 3.8 L (1 U.S. Gal) container and water. For eyes, flush with large amounts
of water for at least 15 minutes. Call
Contact your John Deere Parts Network for local physician. KEEP OUT OF REACH OF
availability. CHILDREN.
If John Deere Low Silicate Antifreeze is not
available, use an ethylene glycol concentrate • John Deere Liquid Coolant Conditioner
meeting ASTM D 4985, SAEJ1941, General Motors
IMPORTANT: ALWAYS mix the 50/50 solution
Performance Specification GM1899M, or
of ethylene glycol concentrate with quality
formulated to GM6038M.
water in a separate container BEFORE
adding the SCA’s. Then add solution to the
Supplemental Coolant Additives radiator. NEVER pour cold water into a hot
(SCA’s) engine, as it may crack cylinder block or head.
John Deere Liquid Coolant Conditioner MUST be
IMPORTANT: Ethylene glycol concentrate
added at a rate of 3% (by volume) to the coolant
(antifreeze) DOES NOT contain sufficient
solution. When adding John Deere Liquid Coolant
additives to prevent liner erosion or pitting
Conditioner, follow the supplier’s recommendations
which could occur in wet sleeve diesel engines.
printed on the container.
ALWAYS mix the coolant solution with a
supplemental coolant additive such as John John Deere Liquid Coolant Conditioner is available
Deere Liquid Coolant Conditioner or spin-on in the following sizes:
coolant filter conditioner element. - RE23182 473 mL (16 oz) container
- RE35992 3.8 L (1 gal) container
Contact your John Deere Parts Network for
availability.
Other approved SCA’s are:
- NALCOOL 3000®
- FLEETGARD®-DCA008-78L DCA2 in 473
mL (16 oz) container
- FLEETGARD®-DCA60-78L DCA4 in 473
mL (16 oz) container
NALCOOL 3000® is a registered trademark of the NALCO Company.

FLEETGARD® is a registered trademark of the Cummins Engine Company.
4/7/95 G-11
IMPORTANT: John Deere Liquid Coolant CHECK EFFECTIVENESS OF

Conditioner does NOT protect against COOLANT SOLUTION
freezing.
Prior to the recommended change interval or if
DO NOT over-concentrate coolant solutions concentration of coolant solution is in question, a
coolant sample should be taken and a COOLSCAN
G with supplemental coolant additives, as this
can cause silicate-dropout. When this analysis performed.
happens, a gel-type deposit is created which COOLSCAN is a John Deere sampling program to
retards heat transfer and coolant flow. DO help you monitor the effectiveness of your engine’s
NOT use soluble oil. coolant solution and identify potential problems
before they cause serious damage.
JOHN DEERE ENGINE COOLING Check with your John Deere dealer for the
FLUID availability of DS0251 COOLSCAN kit. Refer to
instructions provided with kit.
In certain regions of the world, John Deere Engine
Cooling Fluid is marketed for use in the engine Usually recharging your engine coolant with the
cooling system. John Deere Cooling Fluid is recommended amount of John Deere Liquid Coolant
premixed and contains the proper mixture of quality Conditioner at the appropriate time is adequate.
water, low silicate antifreeze to protect the engine However, with a COOLSCAN analysis report, you
from freezing down to -37°C (-35°F), and will be given a more thorough evaluation of your
supplemental coolant additives (SCA’s). engine coolant condition along with a detailed
service recommendation.
IMPORTANT: Additional SCA’s should NOT be
added to the Cooling Fluid.
John Deere Engine Cooling Fluid is available in the
following sizes:
- AL66606 (formally DD14134) - 5 L (1.3 U.S.
Gal) can
- AL66607 (formally DD14345) - 20 L (5.3
U.S. Gal) can
- AL67171 (formally DD14136) - 60 L (15.9
U.S. Gal) drum T6828AB
- AL66608 (formally DD14346) 200 L (53

U.S. Gal) drum
Contact your John Deere Parts Network for local
availability.
G-12 4/7/95
REPLENISHING SUPPLEMENTAL
COOLANT ADDITIVES (SCA’S)
BETWEEN COOLANT CHANGES
Through time and use, original additives eventually
lose their effectiveness and must be recharged with
additional supplemental coolant additives available
G
in the form of liquid coolant conditioner.
NOTE: Service intervals listed are a recommended
engineering guideline. Refer to your vehicle
operator’s manual for a specific service
interval.
At 600 hours or 1 year service interval, it is
recommended to perform a COOLSCAN analysis as RG6262
described earlier. If COOLSCAN analysis is not

available, recharge system per instructions printed See ENGINE COOLANT SPECIFICATIONS
on bottle. earlier in this group for proper mixing of coolant
ingredients before adding to the cooling system.
IMPORTANT: DO NOT CHANGE the spin-on
filter element at the 600 hour or 1 year service
interval. If the filter is replaced at this time, FLUSHING AND SERVICING
the result could be an overcharged system. COOLING SYSTEM
This could cause “solder bloom” in the
radiator because the over concentration of
nitrite will attack the solder. Replace the filter
only if the entire cooling system is drained and
coolant replaced.
IMPORTANT: ALWAYS maintain coolant at
correct level and concentration. DO NOT
operate engine without coolant for even a few
minutes.
If frequent coolant make-up is required, the

glycol concentration should be checked with
JT05460 Refractometer to assure that the
desired freeze point is maintained. Follow TS281
manufacturer’s instructions provided with
refractometer.
CAUTION
Explosive release of fluids from pressurized
cooling system can cause serious burns.
Shut off engine. Remove the radiator filler

cap only when the cap is cool enough to touch
RG6261
with bare hands. Slowly loosen cap to first
stop to relieve pressure before removing
completely.
4/7/95 G-13
IMPORTANT: Air must be expelled from After adding new coolant solution, run engine until
cooling system when system is refilled. Follow it reaches operating temperature. This mixes the
procedure given in your operator’s manual. coolant solution uniformly and circulates it through
the entire system. After running engine, check
Engine coolant MUST BE drained and coolant level and entire cooling system for leaks.
G replaced at a maximum of 1200 hours or 2
years of engine operating time, whichever
Contact your authorized servicing dealer or engine
distributor, if there are further questions.
comes first.
The ethylene glycol base (antifreeze) can become
depleted of SCA’s allowing various acids to form DISPOSING OF COOLANT
that will damage engine components. In addition,
heavy metals, such as lead, copper and zinc,
accumulate in the ethylene glycol base. The heavy
metals come from corrosion that occurs to some
degree within a cooling system. When a coolant is
saturated to the point where it can no longer hold
heavy metals and other dissolved solids, they settle
out and act as abrasives on engine parts.
NOTE: Service intervals listed are a recommended
engineering guideline. Refer to your vehicle
operator’s manual for a specific service
TS1133
interval.
At 1200 hours/2-year service interval, flush cooling Improperly disposing of coolant can threaten the
system and replace thermostats as described in your environment and ecology.
operator’s manual. Clean cooling system with a
heavy duty cooling system cleaner such as Use leakproof containers when draining fluids. Do
FLEETGARD® RESTORE™. Follow the not use food or beverage containers that may
instructions provided with cleaner. Refill cooling mislead someone into drinking from them.
system with the appropriate coolant solution. See Do not pour waste onto the ground, down a drain, or
ENGINE COOLANT SPECIFICATIONS, earlier in into any water source.
this group.
Inquire on the proper way to recycle or dispose of
IMPORTANT: NEVER overfill the system. A waste from your local environmental or recycling
pressurized system needs space for heat center, or from your John Deere dealer.
expansion without overflowing at the top of
the radiator. Coolant level should be
approximately 19 mm (3/4 in.) below bottom
of radiator filler neck.
FLEETGARD® is a registered trademark of the Cummins Engine Company.

RESTORE™ is a registered trademark of FLEETGARD®.
G-14 4/7/95
Repair Information
METRIC BOLT AND CAP SCREW TORQUE VALUES
Property
Class
and
Head
Markings G
Property
Class
and
Nut
TS1163
Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9

a a a a a a
Lubricated Dry Lubricated Dry Lubricated Dry Lubricateda Drya
Size Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft
M6 4.8 3.5 6 4.5 9 6.5 11 8.5 13 9.5 17 12 15 11.5 19 14.5
M8 12 8.5 15 11 22 16 28 20 32 24 40 30 37 28 47 35
M10 23 17 29 21 43 32 55 40 63 47 80 60 75 55 95 70
M12 40 29 50 37 75 55 95 70 110 80 140 105 130 95 165 120
M14 63 47 80 60 120 88 150 110 175 130 225 165 205 150 260 190
M16 100 73 125 92 190 140 240 175 275 200 350 225 320 240 400 300
M18 135 100 175 125 260 195 330 250 375 275 475 350 440 325 560 410
M20 190 140 240 180 375 275 475 350 530 400 675 500 625 460 800 580
M22 260 190 330 250 510 375 650 475 725 540 925 675 850 625 1075 800
M24 330 250 425 310 650 475 825 600 925 675 1150 850 1075 800 1350 1000
M27 490 360 625 450 950 700 1200 875 1350 1000 1700 1250 1600 1150 2000 1500
M30 675 490 850 625 1300 950 1650 1200 1850 1350 2300 1700 2150 1600 2700 2000
M33 900 675 1150 850 1750 1300 2200 1650 2500 1850 3150 2350 2900 2150 3700 2750
M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2750 4750 3500
DO NOT use these values if a different torque value Tighten plastic insert or crimped steel-type lock nuts
or tightening procedure is given for a specific to approximately 50 percent of the dry torque shown
application. Torque values listed are for general use in the chart, applied to the nut, not to the bolt head.
only. Check tightness of fasteners periodically. Tighten toothed or serrated-type lock nuts to the full
torque value.
Shear bolts are designed to fail under predetermined
loads. Always replace shear bolts with identical a “Lubricated” means coated with a lubricant such
grade. as engine oil, or fasteners with phosphate and oil
coatings. “Dry” means plain or zinc plated without
Fasteners should be replaced with the same or higher any lubrication.
grade. If higher grade fasteners are used, these
should only be tightened to the strength of the
original. Make sure fasteners threads are clean and
that you properly start thread engagement. This will
prevent them from failing when tightening.
4/7/95 G-15
Repair Information
UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES
SAE
Grade
G and Head
Markings
No Marks
SAE
Grade
and Nut No Marks
Marking
TS1162
Grade 1 Grade 2b Grade 5, 5.1 or 5.2 Grade 8 or 8.2

a a a a a a
Lubricated Dry Lubricated Dry Lubricated Dry Lubricateda Drya
Size Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft
1/4 3.7 2.8 4.7 3.5 6 4.5 7.5 5.5 9.5 7 12 9 13.5 10 17 12.5
5/16 7.7 5.5 10 7 12 9 15 11 20 15 25 18 28 21 35 26
3/8 14 10 17 13 22 16 27 20 35 26 44 33 50 36 63 46
7/16 22 16 28 20 35 26 44 32 55 41 70 52 80 58 100 75
1/2 33 25 42 31 53 39 67 50 85 63 110 80 120 90 150 115
9/16 48 36 60 45 75 56 95 70 125 90 155 115 175 130 225 160
5/8 67 50 85 62 105 78 135 100 170 125 215 160 215 160 300 225
3/4 120 87 150 110 190 140 240 175 300 225 375 280 425 310 550 400
7/8 190 140 240 175 190 140 240 175 490 360 625 450 700 500 875 650
1 290 210 360 270 290 210 360 270 725 540 925 675 1050 750 1300 975
1-1/8 470 300 510 375 470 300 510 375 900 675 1150 850 1450 1075 1850 1350
1-1/4 570 425 725 530 570 425 725 530 1300 950 1650 1200 2050 1500 2600 1950
1-3/8 750 550 950 700 750 550 950 700 1700 1250 2150 1550 2700 2000 3400 2550
1-1/2 1000 725 1250 925 990 725 1250 930 2250 1650 2850 2100 3600 2650 4550 3350
DO NOT use these values if a different torque value Tighten plastic insert or crimped steel-type lock nuts
or tightening procedure is given for a specific to approximately 50 percent of the dry torque shown
application. Torque values listed are for general use in the chart, applied to the nut, not to the bolt head.
only. Check tightness of fasteners periodically. Tighten toothed or serrated-type lock nuts to the full
torque value.
Shear bolts are designed to fail under predetermined
loads. Always replace shear bolts with identical a “Lubricated” means coated with a lubricant such
grade. as engine oil, or fasteners with phosphate and oil
coatings. “Dry” means plain or zinc plated without
Fasteners should be replaced with the same or higher any lubrication.
grade. If higher grade fasteners are used, these b Grade 2 applies for hex cap screws (not hex bolts)
should only be tightened to the strength of the up to 152 mm (6 in.) long. Grade 1 applies for hex
original. Make sure fasteners threads are clean and cap screws over 152 mm (6 in.) long, and for all
that you properly start thread engagement. This will other types of bolts and screws of any length.
prevent them from failing when tightening.
G-16 4/7/95
Repair Information
CLEAN ENGINE
1. Cap or plug all openings on engine. If electrical
components (starter, alternator, etc.) are not
removed prior to cleaning, cover with plastic and
tape securely to prevent moisture from entering.
G
2. Steam-clean engine thoroughly.
IMPORTANT: Never steam-clean or pour cold
water on an injection pump while it is still
warm. To do so may cause seizure of pump
parts.
DISCONNECT TURBOCHARGER OIL

INLET LINE
1. Drain all engine oil and coolant.
IMPORTANT: When servicing turbocharged
engines on a rollover stand, disconnect
turbocharger oil inlet line before rolling
engine over. Failure to do so may cause a
hydraulic lock upon starting engine.
Hydraulic lock may cause severe engine
damage.
Hydraulic lock occurs when trapped oil in the

oil filter housing drains through the
turbocharger, into exhaust and intake
manifolds, and cylinder head. After starting
the engine, trapped oil in the manifold and
head is released into the cylinder(s) filling
them with oil causing hydraulic lock and
severe engine damage.
2. Disconnect turbocharger oil inlet line at
turbocharger.
4/7/95 G-17
Repair Information
G-18 4/7/95
1
3TN66 AND 3TNA72 (3009)
ENGINES
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Cylinder Head, Valves and Manifolds . . . . . . . . . . . . . . . 1-17
Pistons, Rods and Cylinder Block . . . . . . . . . . . . . . . . . . 1-32
Crankshaft, Main Bearings and Flywheel . . . . . . . . . . . . 1-42
Camshaft and Timing Gear Train. . . . . . . . . . . . . . . . . . . 1-55 3
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-71
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-83
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-91
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-113
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-122
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-131
Checks, Tests and Adjustments. . . . . . . . . . . . . . . . . . . 1-134
Operational Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-152
Section 1
1
Specifications
ENGINE SPECIFICATIONS - 3TN66

Rocker Arm Cover
Special Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 N•m (160 lb-in.)
Rocker Arm Assembly
Mounting Cap Screw and Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.)
Rocker Arm Shaft O.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.97 - 9.99 mm (0.3925 - 0.3933 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.95 mm (0.3920 in.)
Rocker Arm and Shaft Support I.D.'s
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.14 mm (0.005 in.)
1
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.00 - 10.02 mm (0.3937 - 0.3945 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.09 mm (0.3972 in.)
Push Rod Length
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 - 115 mm (4.488 - 4.528 in.)
Push Rod Bend
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08 mm (0.003 in.)
Cylinder Head and Valves
Mounting Cap Screw Torque
First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (97 lb-in.)
Second. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 N•m (195 lb-in.)
Final . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 N•m (25 lb-ft)
Cylinder Head Distortion
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.) or less
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
Maximum Amount of Metal to be Removed . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
Valve Seat Width
Intake Valve
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15 mm (0.045 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.65 mm (0.065 in.)
Exhaust Valve
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 mm (0.056 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.91 mm (0.075 in.)
Intake and Exhaust Valves
Valve Faces
Minimum Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.51 mm (0.020 in.)
Exhaust Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Intake Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
Valve Stem O.D.
Distance A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 mm (0.787 in.)
Distance B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 mm (1.575 in.)
Intake Valve
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.46 - 5.48 mm (0.2149 - 0.2157 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.40 mm (0.2126 in.)
Exhaust Valve
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.44 - 5.46 mm (0.2142 - 0.2149 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.40 mm (0.2126 in.)
Valve Recession
Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.)
Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.85 mm (0.033 in.)
4/7/95 1-1
Specifications
Valve Guides
Valve Guide I.D.
Maximum Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.50 - 5.52 mm (0.216 - 0.217 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.58 mm (0.220 in.)
Valve Guide Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 mm (0.276 in.)
Valve Springs
Spring Free Length
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 mm (1.102 in.)
1 Maximum Spring Inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm (0.032 in.)
Exhaust Manifold
Mounting Cap Screw and Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (97 lb-in.)
Intake Manifold
Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (97 lb-in.)
Valve Seat Angles
Valve Seat Surface
Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
Lower Seat Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70°
Upper Seat Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15°
Piston-to-Cylinder Head Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.59 - 0.74 mm (0.023 - 0.029 in.)
Piston and Connecting Rod Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 N•m (203 lb-in.)
Connecting Rod Bearing I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 - 36.042 mm (1.417 - 1.419 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.07 mm (1.459 in.)
Piston Ring Groove Clearance
First Compression Ring
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.065 - 0.100 mm (0.0026 - 0.0039 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.)
Second Compression Ring
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.030 - 0.065 mm (0.0012 - 0.0026 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.)
Oil Ring
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 - 0.055 mm (0.0008 - 0.0022 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.)
Piston End Ring Gap
Standard
First Compression Ring and Oil Ring. . . . . . . . . . . . . . . . . . . . . 0.15 - 0.35 mm (0.006 - 0.014 in.)
Second Compression Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 - 0.40 mm (0.010 - 0.016 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.0591 in.)
Piston Pin
Pin O.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.991 - 20.00 mm (0.787 - 0.788 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.975 mm (0.786 in.)
Bore I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.045 mm (0.0018 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.00 - 20.008 mm (0.787 - 0.788 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.02 mm (0.788 in.)
1-2 4/7/95
Specifications
Piston Pin, continued

Bushing I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.110 mm (0.0043 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.025 - 20.038 mm (0.788 - 0.789 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.10 mm (0.781 in.)
Piston O.D.
Distance A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 mm (0.197 in.)
Standard Size Piston
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.927 - 65.957 mm (2.596 - 2.597 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.85 mm (2.593 in.) 1
0.25 mm (0.010 in.) Oversize Piston
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.18 - 66.21 mm (2.606 - 2.607 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.10 mm (2.602 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.43 - 66.46 mm (2.615 - 2.616 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.35 mm (2.612 in.)
Cylinder Bore I.D.
Standard Size Bore
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.00 - 66.03 mm (2.599 - 2.600 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.20 mm (2.606 in.)
0.25 mm (0.010 in.) Oversize Bore
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.25 - 66.28 mm (2.609 - 2.610 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.45 mm (2.616 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.50 - 66.53 mm (2.619 - 2.620 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.70 mm (2.626 in.)
Degalzing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 40° cross-hatch pattern
Reboring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 40° cross-hatch pattern
Crankshaft Rear Oil Seal
Seal Case-to-Block Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.)
Oil Pan-to-Seal Case Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.)
Crankshaft and Main Bearings
Main Bearing Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 N•m (40 lb-ft)
Crankshaft Maximum Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.0007 in.)
Connecting Rod Journal O.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.97 - 35.98 mm (1.4161 - 1.4165 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.92 mm (1.414 in.)
Main Bearing Journal O.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.97 - 39.98 mm (1.5736 - 1.5740 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.92 mm (1.572 in.)
Main Bearing I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.00 - 40.042 mm (1.575 - 1.577 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.07 mm (1.578 in.)
Stub Shaft (330/332 LGT, F915 FM)
Stub Shaft-to-Flywheel Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 N•m (44 lb-ft)
Cover-to-Block Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft)
Cover-to-Plate Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.)
4/7/95 1-3
Specifications
Flywheel
Maximum Distortion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.0008 in.)
Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 N•m (61 lb-ft)
Flywheel Plate Mounting Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft)
Camshaft
Camshaft Side Gap
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.15 mm (0.0020 - 0.0060 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.)
1 Maximum Camshaft Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.001 in.)
Lobe Height
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.97 - 30.03 mm (1.180 - 1.182 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.75 mm (1.171 in.)
Journal O.D.
Gear Housing and Flywheel Ends
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.94 - 35.96 mm (1.4150 - 1.4157 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.85 mm (1.4114 in.)
Intermediate
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.91 - 35.94 mm (1.4138 - 1.4150 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.85 mm (1.4114 in.)
Bushing I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.00 - 36.065 mm (1.417 - 1.420 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.10 mm (1.421 in.)
Bore I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.00 - 36.025 mm (1.417 - 1.418 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.10 mm (1.421 in.)
Cam Followers
O.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.950 - 17.968 mm (0.7067 - 0.7074 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.93 mm (0.706 in.)
Bore I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.032 - 0.068 mm (0.0013 - 0.0027 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.00 - 18.018 mm (0.7087 - 0.7094 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.05 mm (0.711 in.)
Timing Gear Cover
Fan Mounting Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.)
Cover Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.)
Crankshaft Pulley Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 N•m (85 lb-ft)
Idler Gear
Shaft O.D
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.959 - 19.980 mm (0.786 - 0.787 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.93 mm (0.785 in.)
Bushing I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.00 - 20.021 mm (0.787 - 0.788 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.08 mm (0.791 in.)
1-4 4/7/95
Specifications
Timing Gear Housing Cap Screw Torque

Aluminum Housing-to-Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.)
Cast Iron Housing-to-Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.)
Oil Pan and Strainer Mounting Cap Screw Torque
Oil Pan-to-Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.)
Oil Pan-to-Seal Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.)
Oil Pan-to-Timing Gear Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.)
Oil Strainer-to-Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.)
Oil Pump
Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (18 lb-ft) 1
Rotor Shaft O.D.-to-Backing Plate I.D. Clearance
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 - 0.048 mm (0.0006 - 0.0035 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0078 in.)
Rotor Recess
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
Outer Rotor-to-Pump Body Clearance
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.09 mm (0.0011 - 0.0035 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.13 mm (0.0057 in.)
Inner-to-Outer Rotor Clearance
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Oil Pressure Regulating Valve
Spring
Compressed Length . . . . . . . . . . . . . . . . . . . . . . . . . . .14.70 mm (0.580 in.) @12 N (2.7 lb-force)
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.90 - 24.50 mm (0.860 - 0.960 in.)
Housing-to-Valve Body Retaining Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 30 N•m (22 lb-ft)
Thermostat
Thermostat Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.)
Water Pump
Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.)
Plate-to-Housing Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.)
Fuel Injection Pump
Mounting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (180 lb-in.)
Fuel Injection Pump Camshaft
Bearing Retaining Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (180 lb-in.)
Minimum Lobe Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.90 mm (1.217 in.)
Fuel Control and Governor Linkage
Governor Shaft O.D. (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.90 mm (0.311 in.)
Governor Shaft Bore I.D.
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15 mm (0.321 in.)
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.)
Sleeve I.D. (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.20 mm (0.323 in.)
Injection Pump Camshaft O.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.90 mm (0.311 in.)
Fuel Injection Nozzles
Mounting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft)
Nozzle Fitting Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft)
Nozzle Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 N•m (37 lb-ft)
Separator Plate Nozzle Contact Surface Maximum Wear . . . . . . . . . . . . . . . . . . 0.10 mm (0.0039 in.)
4/7/95 1-5
Specifications
Starter - Hitachi 0.8 kW

Cover Bushing (Reamed Out). . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.50 - 12.53 mm (0.492 - 0.493 in.)
Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.70 mm (0.303 in.)
Alternator - Kokosan 20A (375 SSL, 330/332 LGT, F915 FM)
Flywheel Assembly-to-Coil Plate Assembly Nut Torque . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft)
Alternator - Nippondenso 35A (655 CUT)
Attaching Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (31 lb-in.)
Rotor Assembly
Pulley Nut Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 N•m (40 lb-ft)
1 Retainer-to-Front Frame Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 N•m (16 lb-in.)
Stator-to-Rectifier Lead Wire Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.50 mm (1.300 in.)
Alternator - Nippondenso 40A (655 CUT)
Minimum Rotor Slip Ring O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 mm (0.550 in.)
Retainer-to-Front Frame Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 N•m (16 lb-in.)
Sheave Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 N•m (51 lb-ft)
Brush Length
New. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.50 mm (0.410 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.50 mm (0.170 in.)
Checks, Tests and Adjustments
Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 mm (0.008 in.)
Connecting Rod Side Play
Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm (0.0079 - 0.0157 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.55 mm (0.0217 in.)
Connecting Rod Bearing Clearance
Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 - 0.072 mm (0.0008 - 0.0028 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Crankshaft End Play
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.33 mm (0.0129 in.)
Crankshaft Main Bearing Clearance
Main Bearing Cap Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 N•m (40 lb-ft)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Valve Lift (Intake and Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 mm (0.300 in.)
Camshaft End Play
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.)
Timing Gear Backlash
Standard Backlash
All Except Crankshaft Gear-to-Oil Pump Gear . . . . . . . . 0.04 - 0.12 mm (0.0016 - 0.0047 in.)
Crankshaft Gear-to-Oil Pump Gear . . . . . . . . . . . . . . . . . 0.11 - 0.19 mm (0.0043 - 0.0075 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.)
Fuel Injection Nozzle
Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11722 ± 480 kPa (1700 ± 70 psi)
Leakage at 11032 kPa (1600 psi) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum of 10 Seconds
Chatter and Spray Pattern at 11722 ± 480 kPa (1700 ± 70 psi)
Slow Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Chatter Sound
Slow Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fine Stream Spray Pattern
Fast Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fine Atomized Spray Pattern
1-6 4/7/95
Specifications
Thermostat
Begin Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71° C (160°F)
Fully Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85° C (184° F)
Minimum Lift Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 mm (0.310 in.)
Coolant Temperature Sensor Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107-113° C (225-235° F)
Starter No-Load Amp Draw/RPM
Maximum Starter Amperage
Hitachi 0.8 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 Amps at 7000 rpm
Minimum Starter RPM
Hitachi 0.8 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7000 1
Fuel Injection Pump Static Timing
Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13° BTDC (Before Top Dead Center)
Distance on Outer Surface of Crankshaft Pulley for
Every 0.1 mm (0.004 in.) of Shim Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1° or 1 mm (3/64 in.)
Engine Crankshaft Position . . . . . . . . . . . . . . . . . . . . . . No. 1 Cylinder on TDC Compression Stroke
Total Shim Pack Thickness (New Shims) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 mm (0.020 in.)
Delivery Valve Fitting Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 N•m (31 lb-ft)
Fan/Alternator Drive Belt Tension
Applied Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 N (22 lb-force)
Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 15 mm (0.400 - 0.600 in.)
Operational Tests
Radiator, Bubble Test
Maximum Air Pressure Into Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2448 kPa (355 psi)
Cooling System
Maximum Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 kPa (17 psi)
Minimum Pressure after 15 Seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 kPa (13 psi)
Radiator Cap
Valve Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 kPa (14 psi)
Cylinder, Compression Pressure
Compression Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2448 kPa (355 psi)
Maximum Difference Between Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490 kPa (71 psi)
Engine Oil Pressure
375 SSL
Idle Speed
Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3625 ± 25 rpm
Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ± 50 rpm
Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294 - 392 kPa (43 - 57 psi)
330/332 LGT
Idle Speed
Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3350 ± 100 rpm
Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ± 50 rpm
655 CUT
Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3425 ± 25 rpm
Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .365 ± 69 kPa (53 ± 10 psi)
F915 FM
Idle Speed
Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3635 ± 35 rpm
Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ± 50 rpm
Air Intake System Holding Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 - 69 kPa (5 - 10 psi)
Fuel Supply Pump Pressure (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 kPa (15 psi)
4/7/95 1-7
Specifications
ENGINE SPECIFICATIONS - 3TNA72 (3009)

Rocker Arm Cover
Rocker Arm Assembly
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.96 - 11.98 mm (0.4711 - 0.4718 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.95 mm (0.4706 in.)
1 Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.14 mm (0.005 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.00 - 12.02 mm (0.4724 - 0.4732 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.09 mm (0.4759 in.)
Push Rod Length
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 - 142 mm (5.550 - 5.590 in.)
Push Rod Bend
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08 mm (0.003 in.)
First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 N•m (168 lb-in.)
Second. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 N•m (28 lb-ft)
Final . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 N•m (45 lb-ft)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
Maximum Amount of Metal to be Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
Valve Seat Width
Intake Valve
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.44 mm (0.057 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.98 mm (0.078 in.)
Exhaust Valve
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.77 mm (0.070 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27 mm (0.089 in.)
Valve Faces
Exhaust Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Intake Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
Valve Stem O.D.
Distance A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 mm (0.984 in.)
Distance B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 mm (1.772 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.94 - 6.96 mm (0.2732 - 0.2740 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.90 mm (0.2717 in.)
Valve Recession
Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.85 mm (0.033 in.)
Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm (0.020 in.)
Valve Guides
Valve Guide I.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.00 - 7.02 mm (0.275 - 0.276 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.08 mm (0.279 in.)
1-8 4/7/95
Specifications
Valve Guides, continued

Valve Guide Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 mm (0.354 in.)
Valve Springs
Spring Free Length
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.40 mm (1.472 in.)
Maximum Spring Inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00 mm 0.040 in.)
Exhaust Manifold
Mounting Cap Screw and Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (30 lb-in.)
Intake Manifold
Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (97 lb-in.) 1
Valve Seat Angles
Valve Seat Surface
Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
Piston and Connecting Rod Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 N•m (203 lb-in.)
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.00 - 40.042 mm (1.575 - 1.577 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.07 mm (1.578 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.075 - 0.110 mm (0.0030 - 0.0043 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.030 - 0.065 mm (0.0012 - 0.0026 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.)
Oil Ring
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 - 0.055 mm (0.0008 - 0.0022 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.)
Piston Ring End Gap
Standard
First Compression Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 - 0.25 mm (0.004 - 0.010 in.)
Second Compression Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 - 0.40 mm (0.010 - 0.016 in.)
Oil Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 - 0.35 mm (0.006 - 0.014 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.0591 in.)
Piston Pin
O.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.991 - 21.00 mm (0.826 - 0.827 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.975 mm (0.825 in.)
Bore I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.045 mm (0.0018 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.00 - 21.009 mm (0.8268 - 0.8271 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.02 mm (0.828 in.)
Bushing I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.110 mm (0.0043 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.025 - 21.038 mm (0.8278 - 0.8282 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.10 mm (0.831 in.)
4/7/95 1-9
Specifications
Piston O.D.
Distance A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 mm (0.315 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.922 - 71.952 mm (2.832 - 2.833 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.81 mm (2.827 in.)
0.25mm (0.10 in.) Oversize Piston
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.17 - 72.20 mm (2.841 - 2.842 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.06 mm (2.837 in.)
1 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.42 - 72.45 mm (2.851 - 2.852 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.31 mm (2.847 in.)
Cylinder Bore I.D.
Standard Size Bore
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.28 mm (0.011 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.00 - 72.03 mm (2.835 - 2.836 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.20 mm (2.843 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.25 - 72.28 mm ((2.845 - 2.846 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.45 mm (2.852 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.50 - 72.53 mm (2.855 - 2.856 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.70 mm (2.862 in.)
Degalzing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 40° cross-hatch pattern
Crankcase Extension Housing
Flywheel Housing/Plate-to-Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft)
Seal Case-to-Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.)
Extension-to-Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft)
Extension-to-Timing Gear Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 N•m (195 lb-in.)
Seal Case-to-Block Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11N•m (96 lb-in.)
Oil Pan-to-Seal Case Cap Screw Torque
(430 LGT, 455 LGT, 755/56 CUT, F925/35 FM) . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.)
Seal Case-to-Extension Cap Screw Torque
(15 EX, 670 CUT, 3009 OEM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.97 - 39.98 mm (1.5736 - 1.5740 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.92 mm (1.572 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.97 - 43.98 mm (1.7311 - 1.7315 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.92 mm (1.729 in.)
Main Bearing I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.00 - 44.042 mm (1.732 - 1.734 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.07 mm (1.735 in.)
1-10 4/7/95
Specifications
Stub Shaft (430 LGT, F925/35 FM)

Stub Shaft-to-Flywheel Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 N•m (44 lb-ft)
Cover-to-Block Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft)
Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 N•m (65 lb-ft)
Cover-to-Plate Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.)
Flywheel
Flywheel Housing/Plate Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft)
Camshaft 1
Camshaft Side Gap
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.15 mm (0.0020 - 0.0060 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.)
Maximum Camshaft Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.001 in.)
Lobe Height
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.95 - 34.05 mm (1.337 - 1.341 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.75 mm (1.329 in.)
Journal O.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.94 - 39.96 mm (1.5724 - 1.5732 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.85 mm (1.5689 in.)
Intermediate
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.91 - 39.94 mm (1.5713 - 1.5724 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.85 mm (1.5689 in.)
Bushing I.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.00 - 40.065 mm (1.575 - 1.577 in.)
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.10 mm (1.579 in.)
Bore I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.00 - 40.025 mm (1.575 - 1.576 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.10 mm (1.579 in.)
Cam Followers
O.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.927 - 20.960 mm (0.8239 - 0.8252 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.93 mm (0.824 in.)
Bore I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.040 - 0.094 mm (0.0016 - 0.0037 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.00 - 21.021 mm (0.8268 - 0.8276 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.05 mm (0.829 in.)
Timing Gear Cover
Fan Mounting Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.)
Cover Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.)
Crankcase Extension Housing-to-Cover Cap Screw Torque . . . . . . . . . . . . . . 22 N•m (195 lb-in.)
Crankshaft Pulley Cap Screw Torque
Early 3TNA72 (430 LGT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 N•m (65 lb-ft)
Later 3TNA72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 N•m (85 lb-ft)
4/7/95 1-11
Specifications
Idler Gear
Shaft O.D
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.959 - 19.980 mm (0.786 - 0.787 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.93 mm (0.785 in.)
Bushing I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.00 - 20.021 mm (0.787 - 0.788 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.08 mm (0.791 in.)
Timing Gear Housing Cap Screw Torque
1 Aluminum Housing-to-Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (73 lb-in.)
Cast Iron Housing-to-Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.)
Crankcase Extension-to-Housing (670 CUT, 15 EX, 3009 OEM). . . . . . . . . . . . . 22 N•m (195 lb-in.)
Oil Pan and Strainer Mounting Cap Screw Torque
Oil Pan/Plate-to-Extension Housing (670 CUT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.)
Oil Pan-to-Block (All Except 670 CUT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.)
Oil Pan-to-Seal Case (All Except 670, 15 EX, 3009 OEM). . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.)
Oil Pan-to-Timing Gear Housing (All Except 670, 15 EX, 3009 OEM) . . . . . . . . . . 9 N•m (78 lb-in.)
Oil Strainer-to-Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.)
Oil Pump - Early 3TNA72 (430 LGT)
Mounting Cap Screw and Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.)
Governor Shaft Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft)
Gear Housing End Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.)
Oil Pump Gear Lock Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft)
Outer Rotor Bore Depth-to-Outer Rotor Thickness Clearance
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08 - 0.15 mm (0.003 - 0.006 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
Outer Rotor-to-Bore Diameter Clearance
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 - 0.15 mm (0.004 - 0.006 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
Inner Rotor-to-Outer Rotor Clearance
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 - 0.15 mm (0.004 - 0.006 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
Rotor Shaft O.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.670 - 12.685 mm (0.4988 - 0.4990 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.650 mm (0.4980 in.)
Rotor Shaft Bore I.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.700 - 12.718 mm (0.5000 - 0.5007 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.100 mm (0.0039 in.)
Rotor Shaft-to-Bore Clearance
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 - 0.048 mm (0.006 - 0.0019 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.100 mm (0.0039 in.)
Oil Pump - Later 3TNA72
Rotor Recess
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 - 0.048 mm (0.0006 - 0.0035 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0078 in.)
1-12 4/7/95
Specifications
Oil Pump - Later 3TNA72, continued

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.09 mm (0.0011 - 0.0035 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.13 mm (0.0057 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Oil Pressure Regulating Valve -Early 3TNA72 (430 LGT)
Spring
Compressed Length . . . . . . . . . . . . . . . . . . 30 mm (1.180 in.) @ 29.4 ± 3.1 N (6.6 ± 0.7 lb-force)
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.50 - 40.50 mm (1.550 - 1.590 in.) 1
Oil Pressure Regulating Valve - Later 3TNA72
Spring
Compressed Length . . . . . . . . . . . . . . . . . . . . . . . . .27.50 mm (1.080 in.) @ 20.5 N (4.6 lb-force)
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.50 - 48.50 mm (1.710 - 1.910 in.)
Housing-to-Valve Body Retaining Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 N•m (22 lb-ft)
Housing-to-Engine Block Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft)
Thermostat
Thermostat Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.)
Water Pump
Plate-to-Housing Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.)
Fuel Supply Pump - (670 CUT, 3009 OEM)
Mounting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.)
Fuel Injection Pump
Mounting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (180 lb-in.)
Fuel Injection Pump Camshaft
Bearing Retaining Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (180 lb-in.)
Gear-to-Camshaft Lock Nut Torque - Early 3TNA72 (430 LGT) . . . . . . . . . . . . . . . 88 N•m (65 lb-ft)
Minimum Lobe Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.90 mm (1.217 in.)
Fuel Control and Governor Linkage - Early 3TNA72 (430 LGT)
Gear Housing End Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.)
Governor Shaft O.D. (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.90 N•m (0.311 in.)
Governor Shaft Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft)
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15 mm (0.321 in.)
Sleeve I.D. (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20 mm (0.362 in.)
Oil Pump Rotor Shaft O.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.15mm (0.006 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.90 mm (0.350 in.)
Fuel Control and Governor Linkage - Later 3TNA72
Governor Shaft O.D. (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.90 mm (0.311 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15 mm (0.321 in.)
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.)
Sleeve I.D. (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.20 mm (0.323 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.90 mm (0.311 in.)
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
4/7/95 1-13
Specifications

Nozzle Fitting Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 N•m (30 lb-ft)
Nozzle Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 N•m (37 lb-ft)
Starter - Hitachi 0.8 kW (3009 OEM)
Cover Bushing (Reamed Out). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.50 - 12.53 (0.492 - 0.493 in.)
Starter Motor - Nippondenso 1.0 kW (All Except 3009 OEM)
1 Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 mm (0.300 in.)
Alternator - Kokosan 20A (670 CUT, 15 EX)
Alternator - Nippondenso 35A (430 LGT, 670 CUT, 755/56 CUT, F925/35 FM)
Rotor Assembly
Retainer-to-Front Frame Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 N•m (16 lb-in.)
Alternator - Nippondenso 40A (455 LGT, 755/56 CUT, 3009 OEM)
Brush Length
New. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.50 mm (0.410 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.50 mm (0.170 in.)
Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.55 mm (0.0217 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Crankshaft End Play
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.33 mm (0.0129 in.)
Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 - 0.072 mm (0.0008 - 0.0028 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Camshaft End Play
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.)
Timing Gear Backlash - Early 3TNA72 (430 LGT)
Standard Backlash
Fuel Injection Pump Gear-to-Oil Pump Gear . . . . . . . . . . 0.11 - 0.19 mm (0.0043 - 0.0075 in.)
All Except Fuel Injection Pump Gear-to-Oil Pump Gear. 0.04 - 0.12 mm (0.0016 -0.0047 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.)
1-14 4/7/95
Specifications
Timing Gear Backlash - Later 3TNA72

Standard Backlash
Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11722 ± 480 kPa (1700 ± 70 psi)
Leakage at 11032 kPa (1600 psi) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum of 10 Seconds
Slow Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Chatter Sound
Slow Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fine Stream Spray Pattern 1
Fast Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fine Atomized Spray Pattern
Thermostat
Begin Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71° C (160°F)
Fully Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85° C (184° F)
Minimum Lift Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 mm (0.310 in.)
Coolant Temperature Sensor Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107-113° C (225-235° F)
Hitachi 0.8 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 Amps at 7000 rpm
Nippondenso 1.0 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 Amps at 3000 rpm
Minimum Starter RPM
Hitachi 0.8 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7000
Nippondenso 1.0 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000
Fuel Injection Pump Static Timing Adjustment - Early 3TNA72 (430 LGT)
Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15° BTDC (Before Top Dead Center)
Engine Crankshaft Position . . . . . . . . . . . . . . . . . . . No. 1 Cylinder on TDC Compression Stroke
Distance On Outer Surface of Crankshaft Pulley for
Every 0.1 mm (0.004 in.) of Shim Thickness . . . . . . . . . . . . . . . . . . . . . . . . . 1° or 1 mm (3/64 in.)
Delivery Valve Fitting Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 N•m (31 lb-ft)
Fuel Injection Pump Static Timing Adjustment - Later 3TNA72
Distance on Outer Surface of Flywheel Per 1° of Rotation . . . . . . . . . . . . . . . 2.62 mm (0.100 in.)
Total Shim Pack Thickness (New Shims) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 mm (0.020 in.)
Delivery Valve Fitting Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 N•m (31 lb-ft)
Applied Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 N (22 lb-force)
Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 15 mm (0.400 - 0.600 in.)
Operational Tests
Maximum Air Pressure Into Cylinder
3009 OEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2455 kPa (356 psi)
All Except 3009 OEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2448 kPa (355 psi)
Cooling System
15 EX, 670 CUT, 3009 OEM
Maximum Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 kPa (14 psi)
Minimum Pressure after 15 Seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 kPa (12.8 psi)
430 LGT, 455 LGT, 755/56 CUT, F925/35 FM
Maximum Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 kPa (17 psi)
Minimum Pressure after 15 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 kPa (13 psi)
4/7/95 1-15
Specifications
Radiator Cap
Valve Opening Pressure
15 EX, 3009 OEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 kPa (12.8 psi)
670 CUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 kPa (8 psi)
430 LGT, 455 LGT, 655 CUT, 755/56 CUT, F925/35 FM . . . . . . . . . . . . . . . . 97 kPa (14 psi)
Compression Pressure
All Except 3009 OEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2448 kPa (355 psi)
3009 OEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2455 kPa (356 psi)
1 Maximum Difference Between Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490 kPa (71 psi)
Engine Oil Pressure
F925/35 FM
Idle Speed
Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3635 ± 35 rpm
Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ± 50 rpm
455 LGT
Idle Speed
Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3350 ± 100 rpm
Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1650 ± 50 rpm
430 LGT, 755/56 CUT, 670 CUT
Fast Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3425 ± 25 rpm
Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .365 ± 69 kPa (53 ± 10 psi)
15 EX
Idle Speed
Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2425 ± 25 rpm
Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 ± 25 rpm
3009 OEM
Low Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1300 rpm
Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 kPa (21 psi)
Minimum Fuel Supply Pump Pressure (670 CUT, 3009 OEM). . . . . . . . . . . . . . . . . . 29 kPa (4.3 psi)
Fuel System Holding Pressure (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 kPa (15 psi)
1-16 4/7/95
Cylinder Head, Valves and Manifolds
SPECIAL OR ESSENTIAL TOOLS

NOTE: Order tools according to information given in the U.S. SERVICE-GARDTM Catalog or in the
European Microfiche Tool Catalog (MTC).
JDG504 Valve Guide Driver
Use to remove and install valve guides in cylinder head on 3TN66 engine.
JDE118 Valve Guide Driver

Use to remove and install valve guides in cylinder head on 3TNA72 (3009) engine.
1
D-20018WI Valve Guide Knurler
Use to knurl inside diameter of valve guides on 3TNA72 (3009) engine.
D-20020WI Valve Guide Reamer
Use to ream out new valve guides on 3TNA72 (3009) engine.
SERVICE PARTS KITS

The following kits are available through your parts catalog:
• Cylinder Head Gasket Kit
4/7/95 1-17
ROCKER ARM COVER

NOTE: Some models may be equipped with an oil
fill extension and/or adaptor with an o-ring.
Special Nut (2)

18 N•m (160 lb-in.)
Oil Filler Cap

1
O-Ring (2)
O-Ring
Breather Fitting
Crankcase Breather
Tube
Rocker Arm Cover
Gasket
Lock Washer (4)
Baffle Breather
Screw (4) Deflector
O-Ring Seal
M82004A
1-18 4/7/95
ROCKER ARM ASSEMBLY IMPORTANT: Install center rocker arm support

on shaft, aligning set screw hole in support
Removal/Installation and with center hole in shaft.
Disassembly/Assembly • Lubricate all parts with clean oil during
assembly.
1. Remove rocker arm cover. (See procedure in this
group.) • Adjust valve clearance. (See Checks, Tests and
Adjustments in this section.)
• Inspect all parts for wear or damage. (See
Inspection procedures.)
1
Mounting Nut (2)

Rocker Arm Shaft M8
26 N•m (226 lb-in.)
Intake Valve Rocker Arm
Exhaust Valve Rocker Arm Set Screw

Rocker Arm
Shaft Spring
Rocker Arm Support (3) Nut
Adjusting Screw
Mounting Cap Screw

M8 x 45
26 N•m (226 lb-in.)
Valve Caps
Push Rod
M82257A
3TN66
4/7/95 1-19
Mounting Nut (2) Mounting Cap Screw

M8 M8 x 45
26 N•m (226 lb-in.) 26 N•m (226 lb-in.)
Exhaust Valve Rocker Arm Shaft

Rocker Arm
1
Rocker Arm
Shaft Spring
Nut
Adjusting Screw
Rocker Arm
Support (3) Set Screw
Valve Caps
Push Rod
3TNA72 (3009) M82258A
Inspection Rocker Arm Shaft O.D. - 3TN66:

• Measure outer diameter of rocker arm shaft at Standard . . . . . . . . . . . . . . . . . 9.97 - 9.99 mm
each rocker arm location. . . . . . . . . . . . . . . . . . . . . . (0.3925 - 0.3933 in.)
Wear Limit. . . . . . . . . . . 9.95 mm (0.3920 in.)
Rocker Arm Shaft O.D. - 3TNA72 (3009):

Standard . . . . . . . . . . . . . . . 11.96 - 11.98 mm
. . . . . . . . . . . . . . . . . . . . . (0.4711 - 0.4718 in.)
Wear Limit. . . . . . . . . . 11.95 mm (0.4706 in.)
Replace rocker arm shaft if less than wear limit.
• Measure inner diameters of rocker arms and
supports.
M35262
1-20 4/7/95
Length
Feeler
Gauge 1
M82023A
M82022A
Push Rod Length:

Rocker Arm and Shaft Support I.D.’s - 3TN66: 3TN66. . . . . . . . . . . . . . . . . . . . . 114 - 115 mm
Standard . . . . . . . . . . . . . . . 10.00 - 10.02 mm . . . . . . . . . . . . . . . . . . . . . . . (4.488 - 4.528 in.)
. . . . . . . . . . . . . . . . . . . . . (0.3937 - 0.3945 in.) 3TNA72 (3009) . . . . . . . . . . . . . 141 - 142 mm
Wear Limit. . . . . . . . . . 10.09 mm (0.3972 in.) . . . . . . . . . . . . . . . . . . . . . . . (5.550 - 5.590 in.)
Clearance . . . . . . . . . . . . . 0.14 mm (0.005 in.)
Push Rod Bend:
Rocker Arm and Shaft Support I.D.’s - Wear Limit. . . . . . . . . . . . 0.08 mm (0.003 in.)
3TNA72 (3009): Replace push rod if not within specifications.
Standard . . . . . . . . . . . . . . . 12.00 - 12.02 mm
. . . . . . . . . . . . . . . . . . . . . (0.4724 - 0.4732 in.)
CYLINDER HEAD AND VALVES
Wear Limit. . . . . . . . . . 12.09 mm (0.4759 in.)
Clearance . . . . . . . . . . . . . 0.14 mm (0.005 in.) Removal/Installation
Replace rocker arms or supports if I.D. is more than 1. Remove rocker arm assembly, push rods and
wear limit. valve caps. (See procedure in this group.)
If shaft and support/arm clearance (support/arm I.D. 2. Remove exhaust and intake manifolds. (See
minus shaft O.D.) exceed wear limit, replace all procedures in this group.)
parts.
3. Remove water pump. (See Cooling System in this
• Measure length and bending of push rod. section.)
4/7/95 1-21
Mounting Cap
Screw (14)
Dip entire cap screw in clean
engine oil before installing.
1
Flywheel
Oil
Passage
Cylinder Head
Gasket
M82259A
4. Remove fuel injection nozzles. (See Fuel System

in this section.) Exhaust Manifold Side
Timing Gear Case Side

5. Remove glow plugs. (See procedure in 7 1 10
Flywheel Side
ACCESSORIES - SERIES 220 POWER UNIT

ENGINES section.)
13 3 6 12
6. Disassemble and inspect cylinder head and
valves. (See Disassembly/ Assembly and
9 2 8
Inspection/Replacement procedures.) 11 5 4 14
IMPORTANT: Oil passage in gasket must be Intake Manifold Side

M82260A
located over oil passage in cylinder block.
Install gasket as shown.
Torque Specifications - 3TN66:
7. Tighten mounting cap screws, in the sequence
shown, in three stages of gradually-increasing First . . . . . . . . . . . . . . . . . . 11 N•m (97 lb-in.)
torque. Second . . . . . . . . . . . . . . . 22 N•m (195 lb-in.)
IMPORTANT: Cylinder head mounting cap Final . . . . . . . . . . . . . . . . . . . 34 N•m (25 lb-ft)
screws must be checked for proper torque
after 50 hours of engine operation. Torque Specifications - 3TNA72 (3009):
First . . . . . . . . . . . . . . . . . 19 N•m (168 lb-in.)
Second . . . . . . . . . . . . . . . . . 38 N•m (28 lb-ft)
Final . . . . . . . . . . . . . . . . . . . 61 N•m (45 lb-ft)
1-22 4/7/95
Disassembly/Assembly IMPORTANT: Do not reuse stem seals if

removed. Used seals will leak.
NOTE: Size and shape of lifting brackets will vary
due to numerous engine applications. • Apply clean engine oil on intake and exhaust
valve stems during assembly.
• Compress valve springs using a valve spring
compressor. • Install springs with smaller pitch end or paint
mark toward cylinder head.
• Intake and exhaust valve guides are press fit.
Remove guides only if replacement is necessary. NOTE: If new valves are installed, measure valve
(See Inspection/Replacement procedures.) recession. (See Inspection/Replacement
procedures.) 1
• On 3TNA72 (3009), intake and exhaust valve
seat inserts are press fit. Remove inserts only if After each valve has been assembled, tap on top of
replacement is necessary. valve stem with a plastic hammer to seat retainer.
Inspection/Replacement procedures.)
Stem Collet Halves (12)

Seal (6)
Replace.
Retainer (6)
Exhaust Valve
Guide (3) Valve Spring (6)
Rocker Arm Assembly

and Cover Mounting
Stud (2) Intake Valve Guide (3)
Lifting
Bracket (2)
Exhaust Manifold
Mounting Stud (2)
Valve Seat Inserts

3TNA72 (3009) Only.
Exhaust Valve
Intake Valve
M82261A
4/7/95 1-23
Inspection/Replacement
Before inspection, thoroughly clean all components
of carbon or dirt.
Cylinder Head:
• Measure cylinder head flatness. Place a straight-
Valve Seat
edge along each of the four sides and each Width
diagonal. Measure clearance between straight
edge and combustion surface with a feeler
1 gauge.
Straight-Edge
M82029A
Valve Seat Width - 3TN66:

Feeler Gauge Intake Valve
Standard . . . . . . . . . . . . . 1.15 mm (0.045 in.)
Wear Limit. . . . . . . . . . . . 1.65 mm (0.065 in.)
Exhaust Valve
M82028A Standard . . . . . . . . . . . . . 1.41 mm (0.056 in.)
Wear Limit. . . . . . . . . . . . 1.91 mm (0.075 in.)
Cylinder Head Distortion: Valve Seat Width - 3TNA72 (3009):

Standard . . . . . . . 0.05 mm (0.002 in.) or less Intake Valve
Wear Limit. . . . . . . . . . . . 0.15 mm (0.006 in.) Standard . . . . . . . . . . . . . 1.44 mm (0.057 in.)
Wear Limit. . . . . . . . . . . . 1.98 mm (0.078 in.)
If distortion exceeds the wear limit, resurface or
Exhaust Valve
replace cylinder head. Remove only enough metal to
make cylinder head flat; but do not remove more Standard . . . . . . . . . . . . . 1.77 mm (0.070 in.)
than 0.20 mm (0.008 in.). Wear Limit. . . . . . . . . . . . 2.27 mm (0.089 in.)
If cylinder head was resurfaced: If necessary, grind valve seats to meet specifications.
• Measure piston-to-cylinder head clearance. (See (See GRIND VALVE SEATS procedure.)
procedure in this group.)
Intake and Exhaust Valves:
• Measure valve recession. (See procedure in this
• Check valve for out-of-round, bent or warped
group.)
condition using a valve inspection center.
• Measure valve seat width. Replace valve if necessary.
1-24 4/7/95
Valve Stem O.D. - 3TN66:

Distance A . . . . . . . . . . . . . . . . .20 mm (0.787 in.)
Distance B . . . . . . . . . . . . . . . . .40 mm (1.575 in.)
Intake Valve
Standard . . . . . . . . . . . . . . . . . 5.46 - 5.48 mm
. . . . . . . . . . . . . . . . . . . . . (0.2149 - 0.2157 in.)
Wear Limit. . . . . . . . . . . 5.40 mm (0.2126 in.)
1
M35307 Exhaust Valve
Standard . . . . . . . . . . . . . . . . . 5.44 - 5.46 mm
. . . . . . . . . . . . . . . . . . . . . (0.2142 - 0.2149 in.)
If valve faces are worn, burned or pitted, grind
valves to proper face angle. If valve face margin is Wear Limit. . . . . . . . . . . 5.40 mm (0.2126 in.)
less than 0.51 mm (0.020 in.) after grinding, replace
Valve Stem O.D. - 3TNA72 (3009):
valve.
Distance A . . . . . . . . . . . . . . . . .25 mm (0.984 in.)
Distance B . . . . . . . . . . . . . . . . .45 mm (1.772 in.)
Valve Face
Valve Angle
Standard . . . . . . . . . . . . . . . . . 6.94 - 6.96 mm
Face . . . . . . . . . . . . . . . . . . . . . (0.2732 - 0.2740 in.)
Margin Exhaust: 45°
Intake: 30° Wear Limit. . . . . . . . . . . 6.90 mm (0.2717 in.)
• Measure valve recession using a depth gauge.
Replace valve or cylinder head if measurement
M82030A exceeds specification.
• Measure valve stem diameter at two locations Valve Recession
shown. Replace valve if measurement exceeds
wear limit.
Cylinder
Head
A B
Depth
Gauge
M82031A
M82032A
4/7/95 1-25
Valve Recession - 3TN66: Intake and exhaust valve guides are different. The
Intake Valve . . . . . . . . . . . 0.40 mm (0.016 in.) exhaust valve guide has one groove and the intake
valve guide has none. Install valve guides with
Exhaust Valve . . . . . . . . . 0.85 mm (0.033 in.)
tapered ends down. Push valve guides down until
top of valve guides are a specified distance (A) from
Valve Recession - 3TNA72 (3009): top of cylinder head.
Intake Valve . . . . . . . . . . . 0.50 mm (0.020 in.)
Exhaust Valve . . . . . . . . . 0.85 mm (0.033 in.) Valve Guide Height “A”:
3TN66. . . . . . . . . . . . . . . . . . .7 mm (0.276 in.)
1 Valve Guides: 3TNA72 (3009) . . . . . . . . . . .9 mm (0.354 in.)
• Clean valve guides using a valve guide brush.
• Ream inside diameter of valve guides using:
• Measure valve guide inside diameter.
- 3TN66: 5.50 mm Valve Guide Reamer
Valve Guide I.D. - 3TN66: - 3TNA72 (3009): D-20020WI Valve Guide
Reamer
Standard . . . . . . . . . . . . . . . . . 5.50 - 5.52 mm
. . . . . . . . . . . . . . . . . . . . . . . (0.216 - 0.217 in.)
Wear Limit. . . . . . . . . . . . 5.58 mm (0.220 in.)
A
Valve Guide I.D. - 3TNA72 (3009):
Standard . . . . . . . . . . . . . . . . . 7.00 - 7.02 mm
. . . . . . . . . . . . . . . . . . . . . . . (0.275 - 0.276 in.)
Wear Limit. . . . . . . . . . . . 7.08 mm (0.279 in.)
If diameter exceeds wear limit, knurl or replace
guide.
If diameter is less than wear limit, determine guide-
to-stem clearance (guide diameter minus stem M82193A
diameter).
If clearance exceeds 0.15 mm (0.006 in.) but is less Valve Springs:
than 0.20 mm (0.008 in.), knurl valve guides. • Measure spring free length. Replace spring if
• Knurl valve guides using: measurement exceeds specification.
- 3TN66: 5.50 mm Valve Guide Knurler

- 3TNA72 (3009): D-20018WI Valve Guide
Knurler
If clearance exceeds 0.20 mm (0.008 in.), replace
valve guides.
• Replace valve guides using:
- 3TN66: JDG504 Valve Guide Driver
- 3TNA72 (3009): JDE118 Valve Guide Driver
M82034A
1-26 4/7/95
Spring Free Length: EXHAUST MANIFOLD - 3TN66

3TN66. . . . . . . . . . . . . . . . . .28 mm (1.102 in.) • Remove muffler and gasket, if equipped.
3TNA72 (3009) . . . . . . . 37.40 mm (1.472 in.) • Tighten all mounting hardware to 11 N•m (97
• Measure spring inclination. Replace spring if lb-in.).
measurement exceeds specification.
Lifting Bracket
Flange Nut (2)

Cap Screw (4) M6 1
M6 x 40
Stud (3)
Gasket
M82262A
330/332 LGT
Spring Inclination
Square Gauge
Flange Nut (2)
M6
Free Length
M82035A
Spring Inclination:
Cap Screw (4)
3TN66. . . . . . . . . . . . . . . . 0.80 mm (0.032 in.) M6 x 40
3TNA72 (3009) . . . . . . . . 1.00 mm (0.040 in.)
Gasket M82263A
375 SSL
Cap Screw (2)

M6 x 70
Stud (3) Flange Nut (2)

M6
Cap Screw (2)

M6 x 40
Gasket
M82264A
655 CUT, F915 FM
4/7/95 1-27
EXHAUST MANIFOLD - 3TNA72 (3009)

Nut and Lock
• Remove muffler and gasket, if equipped. Spring Pin (2) Washer (2)
M8
• Remove extension/elbow and gasket, if
equipped.
• Tighten all mounting hardware to 26 N•m (230
Cap Screw (4)
lb-in.). M8 x 70
1 Cap Screw (2)

M8 x 80
Flange Nut (2) M82266A
Stud (4) M8 Gasket
670 CUT
Cap Screw (2)

M8 x 35
Nut and Lock
Stud (4) Washer (2)
M8
Gasket M82264A
430 LGT (Early), 755/56 CUT, F925/35 FM

Cap Screw (4)
M8 x 40
Cap Screw (2) M82267A

Gasket
Stud (4) M8 x 55 Nut and Lock
Washer (2) 15 EX, 455 LGT
M8
Cap Screw (2)
M8 x 40
Stud (4)
Nut and Lock

Washer (2)
M8
Gasket M82265A
430 LGT (Later)
Cap Screw (4)

Gasket M8 x 40
M82268A
3009 OEM
1-28 4/7/95
INTAKE MANIFOLD - 3TN66

NOTE: On 375 SSL engine application, mounting Gasket
cap screws are 22 mm long.
1. Remove fuel filter assembly mounting cap
screw(s), if equipped. Cap Screw
M6 x 40
2. Remove fuel injection lines, if necessary. (See
Fuel System in this section.)
Cap Screw (2)
M6 x 16
1
Gasket M82270A
3TNA72 (670 CUT)
Gasket
Cap Screw (4)

M6 x 20
11 N•m (97 lb-in.)
Cap Screw
M6 x 40
M82269A
3TN66
Cap Screw (2)

M6 x 16
INTAKE MANIFOLD - 3TNA72 (3009)
M82271A
3TNA72 (15 EX, 3009 OEM)
screw(s), if equipped.
2. Remove fuel injection lines. (See Fuel System in
this section.)
Gasket
3. OEM Power Unit engine (3009):
• Remove air cleaner and mount bracket.
• Remove instrument panel and bracket.
(See procedures in ACCESSORIES - SERIES 220
POWER UNIT ENGINES section.)
Cap Screw (6)
• Tighten all mounting cap screws to 11 N•m (97 M6 x 20
lb-in.). M82272A
3TNA72 (430 and 455 LGT,

F925/35 FM, 755/56 CUT)
4/7/95 1-29
GRIND VALVE SEATS

IMPORTANT: Valve seats should never be cut.
Cutting a valve seat can damage its sealing
surface, which may result in leaks or valve/ Lower Seat
Surface 70°
seat failure. Valve seats should be ground and
lapped.
Valve Upper
Seat Seat
NOTE: LIGHTLY grind valve seats for a few Surface
seconds only to avoid excessive valve seat
1 width. 15°
Seat
Width
1. Grind intake valve seat using a 30° seat grinder
and exhaust valve seat using a 45° seat grinder. Cylinder
Follow tool manufacturers instructions. Head
M82040A
If valve recession exceeds maximum specifications

or seats cannot be reconditioned, replace valves,
Seat Grinder valve seats if equipped and/or cylinder head.
NOTE: Valve seat inserts are available for 4TN78T
engine only.
LAP VALVES
M82039A NOTE: Use a rubber type lapping tool for valves
without a lapping tool groove slit.
2. Measure valve seat width after grinding. If seat does not make proper contact, lap the valve
3. If seat is too wide after grinding, grind lower seat into the seat:
surface using a 70° seat grinder until seat width is 1. Apply small amount of fine lapping compound to
close to specifications. face of valve.
4. Grind upper seat surface using a 15° seat grinder 2. Turn valve to lap valve to seat.
until seat width is narrowed to specifications.
3. Lift valve from seat every 8 to 10 strokes. Lap
5. If valve seats are ground, measure valve recession until a uniform ring appears around the surface of
and check contact pattern between the seat and the valve face.
valve with bluing dye.
4. Wash all parts in solvent to remove lapping
6. Lap valves. (See procedure in this group.) compound. Dry parts.
5. Check position of lap mark on valve face. Lap
mark must be on or near center of valve face.
1-30 4/7/95
Lapping Tool
M82042A
M82041A
Piston-to-Cylinder Head Clearance:

MEASURE PISTON-TO-CYLINDER 3TN66. . . . . . . . . . . . . . . . . . . . 0.59 - 0.74 mm
HEAD CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . (0.023 - 0.029 in.)
1. Place three 10 mm (0.400 in.) long pieces of 1.50 3TNA72 (3009) . . . . . . . . . . . . 0.61 - 0.79 mm
mm (0.060 in.) diameter soft wire in three . . . . . . . . . . . . . . . . . . . . . . . (0.024 - 0.031 in.)
positions on the flat part of the piston head.
If clearance is less than specifications, replace
2. Install cylinder head and old gasket. Install cylinder head.
cylinder head cap screws and tighten in proper
sequence to specified torque. (See CYLINDER
HEAD AND VALVES - Removal/Installation in
this group.)
3. Slowly turn crankshaft one complete revolution.
4. Remove cylinder head and gasket.
5. Measure thickness of flattened section of each
piece of wire. Calculate average thickness of
wires to obtain piston-to-cylinder head clearance
specification.
4/7/95 1-31
Pistons, Rods and Cylinder Block
SERVICE PARTS KITS

• Cylinder Block Gasket Kit
• Oversized Pistons and Rings
• Undersized Connecting Rod Bearing Inserts
1-32 4/7/95
PISTON AND CONNECTING ROD
Removal
1. Remove oil pan and strainer tube. (See
Lubrication System in this section.)
2. Remove cylinder head. (See Cylinder Head,
Valves and Manifolds in this section.)
Piston and
3. Check cylinder bore for ridges. These ridges can
cause damage to piston if ridge is not removed.
Connecting Rod
1
4. If necessary, remove ridge from top of cylinder
bore using a ridge reamer.
5. Measure connecting rod side play. (See Checks,
Tests and Adjustments in this section.)
6. Measure connecting rod bearing clearance. (See
Checks, Tests and Adjustments in this section.) Bearing
Inserts
IMPORTANT: Keep connecting rods and caps
together. Rods and caps are a matched set.
Note alignment marks on each part.
Connecting
7. Remove two cap screws, connecting rod cap and Rod Cap
bearing inserts.
Connecting Rod
IMPORTANT: Pistons and cylinders are Cap Screw
matched. Pistons must be installed in the Replace.
cylinders from which they are removed. M82273A
8. Note connecting rod alignment mark in relation

to the cylinders. Starting at flywheel end with Installation
cylinder number one, then two, etc.
• Apply clean engine oil on all parts during
9. Push piston and connecting rod out of cylinder installation.
bore using a wooden dowl.
• Never reuse connecting rod cap screws, replace
10.Disassemble and inspect all parts for wear or with new.
damage. (See Disassembly and Inspection/
Replacement procedures.) IMPORTANT: Pistons must be installed in
cylinders from which they were removed and
in the same direction. Be careful not to
damage crankshaft rod journal while
installing piston.
1. If new piston rings were installed, deglaze
cylinder bore. (See procedure in this group.)
2. Install piston and connecting rod into the cylinder
from which it was removed, with piston recess on
top of piston toward fuel injection pump.
4/7/95 1-33
IMPORTANT: Do not touch bearing insert Disassembly

surfaces. Oil and acid from your finger will
corrode the bearing surface. IMPORTANT: Pistons must be installed on the
same connecting rod they were removed from.
3. Install bearing inserts on connecting rod and rod
cap, aligning tangs with grooves. • Put a mark on each piston and connecting rod to
aid in assembly.
IMPORTANT: Connecting rod caps must be
installed on the same connecting rods they • Piston pin bushing is press fit in connecting rod.
were removed from. Remove bushing only if replacement is
necessary. (See Inspection/Replacement
1 4. Match the connecting rods to caps using procedures.)
alignment marks. Install caps.
• Inspect all parts for wear or damage. Replace as
5. Dip entire connecting rod cap screws in clean necessary. (See Inspection/Replacement
engine oil. Install new cap screws and tighten to procedures.)
23 N•m (203 lb-in.).
6. If a new piston and connecting rod were installed,
stamp a number corresponding to the cylinder 1st Compression Ring
number on the connecting rod cap and connecting
rod.
2nd Compression Ring
Piston
Recess
Fuel Oil Ring with
Injection Coil Expander
Pump Side
Flywheel
Side Piston
Groove Piston Pin

Retaining
Ring
Tangs Connecting Rod

Cap Alignment
Mark
Piston
Pin
Bushing
Connecting Rod
Groove Connecting Rod

Cap Screw
M82274A
M82273A
7. Install cylinder head. (See Cylinder Head, Valves

and Manifolds in this section.)
8. Install oil pan and strainer tube. (See Lubrication
System in this section.)
1-34 4/7/95
Assembly
• Apply clean engine oil to all parts during Oil Ring
assembly. Expander
IMPORTANT: Pistons must be installed on the

same connecting rod they were removed from. Oil
Ring
1. Assemble piston to connecting rod with piston Gap
Oil Ring
recess on same side as connecting rod “punched” Expander
alignment mark. If a new connecting rod is used,
assemble piston to connecting rod with piston
Ends
1
recess opposite connecting rod bearing insert
groove.
2. Install piston pin and snap rings. Oil Ring
Piston Pin
M82046A
Piston Recess
Piston
5. Install second compression ring, with chamfer
toward top of piston, in middle groove. Turn ring
until gap is 120o away from oil ring gap.
6. Install first compression ring (chrome plated),
Piston Pin
with manufacturer's mark “T”, “R” or “RN”
(near ring gap) toward top of piston, in top
groove. Turn ring until gap is 120o away from
second ring gap.
Retaining Ring 1st Compression Ring
2nd Compression
Ring
Connecting Alignment
Rod Mark
1st Compression
M82275A 2nd 120° Ring
Bearing Insert Groove
Compression 120°
Ring 120°
3. Install oil ring expander in bottom ring groove of
Oil Ring
piston with ends above either end of piston pin.
4. Install oil ring over expander with ring gap
opposite (180o) of expander ends.
M82276A
4/7/95 1-35
Inspection/Replacement If bearing diameter exceeds wear limit, replace

bearing inserts.
1. Inspect all parts for wear or damage. Replace as
necessary. If bearing clearance (bearing I.D. minus crankshaft
journal O.D.) exceeds specification, grind crankshaft
2. Measure crankshaft connecting rod journal connecting rod journals and install undersized
diameter. (See Crankshaft, Main Bearings and bearing inserts, or replace bearing inserts and
Flywheel in this section.) crankshaft.
3. Install connecting rod cap and bearing inserts on 5. With rings installed on piston, measure piston
connecting rod. Install old connecting rod cap ring groove clearance. Measure several places
1 screws and tighten to 23 N•m (203 lb-in.). around each piston.
4. Measure connecting rod bearing diameter.
M35360
Piston Ring Groove Clearance - 3TN66:

M82048A
Standard . . . . . . . . . . . . . . . 0.065 - 0.100 mm
. . . . . . . . . . . . . . . . . . . . . (0.0026 - 0.0039 in.)
Connecting Rod Bearing I.D. - 3TN66: Wear Limit. . . . . . . . . . . 0.20 mm (0.0079 in.)
Standard . . . . . . . . . . . . . . 36.00 - 36.042 mm
. . . . . . . . . . . . . . . . . . . . . . . (1.417 - 1.419 in.) Second Compression Ring
Wear Limit. . . . . . . . . . . 37.07 mm (1.459 in.) Standard . . . . . . . . . . . . . . . 0.030 - 0.065 mm
Clearance . . . . . . . . . . . . . 0.16 mm (0.006 in.) . . . . . . . . . . . . . . . . . . . . . (0.0012 - 0.0026 in.)
Wear Limit. . . . . . . . . . . 0.20 mm (0.0079 in.)
Connecting Rod Bearing I.D. - 3TNA72 (3009):
Standard . . . . . . . . . . . . . . 40.00 - 40.042 mm Oil Ring
. . . . . . . . . . . . . . . . . . . . . . . (1.575 - 1.577 in.) Standard . . . . . . . . . . . . . . . 0.020 - 0.055 mm
Wear Limit. . . . . . . . . . . 40.07 mm (1.578 in.) . . . . . . . . . . . . . . . . . . . . . (0.0008 - 0.0022 in.)
Clearance . . . . . . . . . . . . . 0.16 mm (0.006 in.) Wear Limit. . . . . . . . . . . 0.20 mm (0.0079 in.)
1-36 4/7/95
Piston Ring Groove Clearance - 3TNA72 (3009): Piston Ring End Gap - 3TN66:
First Compression Ring Standard
Standard . . . . . . . . . . . . . . . 0.075 - 0.110 mm First Compression Ring
. . . . . . . . . . . . . . . . . . . . . (0.0030 - 0.0043 in.) and Oil Ring . . . . . . . . . . . . . 0.15 - 0.35 mm
Wear Limit. . . . . . . . . . . 0.20 mm (0.0079 in.) . . . . . . . . . . . . . . . . . . . . . . (0.006 - 0.014 in.)
Second Compression Ring . . 0.25 - 0.40 mm
Second Compression Ring . . . . . . . . . . . . . . . . . . . . . . (0.010 - 0.016 in.)
Standard . . . . . . . . . . . . . . . 0.030 - 0.065 mm
. . . . . . . . . . . . . . . . . . . . . (0.0012 - 0.0026 in.)
Wear Limit. . . . . . . . . . . 1.50 mm (0.0591 in.) 1
Wear Limit. . . . . . . . . . . 0.20 mm (0.0079 in.) Piston Ring End Gap - 3TNA72 (3009):
Standard
Oil Ring
First Compression Ring . . . . 0.10 - 0.25 mm
Standard . . . . . . . . . . . . . . . 0.020 - 0.055 mm
. . . . . . . . . . . . . . . . . . . . . . (0.004 - 0.010 in.)
. . . . . . . . . . . . . . . . . . . . . (0.0008 - 0.0022 in.)
Wear Limit. . . . . . . . . . . 0.20 mm (0.0079 in.)
. . . . . . . . . . . . . . . . . . . . . . (0.010 - 0.016 in.)
If clearance exceeds wear limit, replace rings or
Oil Ring . . . . . . . . . . . . . . . . . 0.15 - 0.35 mm
piston.
. . . . . . . . . . . . . . . . . . . . . . (0.006 - 0.014 in.)
6. Measure piston ring end gap. Push ring into
cylinder bore, using a piston, until ring is Wear Limit: . . . . . . . . . . 1.50 mm (0.0591 in.)
approximately 30 mm (1.181 in.) from bottom of If end gap exceeds wear limit, replace rings.
cylinder bore.
7. Measure piston pin diameter. Measure diameter
at six places.
End Gap
Cylinder
Bore
Measuring Positions
Piston
Ring
Approx.
30 mm
(1.181 in.)
End Gap M82049A M82050A
4/7/95 1-37
Piston Pin O.D. - 3TN66:

Standard . . . . . . . . . . . . . . 19.991 - 20.00 mm
. . . . . . . . . . . . . . . . . . . . . . . (0.787 - 0.788 in.)
Wear Limit. . . . . . . . . . 19.975 mm (0.786 in.)
Piston Pin O.D. - 3TNA72 (3009):

Standard . . . . . . . . . . . . . . 20.991 - 21.00 mm
. . . . . . . . . . . . . . . . . . . . . . . (0.826 - 0.827 in.)
1 Wear Limit. . . . . . . . . . 20.975 mm (0.825 in.)
If pin diameter is less than wear limit, replace pin.
8. Measure piston pin bore diameter in piston.
M82051A
Piston Pin Bushing I.D. - 3TN66:

Standard . . . . . . . . . . . . . 20.025 - 20.038 mm
. . . . . . . . . . . . . . . . . . . . . . . (0.788 - 0.789 in.)
Wear Limit. . . . . . . . . . . 20.10 mm (0.781 in.)
Clearance . . . . . . . . . . . . 0.11 mm (0.0043 in.)
M37683 Piston Pin Bushing I.D. - 3TNA72 (3009):

Standard . . . . . . . . . . . . . 21.025 - 21.038 mm
Piston Pin Bore I.D. - 3TN66: . . . . . . . . . . . . . . . . . . . . . (0.8278 - 0.8282 in.)
Wear Limit. . . . . . . . . . . 21.10 mm (0.831 in.)
Standard . . . . . . . . . . . . . . 20.00 - 20.008 mm
. . . . . . . . . . . . . . . . . . . . . . . (0.787 - 0.788 in.) Clearance . . . . . . . . . . . . 0.11 mm (0.0043 in.)
Wear Limit. . . . . . . . . . . 20.02 mm (0.788 in.) If bushing diameter exceeds wear limit, replace
Clearance . . . . . . . . . . . 0.045 mm (0.0018 in.) bushing.
If bushing clearance (bushing I.D. minus pin O.D.)
Piston Pin Bore I.D. - 3TNA72 (3009): exceeds specification, replace bushing, piston pin or
Standard . . . . . . . . . . . . . . 21.00 - 21.009 mm both.
. . . . . . . . . . . . . . . . . . . . . (0.8268 - 0.8271 in.) Piston pin bushing is press fit. Replace bushing
Wear Limit. . . . . . . . . . . 21.02 mm (0.828 in.) using a driver set. When installing bushing, make
sure to align oil hole in bushing with hole in
Clearance . . . . . . . . . . . 0.045 mm (0.0018 in.) connecting rod.
If piston pin bore exceeds wear limit, replace piston. 10.Measure piston diameter perpendicular to piston
If bore clearance (bore I.D. minus pin O.D.) exceeds pin bore at distance A.
specification, replace piston, piston pin or both.
NOTE: If engine has had a previous major
9. Measure piston pin bushing diameter in overhaul, oversize pistons and rings may
connecting rod. have been installed. Pistons and rings are
available in 0.25 mm (0.010 in.) and 0.50
mm (0.020 in.) oversize.
1-38 4/7/95

Standard . . . . . . . . . . . . . . . 66.18 - 66.21 mm
. . . . . . . . . . . . . . . . . . . . . . . (2.606 - 2.607 in.)
Wear Limit. . . . . . . . . . . 66.10 mm (2.602 in.)

Standard . . . . . . . . . . . . . . . 66.43 - 66.46 mm
. . . . . . . . . . . . . . . . . . . . . . . (2.615 - 2.616 in.)
A
Wear Limit. . . . . . . . . . . 66.35 mm (2.612 in.) 1
M82200A
Piston O.D. - 3TNA72 (3009):
Distance A . . . . . . . . . . . . . . . . . .8 mm (0.315 in.)
Standard . . . . . . . . . . . . . 71.922 - 71.952 mm
. . . . . . . . . . . . . . . . . . . . . . . (2.832 - 2.833 in.)
Wear Limit. . . . . . . . . . . 71.81 mm (2.827 in.)

Standard . . . . . . . . . . . . . . . 72.17 - 72.20 mm
. . . . . . . . . . . . . . . . . . . . . . . (2.841 - 2.842 in.)
Wear Limit. . . . . . . . . . . 72.06 mm (2.837 in.)
M82052A
Standard . . . . . . . . . . . . . . . 72.42 - 72.45 mm
Piston O.D. - 3TN66: . . . . . . . . . . . . . . . . . . . . . . . (2.851 - 2.852 in.)
Distance A . . . . . . . . . . . . . . . . . .5 mm (0.197 in.) Wear Limit. . . . . . . . . . . 72.31 mm (2.847 in.)
If piston diameter is less than wear limit, install a
Standard . . . . . . . . . . . . . 65.927 - 65.957 mm new piston.
. . . . . . . . . . . . . . . . . . . . . . . (2.596 - 2.597 in.)
11.Measure cylinder bore diameter. (See procedure
Wear Limit. . . . . . . . . . . 65.85 mm (2.593 in.) in this group.)
4/7/95 1-39
CYLINDER BORE 0.50 mm (0.020 in.) Oversize Bore

Standard . . . . . . . . . . . . . . . 66.50 - 66.53 mm
Inspection . . . . . . . . . . . . . . . . . . . . . . . (2.619 -2.620 in.)
Measure cylinder bore diameter at three positions; Wear Limit. . . . . . . . . . . 66.70 mm (2.626 in.)
top, middle and bottom. At these three positions,
measure in both directions; along crankshaft center Cylinder Bore I.D. - 3TNA72 (3009):
line and direction of crankshaft rotation.
Standard Size Bore
NOTE: If engine has had a previous major Standard . . . . . . . . . . . . . . . 72.00 - 72.03 mm
1 overhaul, oversize pistons and rings may . . . . . . . . . . . . . . . . . . . . . . . (2.835 - 2.836 in.)
have been installed.
Wear Limit . . . . . . . . . . 72.20 mm (2.843 in.)
Clearance . . . . . . . . . . . . . 0.28 mm (0.011 in.)
Top Position
Standard . . . . . . . . . . . . . . . 72.25 - 72.28 mm
. . . . . . . . . . . . . . . . . . . . . . . (2.845 - 2.846 in.)
Middle Position
Wear Limit. . . . . . . . . . . 72.45 mm (2.852 in.)

Bottom Position Standard . . . . . . . . . . . . . . . 72.50 - 72.53 mm
. . . . . . . . . . . . . . . . . . . . . . . (2.855 - 2.856 in.)
Wear Limit. . . . . . . . . . . 72.70 mm (2.862 in.)
Direction of
Crankshaft Rotation If cylinder bore exceeds wear limit, replace cylinder
block or have cylinder rebored. (See Reboring
procedure.)
Direction of
Crankshaft If cylinder is rebored, oversize pistons and rings
Centerline must be installed. Pistons and rings are available in
0.25 mm (0.010 in.) and 0.50 mm (0.020 in.)
oversize.
M82053A
If clearance (cylinder bore I.D. minus piston O.D.)
exceeds specification, replace cylinder block, piston
or both; or rebore cylinder and install oversize piston
Cylinder Bore I.D. - 3TN66:
and rings.
Standard Size Bore
Standard . . . . . . . . . . . . . . . 66.00 - 66.03 mm
. . . . . . . . . . . . . . . . . . . . . . . (2.599 - 2.600 in.) Deglazing
Wear Limit . . . . . . . . . . 66.20 mm (2.606 in.)
IMPORTANT: If cylinder bores are to be
Clearance . . . . . . . . . . . . . 0.25 mm (0.010 in.) deglazed with crankshaft installed in engine,
put clean shop towels over crankshaft to
0.25 mm (0.010 in.) Oversize Bore protect journal and bearing surfaces from any
Standard . . . . . . . . . . . . . . . 66.25 - 66.28 mm abrasives.
. . . . . . . . . . . . . . . . . . . . . . . (2.609 - 2.610 in.) 1. Deglaze cylinder bores using a flex-hone with
Wear Limit. . . . . . . . . . . 66.45 mm (2.616 in.) 180 grit stones.
1-40 4/7/95
2. Use flex-hone as instructed by manufacturer to 5. Run drill press at about 250 RPM. Move hone up
obtain a 30 - 40° cross-hatch pattern as shown. and down in order to obtain a 30 - 40°crosshatch
pattern.
IMPORTANT: Do not use gasoline, kerosene or
commercial solvents to clean cylinder bores.
Solvents will not remove all abrasives from
cylinder walls.
30 - 40°
3. Remove excess abrasive residue from cylinder
walls using a clean dry rag. Clean cylinder walls
using clean white rags and warm soapy water. 1
Continue to clean cylinder until white rags show
no discoloration.
M52959
NOTE: Measure bore when cylinder is cool.

M82054A
6. Stop press and check cylinder diameter.
NOTE: Finish should not be smooth. It should have

Reboring a 30 - 40o crosshatch pattern.
NOTE: The cylinder block can be rebored to use 7. Remove rigid hone when cylinder is within 0.03
oversize pistons and rings. Pistons and mm (0.001 in.) of desired size.
rings are available in 0.25 mm (0.010 in.)
8. Use a flex hone with 180 grit stones for honing to
and 0.50 mm (0.020 in.) oversize. (See this
final size.
group for cylinder bore I. D. specifications.)
9. Check bore for size, taper and out-of-round. (See
1. Align center of bore to drill press center. Inspection procedures.)
IMPORTANT: Check stone for wear or damage.
IMPORTANT: Do not use solvents to clean
Use a rigid hone with 300 grit stones.
cylinder bore. Solvents will not remove all
2. Adjust hone so lower end is even with lower end metal particles and abrasives produced during
of cylinder bore. honing.
3. Adjust rigid hone stones until they contact 10.Clean cylinder thoroughly using warm soapy
narrowest point of cylinder. water until clean white rags show no
discoloration.
4. Coat cylinder with honing oil. Hone should turn
by hand. Adjust if too tight. 11.Dry cylinder and apply engine oil.
4/7/95 1-41
Crankshaft, Main Bearings and Flywheel
OTHER MATERIALS
Number Name Use
LOCTITE® PRODUCTS
U.S./
Canadian/
LOCTITE No.
TY15130/ John Deere Form-In-Place Seals rear oil seal case, crankcase
1 NA/ Gasket extension housing, (3TNA72 - 670 CUT,
#395 15 EX, 3009 OEM) and flywheel housing
(3TNA72 - 15 EX, 3009 OEM) to engine
block.
SERVICE PARTS KITS

• Undersized Main Bearing Inserts
®LOCTITE is a registered trademark of the Loctite Corp.
1-42 4/7/95
CRANKCASE EXTENSION HOUSING -

3TNA72 (670 CUT)
1. Remove flywheel. (See procedure in this group.)
2. Remove oil pan and oil strainer. (See Lubrication
Cap Screw (4) Cap Screw (3)

M6 x22 M10 x 20
26 N•m (226 lb-in.) 49 N•m (36 lb-ft)
M82056
John Deere
Form-In-Place Gasket
(RTV rubber silicone
sealant)
Crankcase Extension
Housing
Extension-to-Block
Cap Screw (2) Extension-to-Timing Gear Housing
M8 x 45 Cap Screw (4)
27 N•m (20 lb-ft) M8 x 45
22 N•m (195 lb-in.)
Extension-to-Block
Cap Screw (14)
M6 x 85 M82277A
27 N•m (20 lb-ft)
4/7/95 1-43

3TNA72 (15 EX and 3009 OEM)
Cap Screw (3)

Cap Screw (4) M10 x 28
M6 x22 49 N•m (36 lb-ft)
26 N•m (226 lb-in.)
M82056
John Deere
sealant)
Crankcase Extension
Housing
M82202A
1-44 4/7/95
CRANKSHAFT REAR OIL SEAL - CRANKSHAFT REAR OIL SEAL -

3TN66 AND 3TNA72 3TNA72 (15 EX, 670 CUT, 3009 OEM)
(430 LGT, 455 LGT, 755/56 CUT,
F925/35 FM) Replacement
Replacement • Replace oil seal using a driver set. Install seal,
1. Remove flywheel plate. (See procedure in this with lip toward cylinder block. Install seal flush
group.) with surface of oil seal case.
• Replace oil seal using a driver set. Install seal, NOTE: If crankshaft is grooved at oil seal contact
1
with lip toward cylinder block. Install seal flush point, seal can be installed 3 mm (0.120 in.)
with surface of oil seal case. farther into oil seal case.
NOTE: If crankshaft is grooved at oil seal contact
point, seal can be installed 3 mm (0.120 in.) Rear Oil Seal Seal Case-to-Block
farther into oil seal case. Cap Screw (6)
M6 X 22
11N•m (96 lb-in.)
Rear Oil Seal
Oil Seal Case
John Deere Oil Seal Case
Form-In-Place
Gasket
(RTV rubber
silicone sealant)
Seal Case-to-Extension
Cap Screw (4) John Deere
M6 x 22 Form-In-Place
9 N•m (78 lb-in.) Gasket
(RTV rubber
silicone sealant)
Seal Case-to-Block
Cap Screw (6) Oil Pan-to-Seal Case (2) M82280A
M6 X 20 9 N•m (78 lb-in.)
11N•m (96 lb-in.) M82279A
4/7/95 1-45
CRANKSHAFT FRONT OIL SEAL CRANKSHAFT AND MAIN BEARINGS

Replacement Removal
1. Check crankshaft end play. (See Checks, Tests
NOTE: Timing gear covers are similar. The most
and Adjustments in this section.)
common applications are shown.
2. Remove rear oil seal. (See procedure in this
• Remove timing gear cover. (See Camshaft and
group.)
Timing Gear Train in this section.)
3. Remove flywheel housing, if equipped. (See
• Replace oil seal using a driver set. Install seal
1 with lip toward inside of gear housing cover.
Install seal flush with surface of cover. 4. Remove crankcase extension housing, if
equipped. (See procedure in this group.)
Timing Gear Cover 5. Remove timing gear housing. (See Camshaft and
6. Check crankshaft bearing clearance. (See Checks,
Crankshaft IMPORTANT: Connecting rod end caps must be
Front
Oil Seal
installed on the same connecting rods from
which they were removed. Note alignment
marks on caps and rods.
7. Remove connecting rod cap screws and end caps.
8. Push pistons and connecting rods away from
M82281A crankshaft.
3TN66 IMPORTANT: Main bearing caps must be

installed on the same main bearings from
which they were removed.
9. Remove main bearing cap screws, caps and cap
thrust bearings.
Timing Gear Cover
10.Remove crankshaft.
11.Remove block thrust bearings and main bearing
inserts.
Crankshaft 12.Inspect all parts for wear or damage. (See
Front Inspection/Replacement procedures.)
Oil Seal
M82282A
3TNA72
1-46 4/7/95
Crankshaft
Flywheel
End
Block Thrust Bearing
Cap Thrust Bearing
Main Bearing Inserts
Main Bearing Cap

Screw (8)
Main Bearing Cap M82283A
Installation 3. Install crankshaft.

• Apply clean engine oil on all parts during 4. Install smooth bearing inserts in main bearing
installation. caps, aligning tangs with slots in caps.
5. Install cap thrust bearings, with oil grooves
IMPORTANT: Do not touch bearing insert
facing away from cap, in the number “1” main
bearing cap.
corrode the bearing surface.
6. Install main bearing caps in their original
1. Install grooved bearing inserts in crankshaft
locations with arrows pointing toward flywheel
bearing bores, aligning tangs with slots in bores.
side of engine.
2. Install block thrust bearings with oil grooves
facing away from engine block. IMPORTANT: DO NOT use high speed power
tools or air wrenches to tighten main bearing
NOTE: Main bearing caps have “raised arrows” cap screws.
that are stamped with numbers. Both
7. Dip entire main bearing cap screws in clean
correspond to their location on the engine
engine oil. Install cap screws and tighten. DO
block. The number “1” main bearing bore
NOT tighten to specifications.
is at flywheel end. Install bearing caps
beginning with number 1, then 2, etc. The 8. Using a soft-faced hammer, tap the front end of
main bearing cap at gear train end does not the crankshaft then the rear end of the crankshaft
have a number. Also install bearing caps to align the thrust bearings.
with the “arrow” toward the flywheel end.
4/7/95 1-47
Crankshaft
Flywheel
End
Grooved Bearing Insert

1
Cap Thrust Bearing
Tangs Smooth Bearing Insert
Main Bearing Cap
Main Bearing Cap Screw (8) 3

Dip in clean engine oil.
3TN66: 54 N•m (40 lb-ft)
3TNA72 (3009):79 N•m (58 lb-ft)
M82283A
9. Tighten main bearing cap screws to 11.Dip entire connecting rod cap screws in clean
specifications. When tightening, start at center engine oil. Install new cap screws and tighten to
main bearing cap and work your way out, 23 N•m (203 lb-in.).
alternating to the ends. Turn crankshaft by hand.
12.Install timing gear housing. (See Camshaft and
If it does not turn easily, disassemble the parts
and find the cause.
13.Install crankcase extension housing, if equipped.
IMPORTANT: Connecting rod caps must be (See procedure in this group.)
installed on the same connecting rods they
were removed from. 14.Install flywheel housing, if equipped. (See
Never reuse connecting rod cap screws,
replace with new. 15.Install rear oil seal. (See procedure in this group.)
10.Match the connecting rod caps to the rods using

alignment marks. Install caps.
1-48 4/7/95
1. Inspect crankshaft gear for chipped or broken Key
teeth. Replace if necessary.
To replace gear: Crankshaft Gear
Remove gear from crankshaft using a knife-edge
puller and a press.
Timing
Mark
1
CAUTION
DO NOT heat oil over 182° C (360° F). Oil M82060A
fumes or oil can ignite above 193° C (380° F).
Use a thermometer. Do not allow a flame or 2. Inspect crankshaft for bend using v-blocks and a
heating element to come in direct contact dial indicator. Turn crankshaft slowly and read
with the oil. Heat the oil in a well-ventilated variation on indicator. If variation is greater than
area. Plan a safe handling procedure to avoid 0.02 mm (0.0007 in.), replace crankshaft.
burns.
Heat gear to approximately 150oC (300oF). Install
gear with timing mark “A” toward press table. Align
slot in gear with key in shaft. Press crankshaft into
gear until gear is tight against crankshaft shoulder.
Dial Indicator
M82061A
V-Block
4/7/95 1-49
3. Measure crankshaft connecting rod journal and 4. Install bearing inserts and main bearing cap on
main bearing journal diameters. Measure several main bearing. Tighten main bearing cap screws to
places around each journal. specifications.
Main Bearing Cap Screw Torque Specifications:
overhaul, journals may have been ground
and undersized bearing inserts installed. 3TN66. . . . . . . . . . . . . . . . . . 54 N•m (40 lb-ft)
3TNA72 (3009) . . . . . . . . . . 79 N•m (58 lb-ft)
Main
5. Measure main bearing diameter.
1 Bearing
Journal
Connecting
Rod Journal
M82062A
M35408
Connecting Rod Journal O.D. - 3TN66:

Main Bearing I.D. - 3TN66:
Standard . . . . . . . . . . . . . . . 35.97 - 35.98 mm Standard . . . . . . . . . . . . . . 40.00 - 40.042 mm
. . . . . . . . . . . . . . . . . . . . . (1.4161 - 1.4165 in.) . . . . . . . . . . . . . . . . . . . . . . . (1.575 - 1.577 in.)
Wear Limit. . . . . . . . . . . 35.92 mm (1.414 in.)
Wear Limit. . . . . . . . . . . 40.07 mm (1.578 in.)
Connecting Rod Journal O.D. - 3TNA72 (3009): Clearance . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Standard . . . . . . . . . . . . . . . 39.97 - 39.98 mm Main Bearing I.D. - 3TNA72 (3009):
. . . . . . . . . . . . . . . . . . . . . (1.5736 - 1.5740 in.)
Standard . . . . . . . . . . . . . . 44.00 - 44.042 mm
Wear Limit. . . . . . . . . . . 39.92 mm (1.572 in.)
. . . . . . . . . . . . . . . . . . . . . . . (1.732 - 1.734 in.)
Main Bearing Journal O.D. - 3TN66: Wear Limit. . . . . . . . . . . 44.07 mm (1.735 in.)
Standard . . . . . . . . . . . . . . . 39.97 - 39.98 mm Clearance . . . . . . . . . . . . 0.15 mm (0.0059 in.)
. . . . . . . . . . . . . . . . . . . . . (1.5736 - 1.5740 in.)
If bearing diameter exceeds wear limit, replace
Wear Limit. . . . . . . . . . . 39.92 mm (1.572 in.) bearing inserts.
If bearing clearance (bearing I.D. minus crankshaft
Main Bearing Journal O.D. - 3TNA72 (3009): main bearing journal O.D.) exceeds specification,
Standard . . . . . . . . . . . . . . . 43.97 - 43.98 mm replace bearing inserts and crankshaft or have
. . . . . . . . . . . . . . . . . . . . . (1.7311 - 1.7315 in.) crankshaft journals ground undersize by a qualified
machine shop and install undersized bearing inserts.
Wear Limit. . . . . . . . . . . 43.92 mm (1.729 in.)
Bearing inserts are available in 0.25 mm (0.010 in.)
If journal diameter is less than wear limit, replace undersize.
crankshaft or have journals ground undersize by a
qualified machine shop. 6. Clean and inspect oil passages in main bearing
journals, connecting rod journals and main
If journals are ground, undersize bearing inserts bearing bores in cylinder block.
must be installed. Bearing inserts are available in
0.25 mm (0.010 in.) undersize. 7. Inspect crankshaft for cracks or damage. Replace
if necessary.
1-50 4/7/95
STUB SHAFT - 3TN66 (330/332 LGT,

F915 FM) AND 3TNA72 (430 LGT, Cap Screw (2)
M10 x 75 Nut (2)
F925/35 FM) 49 N•m (36 lb-ft) 88 N•m (65 lb-ft)
1. Remove electric clutch. (See procedure in

Machine Technical Manual.)
2. Remove cover.
Cap Screw (5)
M8 x 70 Guide
3. Measure stub shaft TIR (total indicated runout) 26 N•m (226 lb-ft) Pin (2)
using a dial indicator. If TIR exceeds (0.20 mm
(0.008 in.), replace stub shaft. Stub 1
Shaft
Cap Screw (4)

Plug M8 x 20 M82286A
59 N•m (44 lb-ft)
3TNA72
5. Measure stub shaft mounting flange flatness.

Place a straight edge across stub shaft mounting
M35331
surface. Measure clearance between straight edge
and mounting surface with a feeler gauge. If
4. Remove stub shaft. clearance exceeds 0.05 mm (0.002 in.), replace
Cap Screws stub shaft.
330/332 LGT: M10 x 60
F915FM: M10 x 35 Installation is done in reverse order of removal.
49 N•m (36 lb-ft)
Clip
Stud (4)
Cover
Cap Screw (6)

M8 x 50
26 N•m
(226 lb-in.) Guide
Pins
Stub
Shaft
M35338
Cap Screw (4)

M10 x 25 M82285A
59 N•m (44 lb-ft)
3TN66
4/7/95 1-51
FLYWHEEL - 3TNA72 (3009 OEM): Remove bearing

housing.
1. 3TN66 (330/332 LGT and F915 FM) and
3TNA72 (430 LGT and F925/35 FM). Remove - 3TN66 (375 SSL) and 3TNA72 (15 EX):
stub shaft. (See procedure in this group.) Remove center flex coupler. (See procedure
- 3TN66 (655 CUT) and 3TNA72 (455 LGT in Machine Technical Manual.)
and 755/56 CUT): Remove starter and
flywheel guard.
1
Bearing Bearing
Housing Pilot Bushing
3TNA72 (670 CUT)
Only Flywheel
Cap Screw (3)

3TNA72 Nut Clip
(3009 OEM) 755/56 CUT Only
Only
Flywheel Mounting Cap Screw (3)

Replace.
Apply clean engine oil
on threads.
83 N•m (61 lb-ft)
Flywheel
Guard
3TNA72 (455 LGT and 755/56 CUT) Only
Cap Screw
Cap M10 x 20
Screw Clip
M8 x 55
Flywheel
Guard
Cap Screw (2)
M8 x 12 M82287A
3TN66 (655 CUT) Only
1-52 4/7/95
2. Remove mounting cap screws and flywheel.

IMPORTANT: Never reuse flywheel mounting
cap screws. Always install new.
• Inspect pilot bushing, if equipped, for wear or
damage. Replace if necessary using a driver set.
Install bushing flush with flywheel surface.
• Measure flywheel flatness. Place a straight edge
across flywheel surface opposite of ring gear.
Measure clearance between straight edge and 1
flywheel surface with a feeler gauge. If M35336
Units Equipped with Stub Shaft Only
clearance exceeds 0.02 mm (0.0008 in.), replace
flywheel.
FLYWHEEL HOUSING - 3TNA72
(15 EX, 3009 OEM)
2. Remove starter.
M35337
Housing-to-Block
Cap Screw (6) Flywheel Housing
M10 x 25
49 N•m (36 lb-ft)
John Deere Form-In-Place Gasket
(RTV rubber silicone sealant)
Plug
Housing-to-Extension
Cap Screw (3)
M10 x 28
49 N•m (36 lb-ft) M82288A
4/7/95 1-53
FLYWHEEL PLATE - 3TN66 AND Cap Washer (5)

3TNA72 Screw (5)
M8 x 8
(All Except 15 EX and 3009 OEM) Mounting Cap Screw (8) Flywheel
M10 x 20 Plate
1. Remove flywheel. (See procedure in this group.) 49 N•m (36 lb-ft)
2. Remove starter.
1 Mounting Cap
Screw (7)
M10 x 20
49 N•m (36 lb-ft) Foam Seal
Foam Seal Cover

Early 430 LGT
Only
Flywheel Plate
3TNA72 (430 LGT, F925/35 FM)
M82357A
Mounting Cap Screw (7)

3TN66 (655 CUT) M82289A M10 x 20
49 N•m (36 lb-ft)
Mounting Cap Screw (6) Stud

M10 x 20
49 N•m (36 lb-ft)
Flywheel Plate Foam Seal Foam Seal
3TNA72 (455 LGT, 755/56 CUT) M82358A
Flywheel
3TN66 (375 SSL, 330/332 LGT, Plate
F915 FM) M82290A
Mounting
Cap Screw (11)
M10 x 20
49 N•m (36 lb-ft)
3TNA72 (670 CUT) M82359A
1-54 4/7/95
Camshaft and Timing Gear Train

D15001NU Magnetic Follower Holder Kit
Hold cam followers when removing and installing camshaft.
OTHER MATERIALS
Number Name Use 1
LOCTITE® PRODUCTS
U.S./
Canadian/
LOCTITE No.
TY15130/ John Deere Form-In-Place Seals camshaft plug, timing gear cover and
NA/ Gasket housing to engine block.
#395
TY9370/ Thread Lock and Sealer Apply to threads of crankshaft pulley

TY9477/ (Medium Strength) cap screw.
#242
TY9369/ Thread Lock and Sealer Apply to threads of studs in timing

NA/ (Low Strength) gear housing.
#222
SERVICE PARTS KITS

® LOCTITE is a registered trademark of the Loctite Corp.
4/7/95 1-55
CAMSHAFT
Mounting Cap Screws
Removal M8 X 16
1. Remove rocker arm assembly and push rods. (See
Cylinder Head, Valves and Manifolds in this
section.)
2. Remove timing gear cover. (See procedure in this
group.)
1 3. Check camshaft end play. (See Checks, Tests and
4. Check backlash of timing gears. (See Checks,
NOTE: If a magnetic follower holder kit is not Timing
available, turn engine until oil pan is Marks
Camshaft
upward, to hold cam followers away from
camshaft. M35501
Early 3TNA72
5. Hold cam followers away from camshaft using a
magnetic follower holder kit such as D15001NU.
NOTE: Due to the odd number of teeth on the idler
Installation
gear, timing marks will only align • Apply clean engine oil on all parts during
periodically. installation.
6. Rotate crankshaft and align timing marks. IMPORTANT: DO NOT allow camshaft lobes to
IMPORTANT: DO NOT allow camshaft lobes to hit bearing surfaces while installing camshaft.
hit bearing surfaces while removing camshaft. Machined surfaces can be damaged.
Machined surfaces can be damaged. 1. Rotate crankshaft to align timing marks.
7. Remove two cap screws and camshaft. 2. Install camshaft.
8. Inspect all parts for wear or damage. (See 3. Install and tighten mounting cap screws to 11
Inspection/Replacement procedures.) N•m (96 lb-in.).
4. Install timing gear cover. (See procedure in this
Mounting Cap Screws group.)
M8 X 16
5. Install push rods and rocker arm assembly. (See
section.)
Timing
Marks
Camshaft
3TN66, Later 3TNA72 M37832
1-56 4/7/95
Inspection/Replacement Heat gear to approximately 150oC (300oF).

1. Check camshaft side gap using a feeler gauge. IMPORTANT: Be sure thrust plate is not
between camshaft gear and camshaft shoulder
while installing gear.
Camshaft Gear
Install thrust plate if removed. Install gear with
Thrust Plate timing mark “C” side toward press table. Align slot
in gear with key in shaft. Press camshaft into gear
until gear is tight against camshaft shoulder.
Thrust plate must spin freely on camshaft. 1
Key
Camshaft Gear
Side Gap M82067A
Camshaft Side Gap:

Thrust Plate
Standard . . . . . . . . . . . . . . . . . 0.05 - 0.15 mm
. . . . . . . . . . . . . . . . . . . . . (0.0020 - 0.0060 in.) M82068A
Wear Limit. . . . . . . . . . . . 0.40 mm (0.016 in.)

If side gap is at wear limit, remove gear and replace 3. Inspect camshaft for bend using v-blocks and a
thrust plate. dial indicator. Turn camshaft slowly and read
variation on indicator. If variation is greater than
2. Inspect gear for chipped or broken teeth. Replace 0.02 mm (0.001 in.), replace camshaft.
if necessary.
To remove/replace gear: Dial Indicator
Remove gear from camshaft using a knife-edge
puller and a press.
CAUTION
DO NOT heat oil over 182° C (360° F). Oil
fumes or oil can ignite above 193° C (380° F). Camshaft
Central Bearing
Use a thermometer. Do not allow a flame or Areas
heating element to come in direct contact
with the oil. Heat the oil in a well-ventilated
area. Plan a safe handling procedure to avoid V-Block
burns. M82291A
4. Measure camshaft lobe height.
4/7/95 1-57
Intermediate
Standard . . . . . . . . . . . . . . . 35.91 - 35.94 mm
. . . . . . . . . . . . . . . . . . . . . (1.4138 - 1.4150 in.)
Lobe Wear Limit. . . . . . . . . . 35.85 mm (1.4114 in.)
Height
Camshaft Journal O.D. - 3TNA72 (3009):

M82070A Gear Housing and Flywheel Ends
1 Lobe Height - 3TN66: Standard . . . . . . . . . . . . . . . 39.94 - 39.96 mm
. . . . . . . . . . . . . . . . . . . . . (1.5724 - 1.5732 in.)
Standard . . . . . . . . . . . . . . . 29.97 - 30.03 mm
Wear Limit. . . . . . . . . . 39.85 mm (1.5689 in.)
. . . . . . . . . . . . . . . . . . . . . . . (1.180 - 1.182 in.)
Intermediate
Wear Limit. . . . . . . . . . . 29.75 mm (1.171 in.)
Standard . . . . . . . . . . . . . . . 39.91 - 39.94 mm
Lobe Height - 3TNA72 (3009): . . . . . . . . . . . . . . . . . . . . . (1.5713 - 1.5724 in.)
Wear Limit. . . . . . . . . . 39.85 mm (1.5689 in.)
Standard . . . . . . . . . . . . . . . 33.95 - 34.05 mm
. . . . . . . . . . . . . . . . . . . . . . . (1.337 - 1.341 in.) If journal diameters are less than wear limit, replace
camshaft.
Wear Limit. . . . . . . . . . . 33.75 mm (1.329 in.)
6. Measure camshaft bushing diameter at gear
If lobe height is less than wear limit, replace housing end.
camshaft.
5. Measure camshaft end and intermediate journal
diameters. Camshaft Bushing
Flywheel End
Journal
Oil Holes
M82072
Camshaft Bushing I.D. - 3TN66:

Intermediate
Journals Standard . . . . . . . . . . . . . . 36.00 - 36.065 mm
Gear Housing . . . . . . . . . . . . . . . . . . . . . . . (1.417 - 1.420 in.)
End Journal M82292A
Wear Limit. . . . . . . . . . . 36.10 mm (1.421 in.)
Clearance . . . . . . . . . . . . . 0.18 mm (0.007 in.)
Camshaft Journal O.D. - 3TN66:
Gear Housing and Flywheel Ends Camshaft Bushing I.D. - 3TNA72 (3009):
Standard . . . . . . . . . . . . . . . 35.94 - 35.96 mm Standard . . . . . . . . . . . . . . 40.00 - 40.065 mm
. . . . . . . . . . . . . . . . . . . . . (1.4150 - 1.4157 in.) . . . . . . . . . . . . . . . . . . . . . . . (1.575 - 1.577 in.)
Wear Limit. . . . . . . . . . 35.85 mm (1.4114 in.) Wear Limit. . . . . . . . . . . 40.10 mm (1.579 in.)
Clearance . . . . . . . . . . . . . 0.18 mm (0.007 in.)
1-58 4/7/95
If bushing diameter exceeds wear limit, replace Camshaft Bore I.D. - 3TN66:
bushing. Standard . . . . . . . . . . . . . . 36.00 - 36.025 mm
If bushing clearance (bushing I.D. minus camshaft . . . . . . . . . . . . . . . . . . . . . . . (1.417 - 1.418 in.)
journal O.D.) exceeds specification, replace bushing,
Wear Limit. . . . . . . . . . . 36.10 mm (1.421 in.)
camshaft or both.
To replace bushing: Clearance . . . . . . . . . . . . . 0.18 mm (0.007 in.)
Remove bushing using a chisel. Be careful not to Camshaft Bore I.D. - 3TNA72 (3009):
push bushing inside of engine. Align oil holes in
new bushing and cylinder block. Install bushing Standard . . . . . . . . . . . . . . 40.00 - 40.025 mm 1
using a driver set. . . . . . . . . . . . . . . . . . . . . . . . (1.575 - 1.576 in.)
NOTE: Flywheel housing/plate must be removed to Wear Limit. . . . . . . . . . . 40.10 mm (1.579 in.)
measure camshaft intermediate and Clearance . . . . . . . . . . . . . 0.18 mm (0.007 in.)
flywheel end bearing diameters.
7. Measure intermediate and flywheel end camshaft If bore diameter exceeds wear limit, replace cylinder
bore diameters using the following procedures: block.
• Remove flywheel housing/plate. (See If bore clearance (bore I.D. minus camshaft journal
Crankshaft, Main Bearings and Flywheel in this O.D.) exceeds specification, replace camshaft,
section.) cylinder block or both.
• Remove plug using a long wooden dowel. Insert • Apply John Deere Form-In Place Gasket, or an
wooden dowel through gear housing side. equivalent, on outer edge of plug. Install plug
until it bottoms in bore.
• Install flywheel housing/plate.
CAM FOLLOWERS
Removal/Installation
Plug Valves and Manifold in this section.)
M35287
IMPORTANT: Cam followers must be installed
in the same bores from which they were
• Measure intermediate and flywheel end removed.
camshaft bore diameters.
2. Put a mark on each cam follower and cylinder
block bore to aid in installation.
3. Remove cam followers.
Intermediate
Bores 4. Inspect all parts for wear or damage. (See
5. Apply clean engine oil on all parts during
installation.
Flywheel
End Installation is done in the reverse order of removal.
Bore
M82073
4/7/95 1-59
Inspection Cam Follower Bore I.D. - 3TN66:

• Inspect cam follower contact surface for Standard . . . . . . . . . . . . . . 18.00 - 18.018 mm
abnormal wear. Replace if necessary. . . . . . . . . . . . . . . . . . . . . . (0.7087 - 0.7094 in.)
Wear Limit. . . . . . . . . . . 18.05 mm (0.711 in.)
Clearance . . . . . . . . . . . . . . . 0.032 - 0.068 mm
. . . . . . . . . . . . . . . . . . . . . (0.0013 - 0.0027 in.)
Cam Follower Bore I.D. - 3TNA72 (3009):

1
Standard . . . . . . . . . . . . . . 21.00 - 21.021 mm
. . . . . . . . . . . . . . . . . . . . . (0.8268 - 0.8276 in.)
Wear Limit. . . . . . . . . . . 21.05 mm (0.829 in.)
Abnormal Contact
Normal Contact Clearance . . . . . . . . . . . . . . . 0.040 - 0.094 mm
M82293A . . . . . . . . . . . . . . . . . . . . . (0.0016 - 0.0037 in.)
• Measure cam follower diameter. If cam follower bore diameter exceeds wear limit,
replace cylinder block.
If bore clearance (bore I.D. minus follower stem
O.D.) exceeds specification, replace cam follower,
cylinder block or both.
TIMING GEAR COVER - 3TN66
M35268 1. Remove alternator and belt.
2. Remove fan, spacer, if equipped, and pulley.
Cam Follower O.D. - 3TN66: 3. Remove crankshaft pulley cap screw and washer.
Standard . . . . . . . . . . . . . 17.950 - 17.968 mm 4. Remove crankshaft pulley using a two-jaw puller
. . . . . . . . . . . . . . . . . . . . . (0.7067 - 0.7074 in.) kit.
Wear Limit. . . . . . . . . . . 17.93 mm (0.706 in.) 5. Remove tachometer, if equipped.
Cam Follower O.D. - 3TNA72 (3009): Spacer

Pulley
Standard . . . . . . . . . . . . . 20.927 - 20.960 mm (655 CUT Only)
. . . . . . . . . . . . . . . . . . . . . (0.8239 - 0.8252 in.)
Wear Limit. . . . . . . . . . . 20.93 mm (0.824 in.)
If diameter is less than wear limit, replace cam
follower.
• Measure cam follower bore diameter in cylinder
block.
Cap Screw (4)
11 N•m (96 lb-in.)
M82294A
1-60 4/7/95
NOTE: It is not necessary to remove end cover and Installation is done in the reverse order of removal.
o-ring to remove timing gear cover.
• Tighten all mounting cap screws to 9 N•m (78
6. Remove 18 mounting cap screws and timing gear lb-in.)
cover.
• Adjust fan/alternator drive belt tension. (See
Checks, Tests and Adjustments in this section.)
John Deere
Form-In-Place
Gasket 1
(RTV rubber
silicone sealant)

M6 x 50

M6 x 30
Timing Gear Tachometer
Cover
End
Cover
O-Ring
Cap
655 CUT Only
Cap Screw (2)

O-Ring M6 x 18
Crankshaft Pulley
Washer

M6 x 65 Mounting Cap Screw (3)
M6 x 40
Cap Screw
Apply thread lock and
sealer (medium strength)
to threads.
115 N•m (85 lb-ft) M82295A
4/7/95 1-61
TIMING GEAR COVER - EARLY NOTE: It is not necessary to remove auxiliary drive
3TNA72 (430 LGT) cover and gasket, if equipped, or end cover
and o-ring to remove timing gear cover.
Removal/Installation 6. Remove 14 mounting cap screws and timing gear
cover.
1. Remove alternator and belt.
Installation is done in the reverse order of removal.
2. Remove crankshaft pulley cap screw and washer.
3. Remove crankshaft pulley using a two-jaw puller lb-in.).
1 kit.
• Align pin in crankshaft pulley with hole in
4. Remove cotter pin and washer to disconnect fuel crankshaft gear. Install crankshaft pulley.
shutoff solenoid linkage.
• Adjust alternator drive belt tension. (See Checks,
Cotter Pin
and Washer
Hole
Pin
M35272
M35295
5. Remove two nuts and one cap screw to remove
bracket and fuel shutoff solenoid.
Nut (2)
9 N•m (78 lb-in.)
Cap Screw
9 N•m (78 lb-in.)
M35294
1-62 4/7/95
John Deere
Form-In-Place Gasket Timing Gear
(RTV rubber Cover
silicone sealant)
End Cover Cap Screw (2)

M6 x 18
1
Cap Screw (4)
O-Ring M8 x 35
Gasket
Crankshaft Auxiliary
Pulley Drive Cover
Mounting Cap Screw (5) Washer

Mounting Cap Screw (9) M6 x 55
M6 x 25 Cap Screw
to threads.
Early 3TNA72 (430 LGT) 88 N•m (65 lb-ft) M82296A
TIMING GEAR COVER - LATER 3. Remove crankshaft pulley cap screw and washer.
3TNA72 4. Remove crankshaft pulley using a two-jaw puller
Removal/Installation kit.
1. Remove alternator and belt. 5. Remove tachometer, if equipped.
NOTE: 430 LGT (Later) and F925/35 FM 6. 670 CUT: Remove hydraulic pump and steering
application is not equipped with a fan. pump, if equipped. (See procedures in Machine
Alternator belt pulley does not have to be Technical Manual.)
removed to access timing gear cover. NOTE: It is not necessary to remove auxiliary drive
2. Remove fan, spacer/plate, if equipped, and cover and gasket, if equipped, or end cover
pulley. and o-ring to remove timing gear cover.
Spacer 7. Remove mounting cap screws and timing gear
Pulley (3009 OEM, 670 CUT Only) cover.
lb-in.)
Plate Checks, Tests and Adjustments in this section.)
Cap Screw (4)

11 N•m (96 lb-in.)
755/56 CUT
Only M82297A
4/7/95 1-63
John Deere
Form-In-Place Gasket **Mounting Cap Screw (4)
(RTV rubber Timing Gear M6 x 60 (755/56 CUT, 3009 OEM, 455 LGT, 670 CUT, 15 EX)
silicone sealant) Cover M6 x 55 (430 LGT, F935 FM)
Tachometer
**
755/56 CUT, 3009 OEM,

1 670 CUT Only
Gasket Auxiliary
Cap Drive Cover
O-Ring
Cap Screw (4)
O-Ring M8 x 40
End
Cover
**
Cap Screw (2)

**Mounting Cap Screw (6) M6 x 16
M6 x 30 (755/56 CUT, 3009 OEM,
*** 670 CUT, 15 EX)
M6 x 18
*Mounting Cap Screw (6) (430 LGT, F935 FM,
M6 x 80 455 LGT)
Crankshaft Washer Cap Screw

Pulley Apply thread lock and
to threads.
115 N•m (85 lb-ft)
Alternator Bracket
Mounting Cap Screw M10 x 60

15 EX (5)
670 CUT (6)
M6 x 30
M6 x 50
Cap Screw
** ** and Nut (3)
M8 x 65
** 15 EX
** Only
**
*
Mounting Cap
Screw (8)
M6 x 30
455 LGT 670 CUT, 15 EX
Later 3TNA72 M82298A
1-64 4/7/95
IDLER GEAR - EARLY 3TNA72 Idler Gear Shaft O.D.:

(430 LGT) Standard . . . . . . . . . . . . . 19.959 - 19.980 mm
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . (0.786 - 0.787 in.)
1. Remove timing gear cover. (See procedure in this Wear Limit. . . . . . . . . . . 19.93 mm (0.785 in.)
group.) If shaft diameter is less than wear limit, replace idler
2. Check backlash of timing gears. (See Checks, gear shaft.
Tests and Adjustments in this section.) To replace shaft:
NOTE: Due to the odd number of teeth on the idler • Remove set screw in end of shaft. Install a gear 1
gear, timing marks will only align cover mounting cap screw with washer into
periodically. When all timing marks on threaded hole. Remove idler shaft using a slide
gears are aligned, the piston closest to the hammer and puller.
water pump is at TDC on compression
• Install shaft with flange toward cylinder block.
stroke. Number one cylinder is closest to the
Install shaft tight against block using a soft-
flywheel.
faced hammer. Install set screw.
3. Rotate crankshaft and align timing marks.
4. Remove idler gear.
5. Inspect gear and shaft for wear or damage. (See
M35496
• Measure idler gear bushing diameter.
Idler Gear
Idler Shaft
Gear Bushing
M35491
• Inspect gear for chipped or broken teeth.
Replace if necessary.
• Measure idler gear shaft diameter.
M35492
Idler Gear Bushing I.D.:

Standard . . . . . . . . . . . . . . 20.00 - 20.021 mm
. . . . . . . . . . . . . . . . . . . . . . . (0.787 - 0.788 in.)
Wear Limit. . . . . . . . . . . 20.08 mm (0.791 in.)
Clearance . . . . . . . . . . . . 0.15 mm (0.0059 in.)
If bushing diameter exceeds wear limit, replace
M35494
bushing.
4/7/95 1-65
To replace bushing:
Replace bushing using a driver set. Align oil holes in
bushing and idler gear. Install bushing flush with Cap Screw (3)
M6 x 12
surface of idler gear.
If bushing clearance (bushing I.D. minus shaft O.D.)
exceeds specification, replace bushing, shaft or both.
IDLER GEAR - 3TN66 AND LATER

1 3TNA72
Removal/Installation M37834

group.) Idler Gear Shaft O.D.:
2. Check backlash of timing gears. (See Checks, Standard . . . . . . . . . . . . . 19.959 - 19.980 mm
Tests and Adjustments in this section.) . . . . . . . . . . . . . . . . . . . . . . . (0.786 - 0.787 in.)
NOTE: Due to the odd number of teeth on the idler Wear Limit. . . . . . . . . . . 19.93 mm (0.785 in.)
gear, timing marks will only align
periodically. When all timing marks on If shaft diameter is less than wear limit, remove
gears are aligned, the piston closest to the three cap screws and replace idler gear shaft.
water pump is at TDC on compression • Measure idler gear bushing diameter.
stroke. Number one cylinder is closest to the
flywheel.
4. Remove snap ring, washer and gear.
5. Inspect all parts for wear or damage. (See
M35492
Snap Ring
Washer

Standard . . . . . . . . . . . . . . 20.00 - 20.021 mm
. . . . . . . . . . . . . . . . . . . . . . . (0.787 - 0.788 in.)
Wear Limit. . . . . . . . . . . 20.08 mm (0.791 in.)
Clearance . . . . . . . . . . . . 0.15 mm (0.0059 in.)
M37516 bushing.
To replace bushing:
Inspection/Replacement Replace bushing using a driver set. Align oil holes in
bushing and idler gear. Install bushing flush with
• Inspect gear for chipped or broken teeth. surface of idler gear.
• Measure idler gear shaft diameter. exceeds specification, replace bushing, shaft or both.
1-66 4/7/95
TIMING GEAR HOUSING - 3TN66 4. Remove oil pump. (See Lubrication System in
this section.)
Removal/Installation 5. Remove water pump. (See Cooling System in this
1. Remove idler gear. (See procedure in this group.) section.)
2. Remove injection pump camshaft. (See Fuel 6. Remove mounting cap screws and housing.
System in this section.) 7. Replace o-rings.
3. Remove engine camshaft. (See procedure in this Installation is done in the reverse order of removal.
group.)
1
John Deere
Timing Gear Housing

Stud (4) Spring Pin (2)
sealer (low strength) Mounting Cap Screw
to threads. All Except 655 CUT (4)
655 CUT (5)
M6 x 16
Gasket Cast Iron - 11 N•m (96 lb-in.)
Aluminum - 9 N•m (78 lb-in.)
Stud (4)
sealer (low strength)
to threads.
Cover Alignment Dowel (2)
Cap Screw (2)

M6 x 14
O-Rings
Replace.
M82299A
4/7/95 1-67
TIMING GEAR HOUSING - • Tighten all mounting cap screws to:

EARLY 3TNA72 Cast Iron . . . . . . . . . . . . . . . 11 N•m (96 lb-in.)
Removal/Installation Aluminum. . . . . . . . . . . . . . . 9 N•m (73 lb-in.)
1. Remove fuel control and governor linkage. (See
Fuel System in this section.) O-Rings
Replace.
2. Remove idler gear. (See procedure in this group.)
3. Remove injection pump camshaft. (See Fuel
1 System in this section.)
4. Remove engine camshaft. (See procedure in this
group.)
5. Remove water pump. (See Cooling System in this M35508
section.)
6. Remove oil pump. (See Lubrication System in
this section).
7. Remove bracket.
8. Remove mounting cap screws and housing. Special Screw
9. Replace o-rings
Installation is done in reverse order.
• Install special screw before installing gear
housing. M35506
John Deere
Stud (4)
Apply thread lock and Form-In-Place Gasket
sealer (low strength) (RTV rubber silicone sealant)
Bracket to threads.
Spring Pin (2)
Cap Screw (2) Timing Gear Housing
M6 x 14
Alignment Dowel
Cap Screw
M8 x 12
Stud
to threads. Mounting Cap Screw (6)
M6 x 16
Cap Screw (2)

M6 x 14

M6 x 35
Special Screw Mounting Cap Screw (4)

Gasket
Cover M6 x 30
M82300A
1-68 4/7/95
TIMING GEAR HOUSING - LATER 4. Remove engine camshaft. (See procedure in this
3TNA72 group.)
Removal/Installation 5. Remove oil pump. (See Lubrication System in

this section.)
2. 670 CUT and 3009 OEM: Remove fuel supply section.)
pump. (See procedure in ACCESSORIES -
7. Remove mounting cap screws and housing.
SERIES 220 POWER UNIT ENGINES Section.)
8. Replace o-rings.
3. Remove fuel injection pump camshaft. (See Fuel 1
System in this section.) Installation is done in reverse order of removal.
4/7/95 1-69
Cover
All Except 455 LGT, 15 EX,
John Deere 670 CUT, 3009 OEM
Form-In-Place Gasket Cap Screw (4)
(RTV rubber silicone sealant) M8 x 12
Gasket
Stud (4)
1 Spring Pin (2)
to threads.
Timing Gear Housing
Mounting Cap
Screw (7)
Stud (4) M6 x 16
Apply thread lock and Gasket
sealer (low strength) Cast Iron - 11 N•m (96 lb-in.)
to threads. Cover Aluminum - 9 N•m (78 lb-in.)
Alignment Dowel (2)

Cap Screw (2)
M6 x 14
O-Ring (2) Crankcase Extension-to-
Replace. Housing Cap Screw (4)
(670 CUT, 15 EX, 3009 OEM Only)
Fuel M6 x 45 (15 EX, 3009 OEM)
Supply M8 x 45 (670 CUT)
Pump 22 N•m (195 lb-in.)
Cap Screw (2)

M6 x 20
670 CUT, 3009 OEM

Cover
(15 EX Only)
Cap Screw
M8 x 12
(15 EX Only)
455 LGT 15 EX, 670 CUT M82310A
1-70 4/7/95
Lubrication
OTHER MATERIALS
Number Name Use
LOCTITE® PRODUCTS
U.S./
Canadian/
Loctite No.
TY15130/ John Deere Form-In-Place Seals oil pan/plate to crankcase 1

NA/ Gasket extension housing and/or block.
#395
4/7/95 1-71
Lubrication
OIL PAN AND STRAINER - 3TN66 NOTE: On 655 CUT; Engine serial number
( - 012269), uses an aluminum oil pan.
Removal/Installation Engine serial number (012270 - ) uses a
sheet metal oil pan. Size and quantity on
• Approximate crankcase oil capacity is 2.5 L mounting cap screws are different.
(2.6 qt).
• Fill engine with proper engine oil. (See
SPECIFICATIONS AND GENERAL
INFORMATION section.)
1
Oil Strainer
Cap Screw (2)

M6 x 12
O-Ring 11 N•m (96 lb-in.)
Replace. ªªªªªªªª
ªªªªªªªªª
Cap Screw (10)

M6 x 10
11 N•m (96 lb-in.)
Oil Pan-to-Timing Gear
Housing Cap Screw (4)
M6 x 12
9 N•m (78 lb-in.)
Oil Pan-to-Seal Case
Cap Screw (2)
M6 x 12 Oil Pan
9 N•m (78 lb-in.)
Washer
Drain Plug Replace.
M82302A
3TN66 (375 SSL, 330/332 LGT, F915 FM)
1-72 4/7/95
Lubrication

O-Ring
Replace.
Oil Pan-to-Seal Case Tube

Cap Screw (2) (Aluminum Pan)
M6 x30 (Aluminum Pan)
M6 x 25 (Sheet Metal Pan)
9 N•m (78 lb-in.)
Oil Pan
Cap Screw (2)
M6 x 12
1
11 N•m (96 lb-in.) Oil Pan-to-Timing Gear
Housing Cap Screw
(5) M6 x 35 (Aluminum Pan)
(6) M6 x 12 (Sheet Metal Pan)
9 N•m (78 lb-in.)
Oil Strainer
O-Ring Washer Plug

Replace. Replace. (Aluminum Pan)
Drain Plug
Cap Screw
(9) M6 x 20 (Aluminum Pan)
(16) M6 x 10 (Sheet Metal Pan)
11 N•m (96 lb-in.) M82303A
3TN66 (655 CUT)
OIL PAN AND STRAINER - 3TNA72 O-Ring

Replace.
• Approximate crankcase oil capacity is:
15 EX . . . . . . . . . . . . . . . . . . . . . . . . 1.9L (2 qt) Oil Strainer
Cap Screw (2) 3009D F007 OEM
430 LGT, 455 LGT . . . . . . . . . . . . . . 2.8L (3 qt) M6 x 10
11 N•m (96 lb-in.)
670 CUT . . . . . . . . . . . . . . . . . . . . 2.6L (2.7 qt)
755/56 CUT . . . . . . . . . . . . . . . . . 3.2L (3.4 qt)
F925/35 FM . . . . . . . . . . . . . . . . . 3.5L (3.6 qt)
3009 OEM (RTV rubber silicone sealant)
F001 and 005 . . . . . . . . . . . . . . 2.9L (3.1 qt)

F007 . . . . . . . . . . . . . . . . . . . . . 3.8L (3.9 qt)
Cap Screw (20)
• Fill engine with proper engine oil. (See M6 x 45
SPECIFICATIONS AND GENERAL 11 N•m (96 lb-in.) Cap Screw (3)
M6 x 12
INFORMATION section.) 11 N•m (96 lb-in.)
O-Ring
Replace.
Oil Pan
Drain Plug 15 EX, 3009 OEM M82304A
4/7/95 1-73
Lubrication
O-Ring
John Deere Form-In-Place Cap Screw (2) Replace.
Gasket (RTV rubber M6 x 10
O-Ring silicone sealant) 11 N•m (96 lb-in.) John Deere Form-In-Place
Replace. Gasket (RTV rubber
silicone sealant)
Oil Strainer
Cap Screw (2)
M6 x 10
11 N•m (96 lb-in.)
Oil Pan-to-Seal Case
1 Cap Screw (2)
M6 x 12
Oil Strainer 9 N•m (78 lb-in.)
Drain Plug
Washer
Oil Pan/Plate Replace.
Washer
Drain Plug Oil Pan-to-
Timing Gear
Housing Cap
Cap Screw (8) Screw (4)
M8 x 12 M6 x 12
11 N•m (96 lb-in.) 9 N•m
Cap Screw (16)
M82305A M6 x 8 (78 lb-in.)
670 CUT
11 N•m (96 lb-in.)
M82306A
455 LGT
O-Ring
John Deere Form-In-Place Replace.
Gasket (RTV rubber
silicone sealant)
Cap Screw (2)
M6 x 10
11 N•m (96 lb-in.)
Oil Strainer
Oil Pan-to-Seal
Case Cap Screw (2)
M6 x 22
9 N•m (78 lb-in.)
Oil Pan
Washer
Replace.
Oil Pan-to-Timing Gear
Drain Plug Housing Cap Screw (4)
M6 x 22 Early 430 LGT
Cap Screw (15) 9 N•m (78 lb-in.)
M6 x 22
11 N•m (96 lb-in.)
Cap Screw
M6 x 45 M82307A
11 N•m (96 lb-in.)
430 LGT, F925/35 FM, 755/56 CUT
1-74 4/7/95
Lubrication
OIL PUMP - EARLY 3TNA72 (430 LGT)

Removal
1. Remove idler gear, (See Camshaft and Timing
Gear Train in this section.)
2. Loosen oil pump gear lock nut.
3. Remove fuel injection pump camshaft. (See Fuel
4. Remove oil filter and oil dipstick tube.
1
5. Remove two cap screws, bracket and four M35542
washers.
10.Remove governor shaft, washer and spacer.
6. Remove two cap screws, cover and gasket.
Cover and Gasket

Bracket
Spacer
Governor Shaft
Washers (4) and Washer
Replace washer.
M35543
M35539
11.Remove governor linkage assembly.

7. Remove sealing wire.
8. Loosen jam nut. Turn slow idle adjustment screw
counterclockwise several turns.
Sealing Wire
Jam Nut
M35544
Slow Idle
Adjustment Screw
M35540 12.Remove oil pump gear lock nut.
9. Disconnect spring from governor linkage. NOTE: Oil pump gear is press fit on rotor shaft.
13.Remove oil pump gear using a three-jaw puller.
4/7/95 1-75
Lubrication
14.Remove four cap screws, nut cover and gasket.

15.Remove oil pump assembly.
NOTE: See OIL PRESSURE REGULATING VALVE
if service is necessary. Rotor Shaft
Assembly
16.Inspect all parts for wear or damage. (See
Identification
Marks
1 Outer Rotor
Spring Pin (2)
M35557
Gasket Oil Pressure
Regulating
Cover Valve 3. Align splines on rotor shaft with splines in thrust
washer and governor weights. Install thrust
Mounting
washer, governor weights and sleeve on rotor
Nut shaft.
Mounting
Cap Screw
(4)
Oil Pump
Gear
Lock
Nut
Rotor Shaft
Inner Rotor Governor Weights
Outer Rotor
M82308A Rotor Shaft
Sleeve
Installation
Thrust Washer
1. Apply clean engine oil on all parts during
installation.
IMPORTANT: Oil pump assembly must be
installed with identification marks on rotors
facing toward gear housing. M35558
2. Install rotor shaft assembly and outer rotor in 4. Install oil pump gasket and cover.
gear housing with identification marks facing
gear housing. 5. Install four cap screws and nut. Tighten to 9 N•m
(78 lb-in.).
6. Install oil pump gear and lock nut. Leave nut
loose.
7. Install spacer and new washer on governor shaft.
1-76 4/7/95
Lubrication
8. Install governor linkage assembly.
Cover and Gasket Bracket
Washers (4)
1
M35539
M35544
13.Install oil dipstick tube and oil filter.
9. Insert governor shaft through linkage assembly. 14.Install fuel injection pump camshaft. (See Fuel
Tighten shaft to 49 N•m (36 lb-ft). System in this section.)
15.Tighten oil pump gear lock nut to 27 N•m (20 lb-
ft).
Washer
Governor 16.Install idler gear. (See Camshaft and Timing
Linkage Spacer
Inspection
• Measure outer rotor bore depth and outer rotor
thickness.
Governor
Shaft
M35562
10.Connect spring to internal lever, then to governor

assembly.
M35549
M35542
11.Install gasket, cover and two cap screws.

12.Install four washers (two each hole location),
bracket and two cap screws. Tighten all four cap
screws to 9 N•m (78 lb-in.).
M35550
4/7/95 1-77
Lubrication
Outer Rotor-to-Bore Clearance:

Standard . . . . . . . . . . . . . . . . . 0.08 - 0.15 mm
. . . . . . . . . . . . . . . . . . . . . . . (0.003 - 0.006 in.)
Wear Limit. . . . . . . . . . . . 0.25 mm (0.010 in.)
If clearance (bore depth minus rotor thickness) is
more than wear limit, replace timing gear housing.
• Measure outer rotor bore and outer rotor
diameters.
1
M35553
M35551
M35554
Inner Rotor-to-Outer Rotor Clearance:

Standard . . . . . . . . . . . . . . . . . 0.10 - 0.15 mm
. . . . . . . . . . . . . . . . . . . . . . . (0.004 - 0.006 in.)
Wear Limit. . . . . . . . . . . . 0.25 mm (0.010 in.)
If clearance (outer rotor I.D. minus inner rotor O.D.)
is more than wear limit, replace oil pump assembly.
M35552
• Measure rotor shaft diameter.
Outer Rotor-to-Bore Diameter Clearance:

Standard . . . . . . . . . . . . . . . . . 0.10 - 0.15 mm
. . . . . . . . . . . . . . . . . . . . . . . (0.004 - 0.006 in.)
Wear Limit. . . . . . . . . . . . 0.25 mm (0.010 in.)
If clearance (bore I.D. minus rotor O.D.) is more
than wear limit, replace timing gear housing.
• Measure inner rotor O.D. and outer rotor I.D.
M35555
1-78 4/7/95
Lubrication
Rotor Shaft Diameter: OIL PUMP - 3TN66 and LATER

Standard . . . . . . . . . . . . . 12.670 - 12.685 mm 3TNA72
. . . . . . . . . . . . . . . . . . . . . (0.4988 - 0.4990 in.)
Wear Limit. . . . . . . . . 12.650 mm (0.4980 in.)
1. Remove timing gear cover. (See Camshaft and
If shaft diameter is less than wear limit, replace oil Timing Gear Train in this section.)
pump assembly.
2. Check oil pump gear backlash. Replace entire oil
• Measure rotor shaft bore diameter. pump assembly if backlash is more than 0.25 mm
(0.010 in.). 1
3. Remove four mounting cap screws, oil pump and
gasket.
Disassembly/Assembly procedures).
M35556
Rotor Shaft Bore Diameter:

Standard . . . . . . . . . . . . . 12.700 - 12.718 mm
. . . . . . . . . . . . . . . . . . . . . (0.5000 - 0.5007 in.)
Wear Limit. . . . . . . . . . . 12.80 mm (0.504 in.)
Oil Pump
Clearance
Standard . . . . . . . . . . . . 0.015 - 0.048 mm
. . . . . . . . . . . . . . . . . . . (0.006 - 0.0019 in.)
Oil Pump
Wear Limit. . . . . . . 0.100 mm (0.0039 in.) Gasket
If bore diameter is more than wear limit, replace Mounting Cap Screw
timing gear housing. M6 x 20
25 N•m (18 lb-ft) M82309A
If rotor shaft clearance (bore I.D. minus shaft O.D.)
is more than wear limit, replace timing gear housing
and oil pump assembly.
Disassembly/Assembly
• Gear is press fit on rotor shaft. Remove gear
using a knife edge puller and a press.
• Inspect parts for wear or damage. (See
• Coat all parts with clean engine oil.
4/7/95 1-79
Lubrication
• Install outer rotor with identification mark

facing toward rotor shaft assembly.
Outer Rotor
Alignment Pin (2)

Backing Plate
Feeler Gauge
Pump Body Body

1 M37776
Gear
Rotor Shaft
Inner Rotor Outer Rotor-to-Pump Body Clearance:

Outer Rotor Standard . . . . . . . . . . . . . . . . . 0.03 - 0.09 mm
Identification . . . . . . . . . . . . . . . . . . . . . (0.0011 - 0.0035 in.)
Mark
M82301A
Wear Limit. . . . . . . . . . . 0.13 mm (0.0051 in.)
• Check inner-to-outer rotor clearance. If
clearance is more than 0.15 mm (0.0059 in.),
Inspection replace rotor assembly.
• Check rotor shaft outer diameter and the shaft
hole diameter in backing plate. If clearance is
more than wear limit, replace entire assembly. Feeler Gauge
Rotor Shaft and Plate Clearance:

Inner Rotor
Standard . . . . . . . . . . . . . . . 0.015 - 0.048 mm
. . . . . . . . . . . . . . . . . . . . . (0.0006 - 0.0035 in.)
Wear Limit. . . . . . . . . . . 0.20 mm (0.0078 in.)
• Check rotor recess. If rotors are below face of
pump housing more than 0.25 mm (0.010 in.), Outer Rotor M37777
replace rotor assembly.
Feeler Gauge OIL PRESSURE REGULATING

Straight Edge
VALVE - 3TN66
1. Remove oil filter and o-ring.
2. Remove retaining nut and valve assembly.
Housing 3. If adjusting pressure only, remove cap and add
M37775
shims. Each 1 mm (0.039 in.) of shim thickness
Outer Rotor
increases oil pressure 13.8 kPa (2 psi).
• Check outer rotor-to-pump body clearance. If NOTE: Valve components are not serviced
clearance is more than wear limit, replace entire individually. Replace complete regulating
assembly. valve if any components are defective.
1-80 4/7/95
Lubrication
4. Inspect all parts for wear or damage. Replace 3. Inspect all parts for wear or damage. Replace as
complete valve if necessary. necessary.
5. Check spring free and compressed lengths.
Spring Specifications: Valve

Spring
Free Length . . . . . . . . . . . . . 21.90 - 24.50 mm
. . . . . . . . . . . . . . . . . . . . . . . (0.860 - 0.960 in.)
Shims
Compressed Length . . . 14.70 mm (0.580 in.)
. . . . . . . . . . . . . . . . . . . . @12 N (2.7 lb-force) 1
Cap
M35573
Cap
Stake to
Shims valve body. 4. Check spring free and compressed lengths.
Valve Spring Specifications:

Retaining Nut
30 N•m (22 lb-ft) Free Length . . . . . . . . . . . . . 39.50 - 40.50 mm
. . . . . . . . . . . . . . . . . . . . . . . (1.550 - 1.590 in.)
Spring
Compressed Length . . . . . .30 mm (1.180 in.)
. . . . . . . . . @ 29.4 ± 3.1 N (6.6 ± 0.7 lb-force)
Valve Body
IMPORTANT: If oil pressure regulating valve
O-Ring was disassembled to be cleaned, the same
Replace. number and thickness of shims must be
Oil FIlter M82311A installed.
NOTE: Shims are available in 0.20 mm (0.080 in.)

OIL PRESSURE REGULATING and 0.30 mm (0.012 in.) sizes.
VALVE - EARLY 3TNA72 (430 LGT) 5. If adjusting oil pressure only, add shims as
necessary. Each 0.20 mm (0.080 in.) of shim
Removal/Installation thickness increases oil pressure 6 kPa (0.85 psi).
1. Remove timing gear cover. (See Camshaft and Each 0.30 mm (0.012 in.) shim thickness
Timing Gear Train in this section.) increases oil pressure 9 kPa (1.30 psi).
2. Remove cap, shims, if equipped, spring and Installation is done in the reverse order of removal.
valve.
4/7/95 1-81
Lubrication
OIL PRESSURE REGULATING NOTE: Valve components are not serviced

VALVE - LATER 3TNA72 individually. Replace complete regulating
valve if any components are defective.
Removal/Installation 4. Inspect all parts for wear or damage. Replace
complete valve if necessary.
1. Remove oil filter.
5. Check spring free and compressed lengths.
2. Remove three cap screws, valve assembly and
gasket.
Spring Specifications:
1 NOTE: If adjusting engine oil pressure, retaining Free Length . . . . . . . . . . . . . 43.50 - 48.50 mm
nut need not be removed. . . . . . . . . . . . . . . . . . . . . . . . (1.710 - 1.910 in.)
3. If adjusting pressure only, remove cap and add Compressed Length . . . 27.50 mm (1.080 in.)
. . . . . . . . . . . . . . . . . . @ 20.5 N (4.6 lb-force)
increases oil pressure 10.9 kPa (1.6 psi).
Cap
Stake to
O-Ring valve body.
Replace.
Gasket
Cap Screw (3) Housing
M8 x 20
27 N•m (20 lb-ft)
Retaining Nut Shims

30 N•m (22 lb-ft)
Spring
Oil Filter Valve
Valve Body
O-Ring
Replace. M82312A
1-82 4/7/95
Cooling System
OTHER MATERIALS
Number Name Use
LOCTITE® PRODUCTS
U.S./
Canadian/
LOCTITE No.
TY9375/ John Deere Pipe Sealant 3TNA72 (15 EX, 755/56 CUT): Apply
TY9480/ with TEFLON® to threads of plug in water pump 1
#592 housing.

®TEFLON is a registered trademark of the Du Pont Company.
4/7/95 1-83
Cooling System
COOLANT TEMPERATURE SENSOR

Cap Screw (2)
Replacement M8 x 20
9 N•m (78 lb-in.)
NOTE: Some engines may also be equipped with a Cover
coolant temperature switch. Switch is O-Ring
located opposite of sensor in water pump Replace.
housing. Replacement procedures are the
same.
Thermostat
1. Disconnect wiring lead, if equipped.
1
2. Open engine drain valve to drain coolant.
3. Remove sensor and washer.
4. Test sensor. (See Checks, Tests and Adjustments
in this section.)
Installation is done in reverse order of removal.
Coolant Temperature
Sensor
3TN66 M82314A
Water Pump
Housing
Coolant Temperature
Switch Cap Screw
Copper M8 x 55
Cap Screw (2)
Washer M8 x 20 Cap Screw
Replace. 26 N•m (226 lb-in.) M8 x 25
Gasket Later 430 LGT,

Copper
F925/35 FM,
Washer
M82313A Thermostat 755/56 CUT
Replace.
Gasket
(430 LGT Only)
THERMOSTAT
• Replace gaskets.
• Test thermostat. (See Checks, Tests and
3TNA72 M82315A
1-84 4/7/95
Cooling System
WATER PUMP - 3TN66 4. Remove three mounting cap screws, pump and
gasket.
Removal/Installation 5. Inspect all parts for wear or damage. (See
Disassembly/Assembly procedures.)
2. Remove fan/alternator drive belt.
3. Remove fan, spacer, if equipped, and pulley.
1
Gasket
Replace.
O-Ring
Replace. Pulley
Fan
Water Pump
Cap Screw (4)
Mounting Cap Screw (3) 11 N•m (96 lb-in.)
M8 x 45
26 N•m (226 lb-in.)
Spacer
(655 CUT Only)
M82316A
4/7/95 1-85
Cooling System
Disassembly 2. Remove coolant temperature sensor. (See

1. Remove thermostat. (See procedure in this
group.) 3. Apply heat to six plate-to-housing screws.
Remove screws, plate and gasket.
Plate
Gasket
Plate-to-Housing Screw (6) Replace.
1 9 N•m (78 lb-in.)
Bearing
Shaft
Impeller Pulley
Flange
Shaft Seal Assembly
Replace.
Plug Water Pump

Housing M82317A
4. Apply extreme heat to pulley flange. Remove IMPORTANT: Impeller bore is tapered. When
flange using a knife-edge puller set and two small pressing bearing shaft from impeller, allow
nuts. enough clearance between cap screw and
impeller bore to prevent cap screw from
binding.
6. Remove impeller from bearing shaft using a
Two Small Nuts knife-edge puller, a 3/8 in. cap screw and a press.
Pulley Flange
Knife-Edge 7. Remove shaft seal assembly; (seal, ceramic seal
Puller Set and seal cup).
Water Pump necessary.
Housing
M35645
5. Place water pump assembly on a press table.

Install supports under water pump housing,
staying clear of impeller. Press bearing shaft
assembly through water pump housing using a
piece of pipe or a deep socket.
1-86 4/7/95
Cooling System
Assembly 5. Install a knife-edge puller around bearing shaft,

between pulley flange and pump housing. Place
1. Install bearing shaft into pump housing, long end pump housing, with knife-edge puller down, on a
down, using a piece of pipe or deep socket and a press table. Install impeller with ceramic seal
press. Press shaft into pump housing until bearing toward shaft seal.
surface is flush with pump housing surface.
2. Install new shaft seal over impeller side of Press impeller on bearing shaft until top of
bearing shaft, rubber seal side away from pump impeller is even with end of shaft.
housing. Push shaft seal into pump housing, until
it stops, using a 25 mm or 1 in. socket and a 1
press.
IMPORTANT: Support pump housing on
bearing shaft only. DO NOT support on
housing or damage to housing will occur.
3. Place water pump housing on a press table.
Support housing on bearing shaft using a driver
disk. Install pulley flange onto shaft with straight
hub facing away from housing.
M35656
Press pulley flange onto bearing shaft until flange

is flush with end of shaft. 6. Install new gasket, plate and six screws. Tighten
to specifications.
IMPORTANT: DO NOT touch lapped sealing
surface of ceramic seal with bare hands. It 7. Install coolant temperature sensor. (See
must be clean and dry. procedure in this group.)
4. Install seal cup and ceramic seal in impeller. 8. Install thermostat. (See procedure in this group.)
4/7/95 1-87
Cooling System
WATER PUMP - 3TNA72 4. Remove three mounting cap screws, pump and
gasket.
NOTE: 430 LGT and F925/35 FM application is Checks, Tests and Adjustments in this section.)
not equipped with a fan.
• Tighten mounting cap screws to 26 N•m (226
1 3. Remove fan and spacer/plate, if equipped, and lb-in.).
pulley.
Mounting Cap Screw

Gasket (3009 OEM, 455 LGT, 670 CUT Only)
Replace. M8 x 20
Pulley
Spacer
O-Ring (3009 OEM, 655 CUT Only)
Replace.
Fan
Water Pump
Mounting Cap Screw

3009 OEM, 455 LGT,
670 CUT - (3)
All Except - (4)
M8 x 45
Plate
755/56 CUT
Only Cap Screw (4)
11 N•m (96 lb-in.) M82318A
1-88 4/7/95
Cooling System
Disassembly 2. Remove coolant temperature sensor. (See

1. Remove thermostat. (See procedure in this
group.) 3. Apply heat to plate-to-housing screws. Remove
screws, plate and gasket.
Plate-to-Housing Screw Plate Plug

Early 3TNA72 (3) Gasket (15 EX, 755/56 CUT Only)
Later 3TNA72 (5) Replace. Apply Pipe Sealant with
9 N•m (78 lb-in.) TEFLON to threads.
1
Stud
(Early 430 LGT Only)
Bearing
Shaft
Impeller
Pulley
Shaft Seal Assembly
Cap Flange
Replace.
Coolant Temperature
Switch Water Pump
Copper Washer Housing
Replace.
455 LGT
M82319A
4. Apply extreme heat to pulley flange. Remove IMPORTANT: Impeller bore is tapered. When
flange using a knife-edge puller set and two small pressing bearing shaft from impeller, allow
nuts. enough clearance between cap screw and
binding.
Two Small Nuts knife-edge puller, a 3/8 in. cap screw and a press.
Pulley Flange
Knife-Edge 7. Remove shaft seal assembly; (seal, ceramic seal
Puller Set and seal cup).
Water Pump necessary.
Housing
M35645
5. Place water pump assembly on a press table.

Install supports under water pump housing,
staying clear of impeller. Press bearing shaft
4/7/95 1-89
Cooling System

2. Install new shaft seal over impeller side of Press impeller on bearing shaft until top of
bearing shaft, rubber seal side away from pump impeller is even with end of shaft.
1 it stops, using a 25 mm or 1 in. socket and a
press.
M35656
Press pulley flange onto bearing shaft until flange

is flush with end of shaft. 6. Install new gasket, plate and screws. Tighten to
specifications.
surface of ceramic seal with bare hands. It 7. Install coolant temperature sensor. (See
must be clean and dry. procedure in this group.)
4. Install seal cup and ceramic seal in impeller. 8. Install thermostat. (See procedure in this group.)
1-90 4/7/95
Fuel System

JDF13 Nozzle Cleaning Kit
Use to clean fuel injection nozzles.
OTHER MATERIALS
Number Name Use 1
LOCTITE® PRODUCTS
U.S./
Canadian/
LOCTITE No.
TY9369/ Thread Lock and Sealer Apply to threads of fuel shutoff
NA/ (Low Strength) lever set screw.
#222
SERVICE PARTS KITS

• Fuel Injection Nozzle Shim Pack
4/10/95 1-91
Fuel System
FUEL SUPPLY PUMP - 3TNA72

(670 CUT, 3009 OEM)
Replacement
IMPORTANT: Replace all copper washers.
Damaged or used washers may leak.
1
Copper Washer (4)
Replace.
Fuel Supply
Pump
Gasket
Fuel Pump-to-Filter Hose
Fuel Supply-to-
Pump Hose Lock Washer (2) Mounting Screw (2)
M6 x 20
11 N•m (96 lb-in.)
M82135A
1-92 4/10/95
Fuel System
FUEL FILTER ASSEMBLY - IF IMPORTANT: Replace all copper washers.

EQUIPPED Damaged or used washers may leak.
NOTE: As a result of the various engine

applications for each engine model, fuel
filter assemblies may or may not be
mounted on the engine. Fuel filters and line
routing will be different. 3TNA72 (3009
OEM) shown.
1
Nut (3)
Nozzle Leak-Off Hose

(Short) (2)
Bleed Valve
Rubber Washer
* *
Bleed Screw

(Long)
Shutoff Rubber Washer

Valve
To Fuel Tank
Mounting Base
Spring
O-Ring
Shutoff
* Lever
Filter Element
*
Spring
O-Ring
Fuel Supply
Pump-to-Filter
Hose
Filter Cover
Fuel Filter-to- Retaining Ring

*Copper Washers Injection Pump
Replace. Hose
M82133A
4/10/95 1-93
Fuel System
FUEL INJECTION PUMP

Removal
CAUTION
Escaping fluid under pressure can penetrate
the skin causing serious injury. Avoid the
hazard by relieving pressure before
1 disconnecting hydraulic or other lines.
Tighten all connections before applying M37785
pressure. Search for leaks with a piece of
cardboard. Protect hands and body from 4. Disconnect hose from fuel filter or supply pump
high pressure fluids. (670 CUT, 3009 OEM), if equipped.
If an accident occurs, see a doctor 5. Disconnect leak-off hoses to/from injection
immediately. Any fluid injected into the skin pump.
must be surgically removed within a few
hours or gangrene may result. Doctors 6. 375 SSL, 655 CUT, F915 FM, 455 LGT, 755/56
unfamiliar with this type of injury should CUT:
reference a knowledgable source. Such - Disconnect fuel shutoff solenoid link.
information is available from the Deere &
Company Medical Department in Moline, - Remove four nuts, shutoff solenoid bracket
Illinois, U.S.A. and gasket.
IMPORTANT: Never steam clean or pour cold
water on injection pump while the pump is Gasket
Shutoff Solenoid Replace.
running or warm. Doing so can damage the Bracket
pump.
1. Clean the injection pump lines and area around
the pump using a parts cleaning solvent or steam
cleaner.
IMPORTANT: When removing injection lines,
DO NOT turn pump delivery valve fittings. Fuel Shutoff
Turning fittings may damage pump internally. Solenoid Link M37786
2. Loosen fuel injection line connectors slightly to

release pressure in the fuel system. When 430 LGT (Early):
loosening connectors, use another wrench to keep - Remove two cap screws, nut, oil fill cover and
delivery valves from loosening. gasket.
3. Loosen line clamp and remove fuel injection
lines.
1-94 4/10/95
Fuel System
DO NOT attempt to service the injection pump

except for fuel delivery valves. If unit is in need of
repair, it must be serviced by a qualified fuel
injection repair shop. If replacement is necessary,
replace entire unit.
Gasket
Replace. Installationl
Oil Fill Cover
IMPORTANT: If a serviced or replacement fuel 1
injection pump is installed, measure old shim
M35890
thickness and install new shims of the same
thickness.
330/332 LGT, 15 EX, 430 LGT (Later), 670
CUT, F925/35 FM, 3009 OEM: • Early 3TNA72: When installing fuel injection
pump into housing, align controller rack with
- Remove four nuts, cover and gasket. governor linkage fork.
7. 3TN66 and Later 3TNA72: Remove pin and
washer, if equipped. Disconnect governor
linkage. Governor
Linkage Fork
Controller Rack
Pin
M35888
Governor Linkage
NOTE: 3TN66 and Later 3TNA72: Governor
M37787 linkage may have two holes. Connect
governor linkage to injection pump rack
IMPORTANT: If injection pump is being using hole closest to injection pump gear.
removed to be serviced or replaced, the same • 3TN66 and Later 3TNA72: When connecting
number and thickness of new shims must be governor linkage to injection pump rack, attach
installed when pump is assembled. link to rack at hole closest to injection pump
8. Remove four nuts to remove fuel injection pump gear.
and shims. • Bleed the fuel system. (See Operational Tests in
this section.)
• If new injection pump is being installed, check
and adjust injection pump timing. (See Checks,
Fuel Injection Pump
Nut (4) Shims

20 N•m
(180 lb-in.)
M37788
4/10/95 1-95
Fuel System
FUEL INJECTION PUMP CAMSHAFT Installation

- EARLY 3TNA72 (430 LGT) Installation is done in the reverse order of removal.
Removal • After installing camshaft assembly into housing,
tap on end of camshaft gear with a plastic
1. Remove fuel injection pump. (See procedure in hammer to seat bearings in bores.
this group.)
2. Remove idler gear. (See Camshaft and Timing
1 3. Put a shop towel between oil pump and injection
pump gears. Loosen injection pump gear lock
nut.
4. Remove bearing retaining screw.
M35568
Lock Nut
88 N•m (65 lb-ft) Bearing
Retaining Disassembly
Screw
20 N•m NOTE: Injection pump camshaft is tapered on gear
(180 lb-in.)
end. Gear and bearings are press fit on
shaft.
M35536 IMPORTANT: Hold camshaft while removing
gear and bearings. Shaft can be damaged if
IMPORTANT: DO NOT allow fuel injection dropped.
pump camshaft lobes to hit bearing surfaces 1. Remove lock nut and lock washer.
while removing camshaft. Machined surfaces
2. Remove gear using a knife edge puler and a
may be damaged. ª ª
press.
5. Remove fuel injection pump camshaft assembly
3. Remove key.
using a slide hammer, puller set and two
mounting cap screws from gear housing cover.
M37797
M35537
4. Remove bearings using a knife edge puller and a
press.
6. Disassemble and inspect all parts for wear or
damage. (See Disassembly and Inspection 5. Inspect all parts for wear or damage. (See
procedures. Inspection procedures.)
1-96 4/10/95
Fuel System
Assembly 2. 670 CUT and 3009 OEM: Remove fuel supply

pump. (See procedure in this group.)
NOTE: Install large bearing on gear end.
3. Remove fuel control and governor linkage. (See
1. Install bearings on ends of camshaft using a 3/4 procedure in this group.)
in. deep well socket and a press. Press until
bearing races bottom on camshaft shoulders. 4. Remove idler gear. (See Camshaft and Timing
2. Install key.
5. Remove bearing retaining screw.
3. Put camshaft gear on a flat surface and press
camshaft assembly into gear. Press until gear face 1
is flush with end of shaft.
4. Install lock washer and lock nut. Leave nut loose.
Inspection Bearing
Retaining
• Measure height of each camshaft lobe. Replace Screw
20 N•m
camshaft if lobe height is less than 30.90 mm (180 lb-in.)
(1.217 in.).
M37804
IMPORTANT: DO NOT allow fuel injection

pump camshaft lobes to hit bearing surfaces
while removing camshaft. Machined surfaces
may be damaged.
6. Tap the rear of camshaft with plastic hammer to
remove from housing.
M35905
• Inspect camshaft bearing supports in timing gear

housing. Check for cracks, damage or
indications that bearings have spun in support. Camshaft
Replace timing gear housing if bearing bores are
damaged. (See Camshaft and Timing Gear Train
in this section.)
necessary.
M37796
FUEL INJECTION PUMP CAMSHAFT 7. Disassemble and inspect all parts for wear or
- 3TN66 AND LATER 3TNA72 damage. (See Disassembly and Inspection
procedures.)ª ª
Removal
1. Remove fuel injection pump. (See procedure in
this group.)
4/10/95 1-97
Fuel System
Installation Assembly
Installation is done in reverse order of removal. NOTE: Install large bearing on gear end.
• After installing camshaft assembly into housing, 1. Install bearings on ends of camshaft using a 3/4
tap on end of camshaft gear with a plastic in. deep well socket and a press. Press until
hammer to seat bearings in bores. bearing races bottom on camshaft shoulders.
2. Install key.
3. Put camshaft gear on a flat surface and press
1 camshaft assembly into gear. Press until gear face
is flush with end of shaft.
Inspection
• Measure height of each camshaft lobe. Replace
camshaft if lobe height is less than 30.90 mm
(1.217 in.).
M35568
Disassembly
NOTE: Gear and bearings are press fit on shaft.
IMPORTANT: Hold camshaft while removing
gear and bearings. Shaft can be damaged if
dropped.
1. Remove gear using knife edge puller and a press. M35905
2. Remove key.
• Inspect camshaft bearing supports in timing gear
housing. Check for cracks, damage or
indications that bearings have spun in support.
- If rear bearing bore is damaged, replace
timing gear housing. (See Camshaft and
- If front bearing bore is damaged, remove
three cap screws and replace support.
M37797
Front Bearing
3. Remove bearings using a knife edge puller and a Support
press.
M37803

necessary.
1-98 4/10/95
Fuel System
FUEL CONTROL AND GOVERNOR

LINKAGE - EARLY 3TNA72
(430 LGT) Cap Nuts
and Seals
Replace Sealing Wire
Removal seals.
1. Remove fuel injection pump. (See procedure in

this group.) Bracket
2. Remove cotter pin and washer to disconnect fuel

shutoff solenoid linkage. 1
M35929
9. Loosen lock nut and remove fast idle adjustment

screw and seal.
Seal
Replace.
Fast Idle
Adjustment
M35272
Screw
3. Remove oil filter and dipstick tube.

4. Remove two cap screws, bracket and four
washers. M35930
5. Remove two cap screws, cover and gasket. 10.Loosen lock nut and remove fuel controller and
seal.
Bracket
Seal
Replace.
Cover Washers (4)

and Fuel Controller
Gasket
M35928
M35932
6. Remove sealing wire.
7. Remove cap screw and slow idle screw bracket.
8. Remove cap nuts and seals.
4/10/95 1-99
Fuel System
11.Disconnect spring from throttle lever regulator. 14.Remove o-ring, e-clip and spring.
O-Ring
Replace. E-Clip
1 Spring
M35933 M35937
12.Remove nut, throttle lever, regulator and o-ring. 15.Remove governor shaft, bronze washer and
spacer.
Throttle Lever
Regulator
Governor Shaft
O-Ring
Replace.
M35934
M35938
13.Remove set screw and fuel shutoff lever.

16.Turn governor weights until one weight is toward
the engine. Remove governor linkage assembly.
Set Screw
Fuel Shutoff Lever
M35936
M35940
1-100 4/10/95
Fuel System
Installation
• Coat all internal parts with clean engine oil.
1. Align splines on oil pump rotor shaft with splines
in thrust washer and governor weights. Install
thrust washer, governor weights and sleeve on
rotor shaft.
M35939
1
Sleeve
17.Remove spring pin.
Governor
Weights
Thrust
Washer
M35945
2. Install spring, pin and e-clip.

M35943
18.Remove e-clip, pin and spring.
Pin
Pin
E-Clip
E-Clip Spring M35944
Spring M35944 3. Install spring pin.
19.Remove sleeve, governor weights and thrust

washer.
Sleeve
Governor
Weights
Thrust
M35948
Washer
M35945

4/10/95 1-101
Fuel System
4. Turn governor weights until one weight is toward 7. Install spring, e-clip and new o-ring.
the engine. Install governor linkage assembly.
O-Ring E-Clip
1 Spring
M35937
M35940
8. Align groove in fuel shutoff lever with hole in

timing gear housing and install lever. Make sure
groove is visible through hole.
9. Apply thread lock and sealer (low strength) on
threads of set screw. Install and tighten set screw.
Groove
M35939 Hole
5. Install spacer and new bronze washer on

governor shaft.
6. Insert governor shaft through governor linkage
assembly. Tighten shaft to 49 N•m (36 lb-ft). M35951
10.Install new o-ring on regulator.

11.Install throttle lever and nut.
Spacer Washer
Throttle Lever
Regulator
M35949
O-Ring
M35934
1-102 4/10/95
Fuel System
12.Connect spring to throttle lever regulator then to 15.Install slow idle screw bracket so the stop on the
governor linkage assembly. lever contacts the end of slow idle screw. Install
and tighten cap screw.
16.Install fuel shutoff lever spring on slow idle
screw bracket.
Fuel Shutoff
Lever Spring
1
Stop
M35933
Slow Idle Screw

Slow Idle Screw
13.Install new seals and fuel controller. Tighten lock Bracket
nut. M35954
17.Install new gasket, cover and two cap screws.

18.Install four washers (two each hole location),
Seals bracket and two cap screws. Tighten all four cap
screws to 9 N•m (78 lb-in.).
Fuel Controller
Bracket
M35932
14.Install new seals and fast idle adjustment screw.

Tighten lock nut. Cover Washers (4)
and
NOTE: Do not install cap nuts or sealing wire until Gasket
installation procedures have been M35928
completed and fast and slow idle
adjustments have been made. Idle 19.Install oil dipstick tube and oil filter.
adjustments are made after engine has been
installed in the machine. 20.Connect fuel shutoff solenoid linkage and install
washer and cotter pin.
Seals
Fast Idle
Adjustment
Screw
M35930
M35272
4/10/95 1-103
Fuel System
21.Install fuel injection pump. (See procedure in this

group.)
22.Adjust fuel shutoff solenoid. (See Checks, Tests
23.Check and adjust slow and fast idle settings. (See
procedure in Machine Technical Manual.)
Inspection
1 NOTE: Throttle lever bushing is press fit in timing M35942
gear housing. Remove bushing only if
replacement is necessary. Governor Shaft Bore I.D.
1. Inspect throttle lever bushing for wear or damage. Wear Limit. . . . . . . . . . . . 8.15 mm (0.321 in.)
Replace if necessary. Clearance . . . . . . . . . . . . . 0.18 mm (0.007 in.)
To replace bushing: If shaft bore exceeds wear limit, replace governor
Remove bushing using a blind hole puller set. linkage. ª ª
Install bushing with chamfered end toward gear If bore clearance (bore I.D. minus shaft O.D.)
housing using a driver set. Push in bushing until exceeds specification, replace governor shaft,
flush with surface of gear housing. governor linkage or both.
4. Measure inside diameter of sleeve. If I.D. is more
than 9.20 mm (0.362 in.), replace sleeve.
M35946
M35935
2. Measure governor shaft diameter. If O.D. is less 5. Measure oil pump rotor shaft diameter.
than 7.90 mm (0.311 in.), replace governor shaft.
M35947
M35941
Rotor Shaft O.D.
3. Measure governor shaft bore diameter in Wear Limit. . . . . . . . . . . . 8.90 mm (0.350 in.)
governor linkage.
Clearance . . . . . . . . . . . . . 0.15 mm (0.006 in.)
1-104 4/10/95
Fuel System
If shaft diameter is less than wear limit, replace 4. 670 CUT, 15 EX, 375 SSL, 3009 OEM: Remove
pump rotor shaft. Inspect splines on shaft for six cap screws, linkage housing and gasket.
chipped or broken teeth. If necessary, replace oil 430 LGT (Later), 330 LGT, 655 CUT, F915 FM,
pump rotor shaft. (See Lubrication System in this 455 LGT, 755/56 CUT, F925/35 FM:
section.)
- Remove three cap screws and throttle cable
If clearance (sleeve I.D. minus shaft O.D.) exceeds mounting bracket.
specification, replace sleeve, oil pump rotor shaft or - Remove three cap screws, linkage housing
both.
and gasket.
FUEL CONTROL AND GOVERNOR 1
LINKAGE - 3TN66 AND LATER Throttle Cable
3TNA72 Gasket Mounting Bracket
Replace. If equipped.
Removal
1. 375 SSL, 655 CUT, F915 FM, 455 LGT, 755/56
Dipstick
CUT: Tube
- Disconnect fuel shutoff solenoid link. Linkage Housing
- Remove four nuts, shutoff solenoid bracket

M37754
and gasket.
5. Remove sleeve.
Shutoff Solenoid Gasket
Bracket Replace. 6. Remove nut and governor weights.
Governor
Weights
Nut
Fuel Shutoff Solenoid Link M37786
330 LGT, 15 EX, 430 LGT (Later), 670 CUT, Sleeve

M37755
F925/35 FM, 3009 OEM:
- Remove four nuts, cover and gasket. 7. Disassemble and inspect all parts for wear or
2. Remove pin and washer, if equipped, to damage. (See Disassembly and Inspection
disconnect governor linkage. procedures.)
Installation
Pin Installation is done in the reverse order of removal.
• Governor linkage may have two holes. Connect
governor linkage to injection pump rack using
hole closest to injection pump gear.
• Adjust fuel shutoff solenoid. (See Checks, Tests
• Check and adjust slow and fast idle settings.
Governor Linkage
M37787 (See procedure in Machine Technical Manual.)
• Check and adjust slow and fast idle settings.
3. Remove dipstick tube. (See procedure in Machine Technical Manual.)
4/10/95 1-105
Fuel System
Disassembly NOTE: Shims are on all engines except 670 CUT

and 3009 OEM applications.
1. Remove spring.
7. Remove governor shaft, governor linkage
2. Remove seal and sealing wire. assembly, shims and O-ring.
Spring
Governor Linkage
Assembly
1 Seal and
Sealing
Wire
O-Ring
Replace.
M37759
Shims
Governor If equipped.
Shaft
NOTE: Washer is on 670 CUT, 455 LGT and 3009 M37762
OEM only.
3. Remove nut, washer, if equipped, and throttle 8. Rotate throttle shaft assembly as shown.
lever. 9. Remove tapered pin from tapered hole using a
4. Remove cap screw and throttle shaft retaining punch.
plate. 10.Remove throttle shaft, shaft lever and O-ring.
5. Remove cap screw and governor shaft retaining
plate. Tapered Pin Shaft Lever
6. Remove set screw, fuel shutoff lever, spring and

O-ring. Throttle Shaft
Set Screw
Apply thread lock and sealer
(low strength) on threads.
Governor Shaft
Retaining Plate
O-Ring Spring
Replace.
Throttle O-Ring
Shaft Replace.
Retaining
Plate
M37766
Nut
Throttle Lever
Fuel Shutoff Lever

M37760
1-106 4/10/95
Fuel System
11.Remove cover, gasket, fuel controller assembly,

fast idle stop and slow idle stop. Nut
Washer
Stud
Cap Nut Seals
Replace. Tension Lever
Needle
Cap Nut Clip Bearing (2)
Spring Pin
Fuel
Controller
Assembly
Seals
Replace. 1
Slow Idle Shim
Stop (as required)
Gasket
Replace. Spring Spring
Pin
Bracket
Washer
Cover
Cap Screw (3)

Spring
E-Clip
Fast Idle Stop
Governor
Pin Governor Link Lever Spring Pin
Spring Pin (2)
Pin
670 CUT, 3009 OEM M82322A
670 CUT,
3009 OEM
M82320A 13.Inspect all parts for wear or damage. Replace as
necessary. (See Inspection procedures.)
12.Disassemble governor linkage assembly.
Shim (as required) Assembly
Bushing (2)
Tension Lever Assembly is done in the reverse order of
Spring Pin disassembly.
• Apply clean engine oil on all internal parts.
Spring • When installing throttle shaft:
- Install new O-ring, throttle shaft and shaft
lever. Rotate shaft until rounded side of shaft
is facing toward hole.
Governor
Lever - Position shaft lever as shown and install
Washer tapered pin in tapered hole.
Pin Spring
Pin
Pin
Governor
Link M82321A
E-Clip
All Except 670 CUT, 3009 OEM
4/10/95 1-107
Fuel System
2. Measure governor shaft bore diameter in

Tapered Pin governor linkage.
Shaft Lever
O-Ring Governor Shaft Bore I.D.
Wear Limit. . . . . . . . . . . . 8.15 mm (0.321 in.)
Clearance . . . . . . . . . . . . . 0.18 mm (0.007 in.)
If shaft bore exceeds wear limit, replace governor
linkage.
1 Throttle Shaft
M37768 If bore clearance (bore I.D. minus shaft O.D.)
exceeds specification, replace governor shaft,
governor linkage or both.
Throttle Shaft
3. Measure inside diameter of sleeve. If I.D. is more
than 8.20 mm (0.323 in.), replace sleeve.
Rounded
Side
Hole
M37769
M37756
• Seal and sealing wire are not installed until
governor linkage housing installation
procedures have been completed and fast and 4. Measure injection pump camshaft diameter.
slow idle adjustments have been made. Idle
adjustments are made after engine has been
installed in the machine.
Inspection
1. Measure governor shaft diameter. If O.D. is less
than 7.90 mm (0.311 in.), replace governor shaft.
M37757

Wear Limit. . . . . . . . . . . . 7.90 mm (0.311 in.)
Clearance . . . . . . . . . . . . . 0.15 mm (0.006 in.)
If camshaft diameter is less than wear limit, replace
injection pump camshaft. (See procedure in this
group.)
If clearance (sleeve I.D. minus camshaft O.D.)
exceeds specification, replace sleeve, injection pump
camshaft or both.
M37763 necessary.
1-108 4/10/95
Fuel System
FUEL INJECTION NOZZLES NOTE: Nozzles are matched to the cylinders. If

(PINTLE-TYPE) removing more than one nozzle, tag nozzles,
according to the cylinder from which it was
Removal/Installation removed.
IMPORTANT: Never steam clean or pour cold IMPORTANT: When removing injection lines,
water on injection pump while the pump is DO NOT turn pump delivery valve fittings.
running or warm. Doing so can damage the Turning fittings may damage pump internally.
pump. 2. Loosen fuel injection line connectors slightly to
1. Clean the injection pump lines and area around release pressure in the fuel system. When 1
the pump using a parts cleaning solvent or steam loosening connectors, use another wrench to keep
cleaner. delivery valves from loosening.
CAUTION
disconnecting hydraulic or other lines.
Tighten all connections before applying
pressure. Search for leaks with a piece of
cardboard. Protect hands and body from M35885
high pressure fluids.
If an accident occurs, see a doctor 3. Loosen line clamp and remove fuel injection
immediately. Any fluid injected into the skin lines.
must be surgically removed within a few 4. Disconnect long leak-off hose.
hours or gangrene may result. Doctors
unfamiliar with this type of injury should 5. Remove nuts and leak-off hose assembly.
reference a knowledgable source. Such 6. Remove bronze washers and o-rings.
Company Medical Department in Moline, 7. Remove injection nozzle, washers and heat
Illinois, U.S.A. protector.
8. Test injection nozzles. (See Checks, Tests and
4/10/95 1-109
Fuel System
Nut
40 N•m (30 lb-ft)
Bronze Washer
Replace. Leak-Off Hose
Assembly
1 O-Ring
Replace.
Leak-Off Hose (Long) Hose Clamp
Injection Nozzle
50 N•m (37 lb-ft)
Heat Protector
Bronze Washers Replace.
Replace.
ª
ª
M82323A
Disassembly/Assembly Injector Body

Separator
NOTE: If servicing more than one nozzle, keep Plate
parts for each nozzle separate from one
another.
Nozzle Shims
IMPORTANT: If injection nozzles are Valve (as required)
disassembled to be cleaned, the same number
and thickness of shims must be installed.
• Clean and inspect nozzle assembly. (See Nozzle
Body
Cleaning/Inspection procedures.)
• After assembly is complete, test injection Nozzle
Fitting Spring
nozzle. (See Checks, Tests and Adjustments in
40 N•m
this section.) (30 lb-ft)
Spring Seat
M82324A
1-110 4/10/95
Fuel System
CROSS SECTION IMPORTANT: Never use a steel brush to clean

nozzles as this will distort the spray hole.
2. Remove carbon from used nozzles, and clean by
washing in diesel fuel. If parts are coated with
Injector hardened carbon or lacquer, it may be necessary
Body
to use a brass wire brush (supplied in Nozzle
Cleaning Kit).
3. After removing carbon or lacquer from the
exterior of nozzle, inspect sealing surfaces 1
between separator plate and nozzle body for
nicks or scratches.
4. Inspect condition of separator plate and nozzle
Shim body. Contact area of separator plate (both parts)
(as required) must not be scored or pitted. Use an inspection
magnifier (No. 16487 or equivalent) to aid in
making the inspection.
Spring 5. Check nozzle contact surface on separator plate
for wear. If contact surface is more than 0.10 mm
(0.0039 in.), replace nozzle assembly.
Nozzle
Fitting
Spring Nozzle Contact

Seat Surface
Separator Separator
Plate Sealing Surfaces Plate
Nozzle Body
Nozzle
Nozzle Body
Valve M82326A
M82325A
6. Inspect the piston (large) part of nozzle valve to
see that it is not scratched or scored and that
Cleaning/Inspection lower (tip) end of valve is not broken. If any of
these conditions are present, replace the nozzle
NOTE: To clean nozzles properly, JDF13 Nozzle assembly.
Cleaning Kit is recommended. The Cleaning
Kit is available through the John Deere
SERVICEGARD™ Catalog.
1. Remove anti-corrosive grease from new or
reconditioned nozzles by washing them
thoroughly in diesel fuel.
4/10/95 1-111
Fuel System
7. Further inspect the nozzle assembly by

performing a slide test. Use the following
procedure:
• Dip the nozzle valve in clean diesel fuel. Insert
valve in nozzle body. Piston Part of
Nozzle Valve
• Hold nozzle vertical, and pull valve out about
1/3 of its engaged length.
Nozzle Body
• Release valve. Valve should slide down to its
1 seat by its own weight.
Replace nozzle assembly if the valve does not slide M35919
freely to its seat.
1-112 4/10/95
Starter
STARTER - HITACHI 0.8 kW

Negative
Brush
Disassembly/Inspection
Brush Spring
1. Disconnect field lead.
2. Remove two cap screws and two screws from rear
cover.
3. Pry off plastic cap.
4. Remove e-clip, shims and rear cover. 1
M37875
Field
Field Lead
Coil Brush (2) 9. Remove field coil housing from armature/
solenoid assembly.
Rear Cover
Cap
E-Clip
Shims
M37923
Field Coil Housing M37876
5. Inspect cover bushing for wear or damage.
Replace if necessary. 10.Remove two cap screws and pivot bolt, if
To replace bushing: equipped.
Remove bushing using a blind-hole puller set. Install 11.Remove dust cover.
new bushing until it bottoms in cover bore using a
12.Remove solenoid and armature assemblies from
driver set.
end frame.
Ream out bushing to 12.50 - 12.53 mm (0.492 -
0.493 in.).
Cap
Screw (2) End Frame
Armature
Assembly
Rear Cover
Bushing
M37874
6. Remove field coil brushes from brush holder.

7. Pry brush springs away and pull negative brushes Dust
Cover
up enough to allow spring to hold brush in place.
Solenoid Assembly
8. Remove brush holder. M37877
4/7/95 1-113
Starter
13.Inspect end frame bushing for wear or damage. Spring

Replace bushing using a driver set. Install bushing Plunger
flush with face of housing.
Solenoid
Clutch Fork Shims

Pivot
1 M37880
Assembly
Assembly is done in the reverse order of
disassembly.
End Frame • After installing clutch assembly, pinion stopper
Bushing M37830
and retaining wire on armature shaft, use two
14.Slide pinion stopper away from retaining wire pliers to press pinion stopper over retaining
using a piece of pipe or deep socket. Remove wire.
retaining wire, pinion stopper, and clutch
assembly from armature shaft.
15.Inspect clutch assembly for wear or damage.
Gear should rotate in one direction only. Replace
if necessary. Retaining
Wire
Pinion
Stopper
Armature Clutch
Shaft Assembly
Retaining M37831
Wire
• When installing solenoid and armature

assemblies into end frame, make sure fork pivot
seats in notch on clutch fork.
Pinion Clutch Notch

Stopper Assembly
M37879
Fork Pivot
16.Remove clutch fork pivot, plunger, spring and
shim(s) from solenoid.
17.Inspect all parts for wear or damage. Replace as
necessary. M37881
18.Inspect and test brushes, holder, field coil and

armature. (See Test procedures.) IMPORTANT: When installing rear cover, be
sure field coil brush wires do not touch cover.
Turn brush holder slightly to take up slack in
brush wires. Press wires inward to clear rear
cover.
1-114 4/7/95
Starter
Test
1. Measure holder and field coil brush lengths. Field Coil Brush
Minimum brush length is 7.70 mm (0.303 in.).
Replace brush holder or field coil if brush length
is below minimum.
NOTE: Test brush holder using an ohmmeter or test
light.
2. Test brush holder:
Touch one probe of tester to negative brush 1
holder and other probe to field brush holder. If
there is continuity, replace the brush holder.
3. Inspect springs for wear or damage. Replace if
necessary. Field Coil
Housing
Spring (4)
M82235
Negative Brush
Holder
IMPORTANT: Do not clean armature with

solvent. Solvent can damage insulation on
windings. Use only mineral spirits and a
brush.
6. Inspect armature. Look for signs of dragging
against pole shoes.
7. Inspect commutator. Look for roughness, burned
Field Brush Brush Length bars, or any material which might cause short
Holder circuits between bars. If necessary, clean and
M82234 touch up with 400 sandpaper. NEVER use emery
cloth. Clean all dust from armature when
NOTE: Test field coil using an ohmmeter or test finished.
light.
NOTE: Test armature windings using an ohmmeter
4. Test for grounded field winding:
or test light.
Touch one probe of tester to field coil brush and
other probe to field coil housing. Be sure the 8. Test for grounded windings:
brush lead is not touching the frame. If there is Touch probes on one commutator bar and
continuity, the coil is grounded and the field coil armature shaft. Armature windings are connected
housing assembly must be replaced. in series, so only one commutator bar needs to be
checked.
5. Test for open field coil:
Touch one probe of tester to each field coil brush.
If there is no continuity, the field coil is open and
the field coil housing assembly must be replaced.
4/7/95 1-115
Starter
If test shows continuity, a winding is grounded and STARTER MOTOR - NIPPONDENSO

the armature must be replaced. 1.0 kW
9. Test for open circuited windings:
Touch probes on two different commutator bars. Disassembly
If test shows no continuity, there is an open circuit 1. Disconnect field lead.
and the armature must be replaced.
2. Remove two cap screws and two screws.
3. Remove rear cover and o-ring, if equipped.
Commutator Bars
1
Field Lead
Armature Shaft
O-Ring
M82246
10.Test for short circuited windings using a growler.

Screw (2)
Put armature in a growler and hold a hacksaw
blade above each slot while slowly rotating
armature. Rear Cover
If coil is shorted, the blade will vibrate on the slot. Cap Screw (2)
M82233
NOTE: A short circuit most often occurs because of 4. Remove field coil brushes from brush holder.
copper dust or filings between two
commutator segments. 5. Pry brush springs away and pull negative brushes
11.If test indicates short circuited windings, clean
the commutator of dust and filings. Check the 6. Remove brush holder.
armature again. If the test still indicates a short
circuit, replace the armature.
Brush Spring
Field Coil Brush (2)
Hacksaw Blade
Armature
Brush Holder
M36754
Growler M82125A 7. Remove armature from field coil housing.

8. Remove felt washer and o-ring, if equipped.
9. Inspect and test brushes, holder, field coil and
armature. (See Inspection/Test procedures.)
1-116 4/7/95
Starter
Felt Washer Spring (4)

Negative Brush
Armature
Holder
Field Coil Housing
1
O-Ring M36759
Brush
Length
Assembly Field Brush
Holder
Assembly is done in the reverse order of M82234
disassembly.
• Apply multipurpose grease to bearing cup inside NOTE: Test field coil using an ohmmeter or test
rear cover and felt washer, if equipped. light.
IMPORTANT: When installing rear cover, be 4. Test for grounded field winding:
sure field coil brush wires do not touch cover. Touch one probe of tester to field coil brush and
Turn brush holder slightly to take up slack in other probe to field coil housing. Be sure the brush
brush wires. Press wires inward to clear rear lead is not touching the frame. If there is continuity,
cover. the coil is grounded and the field coil housing
assembly must be replaced.
Inspection/Test/Replacement
1. Measure holder and field coil brush lengths.
Minimum brush length is 8.5 mm (0.335 in.). Touch one probe of tester to each field coil brush. If
Replace brush holder or field coil if brush length there is no continuity, the field coil is open and the
is below minimum. field coil housing assembly must be replaced.

light. Field Coil Brush

Touch one probe of tester to negative brush holder
and other probe to field brush holder. If there is
continuity, replace the brush holder.
necessary.
Field Coil
Housing
M82235
4/7/95 1-117
Starter
IMPORTANT: Do not clean armature with NOTE: A short circuit most often occurs because of
solvent. Solvent can damage insulation on copper dust or filings between two
windings. Use only mineral spirits and a commutator segments.
brush.
6. Inspect armature. Look for signs of dragging the commutator of dust and filings. Check the
against pole shoes. armature again. If the test still indicates a short
bars, or any material which might cause short
1 circuits between bars. If necessary, clean and Hacksaw Blade
touch up with 400 sandpaper. NEVER use emery
finished.
Armature
or test light.
8. Test for grounded windings:
Touch probes on one commutator bar and armature
shaft. Armature windings are connected in series, so Growler M82125A
only one commutator bar needs to be checked.
12.Inspect armature cover and housing bearings for
If test shows continuity, a winding is grounded and
wear or damage. Replace if necessary.
the armature must be replaced.
To replace bearings:
9. Test for open circuited windings:
Bearings are press fit. Remove bearings using a
Touch probes on two different commutator bars. If
knife-edge puller set.
test shows no continuity, there is an open circuit and
the armature must be replaced. IMPORTANT: Install both bearings with sealed
side toward armature.
Commutator Bars Install new housing bearing tight against shoulder of
shaft using a piece of pipe.
Install new rear cover bearing tight against shoulder
of shaft using a driver set.
Rear Cover Bearing
Housing Bearing
Armature Shaft
M82236

armature.
M82237
If coil is shorted, the blade will vibrate on the slot.
1-118 4/7/95
Starter
STARTER GEAR TRAIN AND

OVERRUNNING CLUTCH - Plunger Spring
NIPPONDENSO 1.0 kW
1. Remove two motor-to-clutch housing cap screws
and two clutch housing-to-solenoid housing
screws.
1
Motor-to-Clutch
Housing Cap Screws Gear
Clutch Housing
M82239
NOTE: Starter is equipped with either a 33 mm

(1.299 in.), 44 mm (1.732 in.) or 44.5 mm
(1.752 in.) drive gear on end of clutch shaft.
Disassembly procedures are slightly
different.
4. Starter with 33 mm (1.299 in.) drive gear:
Remove clutch assembly from housing.
5. Remove retainer, five rollers and pinion gear.
M82233
6. Remove steel ball.
Steel Ball
Clutch Housing-to- Clutch Assembly

Solenoid Housing
Screws
Pinion Gear
M82238
2. Separate clutch housing from solenoid/motor

Roller (5)
assembly.
Retainer
3. Remove plunger spring and gear, if equipped. M82240
4/7/95 1-119
Starter
7. Put clutch (housing) assembly into a soft-jawed

vice, as shown. Clutch Assembly
Clutch Housing
Starter with 44 or 44.5 mm
8. Tighten vise slowly, until drive gear compresses. (1.732 or 1.752 in.)
drive gear only.
9. Remove retainer and circlip.
Retainer Drive Gear
Circlip
1
Spring
Retainer
Circlip
M82242
(1.732 or 1.752 in.)
Drive Gear Shown
12.Remove washer, toothed washer, spring and
M82241 clutch shaft.
necessary.
CAUTION Clutch Shaft

Shaft could be propelled from clutch unit
with considerable force if spring is not Spring
allowed to extend fully while in vise.
10.While holding clutch assembly, slowly open vise
until all spring compression is relieved.
11.Starter with 33 mm (1.299 in.) drive gear:
Remove drive gear and spring from clutch
assembly. Clutch
Starter with 44 mm (1.732 in.) or 44.5 mm (1.752 Toothed Washer

in.) drive gear: Remove drive gear, spring and clutch
assembly from housing. Large Washer
M82243
Assembly
disassembly.
• Apply multipurpose grease to bearings, clutch
shaft, springs, pinion gears, retainer, rollers and
steel ball.
• Install large washer with flat side toward clutch
assembly.
• Install retainer with cupped side away from
clutch assembly.
1-120 4/7/95
Starter
STARTER SOLENOID -
NIPPONDENSO 1.0 kW
Terminal Bolt
2. Remove three screws and clip. Nut
Washer
3. Remove cover and gasket.
1
Field Lead Contact Plate
Clip O-Ring
Insulator M36771
Assembly
disassembly.
Screw (3) M82244
NOTE: The assembly sequence of the left and right
4. Remove plunger. terminals is similar. Be sure solenoid
terminal lead is installed between terminal
5. Disassemble terminals. Remove parts from each bolt and contact plate. Also, be sure smaller
terminal in order shown. contact plate is on the left side.
6. Inspect copper washer and contact plates for
excessive burning or pitting. Clean burnt areas to
improve electrical contact. Replace contacts or
plunger if necessary. The solenoid is not Solenoid Terminal
serviceable. If defective, replace solenoid Lead
housing assembly.
Contact Plates
Terminal Bolt
Small Contact
Plate M36771
Spring
Plunger
Copper Washer
M82245
4/7/95 1-121
Alternator
ALTERNATOR - KOKOSAN 20A 7. Remove wire clamp.

Disassembly/Inspection 8. Remove connector from harness leads.
1. Remove nut and washers. 9. Remove two screws and stator.
2. Tap on end of shaft with a soft-faced hammer to 10.Inspect all parts for wear or damage. Replace as
separate flywheel assembly from coil plate necessary.
assembly.
Wire Clamp
3. Remove long spacer.
1 Lock Washer
Washer Coil plate
Flywheel Assembly Screw (2)
Nut
27 N•m
(20 lb-ft)
Bearing
Press fit in
coil plate.
Connector Stator M82249A
Coil Plate Assembly

Assembly
Long Spacer Assembly is done in the reverse order of
M82247A disassembly.
NOTE: Bearing and flywheel are press fit on shaft. • With sheave half on shaft, press shaft into
4. Remove shaft from bearing, short spacer, washer, flywheel until sheave half bottoms on flywheel
flywheel and sheave half, using a press. face.
5. Inspect all parts for wear or damage. Replace as • With washer and short spacer installed, press
necessary. new bearing onto shaft until it bottoms on
spacer.
Short Spacer Washer
VOLTAGE REGULATOR -
Flywheel NIPPONDENSO 35A
Replacement
Shaft 1. Remove three attaching screws.
Bearing
Press fit on Altaching Screw (3)
shaft. M5
4 N•m (31 lb-in.)
Sheave Half
M82248A
NOTE: Remove bearing only if replacement is

necessary.
6. Inspect bearing in coil plate for wear or damage.
To replace bearing: M36725
Remove bearing using a spark plug socket and a

press. Install bearing into coil plate until it bottoms 2. Remove end frame-to-rectifier nut.
in bore using a 1 in. socket.
1-122 4/7/95
Alternator
3. Remove nuts and insulators. ALTERNATOR - NIPPONDENSO 35A
Disassembly
End Frame-to-Rectifier Nut 1. Remove three attaching screws.
M5
4 N•m (31 lb-in.)
Attaching Screw (3)
M5
4 N•m (31 lb-in.)
1
Nuts and Insulators
M36726
IMPORTANT: Do not pry against stator wires.

4. Use a screwdriver to pry end frame from stator. M36725
Do not separate stator from front frame.
End
Frame 2. Use a screwdriver to separate rotor assembly
from stator assembly.
Stator
Stator Assembly
Front
Frame
M36727
IMPORTANT: Do not heat connections longer

than necessary to melt solder, as excess heat
will damage rectifier assembly.
5. Use a soldering gun with a least 120 watt
capacity to disconnect terminals. Replace voltage Rotor Assembly
M36730
regulator.
Rotor Assembly:
Voltage Regulator
• Rear bearing is press fit. Replace only if
necessary. Remove bearing using a puller set.
Install bearing until flush with end of rotor shaft.
Press only on inner race of bearing.
3. Put rotor assembly in a soft-jawed vise. Remove
nut, lock washer, sheave, fan and bushing.
4. Put front frame on open jaws of vice. Use a soft-
Terminals faced hammer to remove rotor and spacer.
M36728
5. Remove three screws, retainer, front bearing,
Installation is done in the reverse order of removal. washer and felt washer.
• If additional solder is needed, use ONLY 60-40 6. Inspect all parts for wear or damage. Replace as
rosin-core solder. necessary.
4/7/95 1-123
Alternator
Rear Bearing Fan

Apply multipurpose grease Bushing
to O.D. during assembly.
Sheave
Screw (3)
2 N•m (16 lb-in.) Lock
Washer
1
Front
Bearing
Rotor
Spacer
Retainer Nut
M14
Washer 54 N•m (40 lb-ft)
Felt Washer
Apply multipurpose grease
during assembly. Front Frame
M82250A
7. Test rotor. (See Inspection/Test procedures.) 11.Use a soldering gun with at least 120 watt
capacity to disconnect terminals. Remove voltage
Stator Assembly:
regulator.
8. Remove end frame-to-rectifier nut.
9. Remove nuts and insulators. Voltage Regulator
10.Use a screwdriver to pry end frame from stator.
End Frame-to-Rectifier Nut

M5
4 N•m (31 lb-in.)
Terminals
M36728
12.Melt solder inside the connecting pipes. While

solder is hot, open the flattened pipe with a
Nuts and Insulators needle nose pliers. Pull stator wire from pipe.
M36726
1-124 4/7/95
Alternator
Inspection/Test
Rotor:
• Inspect the rotor slip rings for dirt build-up,
rough spots, or out of roundness. If necessary,
polish the surface of the slip rings using No. 00
sandpaper or 400-grit silicon carbide paper.
• Touch the probes of an ohmmeter to slip rings.
Replace rotor if test indicates no continuity (no
M36739
needle movement). 1
13.Inspect and test brushes, stator and rectifier. (See Ohmmeter
Inspection/Test procedures.)
Assembly
disassembly.
NOTE: The three pair of lead wires on the stator are
not evenly spaced. Rotate the rectifier until Rotor Shaft
the terminal pipes align with the stator Slip Rings M82110A
leads.
• Bend the stator lead wires, as necessary, to • Touch the probes of the ohmmeter to the shaft
obtain an approximate distance of 33.50 mm and one of the slip rings. Repeat for other slip
(1.300 in.) from stator to rectifier. Connect the ring. Replace rotor if test shows continuity
six leads using a soldering gun. (needle movement).
• If additional solder is needed, use ONLY 60-40
rosin-core solder.
Ohmmeter
IMPORTANT: Be sure six stator lead wires do
not contact end frame when installed.
• Before assembling stator assembly to rotor
assembly, push brushes into brush holder and
insert a wire through access hole in rear at end
frame to lock brushes in place.
Rotor Shaft
Slip Rings M82111A
Wire Brushes:
Brushes
• Inspect brush holder and brushes for damage.
Brushes must slide freely and the springs must
hold the brushes firmly against the slip rings of
the rotor.
• Measure brushes for wear. Minimum exposed
M36748
length must be 5.50 mm (0.220 in.) or to wear
limit line on brushes. Replace brushes as
• Assemble rotor assembly to stator assembly and necessary.
fasten with three attaching screws. Remove wire
from access hole.
4/7/95 1-125
Alternator
• Use an ohmmeter or a test light to check for

continuity. Check between the two brushes and
between each brush and ground stud. There Insulator
should be no continuity. Replace brush holder-
rectifier assembly if there is continuity.
Brush Holder
Ground Stud Brush

Brushes
1
Brush Lead
Wire
M36736
• To replace brushes:
- Melt solder from brush lead connections and -
remove brushes and springs. Insulating Washers
- Inspect springs for wear or damage. Replace

M36745
as necessary.
NOTE: If additional solder is needed, use ONLY 60-

40 rosin-core solder.
Stator:
Brush Lead Connections
• Inspect stator for defective insulation,
discoloration or a burned odor. If any of these
defects are found, replace stator.
NOTE: Use an ohmmeter that is sensitive to
resistance of 0 to 1 ohm.
M36737
• Touch probes of an ohmmeter to each pair of
- Push brush lead wire through spring. Insert stator wires. Equal continuity readings should be
spring and brush in brush holder with lead observed between each pair of leads. If readings
protruding through hole in brush holder. are not equal, replace stator.
Make sure the longest side of brush is on side
of brush holder with raised lip.
- Hold brushes in position so that exposed
length is 13 mm (0.500 in.)
- Solder brush leads in this position. Cut off
excess length of brush lead wire.
- Be sure insulating washers and insulator are
in place.
M36740
1-126 4/7/95
Alternator
• Touch one probe of the ohmmeter to the bare • Test the diodes by touching probes to output
metal surface of stator and the other probe to a post and the three outer terminals.
bare stator lead wire. Repeat for each wire.
• Switch the probes and check each terminal
Replace stator if test indicates continuity.
again. There should be continuity in only one
direction between each terminal and the output
post.
M36741
Rectifier: Output Post

M36743
NOTE: The three inner terminals are connected by

a printed circuit in the rectifier. • Test the diodes by touching probes to ground
post and the three outer terminals.
• Test the three inner terminals using an
ohmmeter. Move probes so all terminals are • Switch the probes and check each terminal
cross checked. Replace the rectifier if test shows again. There should be continuity in only one
no continuity. direction between each terminal and the ground
post.
A shorted diode would have continuity in both
directions. An open diode would have no continuity
in either direction. Replace the rectifier assembly if
any of the six diodes are defective.
Inner
Terminals
M36742
Ground
NOTE: Each of the three outer terminals on the Post
rectifier is connected to two diodes
permitting current flow in only one
direction. M36744
4/7/95 1-127
Alternator
VOLTAGE REGULATOR -
NIPPONDENSO 40A Nut
69 N•m (51 lb-ft)
Replacement
1. Remove nut and insulator.
2. Remove three screws and cover.
1 Cover Sheave
M52469
Nut and
Insulator 4. Remove four screws and straighten stator wire
leads.
5. Remove rectifier.
Rectifier
M52470
Stator Wire
Lead (4)
3. Remove two screws, brush holder and cover.
4. Remove three screws. Replace voltage regulator.
Long Screw (2) Voltage

Regulator
M52471
6. Remove two nuts, two screws and end frame

assembly.
Short
Screw
7. Press rotor shaft from end frame.
Brush Holder
8. Remove spring washer.
and Cover M52472
Spring
Installation is done in the reverse order of removal. Washer
IMPORTANT: Make sure to install short screw

at location shown. Longer screw will contact
frame and cause damage to the charging
system.
ALTERNATOR - NIPPONDENSO 40A End Frame

Rotor Assembly
Shaft
Disassembly M52473
1. Remove voltage regulator. (See VOLTAGE 9. Remove four screws and retainer.
REGULATOR - REPLACEMENT in this group.)
2. Remove nut. NOTE: Front bearing is press fit in front frame.
Remove bearing only if replacement is
3. Remove sheave using a puller set. necessary.
1-128 4/7/95
Alternator
10.Inspect bearing in front frame for wear or

damage. Replace if necessary. Replace bearing
Rear Bearing
using a driver set and a press.
Front Frame
Front Bearing
Screw (4)
Slip Rings 1
Rotor Core
2 N•m (16 lb-in.) M52474
Retainer
Brushes:
M52475 • Inspect brush holder, brushes and springs for
damage. Brushes must slide freely and springs
11.Inspect and test brushes, stator and rectifier. (See must hold brushes firmly against the slip rings of
Inspection/Test in this group.) the rotor.
• Measure length of brush protruding from holder.
Assembly If length is less than wear limit, replace brushes.
disassembly.
• After installing rectifier, form a loop in stator
wire leads, insert screws through loop and
secure rectifier and wire leads.
Inspection/Test
Rotor:
M52478
NOTE: Rear bearing and rotor assembly are not
serviced separately. Damaged parts require
that rotor assembly and bearing be replaced Brush Length Specifications
as a unit. New. . . . . . . . . . . . . . . . . 10.50 mm (0.410 in.)
• Inspect bearing for wear or damage. Replace Wear Limit. . . . . . . . . . . . 4.50 mm (0.170 in.)
complete rotor if necessary.
• Check continuity between brush and terminal
• Inspect slip rings for dirt build-up, rough spots “A”. Check continuity between brush and
or out-of-roundness. If necessary, polish the terminal “B”. There should be continuity only at
surface of the slip rings using No. 00 sandpaper these points.
or 400-grit silicone carbide paper. Measure outer
diameter of slip rings. Replace rotor if less than
14 mm (0.550 in.). A B
needle movement).
• Touch probes of ohmmeter to the rotor core and
one of the slip rings. Repeat for other slip ring.
M52479
Replace rotor if test shows continuity (needle
movement).
4/7/95 1-129
Alternator
Stator: Rectifier:
• Inspect stator for defective insulation, NOTE: Set the ohmmeter to the K ohm range.
defects are found, replace stator. • Check continuity between output post and each
diode lead. Reverse ohmmeter leads and
NOTE: Use an ohmmeter that is sensitive to recheck. There should be continuity in one
resistance of 0 to 1 ohm. direction, but not the other.
• Check for continuity between each stator lead A shorted diode would have continuity in both
and stator body. Replace stator if test indicates directions. An open diode would have no continuity
1 continuity. in either direction. Replace the rectifier if any of the
four diodes are defective.
To replace stator:
- Scribe a mark on housing, at notch in stator, to
aid in installation of a new stator.
Diode Lead (4)
- Remove two studs.
- Replace stator using a punch and hammer.
Stator
Lead (4)
Stator Body
Output Post
M52477
Stud (2)
Scribe Mark on Notch

Housing
M82251
1-130 4/7/95
Diagnosis
ENGINE AND FUEL SYSTEM TROUBLESHOOTING CHART
PROBLEM OR
Exhaust smoke black or grey or

Engine will not stay running, or
Engine cranks but will not start
Oil in the coolant or coolant in
Lack of fuel at injection pump.

Engine operating temperature
Engine surges, or has uneven
SYMPTOM
Engine has low oil pressure.
Exhaust smoke blue or uses

low on power. Fuel in oil. Oil
Engine runs rough, misses,
Exhaust smoke white.

Engine will not crank.
or uncontrolled rpm.
uses too much fuel.

noisy, vibrates or
stalls frequently.
or starts hard.
1
too much oil.

CHECK OR
is incorrect.
level high.
SOLU-
the oil.
TION
Fuel pump screen, fuel filter, or fuel

line restricted. Fuel dirty, contains ● ● ● ● ● ● ●
water or wrong grade.
Air filter elements dirty or plugged.
● ● ● ● ● ● ●
Replace.
Fuel shut-off valve turned off, or
restricted. Solenoid linkage ● ● ● ● ● ●
misadjusted. See adjustment.
Muffler or exhaust manifold leak. ● ● 3
Defective glow plugs. ●
Injection pump or governor
malfunctioning. Injection pump ● ● ● ● ●
timing incorrect.
Defective cranking components or
● ●
connectors.
Low compression from worn rings,
cylinder bore, piston, valves or ● ● ● ● ● ●
warped head.
Valve clearance incorrect. ● ● ● ● ● ●
Burned or warped valves and valve
● ● ● ● ● ●
seats. Defective valve spring.
Starter cranking rpm too slow.
Damaged starter. Excessive engine ● ● ●
load.
Fuel pump leaking or not operating.
See Fuel Supply Pump Pressure ● ● ● ● ● ●
Test.
Engine oil viscosity or level
● ● ● ● ●
incorrect.
Injector pressure incorrect or
● ● ● ● ● ● ●
leaking.
Cylinder head gaskets leaking or
● ● ● ● ● ● ● ● ●
damaged.
Radiator. ● ● ●
4/7/95 1-131
Diagnosis
ENGINE SYSTEM DIAGNOSIS

Conditions:
• Engine mounted on level surface.
• Key switch off unless indicated otherwise.
Test Location Normal If Not Normal

1. Engine dipstick Oil level between “L” and “H” marks. Change oil and inspect for source of
and exterior Oil not burnt, or contaminated with contamination. Check gaskets, seals,
1 engine surface- metal particles, fuel, or coolant. No plugs, cylinder head, block, and intake
engine oil check. external leakage, filter clean. manifold and breather. Change oil
filter.
2. Coolant tank and Coolant level between marks on tank Add proper coolant mix.
radiator. when engine is warm.
Coolant in radiator full to top.
- Cooling System
Check. Coolant not contaminated with oil, Drain and flush system. Check for
fuel or discolored brown. source of contamination.
Radiator screen free of debris. Clean or replace.
Hoses not cracked or leaking, clamps Pressure test radiator and cap.
and radiator cap tight.
3 Fan belt tight, not glazed or cracked. Replace and adjust belt tension.
Fan blades not damaged or warped. Replace fan.
3. Fuel tank, pump, Fuel level correct, not contaminated, Drain and clean fuel tank. Add fresh
pump screen, correct grade of fuel, no water. fuel.
lines, filter, filter Fuel pump screen and in-line filter free Replace filters.
shutoff valve. of debris.
- Fuel System Check Fuel shutoff valve in “ON” position. Move to “ON” position.
Fuel hoses not cracked or leaking. Replace.
Fuel hose clamps tight. Replace or tighten.
Fuel tank does not have vacuum. Replace fuel tank check valve.
4. Air filter and air Air filter hose not cracked, clamps Replace and tighten clamps.
intake. tight.
Element not plugged. Air filter Replace element or housing.
- Air Intake System
housing sealed, no dirt tracking inside
Check
filter element.
5. Fuel shutoff Fuel shutoff solenoid must pull in and Check shutoff solenoid adjustment.
solenoid. (Key in stay in. Solenoid must bottom out. Clean any dirt from under solenoid
RUN position.) Shutoff shaft must still move slightly. boot. If solenoid will not pull in and
hold in, see Fuel Shutoff Solenoid
Circuit Test Points in ELECTRICAL
section of Machine TM.
6. Glow plug Indicator light should come on up to See Glow Plug Circuit Test Points in
indicator light. 15 seconds depending on air ELECTRICAL section of Machine
(Key in RUN temperature. TM.
position.)
1-132 4/7/95
Diagnosis
ENGINE SYSTEM DIAGNOSIS - Continued

7. Fuel filter, fuel Fuel level increases in filter. See Fuel Pump Circuit Test Points in
pump. (Key Fuel pump operating - listen for ELECTRICAL section of Machine
switch in RUN humming sound. TM. Test fuel pump pressure. (See
position.) Fuel present in return hose at fuel Operational Tests in this section.)
pump. Replace fuel filter.
8. Throttle lever and Linkage not binding and adjusted Repair, replace or adjust cable. 1
cable. correctly.
9. Intake and Cold engine. Valve clearance within Check and adjust. (See Checks, Tests
exhaust valves. specification. and Adjustments in this section.)
Valves not sticking. Check valve guides and stems.
10. Fuel at injectors. Crack fuel injection lines at injectors. Check spray pattern and cracking
(Key in START Fuel shutoff solenoid pulled in. pressure. (See Checks, Tests and
position - engine Adjustments in this section.) Replace
cranking.) Engine must crank. injectors.See Cranking Circuit Test
Points in ELECTRICAL section of
Machine TM.
11. Injector ports. Cylinder compression within Perform cylinder compression test. 3
(Key in START specification. Pressure difference (See Operational Tests in this section.)
position.) between cylinders within
specification.
12. Flywheel and Minimum cranking rpm within See Starter Amp Draw Test in
starter. specification. ELECTRICAL section of Machine
TM.
13. Injection pump Timing should be correct. Remove Perform injection pump static timing
timing pump as the LAST possible solution. adjustment. (See Checks, Tests and
inspection. (Key Adjustments in this section.) Have
OFF.) pump tested by a qualified Service
Repair Shop.
14. Injection pump Engine runs smooth under load. See Slow Idle and Fast Idle
idle settings. Engine rpm to specification. Adjustments in ENGINE section of
(Engine running). Machine TM.
15. Oil pressure Oil pressure in specification. Test engine oil pressure. (See
sender port. Operational Tests in this section.)
16. Thermostat. Clean from corrosion, rust, or debris. Replace thermostat.
(Engine at Opening temperature within Perform thermostat opening test. (See
operating specification. Checks, Tests and Adjustments in this
temperature.) section.)
17. Muffler. Not restricted. Replace muffler.
4/7/95 1-133
VALVE CLEARANCE, CHECK AND Cylinders

ADJUSTMENT - EARLY 3TNA72 1 2 3
(430 LGT) E I E I E I
Flywheel End
Fan End
Reason:
To achieve correct engine operation.
No. 1 Piston at TDC
Equipment: M82327A
1 • Feeler Gauge
To adjust valves, loosen nut and turn adjusting screw
until clearance is 0.20 mm (0.008 in.). Hold screw
Procedure:
while tightening nut.
NOTE: “Top Dead Center (TDC)” is the piston at
its highest point.
1. Remove rocker arm cover.
Feeler
2. Turn crankshaft pulley clockwise until No.1 Gauge
cylinder timing mark on pulley aligns with arrow
on timing gear cover.
Arrow
T6105BF
5. Turn crankshaft pulley one revolution (360°).

This puts the piston in No. 2 cylinder at TDC
No. 1 Timing Mark compression stroke.
M35256 6. Measure and adjust valve clearance on the valves
(arrows) with No. 2 piston at TDC.
NOTE: No. 1 cylinder is the closest to the flywheel.
Cylinders
3. Try to move both No. 1 cylinder rocker arms or
push rods. 1 2 3
E I E I E I
Flywheel End
If rocker arm push rods are not loose, rotate

Fan End
flywheel one revolution (360°). If both rocker arm

push rods are loose the piston is at TDC on
compression stroke.
4. Measure and adjust valve clearance on the valves No. 2 Piston at TDC
M82327A
1-134 4/7/95
VALVE CLEARANCE, CHECK AND

ADJUSTMENT - 3TN66 AND LATER
3TNA72
No. 1 TDC Mark Index Mark on
Reason: on Flywheel Flywheel Plate
Equipment:
• Feeler Gauge 1
M37501
Procedure:
375 SSL, 670 CUT
NOTE: Location of the index mark will be different
as a result of the various engine
applications. NOTE: No. 1 cylinder is the closest to the flywheel.
The index mark appears on the following: push rods.
- 15 EX, 3009 OEM: Flywheel housing. If rocker arm push rods are not loose, rotate
- 330/332 LGT, F915 FM, 430 LGT (Later),
push rods are loose, the piston is at TDC on
F925/35 FM: Flywheel cover. compression stroke.
- 375 SSL, 670 CUT: Flywheel plate. 5. Measure and adjust valve clearance on the valves
- 655 CUT, 455 LGT, 755/56 CUT: Flywheel (arrows) with No. 1 piston at TDC.
guard and plate.
Cylinders
1. Remove rocker arm cover. 1 2 3
E I E I E I
2. Remove plug from timing hole in flywheel
Flywheel End
Fan End
housing/cover, if equipped.
its highest point.
3. Turn crankshaft pulley clockwise until No.1 No. 1 Piston at TDC
M82327A
cylinder TDC mark on flywheel aligns with index
mark on flywheel housing/cover or plate. To adjust valves, loosen nut and turn adjusting screw
while tightening nut.
No. 1 TDC Mark
on Flywheel
Feeler
Gauge
Index Mark on Flywheel

Housing/Cover
M37500
330/332 LGT, F915 FM, 430 LGT (Later),

F925/35 FM, 15 EX, 3009 OEM
T6105BF
4/7/95 1-135
6. Turn crankshaft pulley one revolution (360°). Specifications:

This puts the piston in No. 2 cylinder at TDC Standard Clearance . . . . . . . . 0.20 - 0.40 mm
compression stroke.
. . . . . . . . . . . . . . . . . . . . . (0.0079 - 0.0157 in.)
7. Measure and adjust valve clearance on the valves Wear Limit. . . . . . . . . . . 0.55 mm (0.0217 in.)
Results:
Cylinders
• If side play exceeds wear limit, replace
1 2 3 connecting rod and connecting rod cap.
1 E I E I E I
Flywheel End
Fan End
CONNECTING ROD BEARING
CLEARANCE CHECK
No. 2 Piston at TDC Reason:
M82327A
To measure oil clearance between connecting rod
CONNECTING ROD SIDE PLAY bearing and crankshaft journal.
CHECK
Equipment:
Reason:
• PLASTIGAGE®
To determine proper side clearance between
crankshaft and connecting rod. Procedure:
Equipment: IMPORTANT: Connecting rod caps must be

installed on the same connecting rod and in
• Feeler Gauge the same direction to prevent crankshaft and
connecting rod damage.
Procedure:
1. Remove connecting rod cap.
1. Insert a feeler gauge, according to specifications,
between connecting rod cap and crankshaft. 2. Wipe oil from bearing insert and crankshaft
journal.
3. Put a piece of PLASTIGAGE, or an equivalent,
along the full length of the bearing insert
approximately 6 mm (0.250 in.) off center.
Feeler Gauge
PLASTIGAGE M35351
M82116A 4. Turn crankshaft approximately 30° from bottom

dead center.
1-136 4/7/95
5. Install connecting rod end cap and original cap Equipment:

screws. Tighten cap screws to 23 N•m (203 lb-
• Dial Indicator
in.).
6. Remove cap screws and connecting rod cap. Procedure:
NOTE: The flattened PLASTIGAGE will be found NOTE: Crankshaft end play can be measured at
on either the bearing insert or crankshaft front end or rear end of crankshaft.
journal. Procedure is performed from the rear end.
7. Use the graduation marks on the envelope to The flywheel is removed to show detail.
compare the width of the flattened 1. Fasten dial indicator to engine and position 1
PLASTIGAGE at its widest point. indicator tip on end of crankshaft.
8. Determine bearing clearance. The number within IMPORTANT: Do not use excessive force when
the graduation marks indicates the bearing moving crankshaft to avoid damaging
clearance in inches or millimeters depending on bearings.
which side of the envelope is used.
2. Push crankshaft toward rear as far as possible.
9. Remove PLASTIGAGE.
3. Zero the dial indicator.
4. Using a bar, gently pry the crankshaft as far
forward as possible.
Graduation Marks
on Envelope
Flattened
PLASTIGAGE M82117A
Specifications:
Standard Clearance . . . . . . 0.020 - 0.072 mm
. . . . . . . . . . . . . . . . . . . . . (0.0008 - 0.0028 in.)
Wear Limit. . . . . . . . . . . 0.15 mm (0.0059 in.)
Dial Indicator
Results:
Crankshaft M82118A
• If clearance exceeds wear limit, replace bearing
inserts. Specifications:
®PLASTIGAGE is a registered trademark of the DANA Standard Clearance . . . . . . 0.090 - 0.271 mm
Corporation. . . . . . . . . . . . . . . . . . . . . . . . (0.004 - 0.011 in.)
Wear Limit. . . . . . . . . . . 0.33 mm (0.0129 in.)
CRANKSHAFT, END PLAY CHECK
Results:
Reason: • If end play exceeds wear limit, replace thrust
To determine proper side clearance between bearings.
crankshaft and engine block.
4/7/95 1-137
CRANKSHAFT MAIN BEARING, 7. Determine main bearing clearance. The number

CLEARANCE CHECK within the graduation marks indicates the bearing
clearance in inches or millimeters depending on
Reason:
8. Remove PLASTIGAGE.
To measure oil clearance between main bearing and
crankshaft journal.
Equipment: Graduation Marks

on Envelope
1 • PLASTIGAGE®
Procedure:
IMPORTANT: Main bearing caps must be Flattened
PLASTIGAGE
installed on the same main bearing and in the M82119AE
same direction to prevent crankshaft and main
bearing damage. Specifications:
1. Remove main bearing cap. Standard Clearance . . . . . . 0.020 - 0.072 mm
2. Wipe oil from bearing insert and crankshaft . . . . . . . . . . . . . . . . . . . . . (0.0008 - 0.0028 in.)
journal. Wear Limit. . . . . . . . . . . 0.15 mm (0.0059 in.)
along the full length of the bearing insert Results:
approximately 6 mm (0.250 in.) off center. • If clearance exceeds wear limit, replace bearing
inserts.
®PLASTIGAGE is a registered trademark of the DANA Corpo-
ration.
PLASTIGAGE
VALVE LIFT CHECK
Reason:
Can indicate excessive wear on cam lobes,
followers, and/or push rods.
Equipment:
M35382
• Dial Indicator
4. Install main bearing cap and cap screws. Tighten
cap screws to: Procedure:
3TN66 . . . . . . . . . . . . . . . . . . 54 N•m (40 lb-ft) 1. Adjust valve clearance. (See procedure in this
3TNA72 (3009) . . . . . . . . . . 79 N•m (58 lb-ft) group.)
5. Remove cap screws and main bearing cap. 2. Remove rocker arm cover. (See Cylinder Head,
NOTE: The flattened PLASTIGAGE will be found
on either the bearing insert or crankshaft 3. Fasten dial indicator to engine and position
journal. indicator tip on valve retainer. Valve must be
fully closed and rocker arm must move freely.
6. Use the graduation marks on the envelope to
compare the width of the flattened 4. Zero the dial indicator.
PLASTIGAGE at its widest point. 5. Manually turn crankshaft pulley clockwise (from
fan end).
1-138 4/7/95
6. Observe dial indicator as valve is moved to the Procedure:

full open position. Valve lift (intake and exhaust)
should be 7.5 mm (0.300 in.).
Repeat for each valve.
2. Fasten dial indicator to engine and position
indicator tip on end of camshaft.
3. Push camshaft toward the rear as far as possible.
5. Pull camshaft forward as far as possible. 1
T6333DT
Results:
• If valve lift is less than specification, remove and
inspect camshaft, followers and push rods. (See M37512
Camshaft and Timing Gear Train and/or

Cylinder Head, Valves and Manifolds in this Specifications:
section.) Standard Clearance . . . . . . . . 0.05 - 0.20 mm
. . . . . . . . . . . . . . . . . . . . . (0.0020 - 0.0079 in.)
CAMSHAFT END PLAY CHECK Wear Limit. . . . . . . . . . . . 0.40 mm (0.016 in.)
Results:
Reason:
• If end play exceeds wear limit, remove camshaft
To determine proper side clearance between and replace thrust plate. (See Camshaft and
camshaft gear end journal and thrust plate. Timing Gear Train in this section.)
Equipment:
• Dial Indicator
4/7/95 1-139
TIMING GEAR BACKLASH, CHECK - All Except

EARLY 3TNA72 (430 LGT) Fuel Injection Pump Gear-to-Oil
Pump Gear. . . . . . . . . . . . . 0.04 - 0.12 mm
Reason: . . . . . . . . . . . . . . . . . . (0.0016 - 0.0047 in.)
To check for wear between meshing gears, resulting Wear Limit. . . . . . . . . . . 0.20 mm (0.0079 in.)
in excessive noise and poor engine performance.
Results:
Equipment: • If backlash exceeds wear limit, replace meshing
1 • Dial Indicator gears as a set:
Idler Gear, Camshaft Gear, Crankshaft Gear, AND/
Procedure: OR Idler Gear, Fuel Injection Pump Gear, and Oil
1. Measure backlash between meshing gears. Pump Gear.
Specifications:
Standard Backlash
Fuel Injection Pump Gear-to-Oil
Pump Gear. . . . . . . . . . . . . 0.11 - 0.19 mm
. . . . . . . . . . . . . . . . . . (0.0043 - 0.0075 in.)
Fuel Injection Pump Gear-to-Idler Gear

Camshaft Gear-to-Idler Gear
Fuel Injection
Pump Gear-to-Oil Idler Gear-to-Crankshaft Gear
Pump Gear
M82328A
1-140 4/7/95
TIMING GEAR BACKLASH, CHECK - All Except

3TN66 AND LATER 3TNA72 Crankshaft Gear-to-Oil
Pump Gear. . . . . . . . . . . . . 0.04 - 0.12 mm
Reason: . . . . . . . . . . . . . . . . . . (0.0016 - 0.0047 in.)
Results:
Equipment: • If backlash exceeds wear limit, replace meshing
• Dial Indicator gears as a set: 1
Idler Gear, Camshaft Gear, Crankshaft Gear, Oil
Procedure: Pump Gear AND/OR Idler Gear, Fuel Injection
1. Measure backlash between meshing gears. Pump Gear.
Specifications:
Standard Backlash
Crankshaft Gear-to-Oil
Pump Gear. . . . . . . . . . . . . 0.11 - 0.19 mm
. . . . . . . . . . . . . . . . . . (0.0043 - 0.0075 in.)

Idler Gear-to-Crankshaft Gear
Crankshaft Gear-to-Oil Pump Gear M82252A
4/7/95 1-141
FUEL INJECTION NOZZLE TEST Equipment:

(PINTLE-TYPE) • D01109AA Diesel Fuel Injection Nozzle Tester
• D01110AA Adapter Set
• 23622 Straight Adapter
CAUTION • Container
Escaping fluid under pressure can penetrate Connections:

1 hazard by relieving pressure before 1. Connect fuel injection nozzle to D01109AA
disconnecting hydraulic or other lines. Diesel Fuel Injection Nozzle Tester using parts
Tighten all connections before applying from D01110AA Adapter Set and 23622 Straight
pressure. Search for leaks with a piece of Adapter.
cardboard. Protect hands and body from IMPORTANT: Use clean filtered diesel fuel
high pressure fluids. when testing injection nozzles to get best test
If an accident occurs, see a doctor results.
immediately. Any fluid injected into the skin
must be surgically removed within a few Procedure 1:
Test fuel injection nozzle opening pressure
unfamiliar with this type of injury should
following the Nozzle Tester manufacturer's
reference a knowledgable source. Such
instructions.
Company Medical Department in Moline,
Illinois, U.S.A. Specifications:
Opening Pressure . . . . . . . . 11722 ± 480 kPa
. . . . . . . . . . . . . . . . . . . . . . . . . (1700 ± 70 psi)
Reason:
To determine opening pressure, leakage, chatter and Results:
spray pattern of the fuel injection nozzle.
• If pressure reading does not meet specification,
disassemble injection nozzle and inspect nozzle
assembly for contamination or stuck valve. If
necessary, add or remove shims to change
opening pressure.
1-142 4/7/95
36352 Fuel Line 23617 90° Adapter

Assembly
23621 Straight Adapter

D01109AA Diesel Fuel
Injection Nozzle Tester Fuel Injection Nozzle
Container
M35913
Procedure 2: Slow Hand

Test fuel injection nozzle leakage following the Lever Movement . . . . . . . . . . . . . Fine Stream
Nozzle Tester manufacturer's instructions. . . . . . . . . . . . . . . . . . . . . . . . . . Spray Pattern
1. Dry nozzle completely using a lint-free cloth.
Fast Hand
2. Pressurize nozzle to 11032 kPa (1600 psi).
Lever Movement . . . . . . . . . . . Fine Atomized
3. Watch for leakage from nozzle spray orifice. . . . . . . . . . . . . . . . . . . . . . . . . . Spray Pattern
Leakage time should be a minimum of 10
seconds. Correct
Results:
• If leakage time does not meet specification, Proper Spray
Angle
assembly for contamination. Inspect valve
seating surface. Replace nozzle assembly if
necessary.
Procedure 3:
Test fuel injection nozzle chatter and spray
Correct Injection Angle
pattern following the Nozzle Tester manufacturer's
instructions.
1. Pressurize nozzle to 11722 ± 480 kPa (1700 ± 70
psi). Poor
2. Listen for “chatter” sound and watch spray

pattern.
Specifications:
Slow Hand
Lever Movement . . . . . . . . . . . Chatter Sound M82121A
4/7/95 1-143
Results:
• If nozzle chatter or spray pattern does not meet
specifications, disassemble injection nozzle and Thermometer
inspect nozzle assembly for contamination.
Inspect valve seating surface. Replace nozzle
assembly if necessary.
• If there is excessive difference in spray angle or
injection angle, incomplete atomization or
1 sluggish starting/stopping of injection, Thermostat
assembly for contamination. Replace nozzle
M82122A
THERMOSTAT OPENING TEST

Reason: Specifications:
To determine opening temperature of thermostat. Begin Opening . . . . . . . . . . . . . 71° C (160° F)
Equipment: Fully Open . . . . . . . . . . . . . . . . 85° C (184° F)
• Thermometer Minimum Lift Height . . . . . .8 mm (0.310 in.)
• Glass Container Results:

• Heating Unit • If thermostat does not open according to
specifications, replace.
Procedure:
• If closing action is not smooth and slow, replace
thermostat.
CAUTION COOLANT TEMPERATURE SENSOR

TEST
DO NOT allow thermostat or thermometer Reason:
to rest against the side or bottom of glass
container when heating water. Either may To determine operating temperature of sensor.
rupture if overheated. Equipment:
1. Suspend thermostat and a thermometer in a • Thermometer
container of water. • Glass Container
2. Heat and stir the water. Observe opening action • Heating Unit
of thermometer and compare temperatures with
specifications. • Ohmmeter
3. Remove thermostat and observe its closing action

as it cools.
1-144 4/7/95
Procedure: Equipment:
• JT05712 Current Gun
CAUTION • JT05719 Hand-Held Digital Tachometer

• Jumper Cables
DO NOT allow switch or thermometer to rest • Jumper Wire
against the side or bottom of glass container
Procedure:
when heating water. Either may rupture if
overheated. 1. Mount starter in a vise. 1
1. Connect lead wires from ohmmeter probes, to NOTE: Check that battery is fully charged and of
sensor terminal and body. proper size to ensure accuracy of test.
2. Suspend sensor and a thermometer in a container 2. Connect jumper cables to a 12 volt battery.
of water.
3. Connect positive (+) cable to solenoid battery
3. Heat and stir the water. Observe water terminal on starter.
temperature when continuity occurs. Water
temperature should be 107 - 113° C (225 - 4. Connect negative (-) cable to starter body.
235°F). 5. Attach Current Gun to positive cable.
IMPORTANT: Complete this test in 20 seconds
Ohmmeter or less to prevent starter damage.
Probes
6. Use a jumper wire to briefly connect positive (+)
starter terminal to solenoid terminal “S”. Starter
should engage and run.
7. Read and record starter amperage and rpm.
Specifications:
Coolant
Hitachi 0.8 kW. . . . . . . 60 Amps at 7000 rpm
Temperature M82123A Nippondenso 1.0 kW. . 90 Amps at 3000 rpm
Sensor
Minimum Starter RPM
Results: Hitachi 0.8 kW. . . . . . . . . . . . . . . . . . . . . 7000
Nippondenso 1.0 kW. . . . . . . . . . . . . . . . 3000
• If continuity does not occur within temperature
listed, replace sensor.
Results:
• If solenoid “clicks” or chatters and motor does
STARTER NO-LOAD AMP not turn, replace solenoid.
DRAW/RPM TEST
• If pinion gear engages and motor doesn't turn,
Reason: repair or replace starter motor.
To determine if starter is binding or has excessive • If starter engages and runs but amperage is more
amperage draw under no load. than specifications, repair or replace starter.
• If rpm is less than specification, with battery
fully charged, repair or replace starter.
4/7/95 1-145
JT05712 Current Gun
JT05719 Hand-Held Digital Tachometer
1
Jumper Wire
Hitachi 0.8 kW M82149A
JT05712 Current Gun
Jumper Wire
Nippondenso 1.0 kW M82150A
1-146 4/7/95
INJECTION PUMP STATIC TIMING

ADJUSTMENT - EARLY 3TNA72
(430 LGT)
Reason: Timing Tool
To make sure that injection pump timing is set to

manufacturers specification.
Equipment: 1
• Timing Tool (No. 1 fuel injection line cut off at M35865
first bend)
5. Remove glow plugs to aid in turning crankshaft
• External fuel supply
pulley.
Procedure: 6. Turn crankshaft pulley in either direction until the
No. 1 cylinder timing mark aligns with arrow on
IMPORTANT: Injection pump timing should be timing gear cover.
correct. Once timing is set, it will not normally
change during the life of the engine, unless it
was altered. Arrow
Check and adjust timing only as the last

option. Check fuel, fuel supply system,
injectors, air intake system and cylinder
compression before continuing.
NOTE: The flywheel turns counterclockwise (as
viewed from the flywheel end). The number No. 1 Timing Mark
one fuel injection line is toward the
M35256
flywheel.
1. Remove the number one fuel injection line and 7. Put a container under timing tool to collect any
delivery valve fitting. fuel.
2. Remove spring and delivery valve. Do not 8. Turn key switch to ON position. DO NOT start
remove delivery valve seat. engine. Push fuel shutoff solenoid plunger to
3. Install delivery valve fitting and tighten to 42 “hold” position.
N•m (31 lb-ft). 9. Turn flywheel clockwise (as viewed from the
flywheel end) until fuel flows in a stream.
Delivery Valve Fitting 10.Slowly turn flywheel counterclockwise until fuel
flow changes from a stream and then stops
Spring completely. This is the point of injection timing
at which the pump is set.
NOTE: If the fuel flow does not stop, the number
Delivery Valve one piston is on the exhaust stroke instead of
the compression stroke. Turn flywheel one
revolution and repeat Steps 6 - 10.
T6333HP
11.Check timing mark on camshaft pulley. The 15°
timing mark must line up with the arrow on
4. Install timing tool (number one fuel line cut off at timing gear cover.
first bend).
4/7/95 1-147
- Install new shims with the THICKEST shim

against the injection pump body and the
THINNEST shim against the gear housing.
15° Timing Mark
• If timing did not change, have pump tested by a
Arrow diesel injection service shop.
• If timing is OK:
- Remove timing tool.
1 M35868
- Remove delivery valve fitting.
- Install delivery valve and spring.
Specifications: - Install new o-ring and delivery valve fitting.
Injection Pump Timing. . . . . . . . . .15° BTDC Tighten to 42 N•m (31 lb-ft).
. . . . . . . . . . . . . . . (Before Top Dead Center)
- Install number one injection line.
Engine Crankshaft
Position. . . . . . . . . . . . . . . . . . . No.1 Cylinder
. . . . . . . . . . . . . on TDC Compression Stroke INJECTION PUMP STATIC TIMING
ADJUSTMENT - 3TN66 AND LATER
Distance On Outer Surface of Crankshaft 3TNA72
Pulley for Every 0.1 mm (0.004 in.) of
Shim Thickness . . . . . . . 1° or 1 mm (3/64 in.) Reason:
Results: To make sure that injection pump timing is set to
• If timing is not according to specifications: manufacturers specification.
- Remove injection pump and shims (See Fuel
System in this section.) Equipment:
- Measure old shims to determine shim • Timing Tool (No. 1 fuel injection line cut off at
thickness. first bend)
- Measure approximate distance between
timing mark and arrow.
NOTE: Crankshaft pulley always turns clockwise Procedure:
when engine is running.
IMPORTANT: Injection pump timing should be
- If timing mark has not reached arrow, correct. Once timing is set, it will not normally
RETARD pump timing by increasing total change during the life of the engine, unless it
shim thickness. If mark has passed arrow, was altered.
ADVANCE timing by decreasing total shim
thickness. Use new shims. Check and adjust timing only as the last
For every 0.1 mm (0.004 in.) of shim injectors, air intake system and cylinder
thickness, there is approximately a 1° or 1 compression before continuing.
mm (3/64 in.) change in crankshaft pulley
timing. NOTE: The flywheel turns counterclockwise (as
viewed from the flywheel end). The number
Shim Pack: Approximate Timing
one fuel injection line is toward the
Change on Crankshaft
flywheel.
Shim Size Pulley
1. Remove the number one fuel injection line and
0.2 mm (0.007 in.) . . . . . . . . 2° or 2 mm (5/64 in.)
delivery valve fitting.
0.3 mm (0.012 in.) . . . . . . . . . 3° or 3 mm (1/8 in.)
0.5 mm (0.020 in.) . . . . . . . 5° or 5 mm (13/64 in.)
1-148 4/7/95
2. Remove spring and delivery valve. Do not

remove delivery valve seat.
3. Install delivery valve fitting and tighten to 42 No. 1 TDC Mark
N•m (31 lb-ft). on Flywheel
Delivery Valve Fitting
Spring Index Mark on Flywheel

Housing/Cover 1
M37500
Delivery Valve 330/332 LGT, F915 FM, 430 LGT (Later),

F925/35 FM, 15 EX, 3009 OEM
T6333HP
4. Install timing tool (number one fuel line cut off at

first bend).
No. 1 TDC Mark Index Mark on
on Flywheel Flywheel Plate
Timing Tool
M37501
375 SSL, 670 CUT
8. Put a container under timing tool to collect any

M35865
fuel.
5. Remove glow plugs to aid turning crankshaft 9. Turn key switch to ON position. DO NOT start
pulley. engine. Push fuel shutoff solenoid plunger to
“hold” position.
6. Remove plug from flywheel housing/cover, if
equipped. 10.Turn flywheel clockwise (as viewed from the
flywheel end) until fuel flows in a stream.
7. Turn crankshaft pulley in either direction until the
No. 1 cylinder top dead center (TDC) mark aligns 11.Slowly turn flywheel counterclockwise until fuel
with the index mark on the flywheel housing/ flow changes from a stream and then stops
cover or plate. completely. This is the point of injection timing
at which the pump is set.
NOTE: If the fuel flow does not stop, the number
one piston is on the exhaust stroke instead of
the compression stroke. Turn flywheel one
revolution and repeat Steps 7 - 11.
12.Check timing mark on flywheel. The index mark
must line up with the 13° mark on flywheel.
4/7/95 1-149
removed. If shim pack thickness is unknown or

new pump is installed, replace with 0.5 mm
Flywheel (0.020 in.) shim pack thickness.
13°
Mark • If timing is OK:
- Install rubber plug in flywheel housing/cover,
TDC Mark on if equipped.
1 Flywheel
1 - Remove delivery valve fitting.

- Install delivery valve and spring.
Index Mark on - Install new o-ring and delivery valve fitting.
Flywheel
Housing/Cover Tighten to 42 N•m (31 lb-ft).
or Plate
FAN/ALTERNATOR DRIVE BELT

ADJUSTMENT
T6471CS Reason:
To keep proper tension on belt to drive water pump
Specifications: and alternator. To prevent shortened belt and bearing
Injection Pump Timing. . . . . . . . . .13° BTDC life.
Equipment:
Engine Crankshaft
Position. . . . . . . . . . . . . . . . . . . No.1 Cylinder • JDG529 or JDST28 Belt Tension Gauge
. . . . . . . . . . . . . on TDC Compression Stroke • Straight Edge
Distance On Outer Surface Of Flywheel
Per 1° Of Rotation. . . . . . 2.62 mm (0.100 in.) Procedure:
1. Check belt tension between fan and alternator
Results: using Belt Tension Gauge and a straight edge.
• If timing is not according to specifications:
- Remove injection pump and shims. (See Fuel
- Install new shim(s) with a total shim pack
thickness of 0.5 mm (0.020 in.).
Belt Deflection
- Install injection pump and recheck timing.
• If engine performance is poor, check air
cleaners, fuel filter, fuel supply, injectors and
cylinder compression before removing pump for M54014
service. Check all timing gears for wear. Retest

performance.
Specifications:
• If performance did not change, have pump tested Applied Force . . . . . . . . . . .98 N (22 lb-force)
by a diesel injection service. When reinstalling
injection pump, use same thickness of shim pack Deflection . . . . . 10 - 15 mm (0.400 - 0.600 in.)
1-150 4/7/95
Results: 4. Move link toward solenoid until it stops.

• If deflection is not within specifications: 5. Turn plunger rod in or out of knuckle until
knuckle and link holes line up. Turn out two
- Loosen both alternator mounting cap screws/
additional turns. The additional turns insure that
nuts. the solenoid bottoms out before the linkage.
- Apply force to FRONT alternator housing 6. Assemble and check for free movement when key
only (near the belt) until tension is correct. switch is turned ON. Also check that linkage
- Tighten cap screws/nuts. returns completely to the STOP position when
key switch is turned OFF. 1
FUEL SHUTOFF SOLENOID
ADJUSTMENT
Link
Reason: Lock Nut
To ensure that fuel shutoff solenoid retracts fully,
moving the injection pump shutoff control lever far
enough to allow full rack travel.
Plunger
Knuckle
Procedure:
M55698
1. Loosen lock nut.
2. Disconnect link from solenoid.
3. Hold solenoid plunger bottomed in solenoid
body.
4/7/95 1-151
Operational Tests
RADIATOR, BUBBLE TEST • If air escapes from muffler, check for worn
exhaust valve.
Reason: • If air escapes from air cleaner, check for worn
To determine if compression pressure is leaking intake valve.
from cylinder. • If air escapes from engine oil fill, check for worn
piston rings.
Equipment:
• JDG472 Adapter COOLING SYSTEM, PRESSURE TEST
1 Reason:
Procedure:
Inspect cooling system for leaks.
1. With coolant at proper level and radiator cap
tight, run engine for 5 minutes to bring to Equipment:
operating temperature. • D05104ST Cooling System Pressure Pump
2. Remove cap from recovery tank. • JDG692 Radiator Pressure Test Kit (Adapters)
3. Check for bubbles coming from overflow hose at Procedure:
bottom of tank.
1. Remove cap and attach pressure pump to radiator.
If bubbles are present, isolate source of compression
leak: 2. Apply pressure according to specifications.
- Remove injection nozzles. 3. Check for leaks throughout cooling system.
- Install JDG472 Adapter in injection port of

cylinder to be tested. Cooling System
Pressure Pump
- Move piston to bottom of stroke with intake
and exhaust valves closed.
- Connect hose from compressed air source to
adapter.
- Apply the specified maximum air pressure
into cylinder:
T6333AW
3TN66 . . . . . . . . . . . . . . . . . 2448 kPa (355 psi)
Specifications - 3TN66:
3TNA72
All Except Maximum Pressure . . . . . . . . 117 kPa (17 psi)
3009 OEM . . . . . . . . . . 2448 kPa (355 psi) Minimum Pressure
after 15 Seconds . . . . . . . . . . . 90 kPa (13 psi)
3009 OEM . . . . . . . . . . 2455 kPa (356 psi)
- Check for bubbles in recovery tank or air Specifications - 3TNA72:
escaping from muffler, air cleaner or oil fill 15 EX, 670 CUT, 3009 OEM
opening. Maximum Pressure. . . . . . . . 97 kPa (14 psi)
- Repeat for each cylinder. Minimum Pressure
after 15 Seconds . . . . . . . . 88 kPa (12.8 psi)
Results: 430 LGT, 455 LGT, 755/56 CUT, F925/35 FM
• If bubbles are present, check for cracks in Maximum Pressure . . . . . . . 117 kPa (17 psi)
cylinder head and block. Check for damaged Minimum Pressure
head gasket. after 15 seconds . . . . . . . . . . . 90 kPa (13 psi)
1-152 4/7/95
Operational Tests
Results: Results:
• Pressure should hold to specifications. If pressure • If cap leaks, retighten and test again. Replace cap
decreases, check for leaks. Repair leaks or replace if pressure is not within specification.
parts as necessary.
• If pressure test still indicates leakage after all CYLINDER, COMPRESSION
external leaks have been stopped, a defective head PRESSURE TEST
gasket, cracked block, or cylinder head may be the
Reason:
cause. Perform RADIATOR BUBBLE TEST. 1
To determine the condition of the pistons, rings,
cylinder walls and valves.
RADIATOR CAP, PRESSURE TEST
Reason: Equipment:
Test radiator cap for operating in correct pressure • JT01682 Compression Gauge Assembly
range.
• JDG472 Adapter
Equipment:
• D05104ST Cooling System Pressure Pump Procedure:
• JDG692 Radiator Pressure Test Kit (Adapters) 1. Run engine for 5 minutes to bring to operating
temperature. Shut off engine.
Procedure:
2. Remove injection nozzles. (See Fuel System in
1. Install radiator cap on pressure pump.
this section.)
2. Apply pressure. Pressure valve in cap should
3. Install Adapter and Compression Gauge
open according to specifications. Assembly in injector port.
4. Disconnect fuel shut-off solenoid connector.
Cooling System
Pressure Pump
5. Crank engine for three seconds with starter.
6. Record pressure reading for each cylinder.
JT01682 Compression
Gauge Assembly
Radiator Cap T6333AX
Specifications:
3TN66. . . . . . . . . . . . . . . . . . . . 97 kPa (14 psi)
3TNA72 JDG472 Adapter
15 EX, 3009 OEM . . . . . . . 88 kPa (12.8 psi)

670 CUT . . . . . . . . . . . . . . . . . . 55 kPa (8 psi)
430 LGT, 455 LGT, 655 CUT, M82143
755/56 CUT,
F925/35 FM . . . . . . . . . . . . . . 97 kPa (14 psi)
4/7/95 1-153
Operational Tests
Specifications: 3. Connect Hose Assembly and Pressure Gauge.

Compression Pressure IMPORTANT: Do not run if no pressure
3TN66 . . . . . . . . . . . . . . . . . 2448 kPa (355 psi) present.
3TNA72 4. Start engine. If pressure reading is below 69 kPa
(10 psi), STOP ENGINE.
All Except
3009 OEM . . . . . . . . . . 2448 kPa (355 psi) 5. Run engine approximately five minutes to heat
oil, then check oil pressure at fast and/or slow
3009 OEM . . . . . . . . . . 2455 kPa (356 psi) idle.
1 Maximum Difference
Between Cylinders . . . . . . . . 490 kPa (71 psi) Specifications - 375 SSL:
Idle Speed
NOTE: Pressure listed is for 300 m (1000 ft) above
sea level. For naturally aspirated engines, Fast . . . . . . . . . . . . . . . . . . . 3625 ± 25 rpm
reduce specification an additional 4% for Slow . . . . . . . . . . . . . . . . . . 1450 ± 50 rpm
each 300 m (1000 ft) of altitude. Engine Oil Pressure . . . . . . . . . 294 - 392 kPa
. . . . . . . . . . . . . . . . . . . . . . . . . . . .(43 - 57 psi)
Results:
• If pressure reading is below specification, squirt Specifications - 330/332 LGT:
approximately two teaspoons of clean engine oil Idle Speed
into cylinders through injector ports and repeat
test. Fast . . . . . . . . . . . . . . . . . . 3350 ± 100 rpm
Slow . . . . . . . . . . . . . . . . . . 1450 ± 50 rpm
• If pressure increases significantly, check piston,
rings and cylinder walls for wear or damage. Engine Oil Pressure . . . . . . . . . 294 - 440 kPa
. . . . . . . . . . . . . . . . . . . . . . . . . . . .(43 - 64 psi)
• If pressure does not increase significantly after
retest, check for leaking valves, valve seats or
cylinder head gasket. Specifications - 655 CUT, 430 LGT,
755/56 CUT, 670 CUT:
Fast Idle . . . . . . . . . . . . . . . . . . 3425 ± 25 rpm
ENGINE OIL PRESSURE TEST
Engine Oil Pressure . . . . . . . . . 365 ± 69 kPa
Reason: . . . . . . . . . . . . . . . . . . . . . . . . . . . (53 ± 10 psi)
To determine if engine bearings or lubrication Specifications - F915 FM, F925/35 FM:

system components are worn.
Idle Speed
Equipment: Fast . . . . . . . . . . . . . . . . . . . 3635 ± 35 rpm
• JT03017 Hose Assembly Slow . . . . . . . . . . . . . . . . . . 1450 ± 50 rpm
• JT05577 Pressure Gauge (100 psi) Engine Oil Pressure . . . . . . . . . 294 - 440 kPa
. . . . . . . . . . . . . . . . . . . . . . . . . . . .(43 - 64 psi)
• JT03349 Connector
(All Except 430 LGT, 15 EX)
Specifications - 455 LGT:
• JT03338 90° Elbow Connector (430 LGT) Idle Speed
• JT05487 Connector (15 EX) Fast . . . . . . . . . . . . . . . . . . 3350 ± 100 rpm
Slow . . . . . . . . . . . . . . . . . . 1650 ± 50 rpm
Procedure:
Engine Oil Pressure . . . . . . . . . 294 - 440 kPa
1. Remove oil pressure sender. . . . . . . . . . . . . . . . . . . . . . . . . . . . .(43 - 64 psi)
2. Install Connector.
1-154 4/7/95
Operational Tests
Specifications - 15 EX: 6. Spray soap solution over all connections from air
Idle Speed cleaner to intake manifold or turbocharger, if
equipped, and check for leaks.
Fast . . . . . . . . . . . . . . . . . . . 2425 ± 25 rpm
Slow . . . . . . . . . . . . . . . . . . . 800 ± 25 rpm IMPORTANT: When reinstalling starting aid
nozzle, position arrow on nozzle pointing
Engine Oil Pressure . . . . . . . . . 117 - 345 kPa against intake air flow.
. . . . . . . . . . . . . . . . . . . . . . . . . . . (17 - 50 psi)
Specifications - 3009 OEM:

Slow Idle. . . . . . . . . . . . . . . . . . . . . . 1300 rpm
1
Engine Oil Pressure . . . . . . 147 kPa (21 psi)
Results:
• If oil pressure is not within specifications,
inspect oil pressure regulating valve parts for
M82124
wear or damage. Add or remove shims as
necessary. (See Lubrication System in this
section.) Results:
• If oil pressure does not increase, see “Engine • Find leaks and repair or replace parts as
Has Low Oil Pressure” in Diagnosis group. necessary.
AIR INTAKE SYSTEM LEAKAGE TEST FUEL SUPPLY PUMP PRESSURE

TEST - 3TNA72 (670 CUT, 3009 OEM)
Reason:
Reason:
Check for leaks in air intake system.
To determine supply pump operating pressure.
Equipment:
Equipment:
• Air Pressure Regulator
• JT03274 Hose Fitting
Procedure: • JT01609 Female Quick Coupler
1. Remove air cleaner restriction indicator/switch, if • JT03115 Gauge w/Male Quick Coupler (0 - 150
equipped and install test fitting. psi)
2. Connect air pressure regulator to manifold using
hose and fitting from air cleaner. Procedure:
3. Remove air cleaner cover and main filter element. 1. Disconnect supply pump-to-filter hose.
4. Put large plastic bag into and over end of main 2. Install Hose Fitting, Coupler and Gauge.
filter element. Install main filter element and 3. Pull fuel shut-off cable out and crank engine
cover. using the starter. Do not run starter for more than
5. Pressurize air intake system between 34 - 69 kPa 10 seconds at a time. Gauge should read more
(5 - 10 psi). If air intake system cannot be than 29 kPa (4.3 psi).
pressurized, turn engine slightly to close valves.
4/7/95 1-155
Operational Tests
JT03115 Gauge w/Male

BLEED FUEL SYSTEM
Quick Coupler
JT01609 Female Quick Reason:
Coupler Any time the fuel system has been opened up for
JT03274 Hose Fitting service (lines disconnected or filters removed), it
will be necessary to bleed air from the system.
Procedure:
1 IMPORTANT: Modification or alteration of the
Fuel Filter
injection pump, pump timing, or the injection
nozzles in any way not approved by the
manufacturer will terminate the warranty
Supply
obligation.
Pump-to 1. Turn fuel filter shutoff valve to “OPEN” position.
Filter Hose M82145A
2. Loosen both air bleed screws on fuel filter base.
Results:
• If pressure is below specification, replace fuel Air Bleed
Screws
supply pump.
FUEL DRAIN BACK TEST
Reason:
Determines if air is entering the fuel system at Shutoff Valve
connections, allowing fuel to siphon back to tank.
RG6594
Procedure: 3. Turn ignition switch to “ON” position.

1. Disconnect fuel supply line and return line at fuel 4. Operate hand primer lever of fuel supply pump, if
tank. equipped, until fuel flows free of air bubbles.
IMPORTANT: Fuel return line MUST extend Tighten bleed screws.
below fuel level in fuel tank before performing
this test. Fill fuel tank if necessary.
2. Drain all fuel from the system, including fuel
supply pump, injection pump, filter(s) and water
separator, if equipped.
3. Plug end of fuel return hose.
4. Pressurize fuel system at fuel supply line, to a
maximum pressure of 103 kPa (15 psi).
5. Apply liquid soap and water solution to all joints
RG6595
and connections in the fuel system and inspect for
leaks.
5. Loosen bleed screw on injection pump. Operate
hand primer, if equipped, and tighten bleed screw
Results: when fuel flows free of air bubbles.
• Find leaks and repair or replace parts as
necessary.
1-156 4/7/95
Operational Tests
6. Start engine. If engine does not start after several 8. Crank engine over with starter.
attempts, proceed with steps 7 through 10.
9. When fuel appears at injectors, tighten line nuts.
10.Start engine. If engine does not start, repeat bleed
procedure.
RG6596
7. Loosen all three injector line nuts using a 17 mm

RG6597
wrench. Be sure not to loosen bottom nut of
injector.
4/7/95 1-157
Operational Tests
1-158 4/7/95
3TN75, 3TN78, 3TNC78 (3011)
3TN82, 3TNA82, AND
2
3TN84 (3014)
ENGINES
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 3
Camshaft and Timing Gear Train. . . . . . . . . . . . . . . . . . . 2-54
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-116
Section 2
2
Specifications
ENGINE SPECIFICATIONS - 3TN75, 3TN78, 3TNC78 (3011)

Rocker Arm Cover
Rocker Arm Assembly
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.97 - 15.98 mm (0.6286 - 0.6293 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.95 mm (0.6280 in.)
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.13 mm (0.005 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.00 - 16.02 mm (0.630 - 0.631 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.09 mm (0.633 in.)
Push Rod Length
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146.65 - 147.35 mm (5.774 - 5.801 in.) 2
Push Rod Bend
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.)
First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.)
Second. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 N•m (31 lb-ft)
Final . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 N•m (51 lb-ft)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
Valve Seat Width
Intake Valve
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.36 - 1.53 mm (0.054 - 0.060 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.98 mm (0.078 in.)
Exhaust Valve
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.66 - 1.87 mm (0.065 - 0.074 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27 mm (0.089 in.)
Valve Faces
Exhaust Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Intake Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
Valve Stem O.D.
Distance A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 mm (1.181 in.)
Distance B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 mm (1.969 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.94 - 6.96 mm (0.2732 - 0.2740 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.90 mm (0.2717 in.)
Valve Recession
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 - 0.50 mm (0.012 - 0.020 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00 mm (0.039 in.)
Valve Guides
Valve Guide I.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.00 - 7.02 mm (0.275 - 0.276 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.08 mm (0.279 in.)
4/7/95 2-1
Specifications
Valve Guides, continued

Valve Guide Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 mm (0.472 in.)
Valve Springs
Spring Free Length
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 mm (1.654 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.50 mm (1.630 in.)
Maximum Spring Inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 mm (0.044 in.)
Exhaust Manifold
Intake Manifold
Valve Seat Angles
Valve Seat Surface
Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
2 Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
Piston-to-Cylinder Head Clearance
3TN75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.59 - 0.77 mm (0.023 - 0.030 in.)
3TN78, 3TNC78 (3011) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.63 - 0.77 mm (0.025 - 0.030 in.)
Piston and Connecting Rod Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 N•m (29 lb-ft)
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 - 43.042 mm (1.693 - 1.695 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.07 mm (1.696 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.070 - 0.105 mm (0.0028 - 0.0041 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.0098 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.035 - 0.070 mm (0.0014 - 0.0028 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.0098 in.)
Oil Ring
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.030 - 0.060 mm (0.0012 - 0.0024 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.)
Piston Ring End Gap
3TN75
Compression Rings and Oil Ring
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm (0.008 - 0.016 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.0591 in.)
3TN78, 3TNC78 (3011)
Standard
Compression Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 - 0.40 mm (0.0010 - 0.016 in.)
Oil Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm (0.008 - 0.016 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.0591 in.)
Piston Pin
Pin O.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.991 - 23.00 mm (0.905 - 0.906 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.90 mm (0.902 in.)
Bore I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.045 mm (0.0018 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.00 - 23.009 mm (0.9055 - 0.9059 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.02 mm (0.906 in.)
2-2 4/7/95
Specifications

Bushing I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.110 mm (0.0043 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.025 - 23.038 mm (0.9065 - 0.9070 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.10 mm (0.909 in.)
Piston O.D.
3TN75
Distance A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.5 mm (0.492 in.)
Standard Piston Size
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.91 - 74.94 mm (2.949 - 2.951 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.81 mm (2.945 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.17 - 75.18 mm (2.959 - 2.960 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.06 mm (2.955 in.)
0.50 mm (0.020 in.) Oversize Piston (F1145 FM Only) 2
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.42 - 75.43 mm (2.969 - 2.970 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.31 mm (2.965 in.)
3TN78, 3TNC78 (3011)
Distance A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 mm (0.905 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77.895 - 77.925 mm (3.067 - 3.068 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77.81 mm (3.063 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.15 - 78.18 mm (3.076 - 3.077 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.05 mm (3.053 in.)
0.50 mm (0.020 in.) Oversize Piston (3011 OEM Only)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.40 - 78.42 mm (3.086 - 3.087 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.30 mm (3.083 in.)
Cylinder Bore I.D.
3TN75
Standard Size Bore
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.22 mm (0.009 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.00 - 75.03 mm (2.953 - 2.954 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.20 mm (2.961 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.25 - 75.28 mm (2.963 - 2.964 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.45 mm (2.970 in.)
0.50 mm (0.020 in.) Oversize Bore (F1145 FM Only)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.50 - 75.53 mm (2.972 - 2.974 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.70 mm (2.980 in.)
3TN78, 3TNC78 (3011)
Standard Size Bore
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.22 mm (0.009 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.00 - 78.03 mm (3.071 - 3.072 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.20 mm (3.079 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.25 - 78.28 mm (3.081 - 3.082 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.45 mm (3.089 in.)
0.50 mm (0.020 in.) Oversize Bore (3011 OEM Only)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.50 - 78.53 mm (3.091 - 3.092 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.70 mm (3.099 in.)
Deglazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 40° cross-hatch pattern
4/7/95 2-3
Specifications

Extension-to-Timing Gear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 N•m (195 lb-in.)
Seal Case-to-Block Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.)
Seal Case-to-Extension Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (180 lb-in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.952 - 42.962 mm (1.6910 - 1.6914 in.)
2 Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.91 mm (1.689 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.952 - 46.962 mm (1.8485 - 1.8489 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.91 mm (1.847 in.)
Main Bearing I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.00 - 47.045 mm (1.850 - 1.852 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.10 mm (1.8541 in.)
Flywheel
3TN75 (F1145 FM) Pulley-to-Isolator Mount Plate Cap Screw Torque . . . . . . . . . . 49 N•m (36 lb-ft)
Camshaft
Camshaft Side Gap
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.)
Lobe Height
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.635 - 38.765 mm (1.521 - 1.526 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.40 mm (1.512 in.)
Journal O.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.92 - 44.95 mm (1.769 - 1.770 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.80 mm (1.764 in.)
Intermediate
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.91 - 44.94 mm (1.768 - 1.769 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.80 mm (1.764 in.)
Bushing I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0078 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.990 - 45.055 mm (1.771 - 1.744 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.10 mm (1.776 in.)
Bore I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.00 - 45.025 mm (1.772 - 1.773 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.10 mm (1.776 in.)
2-4 4/7/95
Specifications
Cam Followers
Stem O.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.975 - 11.990 mm (0.471 - 0.472 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.93 mm (0.470 in.)
Bore I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.000 - 12.018 mm (0.472 - 0.473 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.05 mm (0.474 in.)
Timing Gear Cover
Fan Mounting Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (226 lb-in.)
Cover Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.)
Crankcase Extension Housing-to-Cover Cap Screw Torque . . . . . . . . . . . . . . . . . 22 N•m (195 lb-in.)
Idler Gear
Shaft O.D 2
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.950 - 45.975 mm (1.809 - 1.810 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.93 mm (1.808 in.)
Bushing I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.00 - 46.025 mm (1.811 - 1.812 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.03 mm (1.812 in.)
Timing Gear Cover Mounting Plate Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (220 lb-in.)
Oil Pan and Strainer Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.)
Oil Pump
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 - 0.048 mm (0.0006 - 0.0035 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0078 in.)
Rotor Recess
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.10 mm (0.0020 - 0.0039 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09 - 0.16 mm (0.0035 - 0.0063 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.0098 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 - 0.04 mm (0.0008 - 0.0016 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Spring
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 mm (1.810 in.)
Thermostat and Housing - 3TN78
Housing Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.)
Thermostat - 3TN75, 3TNC78 (3011)
Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (180 lb-in.) 70
Water Pump - 3TN78
Plate-to-Housing Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (134 lb-in.)
Plug-to-Housing Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (130 lb-in.)
4/7/95 2-5
Specifications
Water Pump - 3TN78, continued

Bottom of Pulley Flange-to-Top of Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 mm (0.670 in.)
Top of Impeller-to-Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 mm (0.080 in.) below housing
Water Pump - 3TN75, 3TNC78 (3011)
Adapter-to-Plate Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (78 lb-in.)
Fuel Supply Pump - 3TN75, 3TNC78 (3011)
External Lube Line Mounting Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (130 lb-in.)
2 Fuel Injection Pump
Injection Pump Gear Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 N•m (66 lb-ft)
Lube Line-to-Block Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (217 lb-in.)
Mounting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 N•m (39 lb-in.)
Retaining Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 N•m (31 lb-ft)
Starter - 3TN78 (Hitachi 0.8 kW)
Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 mm (0.354 in.)
Starter Motor - 3TN75, 3TNC78 (3011) (Nippondenso 1.0 kW)
Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 mm (0.335 in.)
Alternator - 3TN78 (Hitachi 25A)
Rotor Assembly
Sheave Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft)
End Frame-to-Rectifier Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (31 lb-in.)
Stator-to-Rectifier Lead Wire Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.50 mm (1.300 in.)
Alternator - 3TN75 (Nippondenso 35A)
Rotor Assembly
Alternator - 3TN75, 3TNC78 (3011) (Nippondenso 40A)
Brush Length
New. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.50 mm (0.410 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.50 mm (0.170 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.55 mm (0.0217 in.)
2-6 4/7/95
Specifications
Checks, Tests and Adjustments, continued

Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.0063 in.)
Crankshaft End Play
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.33 mm (0.0129 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 mm (0.0063 in.)
Camshaft End Play
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.) 2
Standard Backlash
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.)
Leakage at 17640 kPa (2558 psi) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum of 5 Seconds
Slow Hand Lever Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fine Stream Spray Pattern
Thermostat
Begin Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71° C (160°F)
Fully Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85° C (184° F)
Coolant Temperature Switch Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . 107 - 113° C (225 - 235° F)
Hitachi 2.0 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110 Amps at 4500 rpm
Nippondenso 1.0 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 Amps at 3000 rpm
Minimum Starter RPM
Hitachi 2.0 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4500
Nippondenso 1.0 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000
Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . 16° ± 1°BTDC (Before Top Dead Center)
Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 15 mm (0.400 - 0.600 in.)
Operational Tests
3TN75, 3TN78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2448 kPa (355 psi)
3TNC78 (3011). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2158 kPa (313 psi)
Cooling System
3TN75
Minimum Pressure after 15 Seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 kPa (13 psi)
4/7/95 2-7
Specifications
Operational Tests - Cooling System, continued

3TN78, 3TNC78 (3011)
Radiator Cap
3TN75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 kPa (13 psi)
3TN78, 3TNC78 (3011) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 kPa (12.8 psi)
3TN75, 3TN78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2448 kPa (355 psi)
3TNC78 (3011). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2158 kPa (313 psi)
Engine Oil Pressure
2 3TN75
F1145 FM
Slow Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1450 ± 50 rpm
Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3425 rpm
Oil Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294 - 440 kPa (43 - 64 psi)
855/56 CUT
Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3425 ± 25 rpm
Oil Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .365 ± 69 kPa (53 ± 10 psi)
3TN78
Idle Speed
Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 ± 25 rpm
Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2450 ± 25 rpm
Oil Pressure
Slow Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262 kPa (38 psi)
Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .345 ± 48 kPa (50 ± 7 psi)
3TNC78 (3011)
Low Idle Speed
Industrial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1300 rpm
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200 rpm
Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 kPa (21 psi)
Minimum Fuel Supply Pump Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 kPa (4.3 psi)
ENGINE SPECIFICATIONS - 3TN82, 3TNA82, 3TN84 (3014)
Rocker Arm Cover
Rocker Arm Assembly
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.97 - 15.98 mm (0.6286 - 0.6293 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.95 mm (0.6280 in.)
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.13 mm (0.005 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.00 - 16.02 mm (0.630 - 0.631 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.09 mm (0.633 in.)
Push Rod Length
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178.25 - 178.75 mm (7.018 - 7.037 in.)
Push Rod Bend
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.)
2-8 4/7/95
Specifications

First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (212 lb-in.)
Second. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 N•m (36 lb-ft)
Final . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 N•m (58 lb-ft)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
Valve Seat Width
Intake Valve
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.07 - 1.24 mm (0.042 - 0.049 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.74 mm (0.069 in.)
Exhaust Valve
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24 - 1.45 mm (0.049 - 0.057 in.) 2
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.94 mm (0.076 in.)
Valve Faces
Exhaust Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Intake Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
Valve Stem O.D.
Distance A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 mm (1.181 in.)
Distance B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 mm (2.360 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.96 - 7.98 mm (0.3134 - 0.3142 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.90 mm (0.3110 in.)
Valve Recession
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 - 0.50 mm (0.012 - 0.020 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00 mm (0.039 in.)
Valve Guides
Valve Guide I.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.01 - 8.03 (0.315 - 0.316 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10 mm (0.319 in.)
Valve Springs
Spring Free Length
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 mm (1.575 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.50 mm (1.550 in.)
Exhaust Manifold
Intake Manifold
Valve Seat Angles
Valve Seat Surface
Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
4/7/95 2-9
Specifications

Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 - 48.042 mm (1.888 - 1.891 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.07 mm (1.893 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.075 - 0.110 mm (0.0030 - 0.0043 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.0098 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.45 - 0.080 mm (0.0018 - 0.0031 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.0098 in.)
Oil Ring
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.025 - 0.060 mm (0.0010 - 0.0024 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.)
2 Piston Ring End Gap
3TN82, 3TNA82
Standard
First Compression Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 - 0.40 mm (0.010 - 0.016 in.)
Oil Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm (0.008 - 0.016 in.)
Second Compression Ring . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.35 mm (0.008 - 0.014 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.0591 in.)
3TN84 (3014)
Standard
Compression Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm (0.008 - 0.016 in.)
Oil Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 - 0.45 mm (0.010 - 0.018 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.0591 in.)
Piston Pin
Pin O.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.987 - 26.00 mm (1.023 - 1.024 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.90 mm (1.020 in.)
Bore I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.045 mm (0.0018 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.00 - 26.009 mm (1.0236 - 1.0240 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.02 mm (1.024 in.)
Bushing I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.110 mm (0.0043 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.025 - 26.038 mm (1.0246 - 1.0251 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.10 mm (1.028 in.)
Piston O.D.
3TN82, 3TNA82
Distance A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 mm (0.945 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.90 - 81.93 mm (3.224 - 3.225 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.80 mm (3.221 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.15 - 82.17 mm (3.234 - 3.235 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.05 mm (3.230 in.)
0.50 mm (0.020 in.) Oversize Piston (575 SSL Only)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.40 - 82.42 mm (3.244 - 3.245 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.30 mm (3.240 in.)
2-10 4/7/95
Specifications
Piston O.D., continued

3TN84 (3014)
Distance A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 mm (0.945 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.90 - 83.93 mm (3.303 - 3.304 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.80 mm (3.299 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.15 - 84.17 mm (3.313 - 3.314 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.05 mm (3.309 in.)
0.50 mm (0.020 in.) Oversize Piston (3014 OEM Only)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.40 - 84.42 mm (3.323 - 3.324 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.30 mm (3.319 in.)
Cylinder Bore I.D.
3TN82, 3TNA82
Standard Size Bore 2
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 mm (0.014 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.00 - 82.03 mm (3.228 - 3.230 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.20 mm (3.236 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.25 - 82.28 mm (3.238 - 3.239 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.45 mm (3.246 in.)
0.50 mm (0.020 in.) Oversize Bore (575 SSL Only)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.50 - 82.53 mm (3.248 - 3.249 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.70 mm (3.256 in.)
3TN84 (3014)
Standard Size Bore
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 mm (0.014 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.00 - 84.03 mm (3.307 - 3.308 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.20 mm (3.315 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.25 - 84.28 mm (3.317 - 3.318 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.45 mm (3.325 in.)
0.50 mm (0.020 in.) Oversize Bore (3014 OEM Only)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.50 - 84.53 mm (3.327 - 3.328 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.70 mm (3.335 in.)
Seal Case-to-Block Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.952 - 47.962 mm (1.8879 - 1.8883 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.91 mm (1.886 in.)
4/7/95 2-11
Specifications
Crankshaft and Main Bearings, continued

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.952 - 46.962 mm (1.9666 - 1.9670 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49.90 mm (1.965 in.)
Main Bearing I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.00 - 50.045 mm (1.969 - 1.970 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.10 mm (1.972 in.)
Flywheel
Camshaft
2 Camshaft Side Gap
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.)
Lobe Height
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.635 - 38.765 mm (1.521 - 1.526 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.40 mm (1.512 in.)
Journal O.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.92 - 44.95 mm (1.769 - 1.770 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.80 mm (1.764 in.)
Intermediate
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.91 - 44.94 mm (1.768 - 1.769 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.80 mm (1.764 in.)
Bushing I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0078 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.990 - 45.055 mm (1.771 - 1.744 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.10 mm (1.776 in.)
Bore I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.00 - 45.025 mm (1.772 - 1.773 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.10 mm (1.776 in.)
Cam Followers
Stem O.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.975 - 11.990 mm (0.471 - 0.472 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.93 mm (0.470 in.)
Bore I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.000 - 12.018 mm (0.472 - 0.473 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.05 mm (0.474 in.)
Timing Gear Cover
Fan Mounting Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (226 lb-in.)
Oil Pan-to-Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 N•m (195 lb-in.)
Idler Gear
Shaft O.D
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.950 - 45.975 mm (1.809 - 1.810 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.93 mm (1.808 in.)
2-12 4/7/95
Specifications
Idler Gear, continued

Bushing I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.00 - 46.025 mm (1.811 - 1.812 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.03 mm (1.812 in.)
Oil Pump
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 - 0.048 mm (0.0006 - 0.0035 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0078 in.)
Rotor Recess
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.09 mm (0.0011 - 0.0035 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.) 2
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 - 0.17 mm (0.0039 - 0.0067 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.0098 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.105 mm (0.0019 - 0.0041 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Oil Cooler - 3TN84 (955 CUT)
Oil Cooler-to-Valve Body Retaining Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 N•m (22 lb-ft)
Spring
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 mm (1.810 in.)
Thermostat and Housing - 3TN82 (30 EX), 3TN84 (955 CUT, 3014 OEM)
Thermostat - 3TN82 (575 SSL), 3TNA82, 3TN84 (870 CUT)
Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (180 lb-in.)
Water Pump - 3TN82 (30 EX), 3TN84 (955 CUT, 3014 OEM)
Fan Mounting Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.)
3TN82 (30 EX)
Top of Pulley Flange-to-Top of Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 mm (1.060 in.)
Top of Impeller-to-Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 mm (0.040 in.) below housing
3TN84 (955 CUT, 3014 OEM)
Bottom of Pulley Flange-to-Top of Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 mm (0.670 in.)
Water Pump - 3TN82 (575 SSL), 3TNA82, 3TN84 (870 CUT)
Impeller-to-Pump Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 mm (0.080 in.) below housing
4/7/95 2-13
Specifications
Fuel Supply Pump - 3TNA82, 3TN84 (3014)

Fuel Injection Pump
Starter Motor - 3TN82 (30 EX) (Hitachi 2.0 kW)
Starter Motor - 3TNA82, 3TN84 (3014) (Nippondenso 1.0 and 1.2 kW)
2 Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 mm (0.335 in.)
Starter Motor - 3TN82 (575 SSL) (Nippondenso 1.4 kW)
Alternator -3TNA82, 3TN84 (870 CUT) (Kokosan 20A)
Alternator - 3TN82 (30 EX) (Hitachi 25A)
Rotor Assembly
Alternator - 3TN82 (575 SSL), 3TNA82, 3TN84 (870 CUT, 955 CUT) (Nippondenso 35A)
Rotor Assembly
Alternator - 3TN82 (575 SSL), 3TN84 (955 CUT, 3014 OEM) (Nippondenso 40A)
Brush Length
New. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.50 mm (0.410 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.50 mm (0.170 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.55 mm (0.0217 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.0063 in.)
Crankshaft End Play
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.33 mm (0.0129 in.)
2-14 4/7/95
Specifications

Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 mm (0.0063 in.)
Camshaft End Play
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.)
Standard Backlash. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.04 - 0.12 mm (0.0016 - 0.0047 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.)
Leakage at 17640 kPa (2558 psi) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum of 5 Seconds 2
Thermostat
Begin Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71° C (160°F)
Fully Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85° C (184° F)
Nippondenso 1.0 and 1.2 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 Amps at 3000 rpm
Minimum Starter RPM
Hitachi 2.0 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4500
Nippondenso 1.0 and 1.2 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000
Nippondenso 1.4 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3500
Fuel Injection Pump Static Timing Adjustment
Injection Pump Timing
3TN82 (575 SSL) . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 ± 1° BTDC (Before Top Dead Center)
3TN82 (30 EX), 3TNA82, 3TN84 (3014) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 ± 1° BTDC
Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 15 mm (0.400 - 0.600 in.)
Oil Cooler Leakage - 3TN84 (955 CUT)
Applied Air Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206 - 483 kPa (30 - 70 psi)
Operational Tests
3TN82, 3TNA82, 3TN84 (870 CUT, 955 CUT) . . . . . . . . . . . . . . . . . . . . . 2448 kPa (355 psi)
3TN84 (3014 OEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2158 kPa (313 psi)
Cooling System
3TN82, 3TNA82, 3TN84 (870 CUT, 3014 OEM)
4/7/95 2-15
Specifications
Operational Tests - Cooling System, continued

3TN84 (955 CUT)
Minimum Pressure after 15 Seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 kPa (13 psi)
Radiator Cap
3TN82, 3TNA82, 3TN84 (870 CUT, 3014 OEM) . . . . . . . . . . . . . . . . . . . . . 88 kPa (12.8 psi)
3TN84 (955 CUT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 kPa (13 psi)
3TN82, 3TNA82, 3TN84 (870 CUT, 955 CUT) . . . . . . . . . . . . . . . . . . . . . 2448 kPa (355 psi)
3TN84 (3014 OEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2158 kPa (313 psi)
Engine Oil Pressure
2 3TN82 (30 EX)
Idle Speed
Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 ± 25 rpm
Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2450 ± 25 rpm
Oil Pressure
Slow Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262 kPa (38 psi)
Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .345 ± 48 kPa (50 ± 7 psi)
3TN82 (575 SSL)
Idle Speed
Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1250 ± 25 rpm
Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2875 ± 25 rpm
Oil Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294 - 392 kPa (43 - 57 psi)
3TNA82, 3TN84 (870 CUT)
Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2750 - 2800 rpm
Oil Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .365 ± 69 kPa (53 ± 10 psi)
3TN84 (955 CUT)
Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3425 ± 25 rpm
3TN84 (3014 OEM)
Low Idle Speed
Industrial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1300 rpm
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200 rpm
Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 kPa (21 psi)
2-16 4/7/95

Use to knurl inside diameter of valve guides on 3TN75, 3TN78 and 3TNC78 (3011) engine.

Use to knurl inside diameter of valve guides on 3TN82, 3TNA82 and 3TN84 (3014) engines.

Use to remove and install valve guides in cylinder head.
Use to ream out new valve guides on 3TN75, 3TN78 and 3TNC78 (3011) engine. 2
Use to ream out new valve guides on 3TN82, 3TNA82 and 3TN84 (3014) engines.
SERVICE PARTS KITS

• Cylinder Head Gasket Kits
4/7/95 2-17
ROCKER ARM COVER

• Wash packing in a safe solvent and blow dry
with air pressure. If packing comes apart or is
deteriorated, replace it.
Crankcase Breather Oil Filler Cap

Cover
Cap Screw (2)
M8 x 16
O-Ring
2 O-Ring
Replace.
Extension
Packing (575 SSL)
Screen
Special Nut (3)
18 N•m (160 lb-in.)
O-Ring
(575 SSL)
O-Ring (3)
Crankcase Breather
Tube
Rocker Arm Cover
O-Ring Seal
M82329A
2-18 4/7/95
ROCKER ARM ASSEMBLY • Inspect all parts for wear or damage. (See
Removal/Installation and • Lubricate all parts with clean oil during
Disassembly/Assembly assembly.
1. Remove rocker arm cover. (See procedure in this • Adjust valve clearance. (See Checks, Tests and
group.) Adjustments in this section.)
• Remove and install studs using two M8 nuts.
Mounting Cap
Screw (2) 2
M8 x 25
26 N•m (226 lb-in.)
Adjusting Screw
Rocker Arm Nut Rocker Arm Shaft

Center Support (2)
Rocker Arm
Shaft Spring Nut (3) Mounting Cap Screw (6)
M8 M8 x 50
(575 SSL) 26 N•m (226 lb-in.)
Exhaust Valve Rocker Arm

Stud (3)
Valve Cap
Push Rod
Rocker Arm
End Support (2)
M82330A
4/7/95 2-19
Inspection Rocker Arm and Shaft Support I.D.’s:

• Measure outer diameter of rocker arm shaft. Standard . . . . . . . . . . . . . . . 16.00 - 16.02 mm
. . . . . . . . . . . . . . . . . . . . . . . (0.630 - 0.631 in.)
Wear Limit. . . . . . . . . . . 16.09 mm (0.633 in.)
Clearance . . . . . . . . . . . . . 0.13 mm (0.005 in.)
Replace rocker arms or supports if I.D. is more than
wear limit.
If shaft and support/arm clearance (support/arm I.D.
minus shaft O.D.) exceed wear limit, replace all
parts.
• Measure length and bending of push rod.
2 M35262
Rocker Arm Shaft O.D.:

Standard . . . . . . . . . . . . . . . 15.97 - 15.98 mm
. . . . . . . . . . . . . . . . . . . . . (0.6286 - 0.6293 in.)
Length
Wear Limit. . . . . . . . . . 15.95 mm (0.6280 in.)
Replace rocker arm shaft if less than wear limit.
Feeler
• Measure inner diameters of rocker arms and Gauge
supports.
M82023A
Push Rod Length:

3TN75, 3TN78,
3TNC78 (3011) . . . . . . . . 146.65 - 147.35 mm
. . . . . . . . . . . . . . . . . . . . . . . (5.774 - 5.801 in.)
3TN82, 3TNA82,
3TN84 (3014) . . . . . . . . . . 178.25 - 178.75 mm
. . . . . . . . . . . . . . . . . . . . . . . (7.018 - 7.037 in.)
Push Rod Bend:

M82022A
Standard . . . . . . . 0.03 mm (0.001 in.) or less
Wear Limit. . . . . . . . . . . . 0.30 mm (0.012 in.)
Replace push rod if not within specifications.
2-20 4/7/95
CYLINDER HEAD AND VALVES 4. Remove fuel injection nozzles. (See Fuel System
in this section.)
Removal/Installation 5. Disassemble and inspect cylinder head and
1. Remove rocker arm assembly, push rods and
valve caps. (See procedure in this group.)
2. Remove exhaust and intake manifolds. (See IMPORTANT: Oil passage in gasket must be
procedures in this group.) located over oil passage in cylinder block.
section.)
Mounting Cap
Screw (14)
Dip entire cap
2
screw in
clean engine oil
before
installing.
Flywheel
Cylinder Head
Gasket
M82331A
4/7/95 2-21
6. Tighten mounting cap screws, in the sequence Torque Specifications - 3TN82, 3TNA82,
shown, in three stages of gradually-increasing 3TN84 (3014):
torque. First . . . . . . . . . . . . . . . . . 24 N•m (212 lb-in.)
IMPORTANT: Cylinder head mounting cap Second . . . . . . . . . . . . . . . . . 48 N•m (36 lb-ft)
screws must be checked for proper torque Final . . . . . . . . . . . . . . . . . . . 78 N•m (58 lb-ft)
after 50 hours of engine operation.
Exhaust Manifold Side • Compress valve springs using a valve spring
compressor.

Flywheel Side
13 3 6 12
7 1 10 Remove guides only if replacement is necessary.
(See Inspection/Replacement procedures.)
2 • On 3TN75, 3TN84 (955 CUT), intake and
9 2 8
11 5 4 14 exhaust valve seat inserts are press fit. Remove
Intake Manifold Side
inserts only if replacement is necessary.
M82260A
Torque Specifications - 3TN75, 3TN78, Inspection/Replacement procedures.)
3TNC78 (3011): IMPORTANT: Do not reuse stem seals if
First . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.) removed. Used seals will leak.
Second . . . . . . . . . . . . . . . . . 42 N•m (31 lb-ft) • Apply clean engine oil on intake and exhaust
Final . . . . . . . . . . . . . . . . . . . 69 N•m (51 lb-ft) valve stems during assembly.
• Install springs with smaller pitch end or paint
Collet Halves (12)
Stem
Seal (6) Retainer (6)
Replace.
Exhaust Valve
Short Guide (3)
Stud (6) Valve Spring (6)
Intake Valve Guide (3)

Lifting
Bracket (2)
Cap Screw (4)
Exhaust Manifold
Valve Seat Inserts Mounting Stud
3TN75 and 3TN84 (3 Short - 770 CUT, 870 CUT)
(955 CUT)Only. (2 Long - All Except 770 CUT, 870 CUT)
Exhaust Valve
Intake Valve
M82332A
2-22 4/7/95
NOTE: f new valves are installed, measure valve

recession. (See Inspection/Replacement
procedures.)
After each valve has been assembled, tap on top of
valve stem with a plastic hammer to seat retainer.
Inspection/Replacement Valve Seat

Width
of carbon or dirt.
Cylinder Head:
• Measure cylinder head flatness. Place a straight- M82029A
edge along each of the four sides and each

diagonal. Measure clearance between straight 2
Valve Seat Width - 3TN75, 3TN78,
edge and combustion surface with a feeler 3TNC78 (3011):
gauge.
Intake Valve
Standard . . . . . . . . . . . . . . . . . 1.36 - 1.53 mm
Straight-Edge . . . . . . . . . . . . . . . . . . . . . . . (0.054 - 0.060 in.)
Wear Limit. . . . . . . . . . . . 1.98 mm (0.078 in.)
Feeler Gauge
Exhaust Valve
Standard . . . . . . . . . . . . . . . . . 1.66 - 1.87 mm
. . . . . . . . . . . . . . . . . . . . . . . (0.065 - 0.074 in.)
Wear Limit. . . . . . . . . . . . 2.27 mm (0.089 in.)
M82028A
Valve Seat Width - 3TN82, 3TNA82,
3TN84 (3014):
Cylinder Head Distortion: Intake Valve
Standard . . . . . . . 0.05 mm (0.002 in.) or less Standard . . . . . . . . . . . . . . . . . 1.07 - 1.24 mm
Wear Limit. . . . . . . . . . . . 0.15 mm (0.006 in.) . . . . . . . . . . . . . . . . . . . . . . . (0.042 - 0.049 in.)
If distortion exceeds the wear limit, resurface or Wear Limit. . . . . . . . . . . . 1.74 mm (0.069 in.)
make cylinder head flat; but do not remove more Exhaust Valve
than 0.20 mm (0.008 in.).
Standard . . . . . . . . . . . . . . . . . 1.24 - 1.45 mm
If cylinder head was resurfaced: . . . . . . . . . . . . . . . . . . . . . . . (0.049 - 0.057 in.)
• Measure piston-to-cylinder head clearance. (See Wear Limit. . . . . . . . . . . . 1.94 mm (0.076 in.)
If necessary, grind valve seats to meet specifications.
• Measure valve recession. (See procedure in this (See GRIND VALVE SEATS procedure.)
group.)
• Measure valve seat width.
Replace valve if necessary.
4/7/95 2-23
Valve Stem O.D. - 3TN75, 3TN78,

3TNC78 (3011):
Distance A . . . . . . . . . . . . . . . . .30 mm (1.181 in.)
Distance B . . . . . . . . . . . . . . . . .50 mm (1.969 in.)
Standard . . . . . . . . . . . . . . . . . 6.94 - 6.96 mm
. . . . . . . . . . . . . . . . . . . . . (0.2732 - 0.2740 in.)
Wear Limit. . . . . . . . . . . 6.90 mm (0.2717 in.)
M35307 Valve Stem O.D. - 3TN82, 3TNA82,
3TN84 (3014):
• If valve faces are worn, burned or pitted, grind Distance A . . . . . . . . . . . . . . . . .30 mm (1.181 in.)
2 valves to proper face angle. If valve face margin Distance B . . . . . . . . . . . . . . . . .60 mm (2.360 in.)
is less than 0.51 mm (0.020 in.) after grinding,
replace valve. Intake and Exhaust Valves
Standard . . . . . . . . . . . . . . . . . 7.96 - 7.98 mm
. . . . . . . . . . . . . . . . . . . . . (0.3134 - 0.3142 in.)
Wear Limit. . . . . . . . . . . 7.90 mm (0.3110 in.)
Valve Face
Valve Angle
Face
Margin Exhaust: 45° Replace valve or cylinder head if measurement
Intake: 30° exceeds wear limit.
Valve Recession
M82030A
• Measure valve stem diameter at two locations

wear limit.
Cylinder
Head
Depth
Gauge
A B
M82032A
M82031A
2-24 4/7/95
Valve Recession: Valve Guide Height “A”:

Standard . . . . . . . . . . . . . . . . . 0.30 - 0.50 mm 3TN75, 3TN78,
. . . . . . . . . . . . . . . . . . . . . . . (0.012 - 0.020 in.) 3TNC78 (3011) . . . . . . . . . .12 mm (0.472 in.)
Wear Limit. . . . . . . . . . . . 1.00 mm (0.039 in.) 3TN82, 3TNA82,
3TN84 (3014) . . . . . . . . . . . .15 mm (0.591 in.)
Valve Guides:
• Clean valve guides using a valve guide brush. • Ream inside diameter of valve guides using:
• Measure valve guide inside diameter. - 3TN75, 3TN78, 3TNC78 (3011):

Valve Guide I.D. - 3TN75, 3TN78,
3TNC78 (3011): - 3TN82, 3TNA82, 3TN84 (3014):
Standard . . . . . . . . . . . . . . . . . 7.00 - 7.02 mm
. . . . . . . . . . . . . . . . . . . . . . . (0.275 - 0.276 in.)
Wear Limit. . . . . . . . . . . . 7.08 mm (0.279 in.) A
2
Valve Guide I.D. - 3TN82, 3TNA82,
3TN84 (3014):
Standard . . . . . . . . . . . . . . . . . 8.01 - 8.03 mm
. . . . . . . . . . . . . . . . . . . . . . . (0.315 - 0.316 in.)
Wear Limit. . . . . . . . . . . . 8.10 mm (0.319 in.)
If diameter exceeds wear limit, knurl or replace M82193A
guide.
If diameter is less than wear limit, determine guide- Valve Springs:
to-stem clearance (guide diameter minus stem
diameter). • Measure spring free length. Replace spring if
measurement exceeds wear limit.
If clearance exceeds 0.15 mm (0.006 in.) but is less
than 0.20 mm (0.008 in.), knurl valve guides.
• Knurl valve guides using:
- 3TN75, 3TN78, 3TNC78 (3011):
- 3TN82, 3TNA82, 3TN84 (3014):
valve guide.
• Replace valve guides using JDE118 Valve Guide
Driver.
M82034A
Intake and exhaust valve guides are different. The
exhaust valve guide has one groove and the intake Spring Free Length - 3TN75, 3TN78,
valve guide has none. Install valve guides with 3TNC78 (3011):
tapered ends down. Push valve guides down until Standard . . . . . . . . . . . . . . .42 mm (1.654 in.)
top of cylinder head. Wear Limit. . . . . . . . . . . 41.50 mm (1.630 in.)
Spring Free Length - 3TN82, 3TNA82,
3TN84 (3014):
Standard . . . . . . . . . . . . . . .40 mm (1.575 in.)
Wear Limit. . . . . . . . . . . 39.50 mm (1.550 in.)
4/7/95 2-25
• Measure spring inclination. Replace spring if

Nut and Lock Cap Screw (2)
Washer (2) M8 x 60
Later 855/56 CUT
Cap Screw (2)

F1145 FM - M8 x 60
955 CUT - M8 x 80
Exhaust Manifold
Spring Inclination
1.10mm (0.044 in.)
Square Gauge
Cap Screw (2)
F1145 FM,
Later 855/56 CUT -
Free Length M8 x 50
Gasket 955 CUT - M8 x 55
M82035A
3TN75, 3TN84 (955 CUT) M82334A
EXHAUST MANIFOLD Exhaust Nut (2) Stud (4)

Manifold M8
1. Remove muffler and gasket, if equipped.
• Tighten all hardware to 26 N•m (226 lb-in.).
Cap Screw
Stud (4) Nut M8 x 80
Cap Screw (3)

M8 x 60
Cap Screw (4)
M8 x 60
Gasket
3TNC78 (3011 OEM) M82335A
Cap Screw
M8 x 50
Gasket Exhaust Manifold
3TN75 (Early 855/56 CUT) M82333A
2-26 4/7/95
Exhaust Nut (2) Stud (4) 4. OEM Power Unit engines (3011 and 3014):
Manifold M8
• Remove radiator support rod.
lb-in.).
Cap Screw (4)
Gasket M8 x 60 Gasket
3TN78, 3TN82, 3TN84 (3014 OEM) M82336A

2
Intake
Nut and Lock Cap Screw (2) Manifold
Exhaust Manifold Washer (3) M8 x 65
Gasket
Cap Screw (4) M82338A
M8 x 25 3TN75
Intake
Manifold Gasket
Cap Screw
M8 x 115
3TNA82, 3TN84 (870 CUT) M82337A
Cap Screw (4)

M8 x 25
INTAKE MANIFOLD
M82339A
3TN78, 3TN82 (30 EX)
NOTE: Air heater removal/installation is similar to
procedures found in ACCESSORIES -
SERIES 220 POWER UNIT ENGINES Intake
Manifold Gasket
section.
1. Remove intake air heater. (See procedure in
ENGINES section.)
this section.)
Cap Screw (4)
M8 x 25
3TN84 (3014 OEM)
3TNC78 (3011 OEM), 3TN84 (3014 OEM)

M82340A
4/7/95 2-27
Intake
Manifold Gasket and exhaust valve seat using a 45° seat grinder.
Follow tool manufacturers instructions.
Cap Screw (4)

M8 x 25
Seat Grinder
3TN82 (575 SSL) M82341A

2 Gasket
M82039A
Plate
2. Measure valve seat width after grinding.
3. If seat is too wide after grinding, grind lower seat
surface using a 70° seat grinder until seat width is
close to specifications.
Cap Screw (4) 4. Grind upper seat surface using a 15° seat grinder
M8 x 25
Cap Screw (12) 5. If valve seats are ground, measure valve recession
M6 x 14
and check contact pattern between the seat and
3TNA82, 3TN84 (870 CUT) M82342A valve with bluing dye.
6. Lap valves. (See procedure in this group.)
Intake Gasket
Manifold
Lower Seat
Surface 70°
Valve Upper
Cap Screw (4) Seat Seat
M8 x 25 Surface
Seat
15°
Width
3TN84 (955 CUT) M82343A
Cylinder
GRIND VALVE SEATS Head
IMPORTANT: Valve seats should never be cut. M82040A

surface, which may result in leaks or valve/
seat failure. Valve seats should be ground and If valve recession exceeds maximum specifications
lapped. or seats cannot be reconditioned, replace valves,
valve seats if equipped and/or cylinder head.
NOTE: LIGHTLY grind valve seats for a few
seconds only to avoid excessive valve seat NOTE: Valve seat inserts are available for 3TN75
width. and 3TN84 (955 CUT) engines only.
2-28 4/7/95
LAP VALVES 2. Install cylinder head and old gasket. Install

NOTE: Use a rubber type lapping tool for valves sequence to specified torque. (See CYLINDER
without a lapping tool groove slit. HEAD AND VALVES - Removal/Installation in
If seat does not make proper contact, lap the valve this group.)
into the seat: 3. Slowly turn crankshaft one complete revolution.
1. Apply small amount of fine lapping compound to 4. Remove cylinder head and gasket.
face of valve.
2. Turn valve to lap valve to seat. piece of wire. Calculate average thickness of
3. Lift valve from seat every 8 to 10 strokes. Lap wires to obtain piston-to-cylinder head clearance
until a uniform ring appears around the surface of specification.
the valve face.
4. Wash all parts in solvent to remove lapping 2
compound. Dry parts.
5. Check position of lap mark on valve face. Lap
Lapping Tool
M82042A
Piston-to-Cylinder Head Clearance:

3TN75. . . . . . . . . . . . . . . . . . . . 0.59 - 0.77 mm
. . . . . . . . . . . . . . . . . . . . . . . (0.023 - 0.030 in.)
M82041A
3TN78, 3TNC78 (3011) . . . . . 0.63 - 0.77 mm
. . . . . . . . . . . . . . . . . . . . . . . (0.025 - 0.030 in.)
MEASURE PISTON-TO-CYLINDER 3TN82, 3TNA82,
HEAD CLEARANCE 3TN84 (3014) . . . . . . . . . . . . . . 0.64 - 0.82 mm
1. Place three 10 mm (0.400 in.) long pieces of 1.50 . . . . . . . . . . . . . . . . . . . . . . . (0.025 - 0.032 in.)
mm (0.060 in.) diameter soft wire in three If clearance is less than specifications, replace
positions on the flat part of the piston head. cylinder head.
4/7/95 2-29
SERVICE PARTS KITS

2-30 4/7/95
PISTON AND CONNECTING ROD 7. Remove two cap screws, connecting rod cap and
bearing inserts.
Removal IMPORTANT: Pistons and cylinders are
1. Remove oil pan and strainer tube. (See matched. Pistons must be installed in the
Lubrication System in this section.) cylinders from which they are removed.
2. Remove cylinder head. (See Cylinder Head, 8. Note connecting rod alignment mark in relation
Valves and Manifolds in this section.) to the cylinders. Starting at flywheel end with
cause damage to piston if ridge is not removed. 9. Push piston and connecting rod out of cylinder
4. If necessary, remove ridge from top of cylinder
bore using a ridge reamer. 10.Disassemble and inspect all parts for wear or
5. Measure connecting rod side play. (See Checks, Replacement procedures.) 2
Note alignment marks on each part.
Piston and
Connecting Rod
Piston and
Connecting Rod
Bearing
Inserts
Connecting
Rod Cap
Connecting Rod
Bearing
Cap Screw
Inserts Replace.
M82196A
All Except 3TN75

Connecting
Rod Cap
Connecting Rod
Cap Screw
Replace.
M82273A
3TN75
4/7/95 2-31
Installation Connecting Rod Cap Screw Torque

Specifications:
installation. 3TN75, 3TN78,
3TNC78 (3011) . . . . . . . . . . 39 N•m (29 lb-ft)
with new. 3TN82, 3TNA82,
3TN84 (3014) . . . . . . . . . . . . 47 N•m (35 lb-ft)
IMPORTANT: Pistons must be installed in
cylinders from which they were removed and 6. If a new piston and connecting rod were installed,
in the same direction. Be careful not to stamp a number corresponding to the cylinder
damage crankshaft rod journal while number on the connecting rod cap and connecting
installing piston. rod.
cylinder bore. (See procedure in this group.) Piston
2 2. 3TN75: Install piston and connecting rod into the
Recess
Fuel
cylinder from which it was removed, with piston Injection
recess on top of piston toward fuel injection Pump Side
pump.
Flywheel
Side
All Except 3TN75: Install piston and connecting
rod into the cylinder from which it was removed,
with alignment mark on connecting rod and/or
with piston size mark on top of piston toward fuel
injection pump. Groove
IMPORTANT: Do not touch bearing insert

Tangs Connecting Rod
3. Install bearing inserts on connecting rod and rod Cap Alignment
cap, aligning tangs with grooves. Mark

installed on the same connecting rods they
were removed from.
4. Match the connecting rods to caps using Groove Connecting Rod
alignment marks. Install caps. Cap Screw
5. Dip entire connecting rod cap screws in clean M82273A

engine oil. Install new cap screws and tighten to 3TN75
specifications.
2-32 4/7/95
• Piston pin bushing is press fit in connecting rod.

Piston Size Remove bushing only if replacement is
Mark necessary. (See Inspection/Replacement
procedures.)
Fuel
Injection • Inspect all parts for wear or damage. Replace as
Pump Side necessary. (See Inspection/Replacement
procedures.)
Flywheel
Side
1st Compression Ring
Connecting Rod
Alignment Mark
Groove 2nd Compression Ring

2
Oil Ring with
Tangs Coil Expander
Connecting Rod
Piston
Cap Screw
Groove
Piston Pin
M82196A
Retaining
Ring
All Except 3TN75
7. Install cylinder head. (See Cylinder Head, Valves

and Manifolds in this section.)
8. Install oil pan and strainer tube. (See Lubrication Piston
System in this section.) Pin
Bushing
Connecting Rod
Disassembly
M82274A
• Put a mark on each piston and connecting rod to
3TN75
aid in assembly.
4/7/95 2-33
Piston Recess
1st Compression Ring Piston
Piston Pin
Oil Ring with
Coil Expander
Piston
2 Retaining Ring
Piston Pin
Snap Ring Connecting Alignment

Rod Mark
Piston Pin Bushing
Bearing Insert Groove M82275A
3TN75
Connecting Rod
Piston
Size Piston
Mark
M82197A
All Except 3TN75
Assembly
• Apply clean engine oil to all parts during
Piston Pin
assembly.
1. 3TN75: Assemble piston to connecting rod with
recess mark on same side as connecting rod
“punched” alignment mark. If a new connecting Snap Ring
rod is used, assemble piston to connecting rod
with piston recess opposite connecting rod
bearing insert groove.
Rod
All except 3TN75: Assemble piston to Mark
connecting rod with piston size mark on same
side as connecting rod “punched” alignment
mark. If a new connecting rod is used, assemble
piston to connecting rod with piston size mark
opposite connecting rod bearing insert groove.
All Except 3TN75
2-34 4/7/95
2. Install piston pin and retaining/snap rings.

3. Install oil ring expander in bottom ring groove of 1st Compression Ring
piston with ends above either end of piston pin. 2nd Compression
4. Install oil ring over expander with ring gap Ring
Oil Ring
Expander
Oil 1st Compression

Ring Ring
Gap 120°
Oil Ring 2nd
Expander 120°
Compression
Ends Ring 120° 2
Oil Ring
Oil Ring
Piston Pin
M82046A
5. 3TN75: Install second compression ring, with M82199A

chamfer toward top of piston, in middle groove.
Turn ring until gap is 120o ring gap. All Except 3TN75
All Except 3TN75: Install second compression 6. Install first compression ring (chrome plated),
ring, with small diameter of taper toward top of with manufacturer's mark “R”, “T” or “RN”
piston, in middle groove. Turn ring until gap is (near ring gap) toward top of piston, in top
120o away from oil ring gap. groove. Turn ring until gap is 120o away from
second ring gap.
2nd Compression
Ring 1. Inspect all parts for wear or damage. Replace as
necessary.
2. Measure crankshaft connecting rod journal
diameter. (See Crankshaft, Main Bearings and
Flywheel in this section.)
3. Install connecting rod cap and bearing inserts on
1st Compression connecting rod. Install old connecting rod cap
2nd 120° Ring
Compression 120° screws and tighten to specifications.
Ring 120°
Oil Ring Connecting Rod Cap Screw Torque
Specifications:
3TN75, 3TN78,
3TNC78 (3011) . . . . . . . . . . 39 N•m (29 lb-ft)
3TN82, 3TNA82,
3TN84 (3014) . . . . . . . . . . . . 47 N•m (35 lb-ft)
M82276A
3TN75
4/7/95 2-35
M35360
2
M82048A Piston Ring Groove Clearance - 3TN75, 3TN78,
3TNC78 (3011):
Connecting Rod Bearing I.D. - 3TN75,
3TN78, 3TNC78 (3011): Standard . . . . . . . . . . . . . . . 0.070 - 0.105 mm
. . . . . . . . . . . . . . . . . . . . . (0.0028 - 0.0041 in.)
Standard . . . . . . . . . . . . . . . . 43 - 43.042 mm
Wear Limit. . . . . . . . . . . 0.25 mm (0.0098 in.)
. . . . . . . . . . . . . . . . . . . . . . . (1.693 - 1.695 in.)
Wear Limit. . . . . . . . . . . 43.07 mm (1.696 in.)
Clearance . . . . . . . . . . . . . 0.16 mm (0.006 in.)
Standard . . . . . . . . . . . . . . . 0.035 - 0.070 mm
. . . . . . . . . . . . . . . . . . . . . (0.0014 - 0.0028 in.)
Connecting Rod Bearing I.D. - 3TN82, 3TNA82,
3TN84 (3014): Wear Limit. . . . . . . . . . . 0.25 mm (0.0098 in.)
Standard . . . . . . . . . . . . . . . . 48 - 48.042 mm
Oil Ring
. . . . . . . . . . . . . . . . . . . . . . . (1.888 - 1.891 in.)
Standard . . . . . . . . . . . . . . . 0.030 - 0.060 mm
Wear Limit. . . . . . . . . . . 48.07 mm (1.893 in.)
. . . . . . . . . . . . . . . . . . . . . (0.0012 - 0.0024 in.)
Clearance . . . . . . . . . . . . . 0.16 mm (0.006 in.)
Wear Limit. . . . . . . . . . . 0.20 mm (0.0079 in.)
If bearing diameter exceeds wear limit, replace
bearing inserts. Piston Ring Groove Clearance - 3TN82, 3TNA82,
If bearing clearance (bearing I.D. minus crankshaft 3TN84 (3014):
journal O.D.) exceeds specification, grind crankshaft First Compression Ring
connecting rod journals and install undersized
bearing inserts, or replace bearing inserts and Standard . . . . . . . . . . . . . . . 0.075 - 0.110 mm
crankshaft. . . . . . . . . . . . . . . . . . . . . . (0.0030 - 0.0043 in.)
Wear Limit. . . . . . . . . . . 0.25 mm (0.0098 in.)
5. With rings installed on piston, measure piston
ring groove clearance. Measure several places
around each piston. Second Compression Ring
Standard . . . . . . . . . . . . . . . . 0.45 - 0.080 mm
. . . . . . . . . . . . . . . . . . . . . (0.0018 - 0.0031 in.)
Wear Limit. . . . . . . . . . . 0.25 mm (0.0098 in.)
2-36 4/7/95
Oil Ring Piston Ring End Gap - 3TN78, 3TNC78 (3011):

Standard . . . . . . . . . . . . . . . 0.025 - 0.060 mm Standard
. . . . . . . . . . . . . . . . . . . . . (0.0010 - 0.0024 in.) Compression Rings . . . . . . . . 0.25 - 0.40 mm
Wear Limit. . . . . . . . . . . 0.20 mm (0.0079 in.) . . . . . . . . . . . . . . . . . . . . . . (0.010 - 0.016 in.)
If clearance exceeds wear limit, replace rings or Oil Ring . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm
piston. . . . . . . . . . . . . . . . . . . . . . . (0.008 - 0.016 in.)
6. Measure piston ring end gap. Push ring into Wear Limit. . . . . . . . . . . 1.50 mm (0.0591 in.)
cylinder bore, using a piston, until ring is
approximately 30 mm (1.181 in.) from bottom of Piston Ring End Gap - 3TN82, 3TNA82:
cylinder bore.
Standard
. . . . . . . . . . . . . . . . . . . . . . (0.010 - 0.016 in.) 2
End Gap Second Compression Ring . . 0.20 - 0.35 mm
. . . . . . . . . . . . . . . . . . . . . . (0.008 - 0.014 in.)
Oil Ring . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm
. . . . . . . . . . . . . . . . . . . . . . (0.008 - 0.016 in.)
Wear Limit: . . . . . . . . . . 1.50 mm (0.0591 in.)
Cylinder Piston Ring End Gap - 3TN84 (3014):
Bore Standard
Compression Rings . . . . . . . . 0.20 - 0.40 mm
. . . . . . . . . . . . . . . . . . . . . . (0.008 - 0.016 in.)
Oil Ring . . . . . . . . . . . . . . . . . 0.25 - 0.45 mm
. . . . . . . . . . . . . . . . . . . . . . (0.010 - 0.018 in.)
Piston Wear Limit: . . . . . . . . . . 1.50 mm (0.0591 in.)
Ring
If end gap exceeds wear limit, replace rings.
Approx. 7. Measure piston pin diameter. Measure diameter
30 mm at six places.
(1.181 in.)
End Gap M82049A
Piston Ring End Gap - 3TN75:

Standard . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm
. . . . . . . . . . . . . . . . . . . . . . . (0.008 - 0.016 in.)
Wear Limit. . . . . . . . . . . 1.50 mm (0.0591 in.)
4/7/95 2-37
M37683
Piston Pin Bore I.D. - 3TN75, 3TN78,

2 3TNC78 (3011):
Measuring Positions
Standard . . . . . . . . . . . . . . 23.00 - 23.009 mm
. . . . . . . . . . . . . . . . . . . . . (0.9055 - 0.9059 in.)
Wear Limit. . . . . . . . . . . 23.02 mm (0.906 in.)
Clearance . . . . . . . . . . . 0.045 mm (0.0018 in.)
Piston Pin Bore I.D. - 3TN82, 3TNA82,

3TN84 (3014):
M82050A
Standard . . . . . . . . . . . . . . 26.00 - 26.009 mm
. . . . . . . . . . . . . . . . . . . . . (1.0236 - 1.0240 in.)
Piston Pin O.D. - 3TN75, 3TN78, Wear Limit. . . . . . . . . . . 26.02 mm (1.024 in.)
3TNC78 (3011): Clearance . . . . . . . . . . . 0.045 mm (0.0018 in.)
Standard . . . . . . . . . . . . . . 22.991 - 23.00 mm If piston pin bore exceeds wear limit, replace piston.
. . . . . . . . . . . . . . . . . . . . . . . (0.905 - 0.906 in.)
If bore clearance (bore I.D. minus pin O.D.) exceeds
Wear Limit. . . . . . . . . . . 22.90 mm (0.902 in.) specification, replace piston, piston pin or both.
Piston Pin O.D. - 3TN82, 3TNA82, 9. Measure piston pin bushing diameter in
3TN84 (3014): connecting rod.
Standard . . . . . . . . . . . . . . 25.987 - 26.00 mm

. . . . . . . . . . . . . . . . . . . . . . . (1.023 - 1.024 in.)
Wear Limit. . . . . . . . . . . 25.90 mm (1.020 in.)
8. Measure piston pin bore diameter in piston.
M82051A
2-38 4/7/95
Piston Pin Bushing I.D. - 3TN75, 3TN78,

3TNC78 (3011):
Standard . . . . . . . . . . . . . 23.025 - 23.038 mm
. . . . . . . . . . . . . . . . . . . . . (0.9065 - 0.9070 in.)
Wear Limit. . . . . . . . . . . 23.10 mm (0.909 in.)
Clearance . . . . . . . . . . . 0.110 mm (0.0043 in.)
Piston Pin Bushing I.D. - 3TN82, 3TNA82,

3TN84 (3014):
Standard . . . . . . . . . . . . . 26.025 - 26.038 mm
. . . . . . . . . . . . . . . . . . . . . (1.0246 - 1.0251 in.)
Wear Limit. . . . . . . . . . . 26.10 mm (1.028 in.)
Clearance . . . . . . . . . . . 0.110 mm (0.0043 in.)
M82052A 2
bushing. Piston O.D. - 3TN75:
If bushing clearance (bushing I.D. minus pin O.D.) Distance A . . . . . . . . . . . . . . . 12.5 mm (0.492 in.)
exceeds specification, replace bushing, piston pin or Standard Size Piston
both.
Standard . . . . . . . . . . . . . . . 74.91 - 74.94 mm
Piston pin bushing is press fit. Replace bushing . . . . . . . . . . . . . . . . . . . . . . . (2.949 - 2.951 in.)
using a driver set. When installing bushing, make Wear Limit. . . . . . . . . . . 74.81 mm (2.945 in.)
connecting rod. 0.25 mm (0.010 in.) Oversize Piston
10.Measure piston diameter perpendicular to piston Standard . . . . . . . . . . . . . . . 75.17 - 75.18 mm
pin bore at distance A. . . . . . . . . . . . . . . . . . . . . . . . (2.959 - 2.960 in.)
Wear Limit. . . . . . . . . . . 75.06 mm (2.955 in.)
overhaul, oversize pistons and rings may 0.50 mm (0.020 in.) Oversize Piston
have been installed. Pistons and rings are (F1145 FM Only)
available in 0.25 mm (0.010 in.) oversize for Standard . . . . . . . . . . . . . . . 75.42 - 75.43 mm
all engines and 0.50 mm (0.020 in.) oversize . . . . . . . . . . . . . . . . . . . . . . . (2.969 - 2.970 in.)
for 3TN75 (F1145 FM), 3TN82 (575 SSL), Wear Limit. . . . . . . . . . . 75.31 mm (2.965 in.)
3TNC78 (3011 OEM) and 3TN84 (3014
OEM).
Piston O.D. - 3TN78, 3TNC78 (3011):
Distance A . . . . . . . . . . . . . . . . .23 mm (0.905 in.)
Standard . . . . . . . . . . . . . 77.895 - 77.925 mm
. . . . . . . . . . . . . . . . . . . . . . . (3.067 - 3.068 in.)
Wear Limit. . . . . . . . . . . 77.81 mm (3.063 in.)

Standard . . . . . . . . . . . . . . . 78.15 - 78.18 mm
A . . . . . . . . . . . . . . . . . . . . . . . (3.076 - 3.077 in.)
Wear Limit. . . . . . . . . . . 78.05 mm (3.073 in.)
M82200A
4/7/95 2-39
0.50 mm (0.020 in.) Oversize Piston If piston diameter is less than wear limit, install a
(3011 OEM Only) new piston.
Standard . . . . . . . . . . . . . . . 78.40 - 78.42 mm 11.Measure cylinder bore diameter. (See procedure
. . . . . . . . . . . . . . . . . . . . . . . (3.086 - 3.087 in.) in this group.)
Wear Limit. . . . . . . . . . . 78.30 mm (3.083 in.)
CYLINDER BORE
Piston O.D. - 3TN82, 3TNA82:
Distance A . . . . . . . . . . . . . . . . .24 mm (0.945 in.) Inspection
Standard Size Piston Measure cylinder bore diameter at three positions;
Standard . . . . . . . . . . . . . . . 81.90 - 81.93 mm top, middle and bottom. At these three positions,
. . . . . . . . . . . . . . . . . . . . . . . (3.224 - 3.226 in.) measure in both directions; along crankshaft center
line and direction of crankshaft rotation.
2 Wear Limit. . . . . . . . . . . 81.80 mm (3.221 in.)
0.25 mm (0.010 in.) Oversize Piston overhaul, oversize pistons and rings may
Standard . . . . . . . . . . . . . . . 82.15 - 82.17 mm
. . . . . . . . . . . . . . . . . . . . . . . (3.234 - 3.235 in.)
Wear Limit. . . . . . . . . . . 82.05 mm (3.230 in.)
Top Position

(575 SSL Only)
Standard . . . . . . . . . . . . . . . 82.40 - 82.42 mm Middle Position
. . . . . . . . . . . . . . . . . . . . . . . (3.244 - 3.245 in.)
Wear Limit. . . . . . . . . . . 82.30 mm (3.240 in.)
Piston O.D. - 3TN84 (3014): Bottom Position
Distance A . . . . . . . . . . . . . . . . .24 mm (0.945 in.)

Standard Size Piston Direction of
Standard . . . . . . . . . . . . . . . 83.90 - 83.93 mm Crankshaft Rotation
. . . . . . . . . . . . . . . . . . . . . . . (3.303 - 3.304 in.)
Wear Limit. . . . . . . . . . . 83.80 mm (3.299 in.) Direction of
Crankshaft
Centerline
Standard . . . . . . . . . . . . . . . 84.15 - 84.17 mm
. . . . . . . . . . . . . . . . . . . . . . . (3.313 - 3.314 in.) M82053A
Wear Limit. . . . . . . . . . . 84.05 mm (3.309 in.)

(3014 OEM Only) Standard Size Bore
Standard . . . . . . . . . . . . . . . 84.40 - 84.42 mm Standard . . . . . . . . . . . . . . . 75.00 - 75.03 mm
. . . . . . . . . . . . . . . . . . . . . . . (3.323 - 3.324 in.) . . . . . . . . . . . . . . . . . . . . . . . (2.953 -2.954 in.)
Wear Limit. . . . . . . . . . . 84.30 mm (3.319 in.) Wear Limit . . . . . . . . . . 75.20 mm (2.961 in.)
Clearance . . . . . . . . . . . . . 0.22 mm (0.009 in.)
2-40 4/7/95
0.25 mm (0.010 in.) Oversize Bore 0.50 mm (0.020 in.) Oversize Bore
Standard . . . . . . . . . . . . . . . 75.25 - 75.28 mm (575 SSL Only)
. . . . . . . . . . . . . . . . . . . . . . . (2.963 - 2.964 in.) Standard . . . . . . . . . . . . . . . 82.50 - 82.53 mm
Wear Limit. . . . . . . . . . . 75.45 mm (2.970 in.) . . . . . . . . . . . . . . . . . . . . . . . (3.248 - 3.249 in.)
0.50 mm (0.020 in.) Oversize Bore Cylinder Bore I.D. - 3TN84 (3014):
(F1145 FM Only) Standard Size Bore
. . . . . . . . . . . . . . . . . . . . . . . (2.972 - 2.974 in.) . . . . . . . . . . . . . . . . . . . . . . . (3.307 - 3.308 in.)
Wear Limit. . . . . . . . . . . 75.70 mm (2.980 in.) Wear Limit . . . . . . . . . . 84.20 mm (3.315 in.)
Clearance . . . . . . . . . . . . . 0.22 mm (0.009 in.) Clearance . . . . . . . . . . . . . 0.35 mm (0.014 in.) 2
Cylinder Bore I.D. - 3TN78, 3TNC78 (3011): 0.25 mm (0.010 in.) Oversize Bore
Standard Size Bore Standard . . . . . . . . . . . . . . . 84.25 - 84.28 mm
Standard . . . . . . . . . . . . . . . 78.00 - 78.03 mm . . . . . . . . . . . . . . . . . . . . . . . (3.317 - 3.318 in.)
. . . . . . . . . . . . . . . . . . . . . . . (3.071 - 3.072 in.) Wear Limit. . . . . . . . . . . 84.45 mm (3.325 in.)
Wear Limit . . . . . . . . . . 78.20 mm (3.079 in.)
Clearance . . . . . . . . . . . . . 0.22 mm (0.009 in.) 0.50 mm (0.020 in.) Oversize Bore
(3014 OEM Only)
0.25 mm (0.010 in.) Oversize Bore Standard . . . . . . . . . . . . . . . 84.50 - 84.53 mm
Standard . . . . . . . . . . . . . . . 78.25 - 78.28 mm . . . . . . . . . . . . . . . . . . . . . . . (3.327 - 3.328 in.)
. . . . . . . . . . . . . . . . . . . . . . . (3.081 - 3.082 in.) Wear Limit. . . . . . . . . . . 84.70 mm (3.335 in.)
Wear Limit. . . . . . . . . . . 78.45 mm (3.089 in.) If cylinder bore exceeds wear limit, replace cylinder
0.50 mm (0.020 in.) Oversize Bore procedure.)
(3011 OEM Only) If cylinder is rebored, oversize pistons and rings
Standard . . . . . . . . . . . . . . . 78.50 - 78.53 mm must be installed. Pistons and rings are available in
. . . . . . . . . . . . . . . . . . . . . . . (3.091 - 3.092 in.) 0.25 mm (0.010 in.) oversize for all engines and 0.50
Wear Limit. . . . . . . . . . . 78.70 mm (3.099 in.) mm (0.020 in.) oversize for 3TN75 (F1145 FM),
3TN82 (575 SSL), 3TNC78 (3011 OEM), and
3TN84 (3014 OEM).
Cylinder Bore I.D. - 3TN82, 3TNA82:
Standard Size Bore exceeds specification, replace cylinder block, piston
Standard . . . . . . . . . . . . . . . 82.00 - 82.03 mm or both; or rebore cylinder and install oversize piston
. . . . . . . . . . . . . . . . . . . . . . . (3.228 - 3.230 in.) and rings.
Wear Limit . . . . . . . . . . 82.20 mm (3.236 in.)
Clearance . . . . . . . . . . . . . 0.35 mm (0.014 in.)

Standard . . . . . . . . . . . . . . . 82.25 - 82.28 mm
. . . . . . . . . . . . . . . . . . . . . . . (3.238 - 3.239 in.)
Wear Limit. . . . . . . . . . . 82.45 mm (3.246 in.)
4/7/95 2-41
Deglazing 3. Adjust rigid hone stones until they contact

narrowest point of cylinder.
deglazed with crankshaft installed in engine, 4. Coat cylinder with honing oil. Hone should turn
put clean shop towels over crankshaft to by hand. Adjust if too tight.
protect journal and bearing surfaces from any 5. Run drill press at about 250 RPM. Move hone up
abrasives. and down in order to obtain a 30 - 40°crosshatch
1. Deglaze cylinder bores using a flex-hone with pattern.
180 grit stones.
2. Use flex-hone as instructed by manufacturer to
obtain a 30 - 40° cross-hatch pattern as shown.
IMPORTANT: Do not use gasoline, kerosene or 30 - 40°
2 commercial solvents to clean cylinder bores.

cylinder walls.
using clean white rags and warm soapy water.
no discoloration.
M52959

NOTE: Finish should not be smooth. It should have
M82054A
a 30 - 40o crosshatch pattern.
7. Remove rigid hone when cylinder is within 0.03
mm (0.001 in.) of desired size.
Reboring 8. Use a flex hone with 180 grit stones for honing to
NOTE: The cylinder block can be rebored to use final size.
oversize pistons and rings. Pistons and 9. Check bore for size, taper and out-of-round. (See
rings are available in 0.25 mm (0.010 in.) Inspection procedures.)
oversize for all engines and 0.50 mm (0.020
in.) oversize for 3TN75 (F1145 FM), 3TN82 IMPORTANT: Do not use solvents to clean
(575 SSL), 3TNC78 (3011 OEM) and cylinder bore. Solvents will not remove all
3TN84 (3014 OEM). (See this group for metal particles and abrasives produced during
cylinder bore I. D. specifications.) honing.
1. Align center of bore to drill press center. 10.Clean cylinder thoroughly using warm soapy
water until clean white rags show no
IMPORTANT: Check stone for wear or damage. discoloration.
Use a rigid hone with 300 grit stones.
11.Dry cylinder and apply engine oil.
2. Adjust hone so lower end is even with lower end
of cylinder bore.
2-42 4/7/95
OTHER MATERIALS
Number Name Use
LOCTITE® PRODUCTS
U.S./
Canadian/
LOCTITE No.
TY15130/ John Deere Form-In-Place Seals crankcase extension housing,
NA/ Gasket rear oil seal case and flywheel housing
#395 to engine block.
SERVICE PARTS KITS

2
®LOCTITE is a registeredtrademark of the Loctite Corp.
4/7/95 2-43

3TN75, 3TNC78 (3011 OEM),
John Deere
3TN82 (575 SSL), 3TN84 (955 CUT, Form-In-Place
3014 OEM) Gasket
(RTV rubber
1. Remove flywheel. (See procedure in this group.) silicone
sealant)
3. Remove seal case-to-extension cap screws and Extension-to-
Timing Gear
flywheel plate/housing-to-extension cap screws. Cover Cap
Screw (6)
M8 x 45
22 N•m
(195 lb-in.)
2
Extension-
to-Block Cap
Screw (2) (3011DF006 Only)
M8 x 45
27 N•m (20 lb-ft)
M82345A
3TNC78 (3011 OEM)
John Deere Form-In-Place

Seal Case - to- Flywheel Plate/Housing-to- Gasket (RTV rubber
Extension Cap Extension Cap Screw (4) silicone sealant)
Screw (3) M10 x 25 (Flywheel Plate)
M8 x 35 M10 x 30 (Flywheel Housing)
26 N•m (226 lb-in.) 49 N•m (36 lb-ft)
M82056
4. Remove remaining cap screws and extension

housing.
John Deere
Form-In-Place
Gasket Extension-to-Block
(RTV rubber Cap Screw (2)
silicone M8 x 50
sealant) 27 N•m (20 lb-ft) Extension-to-Timing Gear
Cover Cap Screw (2)
M8 x 25
22 N•m (195 lb-in.)
3TN82 (575 SSL), M82346A
3TN84 (955 CUT, 3014 OEM)
Extension-to-
Timing Gear
Cover Cap CRANKCASE EXTENSION HOUSING -
Screw (6)
M8 x 45
3TN78 (25 EX), 3TN82 (30 EX), 3TNA82
Crankcase
Extension
22 N•m (770 CUT), 3TN84 (870 CUT)
(195 lb-in.)
Housing 1. Remove flywheel. (See procedure in this group.)
3TN75 M82344A
2. Remove oil pan/plate. (See Lubrication System in
this section.)
2-44 4/7/95
3. Remove seal case-to-extension cap screws and

flywheel plate/housing-to-extension cap screws.
John Deere Form-In-
Place Gasket (RTV
rubber silicone
selant)
Crankcase
Extension
Housing
2
Seal Case - to- Flywheel Plate/Housing-to-
Extension Cap Extension Cap Screw
Screw (3) Plate: (4) M10 x 20
M8 x 30 Housing: (2) M10 x 25
26 N•m (226 lb-in.) 49 N•m (36 lb-ft) Extension-to-
M82056
Timing Gear Cover
Cap Screw (4)
4. Remove remaining cap screws and extension M8 x 25
housing. 22 N•m (195 lb-in.)
Installation is done in the reverse order of removal. Extension-to-Block Cap Screw (14)
M8 x 85
27 N•m (20 lb-ft)
John Deere Form-In- Extension-to-Block Cap Screw (4)
Place Gasket (RTV M8 x 120
rubber silicone 27 N•m (20 lb-ft)
sealant) M82348A
3TN84 (870 CUT)
CRANKSHAFT REAR OIL SEAL
Replacement
Crankcase 1. Remove flywheel. (See procedure in this group.)
Extension
Housing • Replace oil seal using a driver set. Install seal,
with lip toward cylinder block. Install seal flush
with surface of oil seal case.
Extension - point, seal can be installed 3 mm (0.120 in.)
to-Timing farther into oil seal case.
Gear Cover
Cap Screw (6)
M8 x 25 On 3TN78, 3TN82 (30 EX), 3TNA82, 3TN84
22 N•m
(195 lb-in.) (870 CUT): All nine seal case cap screws
Extension-to-Block are M8 x 30 long.
Cap Screw (4)
M8 x 50
27 N•m (20 lb-ft)
Extension - Extension-to-Block Cap Screw (8)
to-Block Cap M8 x 85
Screw (4) 27 N•m (20 lb-ft)
M8 x 120 M82347A
27 N•m (20 lb-ft)
3TN78 (25 EX), 3TN82 (30 EX), 3TNA82 (770 CUT)
4/7/95 2-45
CRANKSHAFT AND MAIN BEARINGS

Seal Case-to-Block
Cap Screw (6)
Rear Oil Seal Removal
M8 X 30
26 N•m (226 lb-in.)
Oil Seal Case
group.)
3. Remove flywheel housing. (See procedure in this
group.)
4. Remove crankcase extension housing. (See
2 NOTE: On 3TNA82 and 3TN84 (870 CUT),
crankshaft can be removed without
removing timing gear cover mounting plate.
John Deere 5. Remove timing gear cover mounting plate. (See
Form-In-Place Camshaft and Timing Gear Train in this section.)
Seal Case-to-Extension Gasket
Cap Screw (3) (RTV rubber 6. Check crankshaft bearing clearance. (See Checks,
M8 X 35 silicone sealant) Tests and Adjustments in this section.)
21 N•m (180 lb-in.)
M82349A
IMPORTANT: Connecting rod end caps must be
CRANKSHAFT FRONT OIL SEAL marks on caps and rods.
7. Remove connecting rod cap screws and end caps.
Replacement
• Remove timing gear cover. (See Camshaft and crankshaft.
• Replace oil seal using a driver set. Install seal IMPORTANT: Main bearing caps must be
with lip toward inside of gear housing cover. installed on the same main bearings from
Install seal flush with surface of cover. which they were removed.
9. Remove main bearing cap screws, caps and cap
thrust bearings.
Timing Gear Cover
10.Remove crankshaft.
11.Remove block thrust bearings and main bearing
inserts.
Crankshaft
Front
Oil Seal
M82203A
2-46 4/7/95
Crankshaft
Flywheel
End
Cap Thrust Bearing

2
Main Bearing Cap

Screw (8)
Main Bearing Cap M82283A
Installation 5. Install cap thrust bearings, with oil grooves

• Apply clean engine oil on all parts during bearing cap.
installation.
IMPORTANT: Do not touch bearing insert 6. Install main bearing caps in their original
surfaces. Oil and acid from your finger will locations with arrows pointing toward flywheel
corrode the bearing surface. side of engine.
1. Install grooved bearing inserts in crankshaft IMPORTANT: DO NOT use high speed power
bearing bores, aligning tangs with slots in bores. tools or air wrenches to tighten main bearing
cap screws.
2. Install block thrust bearings with oil grooves
facing away from engine block. 7. Dip entire main bearing cap screws in clean
engine oil. Install cap screws and tighten. DO
3. Install crankshaft. NOT tighten to specifications.
4. Install smooth bearing inserts in main bearing 8. Using a soft-faced hammer, tap the front end of
caps, aligning tangs with slots in caps. the crankshaft then the rear end of the crankshaft
NOTE: Main bearing caps have “raised arrows” to align the thrust bearings.
that are stamped with numbers. Both 9. Tighten main bearing cap screws to
correspond to their location on the engine specifications. When tightening, start at center
block. The number “1” main bearing bore main bearing cap and work your way out,
is at flywheel end. Install bearing caps alternating to the ends. Turn crankshaft by hand.
beginning with number 1, then 2, etc. The If it does not turn easily, disassemble the parts
main bearing cap at gear train end does not and find the cause.
have a number. Also install bearing caps
4/7/95 2-47
Crankshaft
Flywheel
End

Cap Thrust Bearing
2 Tangs Smooth Bearing Insert
Main Bearing Cap
Main Bearing Cap Screw (8) 3

3TN75, 3TN78, 3TNC78 (3011):79 N•m (58 lb-ft)
3TN82, 3TNA82, 3TN84 (3014):98 N•m (72 lb-ft)
M82283A
IMPORTANT: Connecting rod caps must be NOTE: On 3TNA82 and 3TN84 (870 CUT),
installed on the same connecting rods they crankshaft can be installed without
were removed from. removing timing gear cover mounting plate.
Never reuse connecting rod cap screws, 12.Install timing gear cover mounting plate. (See
replace with new. Camshaft and Timing Gear Train in this section.)
10.Match the connecting rod caps to the rods using 13.Install crankcase extension housing. (See
alignment marks. Install caps. procedure in this group.)
11.Dip entire connecting rod cap screws in clean 14.Install flywheel housing. (See procedure in this
engine oil. Install new cap screws and tighten to group.)
specifications. 15.Install rear oil seal. (See procedure in this group.)
Connecting Rod Cap Screw Torque

Specifications:
3TN75, 3TN78,
3TNC78 (3011) . . . . . . . . . . 39 N•m (29 lb-ft)
3TN82, 3TNA82,
3TN84 (3014) . . . . . . . . . . . . 47 N•m (35 lb-ft)
2-48 4/7/95
Inspection/Replacement 2. Inspect crankshaft for bend using v-blocks and a

dial indicator. Turn crankshaft slowly and read
1. Inspect crankshaft gear for chipped or broken variation on indicator. If variation is greater than
teeth. Replace if necessary. 0.02 mm (0.0007 in.), replace crankshaft.
To replace gear: 3. Measure crankshaft connecting rod journal and
Remove gear from crankshaft using a knife-edge main bearing journal diameters. Measure several
puller and a press. places around each journal.
and undersized bearing inserts installed.
CAUTION
Main
DO NOT heat oil over 182° C (360° F). Oil Bearing 2
fumes or oil can ignite above 193° C (380° F). Journal
Use a thermometer. Do not allow a flame or
area. Plan a safe handling procedure to avoid
burns.
Connecting
Heat gear to approximately 150oC (300oF). Install Rod Journal
gear with timing mark “A” toward press table. Align M82062A
slot in gear with key in shaft. Press crankshaft into
gear until gear is tight against crankshaft shoulder.
Key
Connecting Rod Journal O.D. - 3TN75, 3TN78,
3TNC78 (3011):
Standard . . . . . . . . . . . . . 42.952 - 42.962 mm
Crankshaft Gear . . . . . . . . . . . . . . . . . . . . . (1.6910 - 1.6914 in.)
Wear Limit. . . . . . . . . . . 42.91 mm (1.689 in.)
Timing Connecting Rod Journal O.D. - 3TN82, 3TNA82,

Mark 3TN84 (3014):
Standard . . . . . . . . . . . . . 47.952 - 47.962 mm
. . . . . . . . . . . . . . . . . . . . . (1.8879 - 1.8883 in.)
M82060A Wear Limit. . . . . . . . . . . 47.91 mm (1.886 in.)
Dial Indicator
M82284A
V-Block
4/7/95 2-49
Main Bearing Journal O.D. - 3TN75, 3TN78, Main Bearing I.D. - 3TN75, 3TN78,
3TNC78 (3011): 3TNC78 (3011):
Standard . . . . . . . . . . . . . 46.952 - 46.962 mm Standard . . . . . . . . . . . . . . 47.00 - 47.045 mm
. . . . . . . . . . . . . . . . . . . . . (1.8485 - 1.8489 in.) . . . . . . . . . . . . . . . . . . . . . . . (1.850 - 1.852 in.)
Wear Limit. . . . . . . . . . . 46.91 mm (1.847 in.) Wear Limit. . . . . . . . . . 47.10 mm (1.8541 in.)
Clearance . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Main Bearing Journal O.D. - 3TN82, 3TNA82,
3TN84 (3014):
Main Bearing I.D. - 3TN82, 3TNA82,
Standard . . . . . . . . . . . . . 46.952 - 46.962 mm 3TN84 (3014):
. . . . . . . . . . . . . . . . . . . . . (1.9666 - 1.9670 in.)
Standard . . . . . . . . . . . . . . 50.00 - 50.045 mm
Wear Limit. . . . . . . . . . . 49.90 mm (1.965 in.)
. . . . . . . . . . . . . . . . . . . . . . . (1.969 - 1.970 in.)
2 If journal diameter is less than wear limit, replace Wear Limit. . . . . . . . . . . 50.10 mm (1.972 in.)
qualified machine shop. Clearance . . . . . . . . . . . . 0.15 mm (0.0059 in.)
If journals are ground, undersize bearing inserts If bearing diameter exceeds wear limit, replace
must be installed. Bearing inserts are available in bearing inserts.
0.25 mm (0.010 in.) undersize.
4. Install bearing inserts and main bearing cap on main bearing journal O.D.) exceeds specification,
main bearing. Tighten main bearing cap screws to replace bearing inserts and crankshaft or have
specifications. crankshaft journals ground undersize by a qualified
3TN75, 3TN78, undersize.
3TNC78 (3011) . . . . . . . . . . 79 N•m (58 lb-ft)
6. Clean and inspect oil passages in main bearing
3TN82, 3TNA82, journals, connecting rod journals and main
3TN84 (3014) . . . . . . . . . . . . 98 N•m (72 lb-ft) bearing bores in cylinder block.
5. Measure main bearing diameter. 7. Inspect crankshaft for cracks or damage. Replace
if necessary.
M82063
2-50 4/7/95
FLYWHEEL • Inspect pilot bushing, if equipped, for wear or

IMPORTANT: Never reuse flywheel mounting Install bushing flush with flywheel surface.
1. 3TN75 (F1145FM): Remove cooling fan, across flywheel surface opposite of ring gear.
isolator, pulley, isolator mount plate and flywheel Measure clearance between straight edge and
guards. flywheel surface with a feeler gauge. If
- 3TN75 (855/56 CUT): Remove flywheel clearance exceeds 0.02 mm (0.0008 in.), replace
guards. flywheel.
- 3TN84 (955 CUT): Remove isolator mount

plate and flywheel guards.
- 3TN78, 3TN82: Remove center flex coupler.
(See procedure in Machine Technical 2
Manual.)
2. Remove mounting cap screws and flywheel.
M35337
Flywheel Guard (Top)
Cap Screw (8) Pilot Bushing

M8 x 16 3TNA82 (770 CUT),
Isolator
Mount Flywheel Flywheel
Plate Guard (Bottom)
Early 855/56 CUT
3TN84 (955 CUT) Bracket

(F1145 FM Only)
Flywheel Mounting
Cap Screw (6)
Replace.
Apply clean engine oil on threads.
83 N•m (61 lb-ft)
Isolator
Cap Screw (3) Flywheel

M10 x 50 Guards
49 N•m
(36 lb-ft)
Pulley
Cap Screw (8) Isolator

M8 x 16 Mount
Plate
3TN75 (F1145FM) M82350A
4/7/95 2-51
FLYWHEEL HOUSING - 3TN78, NOTE: 3TNC78 (3011DF001 OEM) and 3TN84

3TNC78 (3011), 3TN82, 3TN84 (3014) (3014DF001 OEM) engines are equipped
with a flywheel plate in place of a housing.
1. Remove flywheel. (See procedure in this group.) (See procedure in this group.)
2. Remove starter.
Housing-to-Block
Cap Screw (6)
M10 x 25
49 N•m (36 lb-ft)
Housing-to-Extension
Cap Screw (4) Flywheel Housing
2 M10 x 30
49 N•m (36 lb-ft)
Gasket (RTV rubber
silicone sealant)
3TN82 (575 SSL)

M10 x 25
49 N•m (36 lb-ft)
Plug
3TN78 (25 EX) , 3TN82 (30 EX)
M82351A
2-52 4/7/95
FLYWHEEL PLATE - 3TN75, 3TNC78

(3011), 3TNA82, 3TN84 (3014)
2. Remove starter. Mounting Cap
Screw (8)
M10 x 20
49 N•m
Plate-to-Block Cap Screw (6) (36 lb-ft)
M10 x 20
49 N•m (36 lb-ft)
Plate-to-Extension
Cap Screw (4)
M10 x 25
49 N•m
2
(36 lb-ft)
3TN84 (870 CUT) M82353A
3TNA82, 3TN84 (870 CUT)
3TN75,
3TN84
(955 CUT) M82352A
3TN75, 3TNC78 (3011), 3TN84 (955 CUT, 3014 OEM)
4/7/95 2-53

OTHER MATERIALS
Number Name Use
LOCTITE® PRODUCTS
U.S./
Canadian/
2 LOCTITE No.
NA/ Gasket plate to engine block.
#395

#242
SERVICE PARTS KITS

2-54 4/7/95
CAMSHAFT
Mounting Cap Screws
M8 X 16
Removal
section.)
group.)
3. Check camshaft end play. (See Checks, Tests and
Tests and Adjustments in this section.) 2
Timing
NOTE: If a magnetic follower holder kit is not Marks
available, turn engine until oil pan is Camshaft
upward, to hold cam followers away from M37836
camshaft.
magnetic follower holder kit such as D15001NU. Installation
NOTE: Due to the odd number of teeth on the idler • Apply clean engine oil on all parts during
gear, timing marks will only align installation.
periodically. IMPORTANT: DO NOT allow camshaft lobes to
6. Rotate crankshaft and align timing marks. hit bearing surfaces while installing camshaft.
Machined surfaces can be damaged.
IMPORTANT: DO NOT allow camshaft lobes to
hit bearing surfaces while removing camshaft. 1. Rotate crankshaft to align timing marks.
Machined surfaces can be damaged. 2. Install camshaft.
7. Remove two cap screws and camshaft. 3. Install and tighten mounting cap screws to 26
8. Inspect all parts for wear or damage. (See N•m (226 lb-in.).
Inspection/Replacement procedures.) 4. Install timing gear cover. (See procedure in this
group.)
section.)
4/7/95 2-55

Camshaft Gear
Thrust plate must spin freely on camshaft.
Key
2 Camshaft Gear
Side Gap M82067A
Camshaft Side Gap:

Thrust Plate
Standard . . . . . . . . . . . . . . . . . 0.05 - 0.20 mm
. . . . . . . . . . . . . . . . . . . . . (0.0020 - 0.0079 in.) M82068A
Wear Limit. . . . . . . . . . . . 0.40 mm (0.016 in.)

if necessary.
To remove/replace gear: Dial Indicator
puller and a press.
CAUTION
DO NOT heat oil over 182° C (360° F). Oil V-Block
Use a thermometer. Do not allow a flame or Camshaft
heating element to come in direct contact Central Bearing
with the oil. Heat the oil in a well-ventilated Areas
burns. M82291A
2-56 4/7/95
4. Measure camshaft lobe height. If journal diameters are less than wear limit, replace
camshaft.
housing end.
Lobe
Height Camshaft Bushing
M82070A
Lobe Height:
Standard . . . . . . . . . . . . . 38.635 - 38.765 mm 2
. . . . . . . . . . . . . . . . . . . . . . . (1.521 - 1.526 in.)
Oil Holes
Wear Limit. . . . . . . . . . . 38.40 mm (1.512 in.) M82072
If lobe height is less than wear limit, replace

camshaft. Camshaft Bushing I.D.:
5. Measure camshaft end and intermediate journal Standard . . . . . . . . . . . . . 44.990 - 45.055 mm
diameters. . . . . . . . . . . . . . . . . . . . . . . . (1.771 - 1.774 in.)
Wear Limit. . . . . . . . . . . 45.10 mm (1.776 in.)
Flywheel End
Journal Clearance . . . . . . . . . . . . 0.20 mm (0.0078 in.)
bushing.
If bushing clearance (bushing I.D. minus camshaft
camshaft or both.
To replace bushing:
Intermediate
Journals
Remove bushing using a chisel. Be careful not to
Gear Housing
End Journal M82292A
new bushing and cylinder block. Install bushing
using a driver set.
NOTE: Flywheel housing/plate must be removed to
Camshaft Journal O.D.: measure camshaft intermediate and
Gear Housing and Flywheel Ends flywheel end bearing diameters.
Standard . . . . . . . . . . . . . . . 44.92 - 44.95 mm 7. Measure intermediate and flywheel end camshaft
. . . . . . . . . . . . . . . . . . . . . . . (1.769 - 1.770 in.) bore diameters using the following procedures:
Wear Limit. . . . . . . . . . . 44.80 mm (1.764 in.) • Remove flywheel housing/plate. (See
Crankshaft, Main Bearings and Flywheel in this
Intermediate section.)
Standard . . . . . . . . . . . . . . . 44.91 - 44.94 mm • Remove plug using a long wooden dowel. Insert
. . . . . . . . . . . . . . . . . . . . . . . (1.768 - 1.769 in.) wooden dowel through gear housing side.
Wear Limit. . . . . . . . . . . 44.80 mm (1.764 in.)
4/7/95 2-57

removed.
block bore to aid in installation.
4. Remove cam followers.
Plug
M35287 6. Apply clean engine oil on all parts during
installation.
• Measure intermediate and flywheel end Installation is done in the reverse order of removal.
camshaft bore diameters.
2
Inspection
Intermediate • Inspect cam follower contact surface for
Bores abnormal wear. Replace if necessary.
Flywheel
End
Bore
M82073
Camshaft Bore I.D.:

Standard . . . . . . . . . . . . . . 45.00 - 45.025 mm
. . . . . . . . . . . . . . . . . . . . . . . (1.772 - 1.773 in.)
Wear Limit. . . . . . . . . . . 45.10 mm (1.776 in.) Normal Contact
Clearance . . . . . . . . . . . . . 0.20 mm (0.008 in.) Abnormal Contact M82074A
If bore diameter exceeds wear limit, replace cylinder

block. • Measure cam follower stem diameter.
If bore clearance (bore I.D. minus camshaft journal
O.D.) exceeds specification, replace camshaft,
• Apply John Deere Form-In Place Gasket, or an
equivalent, on outer edge of plug. Install plug
• Install flywheel housing.
CAM FOLLOWERS
Removal/Installation M82075A
1. Remove camshaft. (See procedure in this group.)

2. Remove oil pan and strainer. (See Lubrication
2-58 4/7/95
Cam Follower Stem O.D.: 3. Remove crankshaft pulley cap screw and washer.
Standard . . . . . . . . . . . . . 11.975 - 11.990 mm 4. Remove crankshaft pulley using a two-jaw puller
. . . . . . . . . . . . . . . . . . . . . . . (0.471 - 0.472 in.) kit.
Wear Limit. . . . . . . . . . . 11.93 mm (0.470 in.) 5. Remove key, if equipped.
If stem diameter is less than wear limit, replace cam 6. Remove tachometer, if equipped.
follower. 7. 3TNA82 (770 CUT), 3TN84 (870 CUT):
• Measure cam follower bore diameter in cylinder Remove hydraulic pump and steering pump, if
block. equipped. (See procedure in Machine Technical
Manual).
Cam Follower Bore I.D.: NOTE: It is not necessary to remove auxiliary drive
cover and gasket, if equipped, end cover and
Standard . . . . . . . . . . . . . 12.000 - 12.018 mm
o-ring or fuel injection pump gear cover to
. . . . . . . . . . . . . . . . . . . . . . . (0.472 - 0.473 in.)
remove timing gear cover. 2
Wear Limit. . . . . . . . . . . 12.05 mm (0.474 in.) 8. Remove mounting cap screws and timing gear
Clearance . . . . . . . . . . . . . 0.10 mm (0.004 in.) cover.
If cam follower bore diameter exceeds wear limit, Installation is done in the reverse order of removal.
replace cylinder block. • Replace seal washer.
If bore clearance (bore I.D. minus follower stem • Tighten all mounting cap screws to 26 N•m (226
O.D.) exceeds specification, replace cam follower, lb-in.)
• All except 3TNA82 (770 CUT), 3TN84 (870
TIMING GEAR COVER CUT): Align pin in crankshaft pulley with hole
in crankshaft gear. Install crankshaft pulley.
NOTE: 3TN75 (F1145 FM) fan is mounted on Hole
flywheel end of engine. Alternator belt
pulley does not have to be removed to
access timing gear cover.
2. Remove fan, spacer/plate, if equipped, and
pulley. Pin
Plate
M35295
Pulley (3TN78, 3TN82, 3TNA82,
3TN84 (3014 OEM) Only
• 3TNA82 (770 CUT), 3TN84 (870 CUT): Install
key and crankshaft pulley.
Spacer Cap Screw (4)

3TN84 (870 CUT) 11 N•m (96 lb-in.)
M82354A
4/7/95 2-59
Cover
Gasket If equipped.
Cap Screw (2)
M8 x 16

Nut and Lock

Mounting Plate-to-Cover Washer (2)
Cap Screw (3)
All Except 3TNA82, 3TN84 (870 CUT) 3TNA82, 3TN84 (870 CUT)
2 M8 x 20
Cap Screw (2)

Mounting Plate-to- M6 x 16
Cover Cap Screw (3) Timing
3TN75, 3TN84 Gear
(955 CUT) Cover
M8 x 16
Tachometer
3TNC78 (3011), 3TNA82,
3TN84
O-Ring
End Cover
Cap Screw (2)
M6 x 12

M8 x 55
Cap
O-Ring Seal Washer

Replace.
Mounting Cap Screw
M8 x 16
M8 x 45
Key
3TNA82, 3TN84 (870 CUT)
Clamp
3TNC78 (3011), Crankshaft Pulley
3TNA82, 3TN84
(870 CUT, 3014 OEM) Gasket
Injection
Crankcase Extension Pump Washer
Housing-to-Cover Cap Screw Mounting Cap Gear Cap Screw (4)
3TN75, 3TNC78 (3011), Screw (4) Cover M8 x 12
3TN78, 3TN82 (30 EX), M8 x 85
3TNA82 (770 CUT) - (6)
3TN82 (575 SSL), 3TN84 (955 CUT,
3014 OEM) - (2) Oil Pan-to-Cover Cap Screw
Cap Screw (2) Apply thread lock and
3TN84 (870 CUT) - (4) 3TN82 (575 SSL),
22 N•m (195 lb-in.) 3TN84 (955 CUT, 3014 OEM)
22 N•m (195 lb-in.) to threads.
115 N•m (85 lb-ft)
3TN75,
3TNC78 (3011) M82355A
2-60 4/7/95
IDLER GEAR Idler Gear Shaft O.D.:

Standard . . . . . . . . . . . . . 45.950 - 45.975 mm
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . (1.809 - 1.810 in.)
1. Remove timing gear cover. (See procedure in this Wear Limit. . . . . . . . . . . 45.93 mm (1.808 in.)
group.)
If shaft diameter is less than wear limit, replace idler
2. Check backlash of timing gears. (See Checks, gear shaft.
NOTE: Due to the odd number of teeth on the idler
gear, timing marks will only align Idler Gear Bushing I.D.:
periodically. When all timing marks on
Standard . . . . . . . . . . . . . . 46.00 - 46.025 mm
gears align, the piston closest to the water
. . . . . . . . . . . . . . . . . . . . . . . (1.811 - 1.812 in.)
pump is at TDC on compression stroke.
Number one cylinder is closest to the Wear Limit. . . . . . . . . . . 46.03 mm (1.812 in.) 2
flywheel.
Clearance . . . . . . . . . . . . 0.15 mm (0.0059 in.)
4. Remove two cap screws, shaft and gear. bushing.
5. Inspect all parts for wear or damage. (See To replace bushing:
Installation is done in the reverse order of removal. bushing and idler gear. Install bushing flush with
Idler Gear (43T)
Idler Gear Shaft

Idler Gear
Bushing
Idler Gear
Shaft
Cap Screw (2)

M8 x 45 M82209A
M82210A
4/7/95 2-61
Studs
John Deere
2 3TNA82, 3TN84 (870 CUT)
Timing Gear Cover

Mounting Plate
Stud (3)

M8 x 16
25 N•m (220 lb-in.)
O-Rings
Replace. M82356A
TIMING GEAR COVER MOUNTING 4. Remove oil pump. (See Lubrication System in
PLATE this section.)
5. 3TNA82, 3TN84 (870 CUT): Remove hydraulic
Removal/Installation pump drive assembly. (See procedure in Machine
Technical Manual.)
6. Remove mounting cap screws and plate.
7. Replace o-rings.
3. Remove fuel injection pump. (See Fuel System in
this section.) Installation is done in the reverse order of removal.
2-62 4/7/95
Lubrication System
OTHER MATERIALS
Number Name Use
LOCTITE® PRODUCTS
U.S./
Canadian/
Loctite No.
TY15130/ John Deere Form-In-Place Seals oil pan/plate to crankcase

NA/ Gasket extension housing.
#395
4/7/95 2-63
Lubrication System
OIL PAN AND STRAINER John Deere Form-In- Gasket

Place Gasket (RTV rubber Replace.
Removal/Installation silicone sealant) Oil Strainer
3TN75 . . . . . . . . . . . . . . . . . . . . . . 3.9L (4.1 qt) Cap Screw (2)
3TN78, 3TN82 (30 EX), M8 x 35
3TNA82 . . . . . . . . . . . . . . . . . . . . 4.0L (4.2 qt)
3TNC78 (3011)
DF001 and 005. . . . . . . . . . . . . 4.2L (4.4 qt)
DF006. . . . . . . . . . . . . . . . . . . . 6.2L (6.5 qt)
3TN82 (575 SSL) . . . . . . . . . . . . . 6.0L (6.3 qt)
3TN84
2 (870 CUT) . . . . . . . . . . . . . . . . 4.8L (5.1 qt)
(955 CUT) . . . . . . . . . . . . . . . . 4.3L (4.5 qt)
(3014 OEM) Oil Pan
DF001 and 005 . . . . . . . . . . 5.2L (5.4 qt)
DF006 . . . . . . . . . . . . . . . . . 7.4L (7.7 qt)
• Tighten all cap screws to 26 N•m (226 lb-in.).
Cap Screw (16)
• Fill engine with proper engine oil. (See M8 x 45
SPECIFICATIONS AND GENERAL Cap Screw (4)
INFORMATION section.) O-Ring M8 x 16
Replace.
Drain Plug
M82360A
3TN75, 3TNC78 (3011DF001 and 005)
Oil Strainer
Cap Screw (2) Gasket

3TNA82, 3TN84 Replace.
(870 CUT) Only
M8 x 12
Cap Screw (2)

M8 x 35
John Deere Form-In-

Place Gasket
(RTV rubber
Oil Pan/Plate silicone sealant)
Washer
Replace.
Drain Plug
Cap Screw (8)

M8 x 12
M82361A
3TN78, 3TN82 (30 EX), 3TNA82, 3TN84 (870 CUT)
2-64 4/7/95
Lubrication System
Gasket
Replace.
Oil Strainer
Cap Screw (2)

M8 x 35
3TN84 (3014DF001 and 005 OEM)

Oil Pan
2
Spacer
Plate (2)
Cap Screw (4)

M8 x 50
Cap Screw (16)
M8 x 45
O-Ring
Replace. Cap Screw (4) 3TNC78 (3011DF006 OEM),
M8 x 16 3TN84 (3014DF006 OEM)
Drain Plug
3TNC78 (3011DF006 OEM), 3TN82 (575 SSL), 3TN84 (955 CUT, 3014 OEM) M82362A
OIL PUMP 3. Remove mounting cap screws, oil pump and

gasket.
1. Remove timing gear cover. (See Camshaft and Disassembly/Assembly procedures).
pump assembly if backlash is more than 0.25 mm
(0.010 in.).
Oil Pump
Gasket
Oil Pump
Oil Pump
Gasket
Mounting Cap Screw

M6 x 25
Mounting Cap Screw (4) 25 N•m (18 lb-ft)
M6 x 20 M82215A
25 N•m (18 lb-ft) All Except 3TN75
M82363A
3TN75
4/7/95 2-65
Lubrication System
Disassembly/Assembly Rotor Shaft and Plate Clearance:

• Gear is press fit on rotor shaft. Remove gear Standard . . . . . . . . . . . . . . . 0.015 - 0.048 mm
using a knife edge puller and a press. . . . . . . . . . . . . . . . . . . . . . (0.0006 - 0.0035 in.)
• Inspect parts for wear or damage. (See Wear Limit. . . . . . . . . . . 0.20 mm (0.0078 in.)
• Check rotor recess. If rotors are below face of
• Coat all parts with clean engine oil. pump housing more than wear limit, replace
• Install outer rotor with identification mark rotor assembly.
facing toward rotor shaft assembly.
Feeler Gauge
Backing Plate Straight Edge
Alignment Pin (2)

2
Rotor Shaft Pump Body
Gear Housing
Inner Rotor
Outer Rotor M37775
Outer Rotor Identification

Mark Rotor Recess - 3TN75, 3TN78, 3TNC78 (3011):
Standard . . . . . . . . . . . . . . . . . 0.05 - 0.10 mm
M82364A . . . . . . . . . . . . . . . . . . . . . (0.0020 - 0.0039 in.)
3TN75
Wear Limit. . . . . . . . . . . 0.15 mm (0.0059 in.)
Backing Plate Alignment Pin (2)
Rotor Recess - 3TN82, 3TNA82, 3TN84 (3014):
Safety Valve
Non-Adjustable. Standard . . . . . . . . . . . . . . . . . 0.03 - 0.09 mm
DO NOT Remove.
. . . . . . . . . . . . . . . . . . . . . (0.0011 - 0.0035 in.)
Pump Body
Wear Limit. . . . . . . . . . . 0.15 mm (0.0059 in.)
Rotor Shaft
• Check outer rotor-to-pump body clearance. If
Outer Rotor clearance is more than wear limit, replace entire
Gear
assembly.
Identification
Mark
Outer Rotor
Inner Rotor
M82216A
All Except 3TN75
Feeler Gauge
Inspection
• Check rotor shaft outer diameter and the shaft Body
hole diameter in backing plate. If clearance is M37776
more than wear limit, replace entire assembly.
2-66 4/7/95
Lubrication System
Outer Rotor-to-Pump Body Clearance - 3TN75, 3. Disconnect coolant hoses.

3TN78, 3TNC78 (3011):
4. Remove nut, oil cooler and o-rings.
Standard . . . . . . . . . . . . . . . . . 0.09 - 0.16 mm
. . . . . . . . . . . . . . . . . . . . . (0.0035 - 0.0063 in.)
Wear Limit. . . . . . . . . . . 0.25 mm (0.0098 in.)
Outer Rotor-to-Pump Body Clearance - 3TN82,

3TNA82, 3TN84 (3014): Oil Cooler
Standard . . . . . . . . . . . . . . . . . 0.10 - 0.17 mm
. . . . . . . . . . . . . . . . . . . . . (0.0039 - 0.0067 in.) Nut
30 N•m (22 lb-ft)
Wear Limit. . . . . . . . . . . 0.25 mm (0.0098 in.)
2
clearance is more than wear limit, replace rotor
assembly. Drain Plug M48394
Feeler Gauge
O-Rings
Replace.
Inner Rotor
Outer Rotor M37777
M48395
Inner-to-Outer Rotor Clearance - 3TN75, 3TN78,
3TNC78 (3011):
Standard . . . . . . . . . . . . . . . . . 0.02 - 0.04 mm 5. Pressure test oil cooler. (See Checks, Tests and
. . . . . . . . . . . . . . . . . . . . . (0.0008 - 0.0016 in.)
Wear Limit. . . . . . . . . . . 0.15 mm (0.0059 in.)
Inner-to-Outer Rotor Clearance - 3TN82, OIL PRESSURE REGULATING VALVE
3TNA82, 3TN84 (3014):
- 3TN84 (955 CUT)
Standard . . . . . . . . . . . . . . . . 0.05 - 0.105 mm
. . . . . . . . . . . . . . . . . . . . . (0.0019 - 0.0041 in.)
1. Remove oil cooler. (See procedure in this group.)
Wear Limit. . . . . . . . . . . 0.15 mm (0.0059 in.)
2. Remove mounting cap screws, pressure control
valve housing and gasket.
OIL COOLER - 3TN84 (955 CUT)
NOTE: Valve components are not serviced
1. Remove drain plug to drain engine cooling individually. Replace complete regulating
system. valve if any components are defective.
2. Remove oil filter.
4/7/95 2-67
Lubrication System
3. Inspect all parts for wear or damage. Replace OIL PRESSURE REGULATING
complete regulating valve if necessary. VALVE - ALL EXCEPT 3TN84
Installation is done in the reverse order of removal. (955 CUT)
Cap
Stake to valve body. 1. Remove oil filter.
Shims
gasket.
O-Ring
Replace. Valve NOTE: If adjusting engine oil pressure, retaining
Washer nut need not be removed.
Replace.
3. If adjusting pressure only, remove cap and add
Spring
2 Valve Body
Plug NOTE: Valve components are not serviced
individually. Replace complete regulating
Gasket valve if any components are defective.
Replace.
Pressure Control 4. Inspect all parts for wear or damage. Replace
Valve Housing complete valve if necessary.
Mounting Cap Screw (3) 5. Check spring free and compressed length.
M8 x 25
27 N•m (20 lb-ft) M82365A
Free Length . . . . . . . . . . . . .46 mm (1.810 in.)
. . . . . . . . . . . . . . . . . . @ 20.5 N (4.6 lb-force)
Cap
O-Ring Stake to valve body.
Replace.
Gasket
Housing
Shims
Retaining Nut
30 N•m (22 lb-ft) Spring
Valve
Oil Filter
Valve Body
Cap Screw (3)

M8 x 20
27 N•m (20 lb-ft) M82219A
2-68 4/7/95
Cooling System
OTHER MATERIALS
Number Name Use
LOCTITE® PRODUCTS
U.S./
Canadian/
LOCTITE No.
TY9375/ John Deere Pipe Sealant 3TN78, 3TN82 (30 EX), 3TN84
TY9480/ with TEFLON® (955 CUT, 3014 OEM): Apply to threads
#592 of plug and nipple in thermostat housing
and pipe plug in water pump housing.

4/7/95 2-69
Cooling System
COOLANT TEMPERATURE SWITCH THERMOSTAT AND HOUSING -

Replacement 3TN78, 3TN82 (30 EX), 3TN84
(955 CUT, 3014 OEM)
NOTE: Some engines may also be equipped with a
coolant temperature sender. Sender is 1. Drain engine coolant.
located opposite of switch in thermostat 2. Remove upper radiator hose, if equipped.
same. 3. Disconnect coolant temperature switch/sender
wiring lead(s).
4. Loosen alternator-to-bracket mounting cap screw.
5. Loosen clamps and remove thermostat housing-
3. Remove switch and washer. to-water pump hose.
4. Test switch. (See Checks, Tests and Adjustments 6. Remove mounting cap screws, housing and
2 in this section.) gasket.
Installation is done in reverse order of removal. 7. Inspect all parts for wear or damage. Replace as
Copper necessary.
Coolant Temperature Washer Thermostat
Switch Replace. Housing 8. Test thermostat. (See Checks, Tests and
Adjust fan/alternator drive belt tension. (See Checks,
M82220A
Cap Screw (2)

Gasket Plate M8 x 20
Replace. 20 N•m (180 lb-in.) Cover
Gasket Alternator Slide
Replace. Bracket
Copper Washer Thermostat

Replace. Copper Washer
Gasket Replace.
Replace.
Cap
Cap Screw (2)

M6 x 16 Mounting Cap
9 N•m (78 lb-in.) Gasket Screw
Replace. M8 x 60
26 N•m (226 lb-in.)
Coolant Temperature Switch
Plug Nipple
Apply Pipe Sealant with Apply Pipe Sealant
TEFLON to threads. Housing with TEFLON to threads.
Thermostat Housing-to-
Mounting Cap Screw Mounting Cap Screw Water Pump Hose
M8 x 25 M8 x 50
26 N•m (226 lb-in.) 26 N•m (226 lb-in.) M82221A
2-70 4/7/95
Cooling System
THERMOSTAT - 3TN75, 3TNC78 Plate

Pulley
(3011), 3TN82 (575 SSL), 3TNA82, 3TN78, 3TN82 (30 EX),
3TN84 (870 CUT)
Cap Screw
Adjustments in this section.) 11 N•m (96 lb-in.)
Cap Screw (2) Cap Screw

M8 x 65 Cap Screw
M8 x 20 M8 x 25
20 N•m
20 N•m (180 lb-in.) (180 lb-in.) 20 N•m
(180 lb-in.) M82294A
Cover
4. Remove lower radiator hose, if equipped.
Cover 2
to-water pump hose.
3TN82 (575 SSL)
Gasket 6. Remove three mounting cap screws, pump and
Cover gasket.
Gasket
Thermostat Disassembly/Assembly procedures.)
Water Pump Water Pump Hose
M82366A
WATER PUMP - 3TN78, 3TN82 (30 EX),

3TN84 (955 CUT, 3014 OEM)
Gasket
Replace.
1. Drain engine coolant.
2. Remove fan/alternator belt. Mounting Cap Screw (3)
M8 x 60
M82223A
3. 3TN78, 3TN82 (30 EX), 3TN84 (955 CUT): 26 N•m (226 lb-in.)
Remove fan, plate, if equipped, and pulley.
3TN84 (3014 OEM): Remove cooling fan. (See

procedure in ACCESSORIES - SERIES 220
4/7/95 2-71
Cooling System
Disassembly
1. Apply heat to three plate-to-housing screws.
Remove screws, plate and gasket
Plate-to-Housing Screw (3)

15 N•m (134 lb-in.)
Plate
Pipe Plug
Plug Apply Pipe Sealant with
2
Gasket
Replace.
Impeller
Seal Cup and

Ceramic Seal
Replace.
Shaft Seal
Replace.
Water Pump
Housing
Bearing
Shaft
Pulley
Flange M82224A
2. Apply extreme heat to pulley flange. Remove 3. Place water pump assembly on a press table.
flange using a knife-edge puller set and two small Install supports under water pump housing,
nuts. staying clear of impeller. Press bearing shaft
IMPORTANT: Impeller bore is tapered. When
Two Small Nuts
pressing bearing shaft from impeller, allow
Pulley Flange
enough clearance between cap screw and
Knife-Edge impeller bore to prevent cap screw from
Puller Set binding.
Water Pump knife-edge puller, a 3/8 in. cap screw and a press.
Housing
M35645
5. Remove shaft seal, ceramic seal and seal cup.
necessary.
2-72 4/7/95
Cooling System
Assembly 4. Install seal cup and ceramic seal in impeller.

1. Install bearing shaft into pump housing, long end 5. Install a knife-edge puller around bearing shaft,
down, using a piece of pipe or deep socket and a between pulley flange and pump housing. Place
press. Press shaft into pump housing until bearing pump housing, with knife-edge puller down, on a
surface is flush with pump housing surface. press table. Install impeller with ceramic seal
toward shaft seal.
2. Install new shaft seal over impeller side of
bearing shaft, rubber seal side away from pump 3TN82 (30 EX): Press impeller on bearing shaft
housing. Push shaft seal into pump housing, until until top of impeller is 1 mm (0.040 in.) below
it stops, using a 25 mm or 1 in. socket and a housing.
press. 3TN78, 3TN84 (955 CUT, 3014 OEM): Press
IMPORTANT: Support pump housing on impeller on bearing shaft until top of impeller is 2
bearing shaft only. DO NOT support on mm (0.080 in.) below housing.
housing or damage to housing will occur. 2
3TN82 (30 EX): Press pulley flange onto bearing
shaft until top of flange is 27 mm (1.060 in.) from
top of housing.
3TN78, 3TN84 (955 CUT, 3014 OEM): Press pulley
flange onto bearing shaft until bottom of flange is M37905
17 mm (0.670 in.) from top of housing.
IMPORTANT: DO NOT touch lapped sealing 6. Install new gasket, plate, three screws, two cap
surface of ceramic seal with bare hands. It screws and nuts. Tighten to specifications.
must be clean and dry.
4/7/95 2-73
Cooling System
WATER PUMP - 3TN75, 3TNC78 3. Remove four cap screws, fan, spacer/plate, if
(3011), 3TN82 (575 SSL), 3TNA82, equipped, and pulley.
3TN84 (870 CUT) 4. Remove four mounting cap screws, pump and
gasket.
1. Open engine drain valve to drain coolant. Disassembly/Assembly procedures.)
2. Remove fan/alternator drive belt. Installation is done in the reverse order of removal.
NOTE: 3TN75 (F1145 FM): Fan is mounted on
flywheel end of engine.
Gasket Mounting Cap Screw (3)

M8 x 55
Replace.
26 N•m (226 lb-in.)
Spacer 3TN84
(870 CUT)
O-Ring
Replace. Fan
Water Pump
Cap Screw (4)

M6 x 25
Pulley 11 N•m (96 lb-in.)
Mounting Cap Screw
M8 x 60
Plate
26 N•m (226 lb-in.)
3TN82
(575 SSL)
M82367A
3TNA82 Only
2-74 4/7/95
Cooling System
Disassembly 3. Remove two cap screws, adapter and gasket.

1. Remove thermostat. (See procedure in this 4. Apply heat to plate-to-housing cap screws.
group.) Remove cap screws, plate and gasket.
2. Remove coolant temperature switch. (See
Shaft Seal Assembly

Plate-to-Housing Cap Screw (2) Plate
Replace. Plug
M6 x 14 15 N•m (130 lb-in.)
9 N•m (78 lb-in.)
Plug
15 N•m (130 lb-in.)
2
Bearing
Adapter
Shaft
Gasket
Replace. Pulley
Flange
Gasket Impeller
Replace.
Cap
Adapter-to-Plate Cap Screw (2)

M6 x 20
Copper Water Pump 9 N•m (78 lb-in.)
Washer Housing
Replace. M82368A
3TN75, 3TNC78 (3011)
Plate-to-Housing Cap Screw

9 N•m (78 lb-in.) Plate
Gasket
Replace.
Plate-to-Housing Cap Screw (5)
M6 x 14 Cap
9 N•m (78 lb-in.)
Shaft Seal
Replace.
Copper
Washer
Adapter Replace.
Gasket
Replace.
Seal Cup and

Ceramic Seal Pulley
Impeller
Replace. Flange
Water Pump Bearing

Housing Shaft
M6 x 20
9 N•m (78 lb-in.)
M82226A
3TN82 (575 SSL), 3TNA82, 3TN84 (870 CUT)
4/7/95 2-75
Cooling System
5. Apply extreme heat to pulley flange. Remove IMPORTANT: Support pump housing on
flange using a knife-edge puller set and two small bearing shaft only. DO NOT support on
nuts. housing or damage to housing will occur.
Two Small Nuts hub facing away from housing.
Pulley Flange
Knife-Edge Press pulley flange onto bearing shaft until bottom
Puller Set of flange is 17 mm (0.670 in.) from top of housing.
Water Pump
Housing surface of ceramic seal with bare hands. It
2 M35645
4. Install seal cup and ceramic seal (shaft seal
6. Place water pump assembly on a press table. assembly) in impeller.
Install supports under water pump housing, 5. Install a knife-edge puller around bearing shaft,
staying clear of impeller. Press bearing shaft between pulley flange and pump housing. Place
assembly through water pump housing using a pump housing, with knife-edge puller down, on a
piece of pipe or a deep socket. press table. Install impeller with ceramic seal
IMPORTANT: Impeller bore is tapered. When toward shaft seal.
pressing bearing shaft from impeller, allow Press impeller on bearing shaft until top of impeller
enough clearance between cap screw and is 2 mm (0.080 in.) below housing.
binding.
knife-edge puller, a 3/8 in. cap screw and a press.
8. Remove shaft seal (shaft seal assembly), ceramic
seal and seal cup.
necessary.
Assembly
M37906
1. Install bearing shaft into pump housing, long end
down, using a piece of pipe or deep socket and a 6. Install new gasket, plate and cap screws. Tighten
press. Press shaft into pump housing until bearing to specifications.
7. Install new gasket, adapter and cap screws.
2. Install new shaft seal over impeller side of Tighten to specifications.
bearing shaft, rubber seal side away from pump
8. Install coolant temperature switch. (See
it stops, using a 25 mm or 1 in. socket and a
press. 9. Install thermostat. (See procedure in this group.)
2-76 4/7/95
Fuel System

SERVICE PARTS KITS

2
4/7/95 2-77
Fuel System
FUEL SUPPLY PUMP - IF EQUIPPED
Replacement
NOTE: 3TN78 and 3TN82 engines are not equipped
with a fuel supply pump.
Oil will leak out of fuel injection pump
Fill Plug
housing when supply pump is removed.
IMPORTANT: If oil has been drained out of fuel
injection pump housing, add oil as necessary.
Fuel injection pump can become damaged if Supply Pump-to-
operated dry or without proper amount of oil. Filter Hose
2 After fuel supply pump is installed, disconnect
external lube line to fuel injection pump housing.
Remove fill plug and add clean engine oil to Fuel Supply Pump External Lube Line
Tighten mounting bolt to
housing. Add until oil begins to drip out of lube line 15 N•m (130 lb-in.)
hole. (For proper oil specification see
SPECIFICATIONS AND GENERAL M82369
Lock Washer (2)
Packing
Replace.
Mounting Nut (2)

11 N•m (96 lb-in.)
Fuel Supply Pump
M82228A
2-78 4/7/95
Fuel System
FUEL FILTER ASSEMBLY - IF on engine application. 3TN84 (3014 OEM)

EQUIPPED shown.
NOTE: Fuel filter assemblies will be slightly IMPORTANT: Replace all copper washers.
different for each engine model depending Damaged or used washers may leak.
End Cap
Mounting Base
Shutoff Valve
Spring
O-Ring O-Ring
Filter
Element 2
Spring
Shutoff
Lever
O-Ring
Filter
Mounting Cover
Cap Screw
End Cap
Retaining Nozzle Leak-Off Hose
Ring (Short) (2)
Fuel Filter-to-
Injection
Pump Hose Injection Pump
Bleed-Off Hose
* *
Nozzle Leak-Off
Hose (Long)
Fuel Supply *
Pump-to-Filter
Hose
*Copper Washers
Replace.
Air Vent * *
Check Valve
M82370A
4/7/95 2-79
Fuel System
FUEL INJECTION PUMP IMPORTANT: Never steam clean or pour cold

Removal water on injection pump while the pump is
running or warm. Doing so can damage the
pump.
CAUTION 1. Clean the injection pump lines and area around
Escaping fluid under pressure can penetrate cleaner.
hazard by relieving pressure before 2. Loosen fuel injection line connectors slightly to
disconnecting hydraulic or other lines. release pressure in the fuel system. When
Tighten all connections before applying loosening connectors, use another wrench to keep
pressure. Search for leaks with a piece of delivery valves from loosening.
cardboard. Protect hands and body from 3. Loosen line clamp(s) and remove fuel injection
high pressure fluids.
2 lines.
If an accident occurs, see a doctor 4. Disconnect hoses to/from fuel filter, if equipped.
must be surgically removed within a few 5. Remove external lube line.
hours or gangrene may result. Doctors 6. Disconnect fuel shutoff solenoid link.
reference a knowledgable source. Such 7. Note position of timing marks on injection pump
information is available from the Deere & and gear cover mounting plate.
Company Medical Department in Moline, 8. Remove three mounting nuts.
Illinois, U.S.A.
Injection Pump Bleed-Off-to-Filter Hose
Line Clamp
Fuel Injection
Fuel Injection Line Lines
Connectors (3)
Nozzle Leak-Off
Delivery Hose
Valve (3)
Fuel
Filter-to-Injection
Pump Hose
Fuel Shutoff
Solenoid Link
Fuel Supply Pump-to-Filter Hose External

Lube Line M82371
2-80 4/7/95
Fuel System
DO NOT attempt to service the injection pump or

governor. If unit is in need of repair, it must be
serviced by a qualified fuel injection repair shop. If
replacement is necessary, replace entire unit.
Timing Marks
Installation
1. Install new o-ring on injection pump.
Mounting
Nut (3) 2. Put injection pump onto back of gear cover
mounting plate. Align key on shaft with keyway
in gear. Be sure to align marks on gears made
M82230 during removal.
9. Remove fan guard, if equipped. 3. Install lock washer and nut. Tighten to
10.Remove four cap screws, washers, cover and
specification. 2
gasket.
11.Use chalk or paint to mark injection pump gear to
idler gear. Nut and Lock
Washer
12.Remove nut and lock washer. M12 Chalk/Paint
90 N•m (66 lb-ft) Marks
Nut and Lock

Washer
Chalk/Paint
Marks M82231
4. Install new gasket, cover, four washers and cap

screws.
5. Install fan guard, if equipped.
M82231
6. Install three mounting nuts. Do not tighten.
13.Pull gear from injection pump shaft using a two 7. Align marks on mounting plate and injection
jaw puller. pump, to same place as when removed, and
tighten mounting nuts to specifications.
Timing Marks
Mounting
Nut (3)
26 N•m (19 lb-ft)
M37794
M82230
14.Remove injection pump and o-ring.
8. Connect fuel shutoff solenoid link.
9. Connect hoses to/from fuel filter.
4/7/95 2-81
Fuel System
10.Install fuel injection lines and tighten line clamp 12.Install external lube line. When installing line,
cap screws. put one copper washer between mounting bolt
head and lube line and the other between lube
IMPORTANT: If oil has been drained out of fuel line and housing.
Fuel injection pump can become damaged if If new injection pump is being installed, check and
operated dry or without proper amount of oil. adjust injection pump static timing. (See Checks,
11.Remove fill plug and add clean engine oil to
housing. Add until oil begins to drip out of
external lube line inlet. (For proper oil
specification see SPECIFICATIONS AND
GENERAL INFORMATION section.)
2
Line Clamp
Fuel Injection
Fuel Injection Line Lines
Connectors (3)
Nozzle Leak-Off
Delivery Hose
Valve (3)
Fuel
Filter-to-Injection
Pump Hose
Oil Fill Plug
Fuel Shutoff
Solenoid Link
Fuel Supply Pump-to-Filter Hose Lube Line-to-Block Bolt External

25 N•m (217 lb-in.) Lube Line M82371
2-82 4/7/95
Fuel System
FUEL INJECTION NOZZLES

(HOLE-TYPE) Retaining Plate
Hose Clamp
Nut (2) Leak-Off Hose
IMPORTANT: Never steam clean or pour cold 5 N•m
water on injection pump while the pump is (39 lb-in.)
pump. Injection
Nozzle
1. Clean the injection pump lines and area around Ring
Heat
cleaner. Protector
Replace.
2
CAUTION
disconnecting hydraulic or other lines. M82092A
pressure. Search for leaks with a piece of If nozzles are stuck in cylinder head:
cardboard. Protect hands and body from
high pressure fluids. • Grind the head of a cap screw so it fits inside a
nut from an old injection line.
If an accident occurs, see a doctor
immediately. Any fluid injected into the skin • Use two nuts to attach a large flat washer to the
must be surgically removed within a few cap screw.
hours or gangrene may result. Doctors • Install assembly onto nozzle and use a puller and
unfamiliar with this type of injury should slide hammer to pull nozzle from cylinder head.
Company Medical Department in Moline, Large Nuts
Illinois, U.S.A. Flat
Washer
NOTE: Nozzles are matched to the cylinders. If Cap Screw
removing more than one nozzle, tag nozzles, Old Injection
according to the cylinder from which it was Line Nut
removed. Injection
Nozzle
2. Loosen fuel injection line connectors-to-nozzles
slightly to release pressure in the fuel system.
M82126
3. Loosen line clamp(s) and remove fuel injection
lines.
4. Remove clamps and leak-off hoses. Adjustments in this section.)
5. Remove nuts and retaining plates. Installation is done in reverse order of removal.
6. Remove injection nozzle, ring and teflon heat
protector. If ring and protector stay in cylinder
head, thread a cap screw into protector and pull
from cylinder head.
4/7/95 2-83
Fuel System
Disassembly/Assembly Cross Section

NOTE: If servicing more than one nozzle, keep
another. Injector
Body
• Clean and inspect nozzle assembly. (See
• After assembly is complete, test injection
this section.) Fuel Return
Pipe
Shim
Injector Body (as required)
Spring
Shims (as required)
Spring
Spring Seat Spring Seat

Index Pin (2)
Separator Plate
Separator Plate
Nozzle Valve
Index
Pin (2) Retaining Nut
Nozzle Body
Retaining Nut Nozzle Valve
43 N•m (31 lb-ft)
Nozzle Body
M82093A M37684
2-84 4/7/95
Fuel System
Cleaning/Inspection 6. Inspect the piston (large) part of nozzle valve to

NOTE: To clean nozzles properly, JDF13 Nozzle lower (tip) end of valve is not broken. If any of
Cleaning Kit is recommended. The Cleaning these conditions are present, replace the nozzle
Kit is available through the John Deere assembly.
1. Remove anti-corrosive grease from new or performing a slide test. Use the following
reconditioned nozzles by washing them procedure:
IMPORTANT: Never use a steel brush to clean valve in nozzle body.
nozzles as this will distort the spray hole. • Hold nozzle vertical, and pull valve out about
2. Remove carbon from used nozzles, and clean by 1/3 of its engaged length.
washing in diesel fuel. If parts are coated with • Release valve. Valve should slide down to its 2
hardened carbon or lacquer, it may be necessary seat by its own weight.
Cleaning Kit). Replace nozzle assembly if the valve does not slide
freely to its seat.
exterior of nozzle, inspect sealing surfaces
nicks or scratches. Nozzle Valve

body. Contact area of separator plate (both parts) Piston Part of
must not be scored or pitted. Use an inspection Nozzle Valve
making the inspection. Nozzle Body
5. Check nozzle contact surface on separator plate
M82095A
Nozzle Contact Index Pin

Surface
Separator
Sealing Surfaces Plate
Nozzle Body
M82094A
4/7/95 2-85
Starter
STARTER IDENTIFICATION CHART

The various starters covered in this group are Field Coil Brush (2)
identified by manufacturer and output rating.
To help identify the starters, measure the outside
diameter of the motor.
2
M82232
Manufacturer Rated Output Motor Outside Diameter

Hitachi 2.0 kW 80 mm (3.150 in.)
Nippondenso 1.0 kW 68 mm (2.680 in.)
3 Nippondenso 1.2 kW 72 mm (2.835 in.)
2-86 4/7/95
Starter
STARTER MOTOR - HITACHI 2.0 kW 8. Inspect and test brushes, holder, field coil and
Disassembly
1. Remove two cap screws and two screws. Seal Ring
If equipped
2. Remove rear cover.
Field Coil
Housing
Cap Screw (2) Rear Cover Wiring Lead

Armature
Screw (2) M82096 M82098
3. Remove field coil brushes from brush holder. 3

4. Pry brush springs away and pull negative brushes
Assembly
up enough to allow spring to hold brush in place. Assembly is done in the reverse order of
disassembly.
5. Remove brush holder.
• Apply multipurpose grease to bearing cup inside
rear cover.
IMPORTANT: When installing rear cover, be
cover.
Brush Spring (2) Inspection/Test/Replacement

Minimum brush length is 9 mm (0.354 in.).
is below minimum.
Brush Holder
light.
Negative Brush (2)
M82097 Touch one probe of tester to negative brush
6. Disconnect wiring lead. there is continuity, replace the brush holder.
7. Remove field coil housing, armature and seal 3. Inspect springs for wear or damage. Replace if
ring, if equipped. necessary.
4/7/95 2-87
Starter

Spring (4) windings. Use only mineral spirits and a
brush.
Negative Brush 6. Inspect armature. Look for signs of dragging
Holder against pole shoes.
circuits between bars. If necessary, clean and
finished.
2 Field Brush
Holder
or test light.
Brush
Length 8. Test for grounded windings:
Touch probes on one commutator bar and
M82099 armature shaft. Armature windings are connected
in series, so only one commutator bar needs to be
NOTE: Test field coil using an ohmmeter or test checked.
light. If test shows continuity, a winding is grounded
3 4. Test for grounded field winding: and the armature must be replaced.
Touch one probe of tester to field coil brush and 9. Test for open circuited windings:
other probe to field coil housing. Be sure the Touch probes on two different commutator bars.
brush lead is not touching the frame. If there is If test shows no continuity, there is an open
continuity, the coil is grounded and the field coil circuit and the armature must be replaced.
housing assembly must be replaced.
Touch one probe of tester to each field coil brush. Commutator Bars
Field Coil Brush
Armature Shaft
M82101
Field Coil
Housing 10.Test for short circuited windings using a growler.
armature.
M82100
2-88 4/7/95
Starter
NOTE: A short circuit most often occurs because of STARTER OVERRUNNING CLUTCH -
copper dust or filings between two HITACHI 2.0 kW
commutator segments.
11.If test indicates short circuited windings, clean Disassembly
the commutator of dust and filings. Check the
armature again. If the test still indicates a short 1. Disconnect wiring lead.
circuit, replace the armature. 2. Remove two cap screws.
3. Remove starter motor assembly.
Hacksaw Blade
Wiring Lead
Armature
2
Growler M82125A
12.Inspect armature cover and housing bearings for Cap Screw (2)
wear or damage. Replace if necessary. Starter Motor
Assembly 3
To replace bearings: M82096

knife-edge puller set. 4. Remove three cap screws.
IMPORTANT: Install both bearings with sealed 5. Separate clutch housing assembly from starter
side toward armature. housing. Remove gasket.
Install new housing bearing tight against shoulder of

shaft using a piece of pipe. Gasket Clutch Housing
Assembly
of shaft using a driver set. Starter
Housing
Rear Cover Bearing
Housing Bearing
Cap Screw (3)
M82103
M82102
4/7/95 2-89
Starter
6. Remove ring, retainer, spring, clutch assembly

and clutch shaft from clutch housing. Wiring Lead
necessary.
Clutch Shaft
Clutch Assembly
2 Starter Solenoid
Assembly Cap Screws
Spring
M82105
4. Remove clutch arm, clutch arm pivot, plunger

and shim(s), if equipped, from solenoid.
Ring Clutch Housing necessary.
3 Retainer
Solenoid
M82104
Plunger
Assembly Clutch Arm

Pivot
disassembly.
• Apply multipurpose grease to all internal
components during assembly.
• Install retainer with large cupped side toward
Shim(s)
clutch assembly. If equipped.
STARTER SOLENOID - HITACHI Clutch Arm M82106

2.0 kW
Disassembly Assembly
1. Disconnect wiring lead. Assembly is done in the reverse order of
disassembly.
2. Remove cap screws.
3. Remove starter solenoid assembly. components during assembly.
IMPORTANT: Make sure long end of clutch arm
is installed all the way into starter housing.
Clutch arm must be install on end of clutch
shaft or starter will not operate.
2-90 4/7/95
Starter
• Pull clutch shaft away from housing and insert 5. Pry brush springs away and pull negative brushes
clutch arm in starter housing. Push arm in until it up enough to allow spring to hold brush in place.
stops.
Clutch Shaft Brush Spring

Brush Holder
Clutch Arm
2
M36754
M82107
7. Remove armature from field coil housing.
8. Remove felt washer and o-ring, if equipped.
STARTER MOTOR - NIPPONDENSO armature. (See Inspection/Test procedures.)
1.0 kW AND 1.2 kW
3
Felt Washer
Disassembly
Armature
Field Coil Housing
Field Lead
O-Ring M36759
Assembly
O-Ring Assembly is done in the reverse order of
disassembly.
Screw (2) rear cover and felt washer, if equipped.
Rear Cover
M82233 Turn brush holder slightly to take up slack in
Cap Screw (2) brush wires. Press wires inward to clear rear
4. Remove field coil brushes from brush holder. cover.
4/7/95 2-91
Starter
1. Measure holder and field coil brush lengths. Field Coil Brush
is below minimum.
light.
Field Coil
Touch one probe of tester to negative brush holder Housing
continuity, replace the brush holder.
2 3. Inspect springs for wear or damage. Replace if
necessary.
M82235
Spring (4)
Negative Brush
Holder IMPORTANT: Do not clean armature with
3 brush.
against pole shoes.
Brush circuits between bars. If necessary, clean and
Length
Field Brush touch up with 400 sandpaper. NEVER use emery
Holder cloth. Clean all dust from armature when
M82234 finished.
NOTE: Test field coil using an ohmmeter or test
or test light.
light.
shaft. Armature windings are connected in series, so
other probe to field coil housing. Be sure the brush
lead is not touching the frame. If there is continuity,
the coil is grounded and the field coil housing If test shows continuity, a winding is grounded and
assembly must be replaced. the armature must be replaced.
5. Test for open field coil: 9. Test for open circuited windings:
Touch one probe of tester to each field coil brush. If Touch probes on two different commutator bars. If
there is no continuity, the field coil is open and the test shows no continuity, there is an open circuit and
field coil housing assembly must be replaced. the armature must be replaced.
2-92 4/7/95
Starter
IMPORTANT: Install both bearings with sealed

Commutator Bars
Rear Cover Bearing
Housing Bearing
Armature Shaft
M82236
2
armature. M82237
NOTE: A short circuit most often occurs because of 3
copper dust or filings between two STARTER GEAR TRAIN AND
commutator segments. OVERRUNNING CLUTCH -
NIPPONDENSO 1.0 kW AND 1.2 kW
armature again. If the test still indicates a short Disassembly/Inspection
circuit, replace the armature. 1. Remove two motor-to-clutch housing cap screws
and two clutch housing-to-solenoid housing
Hacksaw Blade
screws.
Motor-to-Clutch
Housing Cap Screws
Armature
Growler M82125A

knife-edge puller set. M82233
4/7/95 2-93
Starter
Steel Ball
Clutch Housing-to- Clutch Assembly

Solenoid Housing
Screws
Pinion Gear
M82238
2. Separate clutch housing from solenoid/motor Roller (5)

2 assembly.
Retainer
3. Remove plunger spring and gear, if equipped. M82240

Plunger Spring vice, as shown.
8. Tighten vise slowly, until drive gear compresses.
9. Remove retainer and circlip.
3
Retainer
Circlip
Gear
Clutch Housing
M82239
NOTE: Starter is equipped with either a 33 mm Starter with 44 or 44.5

(1.299 in.), 44 mm (1.732 in.) or 44.5 mm (1.732 or 1.752 in.)
(1.752 in.) drive gear on end of clutch shaft. Drive Gear Shown
M82241
different.
CAUTION
6. Remove steel ball. with considerable force if spring is not
allowed to extend fully while in vise.
2-94 4/7/95
Starter
11.Starter with 33 mm (1.299 in.) drive gear: Assembly

assembly. Assembly is done in the reverse order of
disassembly.
Starter with 44 mm (1.732 in.) or 44.5 mm (1.752 • Apply multipurpose grease to bearings, clutch
in.) drive gear: Remove drive gear, spring and shaft, springs, pinion gears, retainer, rollers and
clutch assembly from housing. steel ball.
Clutch Assembly
Clutch Housing assembly.
(1.732 or 1.752 in.) • Install retainer with cupped side away from
drive gear only. clutch assembly.
Drive Gear STARTER SOLENOID - 2

NIPPONDENSO 1.0 kW AND 1.2 kW
Spring
Retainer 2. Remove three screws and clip.
Circlip
M82242
3
12.Remove washer, toothed washer, spring and Field Lead
clutch shaft.
Clip
necessary.
Clutch Shaft
Spring
Screw (3) M82244
4. Remove plunger.
5. Disassemble terminals. Remove parts from each
terminal in order shown.
Clutch 6. Inspect copper washer and contact plates for
excessive burning or pitting. Clean burnt areas to
Toothed Washer improve electrical contact. Replace contacts or
plunger if necessary. The solenoid is not
Large Washer
serviceable. If defective, replace solenoid
M82243 housing assembly.
4/7/95 2-95
Starter
Contact Plates
Solenoid Terminal
Lead
Spring
Plunger
Terminal Bolt
Copper Washer
Small Contact
2 M82245 Plate M36771
STARTER MOTOR - NIPPONDENSO

Terminal Bolt 1.4 kW
Disassembly
3 Nut 1. Remove two cap screws and two screws.
Washer
2. Remove rear cover and thrust washer, if
equipped.
Contact Plate
O-Ring
Insulator M36771
Assembly
disassembly. Thrust
Washer
NOTE: The assembly sequence of the left and right Cap Screw (2) Rear Cover
terminals is similar. Be sure solenoid
terminal lead is installed between terminal Screw (2) M82096
bolt and contact plate. Also, be sure smaller
contact plate is on the left side.
2-96 4/7/95
Starter
Assembly
Field Coil Brush (2) Assembly is done in the reverse order of
disassembly.
rear cover.
Brush Spring (2)
cover.
Brush Holder 2
Negative Brush (2) Replace brush holder or field coil if brush length
M82097
is below minimum.
6. Disconnect wiring lead and relay leads, if light.
equipped.
7. Remove field coil housing, armature and o-ring,
2. Test brush holder: 3
if equipped. Touch one probe of tester to negative brush holder
8. Inspect and test brushes, holder, field coil and continuity, replace the brush holder.
necessary.
Seal Ring
If equipped
Field Coil Spring (4)

Housing
Negative Brush
Holder
Field Brush
Wiring Lead Holder
Armature
Brush
M82098 Length
M82099

light.
4/7/95 2-97
Starter
Touch one probe of tester to field coil brush and 9. Test for open circuited windings:
Touch probes on two different commutator bars. If
the coil is grounded and the field coil housing
Commutator Bars
Touch one probe of tester to each field coil brush. If
there is no continuity, the field coil is open and the
field coil housing assembly must be replaced.
2 brush.
against pole shoes.
Armature Shaft M82101
touch up with 400 sandpaper. NEVER use emery 10.Test for short circuited windings using a growler.
cloth. Clean all dust from armature when Put armature in a growler and hold a hacksaw
3 finished. blade above each slot while slowly rotating
armature.
Field Coil Brush
NOTE: A short circuit most often occurs because of
Field Coil
Housing
Hacksaw Blade
Armature
M82100

or test light.
Growler M82125A
Touch probes on one commutator bar and armature 12.Inspect armature cover and housing bearings for
shaft. Armature windings are connected in series, so wear or damage. Replace if necessary.
If test shows continuity, a winding is grounded and
2-98 4/7/95
Starter
knife-edge puller set. Wiring Lead
of shaft using a driver set. Cap
Starter Motor Screw (2)
Assembly
Rear Cover Bearing
Housing Bearing
M82096
2
5. Remove three cap screws.
6. Separate end frame assembly from bearing
housing.
M82102
End Cap Screw (3)

Frame
Assembly 3
SOLENOID - NIPPONDENSO 1.4 kW
1. Remove two socket head screws, end cap and
shim(s).
Bearing Housing M37822
7. Inspect seal and needle bearing for wear or

damage. Replace as necessary.
End Cap
To replace needle bearing:
Shim(s)
Remove bearing using a blind-hole puller set. Install
new bearing flush with housing surface using a
driver set.
Bearing Housing
M37820
2. Disconnect wiring lead and relay leads, if

equipped.
3. Remove two cap screws. Seal
4. Remove starter motor assembly from bearing Needle Bearing

housing.
M37823
4/7/95 2-99
Starter
8. Remove two cap screws, plunger, spring, shims 12.Inspect end frame bushing for wear or damage.
and solenoid. Replace if necessary.
Replace bushing using a driver set. Install bushing
End Frame
Shim(s)
Solenoid
Cap Screw (2)

Plunger
2 Spring
End Frame
M37824
Bushing M37830
9. Remove shims from ring gear shaft. 13.Slide pinion stopper away from retaining wire
using a piece of pipe or deep socket. Remove
assembly from ring gear shaft.
3 14.Inspect all parts for wear or damage. Replace as
necessary.
Clutch Pinion
Shims Assembly Stopper
Ring Gear Shaft M37821
10.Remove pivot bolt, clutch fork and clutch Retaining

assembly. Wire
Ring Gear
11.Inspect shoes on fork for wear or damage. Shaft
Replace fork if necessary. M37827
End Frame Shoes Clutch

15.Remove snap ring, washer, spring cap, and spring
Assembly from clutch.
necessary.
Pivot Bolt
Clutch Fork
M37825
2-100 4/7/95
Starter
Clutch
Snap Ring
Spring
Spring Cap
Washer M37829
Assembly 2
disassembly.
• After installing clutch assembly, pinion stopper
and retaining wire on ring gear shaft, use two
pliers to press pinion stopper over retaining
wire.
3
Retaining Pinion
Wire Stopper
Clutch
Assembly
M37831
4/7/95 2-101
Alternator
ALTERNATOR - KOKOSAN 20A 6. Inspect bearing in coil plate for wear or damage.
Disassembly/Inspection To replace bearing:
1. Remove nut and washers.
press. Install bearing into coil plate until it bottoms
2. Tap on end of shaft with a soft-faced hammer to in bore using a 1 in. socket.
separate flywheel assembly from coil plate
7. Remove wire clamp.
assembly.
8. Remove connector from harness leads.
9. Remove two screws and stator.
Lock Washer 10.Inspect all parts for wear or damage. Replace as
Washer
necessary.
2 Flywheel Assembly
Wire Clamp
Nut
27 N•m
(20 lb-ft)
Coil plate
Screw (2)
Coil Plate Assembly
Long Spacer
Bearing
M82247A Press fit in
coil plate.
Connector Stator
NOTE: Bearing and flywheel are press fit on shaft. M82249A
4. Remove shaft from bearing, short spacer, washer,

flywheel and sheave half, using a press. Assembly
necessary.
disassembly.
Short Spacer
• With sheave half on shaft, press shaft into
flywheel until sheave half bottoms on flywheel
Washer
face.
• With washer and short spacer installed, press
Flywheel new bearing onto shaft until it bottoms on
spacer.
Shaft
Bearing
Press fit on
shaft.
Sheave Half
M82248A

necessary.
2-102 4/7/95
Alternator
VOLTAGE REGULATOR -
HITACHI 25A
Attaching Screw (4)

Two Nuts and Insulator
M5
4 N•m (31 lb-in.)
Stator
End Frame-to-Rectifier Nuts (4)

Grommet M5
4 N•m (31 lb-in.)
Wire Clamp 2
Front Frame
End Frame
M82108
Replacement 7. Use a soldering gun with at least 120 watt

capacity to disconnect five terminals. Replace
1. Remove three screws and cover. voltage regulator.
2. Remove four attaching screws, wire clamp and • If additional solder is needed, use ONLY 60-40
grommet. rosin-core solder.
3. Remove four end frame-to-rectifier nuts.
4. Remove two nuts and insulator. ALTERNATOR - HITACHI 25A
Disassembly
5. Use a screwdriver to pry end frame from stator.
Do not separate stator from front frame. 1. Remove three screws and cover.
6. Remove two screws and insulator. 2. Remove four attaching screws, wire clamp and
grommet.
Insulator Attaching Screws (4)

Terminals
M5
Voltage 4 N•m (31 lb-in.)
Regulator
Brush
Holder
Screw (2)
M51602
Grommet

Wire Clamp
M82108
4/7/95 2-103
Alternator
IMPORTANT: Do not pry against stator wires. Rotor Assembly:

3. Use a screwdriver to separate rotor assembly • Rear bearing is press fit. Replace only if
from stator assembly. necessary. Remove bearing using a puller set.
Stator Assembly
faced hammer to remove rotor and spacer.
6. Remove three screws, retainer and front bearing.
2 necessary.
8. Test rotor. (See Inspection/Test procedures.)
Rotor Assembly M36730
Rear Bearing
Screw (3)
2 N•m (16 lb-in.)
Clip Bushing
Rotor
Spacer
Retainer
Nut
Front M14
Bearing 49 N•m (36 lb-ft)
Front
Frame
Fan
Sheave
Lock
Washer
M82109A
2-104 4/7/95
Alternator
Stator Assembly: IMPORTANT: Be sure stator lead wires do not

contact end frame when installed.
10.Remove two nuts and insulator.
IMPORTANT: Do not pry against stator wires. insert a wire through access hole to lock brushes
in place.
11.Use a screwdriver to pry end frame from stator
• Assemble rotor assembly to stator assembly and
fasten with four attaching screws. Remove wire
Two Nuts and from access hole.
Insulator
End
Frame Access Hole
2
End Frame-to-Rectifier Nuts

M5
4 N•m (31 lb-in.) M51595
12.Use a soldering gun with at least 120 watt End Frame

capacity to disconnect three stator leads. Remove M51595
rectifier.
Inspection/Test
Rectifier
Rotor:
Stator sandpaper or 400-grit silicon carbide paper.
Leads (3)
Stator needle movement).
M51605

Assembly
disassembly.
• Bend the stator lead wires, as necessary, to Rotor Shaft
obtain an approximate distance of 33.50 mm
Slip Rings M82110A
(1.300 in.) from stator to rectifier. Connect the
three leads using a soldering gun.
• Touch the probes of the ohmmeter to the shaft
• If additional solder is needed, use ONLY 60-40 and one of the slip rings. Repeat for other slip
rosin-core solder. ring. Replace rotor if test shows continuity
(needle movement).
4/7/95 2-105
Alternator

Ohmmeter
between each brush and ground stud. There
• To replace brushes, melt solder from connection.
Remove voltage regulator if necessary. (See
VOLTAGE REGULATOR REPLACEMENT in
this group.)
Rotor Shaft
Slip Rings M82111A 40 rosin-core solder.
Stator:
Brushes:
2 • Inspect brush holder and brushes for damage.
the rotor. NOTE: Use an ohmmeter that is sensitive to
• Measure brushes for wear. Minimum exposed resistance of 0 to 1 ohm.
length must be 5.50 mm (0.220 in.) or to wear • Touch probes of an ohmmeter to lead wires of
limit line on brushes. Replace brushes as stator in three possible combinations. Continuity
necessary. should read approximately 0.26 ohms. If
readings are not equal, replace stator.
Brush Length Ohmmeter
Rectifier
Voltage
Regulator
Stator
Brushes
M82113A
• Touch one probe of the ohmmeter to the bare

metal surface of stator and the other probe to a
Ground
Ohmmeter
Stud
Brush
Holder
Soldered
Connection
M82112
Stator
M82114A
2-106 4/7/95
Alternator
Rectifier: VOLTAGE REGULATOR -

• Test the diodes by touching probes to ground NIPPONDENSO 35A
• Switch the probes and check each terminal Replacement
again. There should be continuity in only one 1. Remove three attaching screws.
combination of each terminals and the ground
post.
Attaching Screw (3)
• Test the diodes by touching probes to output M5
4 N•m (31 lb-in.)
combination of each terminal and the output
post. 2
in either direction. Replace the rectifier assembly if M36725
any of the three diodes are defective.

• To replace rectifier, melt solder from
connection. 3. Remove nuts and insulators.

M5
4 N•m (31 lb-in.)
Soldered
Connection
Nuts and Insulators

M36726

Outer Outer Do not separate stator from front frame.
Terminal Terminals
End
Frame
Output Ground
Post Post M82115
Stator
Front
Frame
M36727
4/7/95 2-107
Alternator
IMPORTANT: Do not heat connections longer IMPORTANT: Do not pry against stator wires.
2. Use a screwdriver to separate rotor assembly
capacity to disconnect terminals. Replace voltage
Stator Assembly
regulator.
Voltage Regulator
2
Rotor Assembly
Terminals M36730
M36728
Rotor Assembly:
rosin-core solder.
ALTERNATOR - NIPPONDENSO 35A 3. Put rotor assembly in a soft-jawed vise. Remove
Disassembly 4. Put front frame on open jaws of vice. Use a soft-
1. Remove three attaching screws. faced hammer to remove rotor and spacer.
Attaching Screw (3) washer and felt washer.
M5
4 N•m (31 lb-in.) 6. Inspect all parts for wear or damage. Replace as
necessary.
M36725
2-108 4/7/95
Alternator
Rear Bearing Fan

Sheave
Screw (3)
Washer
Front
Bearing
Rotor
2
Spacer
Retainer Nut
M14
Felt Washer
M82250A
Stator Assembly:
regulator.

M5
4 N•m (31 lb-in.)
Terminals
M36728

M36726
4/7/95 2-109
Alternator

from access hole.
Inspection/Test
Rotor:
M36739
13.Inspect and test brushes, stator and rectifier. (See Replace rotor if test indicates no continuity (no
2 Inspection/Test procedures.) needle movement).
Assembly
Ohmmeter
disassembly.
not evenly spaced. Rotate the rectifier until
the terminal pipes align with the stator
leads.
Rotor Shaft
• Bend the stator lead wires, as necessary, to
obtain an approximate distance of 33.50 mm Slip Rings M82110A
six leads using a soldering gun. • Touch the probes of the ohmmeter to the shaft
(needle movement).
Ohmmeter
Rotor Shaft
Wire
Brushes Slip Rings M82111A
Brushes:
M36748 the rotor.
2-110 4/7/95
Alternator

limit line on brushes. Replace brushes as Insulator
necessary.
• Use an ohmmeter or a test light to check for Brush Holder
should be no continuity. Replace brush holder- Brush
Ground Stud
Brushes Brush Lead 2
Wire
Insulating Washers
M36736
M36745
• To replace brushes:
- Melt solder from brush lead connections and - NOTE: If additional solder is needed, use ONLY 60-
remove brushes and springs. 40 rosin-core solder.
- Inspect springs for wear or damage. Replace as
necessary. Stator:
stator wires. Equal continuity readings should be
observed between each pair of leads. If readings
are not equal, replace stator.
M36737
- Push brush lead wire through spring. Insert

spring and brush in brush holder with lead
protruding through hole in brush holder. Make
sure the longest side of brush is on side of brush
holder with raised lip.
- Hold brushes in position so that exposed length
is 13 mm (0.500 in.)
excess length of brush lead wire. M36740
- Be sure insulating washers and insulator are in
place.
4/7/95 2-111
Alternator

Output Post
M36743
• Test the diodes by touching probes to ground

2 post and the three outer terminals.
M36741 • Switch the probes and check each terminal
Rectifier: direction between each terminal and the ground
post.
a printed circuit in the rectifier. A shorted diode would have continuity in both
• Test the three inner terminals using an in either direction. Replace the rectifier assembly if
ohmmeter. Move probes so all terminals are any of the six diodes are defective.
cross checked. Replace the rectifier if test shows
no continuity.
Inner
Terminals Ground
Post
M36744
M36742
VOLTAGE REGULATOR -
NOTE: Each of the three outer terminals on the NIPPONDENSO 40A
direction. Replacement
• Test the diodes by touching probes to output 1. Remove nut and insulator.
post and the three outer terminals. 2. Remove three screws and cover.
post.
2-112 4/7/95
Alternator
Cover Nut
69 N•m (51 lb-ft)
Nut and
Insulator
Sheave
M52470 M52469
3. Remove two screws, brush holder and cover. 4. Remove four screws and straighten stator wire
leads. 2
Regulator Rectifier
Stator Wire
Lead (4)
Short
Screw
Brush Holder
and Cover M52472
M52471
IMPORTANT: Make sure to install short screw assembly.
frame and cause damage to the charging 7. Press rotor shaft from end frame.
system. 8. Remove spring washer.
ALTERNATOR - NIPPONDENSO 40A Spring

Washer
Disassembly
1. Remove voltage regulator. (See VOLTAGE
2. Remove nut.
End Frame
3. Remove sheave using a puller set. Assembly
Rotor
Shaft
M52473
4/7/95 2-113
Alternator
9. Remove four screws and retainer. • Touch the probes of an ohmmeter to slip rings.
NOTE: Front bearing is press fit in front frame. needle movement).
necessary. • Touch probes of ohmmeter to the rotor core and
10.Inspect bearing in front frame for wear or Replace rotor if test shows continuity (needle
damage. Replace if necessary. Replace bearing movement).
Rear Bearing
Front Frame
Front Bearing
2
Screw (4)
2 N•m (16 lb-in.)
Retainer Slip Rings

Rotor Core
M52474
M52475
Brushes:
11.Inspect and test brushes, stator and rectifier. (See
Inspection/Test in this group.) • Inspect brush holder, brushes and springs for
must hold brushes firmly against the slip rings of
Assembly the rotor.
disassembly.
If length is less than wear limit, replace brushes.
Inspection/Test
Rotor:
that rotor assembly and bearing be replaced M52478
as a unit.
• Inspect bearing for wear or damage. Replace Brush Length Specifications
New. . . . . . . . . . . . . . . . . 10.50 mm (0.410 in.)
• Inspect slip rings for dirt build-up, rough spots Wear Limit. . . . . . . . . . . . 4.50 mm (0.170 in.)
or out-of-roundness. If necessary, polish the
surface of the slip rings using No. 00 sandpaper • Check continuity between brush and terminal
or 400-grit silicone carbide paper. Measure outer “A”. Check continuity between brush and
diameter of slip rings. Replace rotor if less than terminal “B”. There should be continuity only at
14 mm (0.550 in.). these points.
2-114 4/7/95
Alternator
Rectifier:
A B NOTE: Set the ohmmeter to the K ohm range.
• Check continuity between output post and each
recheck. There should be continuity in one
direction, but not the other.
M52479 A shorted diode would have continuity in both
Stator: in either direction. Replace the rectifier if any of the
defects are found, replace stator. 2
Diode Lead (4)
• Check for continuity between each stator lead
and stator body. Replace stator if test indicates
continuity.
To replace stator:
Output Post
- Scribe a mark on housing, at notch in stator, M52477
to aid in installation of a new stator.
- Remove two studs.
Stator
Lead (4)
Stator Body
Stud (2)

Housing
M82251
4/7/95 2-115
Diagnosis
PROBLEM OR


SYMPTOM


uses too much fuel.

noisy, vibrates or
stalls frequently.
or starts hard.
too much oil.

CHECK OR
is incorrect.
level high.
SOLU-
the oil.
TION
2 Fuel pump screen, fuel filter, or fuel

● ● ● ● ● ● ●
Replace.
3 Muffler or exhaust manifold leak. ● ●
Defective manifold heater. ●
timing incorrect.
● ●
connectors.
warped head.
● ● ● ● ● ●
load.
Test.
● ● ● ● ●
incorrect.
● ● ● ● ● ● ●
leaking.
● ● ● ● ● ● ● ● ●
damaged.
Radiator/oil cooler leak. ● ● ●
2-116 4/7/95
Diagnosis

Conditions:

engine surface- metal particles, fuel, or coolant. No plugs, cylinder head, block, and intake
filter.
radiator. when engine is warm. 2
- Cooling System
Fan belt tight, not glazed or cracked. Replace and adjust belt tension. 3
intake. tight.
- Air Intake System
Check
filter element.
6. Air heater Indicator light should come on up to See Air Heater Circuit Test Points in
position.)
4/7/95 2-117
Diagnosis

8. Throttle lever and Linkage not binding and adjusted Repair, replace or adjust cable.
cable. correctly.
2 Valves not sticking. Check valve guides and stems.
Machine TM.
3 11. Injector ports. Cylinder compression within Perform cylinder compression test.
specification.
TM.
Repair Shop.
2-118 4/7/95
VALVE CLEARANCE, CHECK AND

ADJUSTMENT
Reason:
To achieve correct engine operation. No. 1 TDC Mark Index Mark on
on Flywheel Flywheel Plate
Equipment:
• Feeler Gauge
Procedure:
NOTE: Location of the index mark will be different
as a result of the various engine M37501
applications. 3TN75, 3TNC78 (3011DF001 OEM), 3TNA82,
3TN84 (870 CUT, 955 CUT, 3014DF001 OEM)
The index mark appears on the following: 2
- 3TN75 (F1145 FM): Edge of flywheel guard NOTE: No. 1 cylinder is the closest to the flywheel.
and plate. 4. Try to move both No. 1 cylinder rocker arms or
- 3TN75 (855/56 CUT), 3TNC78 (3011DF001 push rods.
OEM), 3TN84 (870 CUT, 955 CUT, If rocker arm push rods are not loose, rotate
3014DF001 OEM): Flywheel plate. flywheel one revolution (360°). If both rocker arm
- 3TN78, 3TNC78 (3011DF001, 005, 006 push rods are loose the piston is at TDC on
OEM), 3TN82, 3TN84 (3014DF001, 005, 006 compression stroke.
OEM): Flywheel housing. 5. Measure and adjust valve clearance on the valves
1. Remove rocker arm cover. (arrows) with No. 2 piston at TDC.
2. Remove plug from timing hole in flywheel Cylinders

housing, if equipped. 1 2 3
E I E I E I
Flywheel End
Fan End
its highest point.
3. Turn crankshaft pulley clockwise until No.1
mark on flywheel housing or plate. No. 1 Piston at TDC
M82327A

TDC Mark on until clearance is 0.20 mm (0.008 in.). Hold screw
Flywheel while tightening nut.
Index Mark on
Flywheel Housing
Feeler
Gauge
M82372A
3TN78, 3TNC78 (3011), 3TN82, 3TN84 (3014 OEM)
T6105BF
4/7/95 2-119
6. Turn crankshaft pulley one revolution (360°). Specifications:

This puts the piston in No. 2 cylinder at TDC Standard Clearance . . . . . . . . 0.20 - 0.40 mm
compression stroke.
. . . . . . . . . . . . . . . . . . . . . (0.0079 - 0.0157 in.)
7. Measure and adjust valve clearance on the valves Wear Limit. . . . . . . . . . . 0.55 mm (0.0217 in.)
Cylinders
Results:
1 2 3 • If side play exceeds wear limit, replace
E I E I E I connecting rod and connecting rod cap.
Flywheel End
Fan End
CLEARANCE CHECK
2 No. 2 Piston at TDC
M82327A Reason:
bearing and crankshaft journal.
CONNECTING ROD SIDE PLAY
CHECK Equipment:
Reason: • PLASTIGAGE®
Procedure:
crankshaft and connecting rod.
Equipment: installed on the same connecting rod and in
• Feeler Gauge the same direction to prevent crankshaft and
connecting rod damage.
Procedure: 1. Remove connecting rod cap.
1. Insert a feeler gauge, according to specifications, 2. Wipe oil from bearing insert and crankshaft
between connecting rod cap and crankshaft. journal.
Feeler Gauge
PLASTIGAGE M35351
M82116A 4. Turn crankshaft approximately 30° from bottom

dead center.
2-120 4/7/95
5. Install connecting rod end cap and original cap CRANKSHAFT, END PLAY CHECK
screws. Tighten cap screws to:
Reason:
3TN75, 3TN78,
3TNC78 (3011) . . . . . . . . . . 39 N•m (29 lb-ft) To determine proper side clearance between
crankshaft and engine block.
3TN82, 3TNA82,
3TN84 (3014) . . . . . . . . . . . . 47 N•m (35 lb-ft) Equipment:
6. Remove cap screws and connecting rod cap. • Dial Indicator

Procedure:
on either the bearing insert or crankshaft NOTE: Crankshaft end play can be measured at
journal. front end or rear end of crankshaft.
Procedure is performed from the rear end.
The flywheel is removed to show detail.
compare the width of the flattened
PLASTIGAGE at its widest point. 1. Fasten dial indicator to engine and position
2
indicator tip on end of crankshaft.
8. Determine bearing clearance. The number within
the graduation marks indicates the bearing IMPORTANT: Do not use excessive force when
clearance in inches or millimeters depending on moving crankshaft to avoid damaging
which side of the envelope is used. bearings.
9. Remove PLASTIGAGE. 2. Push crankshaft toward rear as far as possible.
Graduation Marks
on Envelope
Flattened
PLASTIGAGE M82117A
Specifications:
. . . . . . . . . . . . . . . . . . . . . (0.0015 - 0.0035 in.)
Wear Limit. . . . . . . . . . . 0.16 mm (0.0063 in.)
Dial Indicator
Results:
Crankshaft M82118A
inserts. Specifications:
®PLASTIGAGE is a registered trademark of the DANA Standard Clearance . . . . . . 0.090 - 0.271 mm
Corporation.
. . . . . . . . . . . . . . . . . . . . . . . (0.004 - 0.011 in.)
Wear Limit. . . . . . . . . . . 0.33 mm (0.0129 in.)
Results:
• If end play exceeds wear limit, replace thrust
bearings.
4/7/95 2-121
CRANKSHAFT MAIN BEARING, 7. Determine main bearing clearance. The number

CLEARANCE CHECK within the graduation marks indicates the bearing
Reason: which side of the envelope is used.
To measure oil clearance between main bearing and 8. Remove PLASTIGAGE.
crankshaft journal.
Equipment:
• PLASTIGAGE®
Graduation Marks
Procedure: on Envelope
IMPORTANT: Main bearing caps must be

installed on the same main bearing and in the
2 same direction to prevent crankshaft and main
bearing damage. Flattened
PLASTIGAGE
1. Remove main bearing cap. M82119AE
2. Wipe oil from bearing insert and crankshaft

journal.
Specifications:
3. Put a piece of PLASTIGAGE, or an equivalent, Standard Clearance . . . . . . 0.038 - 0.090 mm
. . . . . . . . . . . . . . . . . . . . . (0.0015 - 0.0035 in.)
Wear Limit. . . . . . . . . . . 0.06 mm (0.0063 in.)
Results:
PLASTIGAGE
inserts.
ration.
VALVE LIFT CHECK

M35382 Reason:
cap screws to:
3TN75, 3TN78, Equipment:
3TNC78 (3011) . . . . . . . . . . 79 N•m (58 lb-ft)
• Dial Indicator
3TN82, 3TNA82,
3TN84 (3014) . . . . . . . . . . . . 98 N•m (72 lb-ft)
Procedure:
5. Remove cap screws and main bearing cap.
1. Adjust valve clearance. (See procedure in this
NOTE: The flattened PLASTIGAGE will be found group.)
on either the bearing insert or crankshaft 2. Remove rocker arm cover. (See Cylinder Head,
journal. Valves and Manifolds in this section.)
6. Use the graduation marks on the envelope to 3. Fasten dial indicator to engine and position
compare the width of the flattened indicator tip on valve retainer. Valve must be
PLASTIGAGE at its widest point. fully closed and rocker arm must move freely.
2-122 4/7/95

5. Manually turn crankshaft pulley clockwise (from
fan end).
6. Observe dial indicator as valve is moved to the
M37512
Specifications: 2
Standard Clearance . . . . . . . . 0.05 - 0.20 mm
. . . . . . . . . . . . . . . . . . . . . (0.0020 - 0.0079 in.)
Wear Limit. . . . . . . . . . . . 0.40 mm (0.016 in.)
T6333DT Results:
Results: and replace thrust plate. (See Camshaft and
inspect camshaft, followers and push rods. (See
Camshaft and Timing Gear Train and/or TIMING GEAR BACKLASH, CHECK
section.) Reason:
To check for wear between meshing gears, resulting
CAMSHAFT END PLAY CHECK in excessive noise and poor engine performance.
Reason: Equipment:
To determine proper side clearance between • Dial Indicator
camshaft gear end journal and thrust plate. Procedure:
1. Measure backlash between meshing gears.
Equipment:
• Dial Indicator Specifications - 3TN75, 3TN78,
3TNC78 (3011):
Procedure: Standard Backlash
1. Remove timing gear cover. (See Camshaft and Crankshaft Gear-to-Oil
Timing Gear Train in this section.) Pump Gear. . . . . . . . . . . . . 0.11 - 0.19 mm
2. Fasten dial indicator to engine and position . . . . . . . . . . . . . . . . . . (0.0043 - 0.0075 in.)
indicator tip on end of camshaft. All Except Crankshaft Gear-to-Oil
3. Push camshaft toward the rear as far as possible. Pump Gear. . . . . . . . . . . . . 0.04 - 0.12 mm
. . . . . . . . . . . . . . . . . . (0.0016 - 0.0047 in.)
Wear Limit. . . . . . . . . . . 0.20 mm (0.0079 in.)
5. Pull camshaft forward as far as possible.
4/7/95 2-123
Specifications - 3TN82, 3TNA82, Results:

3TN84 (3014):
• If backlash exceeds wear limit, replace meshing
Standard Backlash . . . . . . . . . 0.04 - 0.12 mm gears as a set:
. . . . . . . . . . . . . . . . . . . . . (0.0016 - 0.0047 in.)
Wear Limit. . . . . . . . . . . 0.20 mm (0.0079 in.) Pump Gear AND/OR Idler Gear, Fuel Injection
Pump Gear.

2-124 4/7/95

(HOLE-TYPE) • D01109AA Diesel Fuel Injection Nozzle Tester

hazard by relieving pressure before 1. Connect fuel injection nozzle to D01109AA
cardboard. Protect hands and body from IMPORTANT: Use clean filtered diesel fuel 2
instructions.
. . . . . . . . . . . . . . . . . . . . . . . . . (2843 ± 70 psi)
Reason:
opening pressure.
4/7/95 2-125

Assembly

2 Container
M35913
Procedure 2: 1. Pressurize nozzle to 19600 ± 480 kPa (2843 ± 70

psi).
Test fuel injection nozzle leakage following the
Nozzle Tester manufacturer's instructions. 2. Listen for “chatter” sound and watch spray
pattern.
2. Pressurize nozzle to 17640 kPa (2558 psi). Specifications:
3. Watch for leakage from nozzle spray orifice. Slow Hand
Leakage time should be a minimum of 5 seconds.
Lever Movement . . . . . . . . . . . Chatter Sound
Results:
Slow Hand
• If leakage time does not meet specification,
Lever Movement . . . . . . . . . . . . . Fine Stream
. . . . . . . . . . . . . . . . . . . . . . . . . Spray Pattern
necessary. Fast Hand
Procedure 3: . . . . . . . . . . . . . . . . . . . . . . . . . Spray Pattern
instructions.
2-126 4/7/95
Procedure:
Correct
Proper Spray
CAUTION
Angle
DO NOT allow thermostat or thermometer
container when heating water. Either may
rupture if overheated.
1. Suspend thermostat and a thermometer in a

Correct Injection Angle container of water.
2. Heat and stir the water. Observe opening action 2
Poor
specifications.
as it cools.
Thermometer
M82121A
Results:
specifications, disassemble injection nozzle and Thermostat
• If there is excessive difference in spray angle or M82122A

sluggish starting/stopping of injection,
disassemble injection nozzle and inspect nozzle Specifications:
assembly for contamination. Replace nozzle Begin Opening . . . . . . . . . . . . . 71° C (160° F)
assembly if necessary. Fully Open . . . . . . . . . . . . . . . . 85° C (184° F)
Minimum Lift Height . . . . . .8 mm (0.310 in.)
Results:
Reason: • If thermostat does not open according to
To determine opening temperature of thermostat. specifications, replace.
Equipment: thermostat.
• Thermometer
• Glass Container
• Heating Unit
4/7/95 2-127
COOLANT TEMPERATURE SWITCH 2. Suspend sender and a thermometer in a container

TEST of water.
3. Heat and stir the water. Observe water
Reason: temperature when continuity occurs. Water
To determine operating temperature of sender. temperature should be 107 - 113° C (225 -
235°F).
Equipment:
• Thermometer
Ohmmeter
• Glass Container Probes
• Heating Unit
• Ohmmeter
2 Procedure:
CAUTION
Coolant
DO NOT allow switch or thermometer to rest Temperature
Switch M82123A
when heating water. Either may rupture if
overheated. Results:
1. Connect lead wires from ohmmeter probes, to
listed, replace sender.
sender terminal and body.
2-128 4/7/95
STARTER NO-LOAD AMP Specifications:

DRAW/RPM TEST Maximum Starter Amperage
Reason: Hitachi 2.0 kW. . . . . . 110 Amps at 4500 rpm
Nippondenso 1.0 kW
To determine if starter is binding or has excessive
and 1.2 kW. . . . . . . . . . 90 Amps at 3000 rpm
amperage draw under no load.
Nippondenso 1.4 kW. . 90 Amps at 3500 rpm
Equipment: Minimum Starter RPM
• JT05712 Current Gun Hitachi 2.0 kW. . . . . . . . . . . . . . . . . . . . . 4500
• JT05719 Hand-Held Digital Tachometer Nippondenso 1.0 kW
• Jumper Cables and 1.2 kW. . . . . . . . . . . . . . . . . . . . . . . . 3000
• Jumper Wire Nippondenso 1.4 kW. . . . . . . . . . . . . . . . 3500
2
Procedure: Results:
1. Mount starter in a vise. • If solenoid “clicks” or chatters and motor does
not turn, replace solenoid.
NOTE: Check that battery is fully charged and of
proper size to ensure accuracy of test. • If pinion gear engages and motor doesn't turn,
repair or replace starter motor.
2. Connect jumper cables to a 12 volt battery.
• If starter engages and runs but amperage is more
3. Connect positive (+) cable to solenoid battery than specifications, repair or replace starter.
terminal on starter.
If rpm is less than specification, with battery fully
4. Connect negative (-) cable to starter body. charged, repair or replace starter.
5. Attach Current Gun to positive cable.
or less to prevent starter damage.
4/7/95 2-129
JT05712 Current Gun
Jumper Wire
All Except Nippondenso 1.0 kW and 1.2 kW M82149A
JT05712 Current Gun
Jumper Wire
Nippondenso 1.0 kW and 1.2 kW M82150A
2-130 4/7/95

ADJUSTMENT
Reason:
Equipment:
• Timing Tool (No. 1 fuel injection line cut off at 3TN75,
first bend) 3TN84 (3014)
M82256A

NOTE: Normal rotation, as viewed from the
Procedure: flywheel end, is counterclockwise. The 2
number one fuel injection line is toward the
IMPORTANT: Injection pump timing should be flywheel.
correct. Once timing is set, it will not normally 2. Remove the number one fuel injection line.
change during the life of the engine, unless it
was altered. 3. Install timing tool (number one fuel line cut off at
first bend).
Timing Tool
NOTE: If injection pump has been removed from
engine without disturbing engine crankshaft
and pump shaft, perform Step 1 only.
Otherwise, perform the entire timing
procedure.
1. 3TN78, 3TNC78 (3011), 3TN82, 3TNA82: Align
arrow or line on injection pump flange with the T6530AB
sixth mark (line) on timing gear mounting plate.

4. Remove rubber plug from flywheel housing, if
3TN75, 3TN84 (3014): Align arrow or line on equipped.
injection pump flange between third and fourth 5. Turn crankshaft pulley in either direction until the
marks (lines) on timing gear mounting plate. No. 1 cylinder top dead center (TDC) mark aligns
with the index mark on the flywheel housing/
plate.
TDC Mark
on Flywheel
1
3TN78, 3TNC78
(3011), 3TN82,
3TNA82 Index Mark on
M82255A
Flywheel
Housing/Plate
T6530AC
4/7/95 2-131
6. Prime pump to fill it with fuel. 1 L (1.06 qt) of Engine Crankshaft

fuel is more than adequate. Position. . . . . . . . . . . . . . . . . . . No.1 Cylinder
7. Hold throttle lever in run position. . . . . . . . . . . . . . on TDC Compression Stroke
8. Turn flywheel clockwise (as viewed from the
Results:
flywheel end) until tip of Timing Tool has
become MOIST with solid fuel. • If timing is not according to specifications,
loosen pump mounting bolts and turn pump
9. Check timing mark on flywheel. The index mark
towards engine block to retard timing or away
must line up with the injection pump timing mark
from block to advance timing. Recheck timing.
on flywheel. See specifications.
• If timing did not change, remove pump and have
tested by a diesel injection service shop.
2 Injection Pump
25°
- Install rubber plug in flywheel housing, if
20° Flywheel
Timing Marks equipped.
15°
TDC Mark on
Flywheel
1
FAN/ALTERNATOR DRIVE BELT

ADJUSTMENT
Reason:
Index Mark
on Flywheel To keep proper tension on belt to drive water pump
Housing and alternator. To prevent shortened belt and bearing
life.
Equipment:
• JDG529 or JDST28 Belt Tension Gauge
M82373A • Straight Edge
Specifications: Procedure:
Injection Pump Timing Mark 1. Check belt tension between fan and alternator
3TN75 (F1145 FM, using Belt Tension Gauge and a straight edge.
855/56 CUT). . . . . . . . . . . . . . .16° ± 1° BTDC
3TN78 (25 EX). . . . . . . . . . . . .16° ± 1° BTDC
3TNC78 (3011 OEM) . . . . . . .16° ± 1° BTDC
3TN82 Belt Deflection
(575 SSL) . . . . . . . . . . . . . .17° ± 1° BTDC
(30 EX) . . . . . . . . . . . . . . . .16° ± 1° BTDC
3TNA82 (770 CUT) . . . . . . . . .16° ± 1° BTDC M54014
3TN84 (870 CUT, 955

CUT, 3014 OEM) . . . . . . . . . .16° ± 1° BTDC
2-132 4/7/95
Specifications: FUEL SHUTOFF SOLENOID

Applied Force . . . . . . . . . . .98 N (22 lb-force) ADJUSTMENT
Deflection . . . . . 10 - 15 mm (0.400 - 0.600 in.)
Reason:
Results: To ensure that fuel shutoff solenoid retracts fully,
• If deflection is not within specifications:
nuts. Procedure:
- Apply force to FRONT alternator housing 1. Loosen lock nut.
only (near the belt) until tension is correct.
- Tighten cap screws/nuts. 3. Hold solenoid plunger bottomed in solenoid 2
body.
ENGINE OIL COOLER LEAKAGE 4. Move link toward solenoid until it stops
TEST - 3TN84 (955 CUT) 5. Turn plunger rod in or out of knuckle until
knuckle and link holes line up. Turn out two
Reason: additional turns. The additional turns insure that
Inspect oil cooler for leaks. the solenoid bottoms out before the linkage.
6. Assemble and check for free movement when key
Procedure: switch is turned ON. Also check that linkage
1. Plug one end of coolant inlet or outlet passage. returns completely to the STOP position when
key switch is turned OFF.
2. Apply regulated air pressure of 206 - 483 kPa
(30 - 70 psi) to other end.
3. Dip oil cooler into water and check for leaks. Plunger
Link
Optional test:
If a leak did not appear, use a hot water bath to
possibly open crack(s).
Results:
Knuckle
• Repair leak(s) or replace oil cooler if necessary. Lock Nut
M82141
4/7/95 2-133
Operational Tests
RADIATOR, BUBBLE TEST • If air escapes from air cleaner, check for worn
intake valve.
Reason: • If air escapes from engine oil fill, check for worn
To determine if compression pressure is leaking piston rings.
from cylinder.
COOLING SYSTEM, PRESSURE TEST
Equipment:
• JDG560 Adapter Reason:
Procedure:
1. With coolant at proper level and radiator cap Equipment:
tight, run engine for 5 minutes to bring to
2 operating temperature.
• D05104ST Cooling System Pressure Pump
• JDG692 Radiator Pressure Test Kit (Adapters)
2. Remove cap from recovery tank.
bottom of tank.
2. Apply pressure according to specifications.
leak:
3. Check for leaks throughout cooling system.
- Remove injection nozzles.
cylinder to be tested.
Cooling System
- Move piston to bottom of stroke with intake Pressure Pump
adapter.
into cylinder:
T6333AW
3TN75, 3TN78, 3TN82, 3TNA82, 3TN84
(870 CUT, 955 CUT) . . . . . 2448 kPa (355 psi)
3TNC78 (3011 OEM), Specifications - 3TN75, 3TN84 (955 CUT):
3TN84 (3014 OEM). . . . . . 2158 kPa (313 psi)
Maximum Pressure . . . . . . . . 117 kPa (17 psi)
- Check for bubbles in recovery tank or air Minimum Pressure
escaping from muffler, air cleaner or oil fill after 15 Seconds . . . . . . . . . . . 90 kPa (13 psi)
opening.
- Repeat for each cylinder. Specifications - 3TN78, 3TNC78 (3011), 3TN82,
3TNA82, 3TN84 (870 CUT, 3014 OEM):
Results: Maximum Pressure . . . . . . . . . 97 kPa (14 psi)
• If bubbles are present, check for cracks in Minimum Pressure
cylinder head and block. Check for damaged after 15 Seconds . . . . . . . . . 88 kPa (12.8 psi)
head gasket.
• If air escapes from muffler, check for worn
exhaust valve.
2-134 4/7/95
Operational Tests
Results: Results:
parts as necessary.
cause. Perform RADIATOR BUBBLE TEST. Reason:
Reason:
Equipment: 2
• JT01682 Compression Gauge Assembly
Test radiator cap for operating in correct pressure
range. • JDG560 Adapter
Equipment: Procedure:
• D05104ST Cooling System Pressure Pump 1. Run engine for 5 minutes to bring to operating
Procedure: this section.)
1. Install radiator cap on pressure pump. 3. Remove heat protector from end of injector and
install on Adapter.
open according to specifications.
Assembly in injector port. Install retaining plate
and tighten nuts to 4.5 N•m (39 lb-in.)
5. Hold fuel shut-off knob in shut-off position.
Cooling System
Pressure Pump 6. Crank engine for three seconds with starter.
Specifications:
3TN75,
3TN84 (955 CUT) . . . . . . . . . . 90 kPa (13 psi)
3TN78, 3TNC78 (3011), JDG560 Adapter
3TN82, 3TNA82, 3TN84 JT01682 Compression
T6333EU
(870 CUT, 3014 OEM) . . . . 88 kPa (12.8 psi) Gauge Assembly
4/7/95 2-135
Operational Tests
Specifications: 5. Run engine approximately five minutes to heat

Compression Pressure oil, then check oil pressure at fast and/or slow
idle.
3TN75, 3TN78, 3TN82,
3TNA82, 3TN84 Specifications - 3TN75:
(870 CUT, 955 CUT) . . . . . 2448 kPa (355 psi) F1145 FM
3TNC78 (3011 OEM), Slow Idle. . . . . . . . . . . . . . . . . . 1450 ± 50 rpm
3TN84 (3014 OEM). . . . . . 2158 kPa (313 psi) Fast Idle . . . . . . . . . . . . . . . . . . . . . . 3425 rpm
Maximum Difference Between Oil Pressure . . . . . . . . . . . . . . . . 294 - 440 kPa
Cylinders . . . . . . . . . . . . . . . . . . . 490 kPa (71 psi) . . . . . . . . . . . . . . . . . . . . . . . . . . . .(43 - 64 psi)
NOTE: Pressure listed is for 300 m (1000 ft) above 855/56 CUT
sea level. For naturally aspirated engines, Fast Idle . . . . . . . . . . . . . . . . . . 3425 ± 25 rpm
2 reduce specification an additional 4% for
each 300 m (1000 ft) of altitude.
Oil Pressure . . . . . . . . . . . . . . . . 365 ± 69 kPa
. . . . . . . . . . . . . . . . . . . . . . . . . . . (53 ± 10 psi)
Results:
Specifications - 3TN78, 3TN82 (30 EX):
• If pressure reading is below specification, squirt
approximately two teaspoons of clean engine oil Idle Speed
into cylinders through injector ports and repeat Slow . . . . . . . . . . . . . . . . . . . . . . 800 ± 25 rpm
test. Fast . . . . . . . . . . . . . . . . . . . . . . 2450 ± 25 rpm
• If pressure increases significantly, check piston, Oil Pressure
rings and cylinder walls for wear or damage. Slow Idle. . . . . . . . . . . . . . . . . 262 kPa (38 psi)
• If pressure does not increase significantly after Fast Idle . . . . . . . . . . . . . . . . . . . 345 ± 48 kPa
retest, check for leaking valves, valve seats or . . . . . . . . . . . . . . . . . . . . . . . . . . . . (50 ± 7 psi)
cylinder head gasket.
Specifications - 3TNC78 (3011), 3TN84 (3014):
ENGINE OIL PRESSURE TEST Low Idle Speed
Reason: Industrial . . . . . . . . . . . . . . . . . . . . . 1300 rpm
To determine if engine bearings or lubrication Generator. . . . . . . . . . . . . . . . . . . . . 1200 rpm
system components are worn. Oil Pressure . . . . . . . . . . . . . . . . . 147 kPa (21 psi)
Equipment: Specifications - 3TN82 (575 SSL):
• JT03017 Hose Assembly Idle Speed
• JT05577 Pressure Gauge (100 psi) Slow . . . . . . . . . . . . . . . . . . . . . 1250 ± 25 rpm
Fast . . . . . . . . . . . . . . . . . . . . . . 2875 ± 25 rpm
• JT05487 Connector (4TN78T)
Oil Pressure . . . . . . . . . . . . . . . . . . . 294 - 392 kPa
• JT03349 Connector (All Except 4TN78T) . . . . . . . . . . . . . . . . . . . . . . . . . . . .(43 - 57 psi)
Procedure:
Specifications - 3TNA82, 3TN84 (870 CUT):
1. Remove oil pressure sender. Fast Idle . . . . . . . . . . . . . . . . .2750 - 2800 rpm
2. Install Connector. Oil Pressure . . . . . . . . . . . . . . . . 365 ± 69 kPa
. . . . . . . . . . . . . . . . . . . . . . . . . . . (53 ± 10 psi)
3. Connect Hose Assembly and Pressure Gauge.
Specifications - 3TN84 (955 CUT):
IMPORTANT: Do not run if no pressure
present. Fast Idle . . . . . . . . . . . . . . . . . . 3425 ± 25 rpm
Oil Pressure . . . . . . . . . . . . . . . . 365 ± 69 kPa
4. Start engine. If pressure reading is below 69 kPa
. . . . . . . . . . . . . . . . . . . . . . . . . . . (53 ± 10 psi)
2-136 4/7/95
Operational Tests
Results:
section.)
• If oil pressure does not increase, see “Engine
Has Low Oil Pressure” in Diagnosis group.
AIR INTAKE SYSTEM LEAKAGE TEST M82124
Reason: Results: 2
Check for leaks in air intake system. • Find leaks and repair or replace parts as
necessary.
Equipment:
• Air Pressure Regulator FUEL SUPPLY PUMP PRESSURE
TEST - IF EQUIPPED
Procedure:
NOTE: 3TN78 and 3TN82 engines are not equipped
1. Remove air cleaner restriction indicator/switch
with a fuel supply pump.
and install test fitting.
2. Connect air pressure regulator to manifold using Reason:
hose and fitting from air cleaner.
3. Remove air cleaner cover and main filter element.
4. Put large plastic bag into and over end of main Equipment:
filter element. Install main filter element and • JT03274 Hose Fitting
cover.
• JT01609 Female Quick Coupler
5. Pressurize air intake system between 34 - 69 kPa
(5 - 10 psi). If air intake system cannot be • JT03115 Gauge w/Male Quick Coupler (0 - 150
pressurized, turn engine slightly to close valves. psi)
6. Spray soap solution over all connections from air
cleaner to intake manifold or turbocharger, if
IMPORTANT: When reinstalling starting aid
against intake air flow.
4/7/95 2-137
Operational Tests
Procedure: Procedure:
1. Disconnect supply pump-to-filter hose. 1. Disconnect fuel supply line and return line at fuel
tank.
2. Install Hose Fitting, Coupler and Gauge.
3. Pull fuel shut-off cable out and crank engine IMPORTANT: Fuel return line MUST extend
using the starter. Do not run starter for more than below fuel level in fuel tank before performing
10 seconds at a time. Gauge should read more this test. Fill fuel tank if necessary.
than 29 kPa (4.3 psi). 2. Drain all fuel from the system, including fuel
JT03115 Gauge w/Male 3. Plug end of fuel return hose.
Quick Coupler
JT01609 Female Quick
2 Coupler
JT03274 Hose Fitting
leaks.
Results:
Fuel Filter necessary.
Supply BLEED FUEL SYSTEM

Pump-to
Filter Hose IMPORTANT: Modification or alteration of the
M82145A
Results: obligation.
• If pressure is below specification, repair or All engines are equipped with an automatic air
replace fuel supply pump. venting system which makes the fuel system self-
bleeding.
FUEL DRAIN BACK TEST • Assure that all fuel line connections are securely
tightened.
Reason: • Add fuel to fuel tank.
Determines if air is entering the fuel system at • Crank engine to allow fuel system to bleed itself.
2-138 4/7/95
4TN78T, 4TN82 AND
4TN84(T) (4019)
ENGINES
3
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-119
Section 3
3
Specifications
ENGINE SPECIFICATIONS - 4TN78T

Rocker Arm Cover
Rocker Arm Assembly
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.97 - 15.98 mm (0.6286 - 0.6293 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.95 mm (0.6280 in.)
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.13 mm (0.005 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.00 - 16.02 mm (0.630 - 0.631 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.09 mm (0.633 in.)
Push Rod Length
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146.65 - 147.35 mm (5.774 - 5.801 in.)
Push Rod Bend
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.) 3
First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 N•m (16 lb-ft)
Second. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 N•m (32 lb-ft)
Final . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 N•m (51 lb-ft)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
Valve Seat Width
Intake Valve
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.36 - 1.53 mm (0.054 - 0.060 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.98 mm (0.078 in.)
Exhaust Valve
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.66 - 1.87 mm (0.065 - 0.074 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27 mm (0.089 in.)
Valve Faces
Exhaust Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Intake Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
Valve Stem O.D.
Distance A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 mm (1.181 in.)
Distance B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 mm (1.969 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.94 - 6.96 mm (0.2732 - 0.2740 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.90 mm (0.2717 in.)
Valve Recession
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 - 0.50 mm (0.012 - 0.020 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00 mm (0.039 in.)
4/7/95 3-1
Specifications
Valve Guides
Valve Guide I.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.00 - 7.02 mm (0.275 - 0.276 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.08 mm (0.279 in.)
Valve Springs
Spring Free Length
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 mm (1.575 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.50 mm (1.550 in.)
Exhaust Manifold
Intake Manifold
Valve Seat Angles
Valve Seat Surface
3 Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 - 43.042 mm (1.693 - 1.695 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.07 mm (1.696 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.070 - 0.105 mm (0.0028 - 0.0041 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.0098 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.035 - 0.070 mm (0.0014 - 0.0028 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.0098 in.)
Oil Ring
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.030 - 0.060 mm (0.0012 - 0.0024 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0078 in.)
Piston Ring End Gap
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm (0.008 - 0.016 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.0591 in.)
Piston Pin
Pin O.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.991 - 23.00 mm (0.905 - 0.906 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.90 mm (0.902 in.)
Bore I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.018 mm (0.0007 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.00 - 23.009 mm (0.9055 - 0.9059 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.02 mm (0.906 in.)
3-2 4/7/95
Specifications

Bushing I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.110 mm (0.0043 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.025 - 23.038 mm (0.9065 - 0.9070 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.10 mm (0.909 in.)
Piston O.D.
Distance A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 mm (0.905 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77.895 - 77.925 mm (3.067 - 3.068 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77.81 mm (3.063 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.15 - 78.18 mm (3.076 - 3.077 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.05 mm (3.073 in.)
Cylinder Bore I.D.
Standard Size Bore
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.22 mm (0.009 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.00 - 78.03 mm (3.071 - 3.072 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.20 mm (3.079 in.) 3
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.25 - 78.28 mm (3.081 - 3.082 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.45 mm (3.089 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.952 - 42.962 mm (1.6910 - 1.6914 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.91 mm (1.689 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.952 - 46.962 mm (1.8485 - 1.8489 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.91 mm (1.847 in.)
Main Bearing I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.00 - 47.045 mm (1.850 - 1.852 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.10 mm (1.8541 in.)
Flywheel
Flywheel Housing Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft)
4/7/95 3-3
Specifications
Camshaft
Camshaft Side Gap
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.)
Lobe Height
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.635 - 38.765 mm (1.521 - 1.526 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.40 mm (1.512 in.)
Journal O.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.92 - 44.95 mm (1.769 - 1.770 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.80 mm (1.764 in.)
Intermediate
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.91 - 44.94 mm (1.768 - 1.769 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.80 mm (1.764 in.)
Bushing I.D.
3 Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.990 - 45.055 mm (1.771 - 1.744 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.10 mm (1.776 in.)
Bore I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.00 - 45.025 mm (1.772 - 1.773 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.10 mm (1.776 in.)
Cam Followers
Stem O.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.975 - 11.990 mm (0.471 - 0.472 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.93 mm (0.470 in.)
Bore I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.000 - 12.018 mm (0.472 - 0.473 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.05 mm (0.474 in.)
Timing Gear Cover
Idler Gear
Shaft O.D
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.950 - 45.975 mm (1.809 - 1.810 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.93 mm (1.808 in.)
Bushing I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.00 - 46.025 mm (1.811 - 1.812 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.08 mm (1.814 in.)
3-4 4/7/95
Specifications
Oil Pump
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 - 0.048 mm (0.0006 - 0.0035 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0078 in.)
Rotor Recess
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.10 mm (0.0020 - 0.0039 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09 - 0.16 mm (0.0035 - 0.0063 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.0098 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 - 0.04 mm (0.0008 - 0.0016 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Oil Cooler
Oil Cooler-to-Mounting Block Mounting Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . 30 N•m (22 lb-ft)
Mounting Block-to-Engine Block Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft)
Piston Cooling Nozzle Mounting Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (130 lb-in.) 3
Thermostat and Housing
Water Pump
Fuel Injection Pump
Starter - Hitachi 0.8 kW
Cover Bushing (Reamed Out). . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.50 - 12.53 mm (0.492 - 0.493 in.)
Alternator - Hitachi 25A
Rotor Assembly
4/7/95 3-5
Specifications

Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.55 mm (0.0217 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.0063 in.)
Crankshaft End Play
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.33 mm (0.0129 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 mm (0.0063 in.)
Camshaft End Play
3 Standard Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.)
Standard Backlash
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.)
Thermostat
Begin Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71° C (160°F)
Fully Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85° C (184° F)
Hitachi 0.8 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 Amps at 7000 rpm
Minimum Starter RPM
Hitachi 0.8 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7000
Distance on Outer Surface of Flywheel Per 1° of Rotation . . . . . . . . . . . . . . . 2.88 mm (0.110 in.)
Timing Lines on Pump Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5° Apart
3-6 4/7/95
Specifications

Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 15 mm (0.400 - 0.600 in.)
Oil Cooler Leakage
Operational Tests
Maximum Air Pressure Into Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2448 kPa (355 psi)
Cooling System
Maximum Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 kPa (14 psi)
Minimum Pressure after 15 Seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 kPa (12.8 psi)
Radiator Cap
Valve Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 kPa (12.8 psi)
Minimum Compression Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2448 kPa (355 psi)
Engine Oil Pressure 3
Idle Speed
Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2750 ± 25 rpm
Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 ± 25 rpm
Oil Pressure
Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345 ± 48kPa (50 ± 7 psi)
Slow Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 kPa (31 psi)
ENGINE SPECIFICATIONS - 4TN82, 4TN84(T) (4019)

Rocker Arm Cover
Rocker Arm Assembly
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.97 - 15.95 mm (0.6286 - 0.6293 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.96 mm (0.6280 in.)
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.13 mm (0.005 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.00 - 16.02 mm (0.630 - 0.631 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.09 mm (0.633 in.)
Push Rod Length
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178.25 - 178.75 mm (7.018 - 7.037 in.)
Push Rod Bend
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.)
4/7/95 3-7
Specifications

First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (18 lb-ft)
Second. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft)
Final . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 N•m (58 lb-ft)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
Valve Seat Width
Intake Valve
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.07 - 1.24 mm (0.042 - 0.049 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.74 mm (0.069 in.)
Exhaust Valve
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24 - 1.45 mm (0.049 - 0.057 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.94 mm (0.076 in.)
3 Valve Faces
Exhaust Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Intake Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
Valve Stem O.D.
Distance A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 mm (1.181 in.)
Distance B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 mm (2.360 in.)
Intake Valve
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.96 - 7.98 mm (0.3134 - 0.3142 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.90 mm (0.3110 in.)
Exhaust Valve
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.96 - 7.97 mm (0.3134 - 0.3138 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.90 mm (0.3110 in.)
Valve Recession
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 - 0.50 mm (0.012 - 0.020 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00 mm (0.039 in.)
Valve Guides
Valve Guide I.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.01 - 8.03 (0.315 - 0.316 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10 mm (0.319 in.)
Valve Springs
Spring Free Length
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 mm (1.575 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.50 mm (1.550 in.)
Exhaust Manifold
Intake Manifold
3-8 4/7/95
Specifications
Valve Seat Angles

Valve Seat Surface
Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 - 48.042 mm (1.888 - 1.891 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.07 mm (1.893 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.075 - 0.110 mm (0.0030 - 0.0043 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.0098 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.45 - 0.080 mm (0.0018 - 0.0031 in.) 3
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.0098 in.)
Oil Ring
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.025 - 0.060 mm (0.0010 - 0.0024 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.)
Piston Ring End Gap
4TN82
Standard
First Compression Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 - 0.40 mm (0.010 - 0.016 in.)
Oil Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm (0.008 - 0.016 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.0591 in.)
4TN84 (4019D)
Standard
Compression Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm (0.008 - 0.016 in.)
Oil Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 - 0.45 mm (0.010 - 0.018 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.0591 in.)
4TN84T (4019T)
Standard
First Compression Ring and Oil Ring. . . . . . . . . . . . . . . . . . 0.25 - 0.45 mm (0.010 - 0.018 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.0591 in.)
Piston Pin
Pin O.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.987 - 26.00 mm (1.023 - 1.024 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.90 mm (1.020 in.)
Bore I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.022 mm (0.0009 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.00 - 26.009 mm (1.0236 - 1.0240 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.02 mm (1.024 in.)
4/7/95 3-9
Specifications

Bushing I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.110 mm (0.0043 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.025 - 26.038 mm (1.0246 - 1.0251 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.10 mm (1.028 in.)
Piston O.D.
4TN82
Distance A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 mm (0.945 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.90 - 81.93 mm (3.224 - 3.225 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.80 mm (3.220 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.15 - 82.18 mm (3.234 - 3.235 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.05 mm (3.230 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.40 - 82.42 mm (3.244 - 3.245 in.)
Wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.30 mm (3.240 in.)
3 4TN84(T) (4019)
Distance A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 mm (0.945 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.90 - 83.93 mm (3.303 - 3.304 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.80 mm (3.299 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.15 - 84.18 mm (3.313 - 3.314 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.05 mm (3.309 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.40 - 84.42 mm (3.323 - 3.324 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.30 mm (3.319 in.)
Cylinder Bore I.D.
4TN82
Standard Size Bore
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 mm (0.014 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.00 - 82.03 mm (3.228 - 3.230 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.20 mm (3.236 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.25 - 82.28 mm (3.238 - 3.239 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.45 mm (3.246 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.50 - 82.53 mm (3.248 - 3.249 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.70 mm (3.256 in.)
4TN84(T) (4019)
Standard Size Bore
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 mm (0.014 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.00 - 84.03 mm (3.307 - 3.308 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.20 mm (3.315 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.25 - 84.28 mm (3.317 - 3.318 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.45 mm (3.325 in.)
3-10 4/7/95
Specifications
4TN84(T) (4019), continued

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.50 - 84.53 mm (3.327 - 3.328 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.70 mm (3.335 in.)
Balancer Assembly - 4TN82RJK, 4TN84RJK
Drive Gear Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 N•m (78 lb-ft)
Retaining Plate Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft)
Seal Case-to-Block Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.) 3
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.952 - 47.962 mm (1.8879 - 1.8883 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.91 mm (1.886 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.952 - 46.962 mm (1.9666 - 1.9670 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49.90 mm (1.965 in.)
Main Bearing I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.00 - 50.045 mm (1.969 - 1.970 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.10 mm (1.972 in.)
Flywheel
Flywheel Plate Mounting Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft)
Camshaft
Camshaft Side Gap
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.)
Lobe Height
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.635 - 38.765 mm (1.521 - 1.526 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.40 mm (1.512 in.)
4/7/95 3-11
Specifications
Camshaft, continued
Journal O.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.92 - 44.95 mm (1.769 - 1.770 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.80 mm (1.764 in.)
Intermediate
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.91 - 44.94 mm (1.768 - 1.769 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.80 mm (1.764 in.)
Bushing I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.990 - 45.055 mm (1.771 - 1.744 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.10 mm (1.776 in.)
Bore I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.00 - 45.025 mm (1.772 - 1.773 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.10 mm (1.776 in.)
Cam Followers
3 Stem O.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.975 - 11.990 mm (0.471 - 0.472 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.93 mm (0.470 in.)
Bore I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.000 - 12.018 mm (0.472 - 0.473 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.05 mm (0.474 in.)
Timing Gear Cover
Idler Gear
Shaft O.D
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.950 - 45.975 mm (1.809 - 1.810 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.93 mm (1.808 in.)
Bushing I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.00 - 46.025 mm (1.811 - 1.812 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.08 mm (1.814 in.)
Oil Pump
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 - 0.048 mm (0.0006 - 0.0035 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0078 in.)
Rotor Recess
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.09 mm (0.0011 - 0.0035 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
3-12 4/7/95
Specifications
Oil Pump, continued

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 - 0.17 mm (0.0039 - 0.0067 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.0098 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.105 mm (0.0019 - 0.0041 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Oil Cooler - 4TN84T (4019TF001 and 005)
Oil Cooler-to-Mounting Block Mounting Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . 30 N•m (22 lb-ft)
Mounting Block-to-Engine Block Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft)
Oil Pressure Regulating Valve - All Except 4TN84T (4019TF001 and 005)
Spring
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 mm (1.810 in.)
Piston Cooling Nozzles - 4TN84T (4019TF001 and 005)
Mounting Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (130 lb-in.) 3
Thermostat and Housing - 4TN82RJE, 4TN82ESP and 4TN84(T) (4019)
Thermostat - 4TN82RJK and 4TN84RJK
Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (180 lb-in.)
Water Pump - 4TN82RJE, 4TN82ESP and 4TN84(T) (4019)
4TN82RJE and 4TN82ESP
4TN84(T) (4019)
Water Pump - 4TN82RJK and 4TN84RJK
4TN82RJK
Impeller-to-Pump Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 mm (0.040 in.) below housing
4TN84RJK
Impeller-to-Pump Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 mm (0.080 in.) below housing
Fuel Supply Pump - All Except 4TN82RJE and 4TN82ESP
4/7/95 3-13
Specifications
Fuel Injection Pump

Starter Motor - 4TN82RJE (Hitachi 2.0 kW)
Starter Motor - 4TN82RJK, 4TN84RJK (Nippondenso 1.0 kW)
Starter Motor - 4TN82ESP, 4TN84(T) (4019) (Nippondenso 1.4 kW)
Alternator - 4TN82RJK, 4TN84RJK (Kokosan 20A)
Alternator - 4TN82, 4TN84RJK (Nippondenso 35A)
3 Attaching Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (31 lb-in.)
Rotor Assembly
Alternator - 4TN82ESP/RJE, 4TN84(T) (4019) (Nippondenso 40A)
Brush Length
New. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.50 mm (0.410 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.50 mm (0.170 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.55 mm (0.0217 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.0063 in.)
Crankshaft End Play
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.33 mm (0.0129 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 mm (0.0063 in.)
3-14 4/7/95
Specifications

Camshaft End Play
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.)
Thermostat
Begin Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71° C (160°F)
Fully Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85° C (184° F)
Minimum Lift Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 mm (0.310 in.) 3
Minimum Starter RPM
Hitachi 2.0 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4500
Nippondenso 1.0 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000
Nippondenso 1.4 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3500
Fuel Injection Pump Static Timing Adjustment
Injection Pump Timing Mark
4TN82 (970 CUT, 675 SSL, 3325/65 GM) . . . . . . 15° ± 1° BTDC (Before Top Dead Center)
4TN84
(1070 CUT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15° ± 1° BTDC
(4019D OEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16° ± 1° BTDC
4TN84T (4019T OEM)
4019TF001 and 005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15° ± 1° BTDC
4019TF006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12° ± 1° BTDC
Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 15 mm (0.400 - 0.600 in.)
Oil Cooler Leakage - 4TN84T (4019TF001 and 005)
Operational Tests
4TN82RJK, 4TN84RJK,
4TN82RJE, 4TN82ESP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2448 kPa (355 psi)
4TN84(T) (4019) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2158 kPa (313 psi)
4/7/95 3-15
Specifications
Cooling System
4TN82RJK, 4TN84RJK, 4TN84(T) (4019)
4TN82RJE, 4TN82ESP
Minimum Pressure after 15 Seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 kPa (8 psi)
Radiator Cap
4TN82RJK, 4TN84RJK, 4TN84(T) (4019) . . . . . . . . . . . . . . . . . . . . . . . . . . 88 kPa (12.8 psi)
4TN82RJE, 4TN82ESP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 kPa (8 psi)
Minimum Compression Pressure
4TN82RJK, 4TN84RJK,
4TN82RJE, 4TN82ESP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2448 kPa (355 psi)
4TN84(T) (4019) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2158 kPa (313 psi)
3 Engine Oil Pressure
4TN82RJE
Idle Speed
Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2800 rpm
Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 ± 50 rpm
4TN82ESP
Idle Speed
Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2875 ± 25 rpm
Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900 ± 25 rpm
4TN82RJK, 4TN84RJK
Fast Idle Speed
4TN82RJK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2750 - 2800 rpm
4TN84RJK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2850 - 2900 rpm
4TN84(T) (4019)
Low Idle Speed
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200 rpm
Industrial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1300 rpm
Oil Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 kPa (21 psi)
3-16 4/7/95

Use to knurl inside diameter of valve guides on 4TN78T engine.

Use to knurl inside diameter of valve guides on 4TN82 and 4TN84(T)(4019) engines.

Use to ream out new valve guides on 4TN78T engine.

Use to ream out new valve guides on 4TN82 and 4TN84(T)(4019) engines.
3
SERVICE PARTS KITS
• Cylinder Head Gasket Kits
3
4/7/95 3-17
ROCKER ARM COVER

• Wash packing in a safe solvent and blow dry
with air pressure. If packing comes apart or is
deteriorated, replace it.
Crankcase Breather
Cover Oil Filler Cap
Cap Screw (2)
M8 x 16
O-Ring
O-Ring
Replace.
Extension
Packing If Equipped.
Special Nut (3)
18 N•m (160 lb-in.)
Screen
3
O-Ring (3)
O-Ring
If Equipped.
3
Crankcase Breather
Tube
Rocker Arm Cover
O-Ring Seal
M82189A
3-18 4/7/95
ROCKER ARM ASSEMBLY • Inspect all parts for wear or damage. (See
Removal/Installation and • Lubricate all parts with clean oil during
Disassembly/Assembly assembly.
1. Remove rocker arm cover. (See procedure in this • Adjust valve clearance. (See Checks, Tests and
group.) Adjustments in this section.)
• Remove and install studs using two M8 nuts.
Rocker Arm Shaft

Mounting Cap Rocker Arm
Screw (3) Shaft Spring
M8 x 25
26 N•m (226 lb-in.) 3
M8 x 50
26 N•m (226 lb-in.) 3
Rocker Arm Center Support (3) Nut
Nut (3)
M8
Stud (3)
Valve Cap
Adjusting Screw
Rocker Arm
Push Rod End Support (2)
M82190A
4/7/95 3-19

• Measure outer diameter of rocker arm shaft. Standard. . . . . . . . . . . . . . . . 16.00 - 16.02 mm
. . . . . . . . . . . . . . . . . . . . . . . .(0.630 - 0.631 in.)
Wear Limit . . . . . . . . . . . 16.09 mm (0.633 in.)
Clearance . . . . . . . . . . . . . 0.13 mm (0.005 in.)
wear limit.
parts.
M35262

3 Standard. . . . . . . . . . . . . . . . 15.97 - 15.95 mm
. . . . . . . . . . . . . . . . . . . . . .(0.6286 - 0.6293 in.)
Length
Wear Limit. . . . . . . . . . 15.95 mm (0.6280 in.)
3 Replace rocker arm shaft if less than wear limit. Feeler

supports.
M82023A
Push Rod Length:

4TN78T. . . . . . . . . . . . . . . 146.65 - 147.35 mm
. . . . . . . . . . . . . . . . . . . . . . . .(5.774 - 5.801 in.)
4TN82,
4TN84(T)(4019) . . . . . . . . 178.25 - 178.75 mm
. . . . . . . . . . . . . . . . . . . . . . . .(7.018 - 7.037 in.)
Push Rod Bend:

M82022A Standard. . . . . . . . 0.03 mm (0.001 in.) or less
Wear Limit . . . . . . . . . . . . 0.30 mm (0.012 in.)
3-20 4/7/95
CYLINDER HEAD AND VALVES 4. Remove fuel injection nozzles. (See Fuel System
in this section.)
1. Remove rocker arm assembly, push rods and
valve caps. (See procedure in this group.)
section.)
3
Mounting Cap
Screw (18)
Dip entire cap
screw in
clean engine oil
before
3
installing.
Flywheel
Cylinder Head
Gasket
M82191A
4/7/95 3-21
6. Tighten mounting cap screws, in the sequence Torque Specifications - 4TN82, 4TN84(T)(4019):
shown, in three stages of gradually-increasing First . . . . . . . . . . . . . . . . . . . 24 N•m (18 lb-ft)
torque.
Second . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft)
IMPORTANT: Cylinder head mounting cap Final . . . . . . . . . . . . . . . . . . . 78 N•m (58 lb-ft)
screws must be checked for proper torque
after 50 hours of engine operation.
• Compress valve springs using a valve spring
Exhaust Manifold Side compressor.

Flywheel Side
18 12 10 3 1 5 7 13 15 Remove guides only if replacement is necessary.

(See Inspection/Replacement procedures.)
• On 4TN78T, intake and exhaust valve seat
14 6 4 11 inserts are press fit. Remove inserts only if
16 8 2 9 17
replacement is necessary.
Intake Manifold Side • Inspect all parts for wear or damage. (See
3 M82025A
IMPORTANT: Do not reuse stem seals if
Torque Specifications - 4TN78T:
removed. Used seals will leak.
3 First . . . . . . . . . . . . . . . . . . . 22 N•m (16 lb-ft)
• Apply clean engine oil on intake and exhaust
Second . . . . . . . . . . . . . . . . . 43 N•m (32 lb-ft) valve stems during assembly.
Final . . . . . . . . . . . . . . . . . . . 69 N•m (51 lb-ft) • Install springs with smaller pitch end or paint

Seal (8)
Replace. Retainer (8)
Short
Stud (8) Valve Spring (8)
Exhaust Valve
Guide (4)
Lifting Intake Valve Guide (4)
Bracket (2)
Cap Screw (4)

M10 x 20
Exhaust Manifold
Mounting Stud
(2-Long or 4-Short)
If equipped.
Valve Seat Inserts
4TN78T Only.
Exhaust Valve
Intake Valve M82192A
3-22 4/7/95
NOTE: If new valves are installed, measure valve • Measure valve recession. (See procedure in this
recession. (See Inspection/Replacement group.)
procedures.)
of carbon or dirt.
Cylinder Head:
Valve Seat
• Measure cylinder head flatness. Place a straight- Width
diagonal. Measure clearance between straight
edge and combustion surface with a feeler
gauge.
M82029A
3
Valve Seat Width - 4TN78T:
Intake Valve
Standard . . . . . . . . . . . . . . . . . 1.36 - 1.53 mm
3
. . . . . . . . . . . . . . . . . . . . . . . (0.054 - 0.060 in.)
M82027A
Wear Limit. . . . . . . . . . . . 1.98 mm (0.078 in.)
Exhaust Valve
Straight-Edge Standard . . . . . . . . . . . . . . . . . 1.66 - 1.87 mm
. . . . . . . . . . . . . . . . . . . . . . . (0.065 - 0.074 in.)
Wear Limit. . . . . . . . . . . . 2.27 mm (0.089 in.)
Feeler Gauge
Valve Seat Width - 4TN82, 4TN84(T)(4019):
Intake Valve
Standard . . . . . . . . . . . . . . . . . 1.07 - 1.24 mm
M82028A
. . . . . . . . . . . . . . . . . . . . . . . (0.042 - 0.049 in.)
Wear Limit. . . . . . . . . . . . 1.74 mm (0.069 in.)
Cylinder Head Distortion: Exhaust Valve

Standard . . . . . . . 0.05 mm (0.002 in.) or less Standard . . . . . . . . . . . . . . . . . 1.24 - 1.45 mm
Wear Limit. . . . . . . . . . . . 0.15 mm (0.006 in.) . . . . . . . . . . . . . . . . . . . . . . . (0.049 - 0.057 in.)
If distortion exceeds the wear limit, resurface or Wear Limit. . . . . . . . . . . . 1.94 mm (0.076 in.)
replace cylinder head. Remove only enough metal to If necessary, grind valve seats to meet specifications.
make cylinder head flat; but do not remove more (See GRIND VALVE SEATS procedure.)
than 0.20 mm (0.008 in.).
If cylinder head was resurfaced:
• Measure piston-to-cylinder head clearance. (See condition using a valve inspection center.
procedure in this group.) Replace valve if necessary.
4/7/95 3-23
Valve Stem O.D. - 4TN78T:

Distance A . . . . . . . . . . . . . . . . .30 mm (1.181 in.)
Distance B . . . . . . . . . . . . . . . . .50 mm (1.969 in.)
Standard . . . . . . . . . . . . . . . . . 6.94 - 6.96 mm
. . . . . . . . . . . . . . . . . . . . . (0.2732 - 0.2740 in.)
Wear Limit. . . . . . . . . . . 6.90 mm (0.2717 in.)
Valve Stem O.D. - 4TN82, 4TN84(T)(4019):
M35307
Distance A . . . . . . . . . . . . . . . . .30 mm (1.181 in.)
Distance B . . . . . . . . . . . . . . . . .60 mm (2.360 in.)
• If valve faces are worn, burned or pitted, grind
valves to proper face angle. If valve face margin Intake Valve
is less than 0.51 mm (0.020 in.) after grinding, Standard . . . . . . . . . . . . . . . . . 7.96 - 7.98 mm
replace valve. . . . . . . . . . . . . . . . . . . . . . (0.3134 - 0.3142 in.)
Wear Limit. . . . . . . . . . . 7.90 mm (0.3110 in.)
3 Exhaust Valve
Valve Face Standard . . . . . . . . . . . . . . . . . 7.96 - 7.97 mm
Valve Angle
Face . . . . . . . . . . . . . . . . . . . . . (0.3134 - 0.3138 in.)
3 Margin Exhaust: 45°
Intake: 30° Wear Limit. . . . . . . . . . . 7.90 mm (0.3110 in.)
M82030A exceeds wear limit.
• Measure valve stem diameter at two locations Valve Recession

wear limit.
Cylinder
A B Head
Depth
Gauge
M82031A
M82032A
3-24 4/7/95
Valve Recession: • Ream inside diameter of valve guides using:

Standard . . . . . . . . . . . . . . . . . 0.30 - 0.50 mm - 4TN78T: D-20020WI Valve Guide Reamer
. . . . . . . . . . . . . . . . . . . . . . . (0.012 - 0.020 in.)
- 4TN82, 4TN84(T)(4019): D-20021WI Valve
Wear Limit . . . . . . . . . . . 1.00 mm (0.039 in.) Guide Reamer
Valve Guides:
Clean valve guides using a valve guide brush.
Measure valve guide inside diameter. A
Valve Guide I.D. - 4TN78T:
Standard . . . . . . . . . . . . . . . . . 7.00 - 7.02 mm
. . . . . . . . . . . . . . . . . . . . . . . (0.275 - 0.276 in.)
Wear Limit . . . . . . . . . . . 7.08 mm (0.279 in.)
Maximum Clearance . . . 0.20 mm (0.008 in.)
Valve Guide I.D. - 4TN82, 4TN84(T)(4019):
Standard . . . . . . . . . . . . . . . . . 8.01 - 8.03 mm 3
. . . . . . . . . . . . . . . . . . . . . . . (0.315 - 0.316 in.) M82193A
Wear Limit . . . . . . . . . . . 8.10 mm (0.319 in.)

Valve Springs:
If diameter exceeds wear limit, knurl or replace
guide.
• Measure spring free length. Replace spring if 3
If diameter is less than wear limit, determine guide-
to-stem clearance (guide diameter minus stem
diameter).
than 0.20 mm (0.008 in.), knurl valve guides.
• Knurl valve guides using:
- 4TN78T: D-20018WI Valve Guide Knurler
- 4TN82, 4TN84(T)(4019): D-20019WI Valve
Guide Knurler
valve guide.
• Replace valve guides using JDE118 Valve Guide M82034A
Driver.
Intake and exhaust valve guides are different. The
exhaust valve guide has one groove and the intake Spring Free Length:
valve guide has none. Install valve guides with Standard . . . . . . . . . . . . . . . 40 mm (1.575 in.)
tapered ends down. Push valve guides down until
Wear Limit . . . . . . . . . . 39.50 mm (1.550 in.)
top of cylinder head.
Valve Guide Height “A”:

4TN78T . . . . . . . . . . . . . . . . 12 mm (0.472 in.)
4TN82, 4TN84(T)(4019) . . . 15 mm (0.591 in.)
4/7/95 3-25
• Measure spring inclination. Replace spring if EXHAUST MANIFOLD

1. Remove muffler and gasket, if equipped.
NOTE: Turbocharger removal/installation
procedures are similar to unit used on
Series 220 Engines. Follow procedures used
in ACCESSORIES - SERIES 220 POWER
UNIT ENGINES section. Service
procedures are also similar.
2. Remove turbocharger, if equipped. (See
POWER UNIT ENGINES section).
Spring Inclination
1.10mm (0.044 in.)
3 Square Gauge
Free Length
3 M82035A
INTAKE MANIFOLD
procedures found in ACCESSORIES -
SERIES 220 POWER UNIT ENGINES
section.
ENGINES section.)
this section.)
4. OEM Power Unit engine (4019):
• Remove radiator support rod.
3-26 4/7/95
Exhaust Manifold Nut (4) Cap Screw (2) Cap Screw (6)
M8 M8 x 60 M8 x 80
26 N•m (226 lb-in.) 26 N•m (226 lb-in.) Stud (4) 26 N•m (226 lb-in.)
Gasket
Nut (2)
Cap Screw M10
Long 26 N•m (226 lb-in.)
26 N•m (226 lb-in.)
4TN82RJK, 4TN84RJK
4TN82ESP/RJE, 4TN84(4019D)
Exhaust
Manifold
Stud (3)
Gasket 3
Exhaust
Manifold
Cap Screw
Gasket M8 x 85
26 N•m (226 lb-in.) 3
Cap Screw (4)
M8 x 100
26 N•m (226 lb-in.)
Cap Screw (3)

M8 x 65
26 N•m (226 lb-in.)
4TN78T, 4TN84T(4019T)
M82195A
Intake Manifold Gasket
Intake Manifold
Gasket
Cap Screw (5)
M8 x 35
Cap Screw (5) 26 N•m (226 lb-in.)
M8 x 35
26 N•m (226 lb-in.)
4TN78T, 4TN82, 4TN84 4TN84(T)(4019)
M82194A
4/7/95 3-27
GRIND VALVE SEATS

surface, which may result in leaks or valve/ Lower Seat
Surface 70°
seat failure. Valve seats should be ground and
lapped.
Valve Upper
Seat Seat
NOTE: LIGHTLY grind valve seats for a few Surface
seconds only to avoid excessive valve seat Seat
width. 15°
Width
and exhaust valve seat using a 45° seat grinder. Cylinder
Follow tool manufacturers instructions. Head
M82040A
3
or seats cannot be reconditioned, replace valves,
Seat Grinder valve seats if equipped and/or cylinder head.
3
NOTE: Valve seat inserts are available for 4TN78T
engine only.
LAP VALVES
M82039A NOTE: Use a rubber type lapping tool for valves
without a lapping tool groove slit.
2. Measure valve seat width after grinding. If seat does not make proper contact, lap the valve
3. If seat is too wide after grinding, grind lower seat into the seat:
surface using a 70° seat grinder until seat width is 1. Apply small amount of fine lapping compound to
close to specifications. face of valve.
4. Grind upper seat surface using a 15° seat grinder 2. Turn valve to lap valve to seat.
3. Lift valve from seat every 8 to 10 strokes. Lap
5. If valve seats are ground, measure valve recession until a uniform ring appears around the surface of
and check contact pattern between the seat and the valve face.
valve with bluing dye.
4. Wash all parts in solvent to remove lapping
6. Lap valves. (See procedure in this group.) compound. Dry parts.
3-28 4/7/95
5. Check position of lap mark on valve face. Lap 3. Slowly turn crankshaft one complete revolution.
specification.
Lapping Tool
M82041A
3
MEASURE PISTON-TO-CYLINDER
HEAD CLEARANCE M82042A
1. Place three 10 mm (0.400 in.) long pieces of 1.50 3

mm (0.060 in.) diameter soft wire in three
positions on the flat part of the piston head. Piston-to-Cylinder Head Clearance:
2. Install cylinder head and old gasket. Install 4TN78T . . . . . . . . . . . . . . . . . . .0.59 - 0.77 mm
cylinder head cap screws and tighten in proper . . . . . . . . . . . . . . . . . . . . . . . (0.023 - 0.030 in.)
sequence to specified torque. (See CYLINDER 4TN82, 4TN84(T)(4019) . . . . .0.64 - 0.82 mm
this group.) . . . . . . . . . . . . . . . . . . . . . . . (0.025 - 0.032 in.)
If clearance is less than specifications, replace
cylinder head.
4/7/95 3-29
SERVICE PARTS KITS

3-30 4/7/95
Removal
cause damage to piston if ridge is not removed. Piston and
4. If necessary, remove ridge from top of cylinder Connecting Rod
Inserts 3
Note alignment marks on each part. Connecting
Rod Cap
7. Remove two cap screws, connecting rod cap and
bearing inserts.
Connecting Rod
matched. Pistons must be installed in the Replace.

installing piston.
from which it was removed, with piston size
mark on top of piston toward fuel injection pump.
4/7/95 3-31
IMPORTANT: Do not touch bearing insert 7. Install cylinder head. (See Cylinder Head, Valves
surfaces. Oil and acid from your finger will and Manifolds in this section.)
3. Install bearing inserts on connecting rod and rod System in this section.)
cap, aligning tangs with grooves.
IMPORTANT: Connecting rod caps must be Disassembly
installed on the same connecting rods they IMPORTANT: Pistons must be installed on the
were removed from. same connecting rod they were removed from.
4. Match the connecting rods to caps using • Put a mark on each piston and connecting rod to
alignment marks. Install caps. aid in assembly.
5. Dip entire connecting rod cap screws in clean • Piston pin bushing is press fit in connecting rod.
engine oil. Install new cap screws and tighten to Remove bushing only if replacement is
specifications. necessary. (See Inspection/Replacement
procedures.)
Specifications: • Inspect all parts for wear or damage. Replace as
3 necessary. (See Inspection/Replacement
4TN78T . . . . . . . . . . . . . . . . 39 N•m (29 lb-ft) procedures.)
4TN82, 4TN84(T)(4019) . . . 47 N•m (35 lb-ft)
6. If a new piston and connecting rod were installed,
stamp a number corresponding to the cylinder 1st Compression Ring
number on the connecting rod cap and connecting
rod
Piston Size
Mark
Oil Ring with
Coil Expander
Fuel
Injection
Pump Side
Piston
Flywheel
Side
Piston Pin
Snap Ring
Groove
Connecting Rod
Cap Alignment Piston Pin Bushing
Tangs
Mark
Connecting Rod
Cap Screw Connecting Rod
Groove
M82197A
M82196A
3-32 4/7/95
Assembly
assembly. Expander

Ring
Oil Ring
size mark on same side as connecting rod Expander
“punched” alignment mark. If a new connecting Ends
rod is used, assemble piston to connecting rod
with piston size mark opposite connecting rod
bearing insert groove.
Piston Pin
M82046A
Piston
Size Piston
Mark 5. Install second compression ring, with small
diameter of taper toward top of piston, in middle 3
groove. Turn ring until gap is 120o away from oil
ring gap.
6. Install first compression ring (chrome plated),
Piston Pin
with manufacturer's mark “R”, “T” or “RN”
(near ring gap) toward top of piston, in top
groove. Turn ring until gap is 120o away from
second ring gap.

Snap Ring
2nd Compression
Ring
Rod Mark
1st Compression
Ring
2nd 120°
120°
Compression
3. Install oil ring expander in bottom ring groove of Ring 120°
piston with ends above either end of piston pin. Oil Ring
M82199A
4/7/95 3-33
Inspection/Replacement If bearing diameter exceeds wear limit, replace

bearing inserts.
necessary. If bearing clearance (bearing I.D. minus crankshaft
journal O.D.) exceeds specification, grind crankshaft
2. Measure crankshaft connecting rod journal connecting rod journals and install undersized
diameter. (See Crankshaft, Main Bearings and bearing inserts, or replace bearing inserts and
Flywheel in this section.) crankshaft.
3. Install connecting rod cap and bearing inserts on 5. With rings installed on piston, measure piston
connecting rod. Install old connecting rod cap ring groove clearance. Measure several places
screws and tighten to specifications. around each piston.
Specifications:
4TN78T . . . . . . . . . . . . . . . . 39 N•m (29 lb-ft)
4TN82, 4TN84(T) (4019) . . 47 N•m (35 lb-ft)
3
M35360
Piston Ring Groove Clearance - 4TN78T:

Standard . . . . . . . . . . . . . . . 0.070 - 0.105 mm
. . . . . . . . . . . . . . . . . . . . . (0.0028 - 0.0041 in.)
Wear Limit. . . . . . . . . . . 0.25 mm (0.0098 in.)
M82048A Second Compression Ring

Standard . . . . . . . . . . . . . . . 0.035 - 0.070 mm
Connecting Rod Bearing I.D. - 4TN78T: . . . . . . . . . . . . . . . . . . . . . (0.0014 - 0.0028 in.)
Standard . . . . . . . . . . . . . . . . 43 - 43.042 mm Wear Limit. . . . . . . . . . . 0.25 mm (0.0098 in.)
. . . . . . . . . . . . . . . . . . . . . . . (1.693 - 1.695 in.)
Oil Ring
Wear Limit. . . . . . . . . . . 43.07 mm (1.696 in.)
Standard . . . . . . . . . . . . . . . 0.030 - 0.060 mm
Clearance . . . . . . . . . . . . . 0.16 mm (0.006 in.)
. . . . . . . . . . . . . . . . . . . . . (0.0012 - 0.0024 in.)
Connecting Rod Bearing I.D. - 4TN82, Wear Limit. . . . . . . . . . . 0.20 mm (0.0078 in.)
4TN84(T)(4019):
Standard . . . . . . . . . . . . . . . . 48 - 48.042 mm
. . . . . . . . . . . . . . . . . . . . . . . (1.888 - 1.891 in.)
Wear Limit. . . . . . . . . . . 48.07 mm (1.893 in.)
Clearance . . . . . . . . . . . . . 0.16 mm (0.006 in.)
3-34 4/7/95
Piston Ring Groove Clearance - 4TN82, Piston Ring End Gap - 4TN78T:
4TN84(T)(4019): Compression Rings and Oil Ring
First Compression Ring Standard . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm
Standard . . . . . . . . . . . . . . . 0.075 - 0.110 mm . . . . . . . . . . . . . . . . . . . . . . . (0.008 - 0.016 in.)
. . . . . . . . . . . . . . . . . . . . . (0.0030 - 0.0043 in.)
Wear Limit. . . . . . . . . . . 1.50 mm (0.0591 in.)
Wear Limit. . . . . . . . . . . 0.25 mm (0.0098 in.)
Piston Ring End Gap - 4TN82:
Standard
Standard . . . . . . . . . . . . . . . . 0.45 - 0.080 mm
. . . . . . . . . . . . . . . . . . . . . (0.0018 - 0.0031 in.)
. . . . . . . . . . . . . . . . . . . . . . (0.010 - 0.016 in.)
Wear Limit. . . . . . . . . . . 0.25 mm (0.0098 in.)
Oil Ring . . . . . . . . . . . . . . . . . . . . . . (0.008 - 0.014 in.)
Standard . . . . . . . . . . . . . . . 0.025 - 0.060 mm Oil Ring . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm
. . . . . . . . . . . . . . . . . . . . . (0.0010 - 0.0024 in.) . . . . . . . . . . . . . . . . . . . . . . (0.008 - 0.016 in.)
Wear Limit. . . . . . . . . . . 0.20 mm (0.0079 in.) Wear Limit: . . . . . . . . . . 1.50 mm (0.0591 in.) 3
If clearance exceeds wear limit, replace rings or Piston Ring End Gap - 4TN84 (4019D):
piston. Standard
6. Measure piston ring end gap. Push ring into Compression Rings . . . . . . . . 0.20 - 0.40 mm
cylinder bore, using a piston, until ring is . . . . . . . . . . . . . . . . . . . . . . (0.008 - 0.016 in.)
approximately 30 mm (1.181 in.) from bottom of
cylinder bore. Oil Ring . . . . . . . . . . . . . . . . . 0.25 - 0.45 mm
. . . . . . . . . . . . . . . . . . . . . . (0.010 - 0.018 in.)
Wear Limit: . . . . . . . . . . 1.50 mm (0.0591 in.)
Piston Ring End Gap - 4TN84T (4019T):
End Gap
Standard
and Oil Ring . . . . . . . . . . . . . 0.25 - 0.45 mm
. . . . . . . . . . . . . . . . . . . . . . (0.010 - 0.018 in.)
Cylinder . . . . . . . . . . . . . . . . . . . . . . (0.008 - 0.016 in.)
Bore
Wear Limit. . . . . . . . . . . 1.50 mm (0.0591 in.)
at six places.
Piston
Ring
Approx.
30 mm
(1.181 in.)
End Gap M82049A
4/7/95 3-35
Piston Pin Bore I.D. - 4TN78T:

Standard . . . . . . . . . . . . . . 23.00 - 23.009 mm
. . . . . . . . . . . . . . . . . . . . . (0.9055 - 0.9059 in.)
Wear Limit. . . . . . . . . . . 23.02 mm (0.906 in.)
Clearance . . . . . . . . . . . 0.018 mm (0.0007 in.)
Piston Pin Bore I.D. - 4TN82, 4TN84(T)(4019):

Standard . . . . . . . . . . . . . . 26.00 - 26.009 mm
. . . . . . . . . . . . . . . . . . . . . (1.0236 - 1.0240 in.)
Wear Limit. . . . . . . . . . . 26.02 mm (1.024 in.)
Clearance . . . . . . . . . . . 0.022 mm (0.0009 in.)
If piston pin bore exceeds wear limit, replace piston.
Measuring Positions If bore clearance (bore I.D. minus pin O.D.) exceeds
specification, replace piston, piston pin or both.
3 9. Measure piston pin bushing diameter in
connecting rod.
M82050A
Piston Pin O.D. - 4TN78T:

Standard . . . . . . . . . . . . . . 22.991 - 23.00 mm
. . . . . . . . . . . . . . . . . . . . . . . (0.905 - 0.906 in.)
Wear Limit. . . . . . . . . . . 22.90 mm (0.902 in.)
Piston Pin O.D. - 4TN82, 4TN84(T)(4019):

Standard . . . . . . . . . . . . . . 25.987 - 26.00 mm
. . . . . . . . . . . . . . . . . . . . . . . (1.023 - 1.024 in.)
Wear Limit. . . . . . . . . . . 25.90 mm (1.020 in.) M82051A

8. Measure piston pin bore diameter in piston. Piston Pin Bushing I.D. - 4TN78T:
Standard . . . . . . . . . . . . . 23.025 - 23.038 mm
. . . . . . . . . . . . . . . . . . . . . (0.9065 - 0.9070 in.)
Wear Limit. . . . . . . . . . . 23.10 mm (0.909 in.)
Clearance . . . . . . . . . . . 0.110 mm (0.0043 in.)
Piston Pin Bushing I.D. - 4TN82,4TN84(T)(4019):

Standard . . . . . . . . . . . . . 26.025 - 26.038 mm
. . . . . . . . . . . . . . . . . . . . . (1.0246 - 1.0251 in.)
Wear Limit. . . . . . . . . . . 26.10 mm (1.028 in.)
M37683 Clearance . . . . . . . . . . . 0.110 mm (0.0043 in.)
3-36 4/7/95
If bushing diameter exceeds wear limit, replace Piston O.D. - 4TN78T:

bushing. Distance A . . . . . . . . . . . . . . . . .23 mm (0.905 in.)
If bushing clearance (bushing I.D. minus pin O.D.) Standard Size Piston
exceeds specification, replace bushing, piston pin or
both. Standard . . . . . . . . . . . . . 77.895 - 77.925 mm
. . . . . . . . . . . . . . . . . . . . . . . (3.067 - 3.068 in.)
Piston pin bushing is press fit. Replace bushing
Wear Limit. . . . . . . . . . . 77.81 mm (3.063 in.)
using a driver set. When installing bushing, make
connecting rod. 0.25 mm (0.010 in.) Oversize Piston
10.Measure piston diameter perpendicular to piston Standard . . . . . . . . . . . . . . . 78.15 - 78.18 mm
pin bore at distance A. . . . . . . . . . . . . . . . . . . . . . . . (3.076 - 3.077 in.)
Wear Limit. . . . . . . . . . . 78.05 mm (3.073 in.)
overhaul, oversize pistons and rings may
have been installed. Pistons and rings are Piston O.D. - 4TN82:
available in 0.25 mm (0.010 in.) oversize for Distance A . . . . . . . . . . . . . . . . .24 mm (0.945 in.)
all engines and 0.50 mm (0.020 in.) oversize Standard Size Piston
for 4TN82 and 4TN84(T)(4019). 3
Standard . . . . . . . . . . . . . . . 81.90 - 81.93 mm
. . . . . . . . . . . . . . . . . . . . . . . (3.224 - 3.225 in.)
Wear Limit. . . . . . . . . . . 81.80 mm (3.220 in.)

Standard . . . . . . . . . . . . . . . 82.15 - 82.18 mm
. . . . . . . . . . . . . . . . . . . . . . . (3.234 - 3.235 in.)
Wear Limit. . . . . . . . . . . 82.05 mm (3.230 in.)

A
Standard . . . . . . . . . . . . . . . 82.40 - 82.42 mm
. . . . . . . . . . . . . . . . . . . . . . . (3.244 - 3.245 in.)
Piston O.D. - 4TN84(T)(4019)

Distance A . . . . . . . . . . . . . . . . .24 mm (0.945 in.)
Standard . . . . . . . . . . . . . . . 83.90 - 83.93 mm
. . . . . . . . . . . . . . . . . . . . . . . (3.303 - 3.304 in.)
Wear Limit. . . . . . . . . . . 83.80 mm (3.299 in.)

Standard . . . . . . . . . . . . . . . 84.15 - 84.18 mm
. . . . . . . . . . . . . . . . . . . . . . . (3.313 - 3.314 in.)
Wear Limit. . . . . . . . . . . 84.05 mm (3.309 in.)
M82052A
4/7/95 3-37
0.50 mm (0.020 in.) Oversize Piston Cylinder Bore I.D. - 4TN78T:

Standard . . . . . . . . . . . . . . . 84.40 - 84.42 mm Standard Size Bore
. . . . . . . . . . . . . . . . . . . . . . . (3.323 - 3.324 in.) Standard . . . . . . . . . . . . . . . 78.00 - 78.03 mm
Wear Limit. . . . . . . . . . . 84.30 mm (3.319 in.) . . . . . . . . . . . . . . . . . . . . . . . (3.071 - 3.072 in.)
If piston diameter is less than wear limit, install a Wear Limit . . . . . . . . . . 78.20 mm (3.079 in.)
new piston. Clearance . . . . . . . . . . . . . 0.22 mm (0.009 in.)
in this group.) 0.25 mm (0.010 in.) Oversize Bore
Standard . . . . . . . . . . . . . . . 78.25 - 78.28 mm
CYLINDER BORE . . . . . . . . . . . . . . . . . . . . . . . (3.081 - 3.082 in.)
Wear Limit. . . . . . . . . . . 78.45 mm (3.089 in.)
Inspection
Measure cylinder bore diameter at three positions;
top, middle and bottom. At these three positions, Standard Size Bore
measure in both directions; along crankshaft center Standard . . . . . . . . . . . . . . . 82.00 - 82.03 mm
3 line and direction of crankshaft rotation. . . . . . . . . . . . . . . . . . . . . . . . (3.228 - 3.230 in.)
NOTE: If engine has had a previous major Wear Limit . . . . . . . . . . 82.20 mm (3.236 in.)
overhaul, oversize pistons and rings may Clearance . . . . . . . . . . . . . 0.35 mm (0.014 in.)
Standard . . . . . . . . . . . . . . . 82.25 - 82.28 mm
Top Position . . . . . . . . . . . . . . . . . . . . . . . (3.238 - 3.239 in.)
Wear Limit. . . . . . . . . . . 82.45 mm (3.246 in.)
Middle Position
Standard . . . . . . . . . . . . . . . 82.50 - 82.53 mm
. . . . . . . . . . . . . . . . . . . . . . . (3.248 - 3.249 in.)
Wear Limit. . . . . . . . . . . 82.70 mm (3.256 in.)
Bottom Position
Cylinder Bore I.D. - 4TN84(T)(4019):

Direction of
Standard Size Bore
Crankshaft Rotation Standard . . . . . . . . . . . . . . . 84.00 - 84.03 mm
. . . . . . . . . . . . . . . . . . . . . . . (3.307 - 3.308 in.)
Direction of Wear Limit . . . . . . . . . . 84.20 mm (3.315 in.)
Crankshaft
Centerline
Clearance . . . . . . . . . . . . . 0.35 mm (0.014 in.)

M82053A
Standard . . . . . . . . . . . . . . . 84.25 - 84.28 mm
. . . . . . . . . . . . . . . . . . . . . . . (3.317 - 3.318 in.)
Wear Limit. . . . . . . . . . . 84.45 mm (3.325 in.)
3-38 4/7/95

Standard . . . . . . . . . . . . . . . 84.50 - 84.53 mm
. . . . . . . . . . . . . . . . . . . . . . . (3.327 - 3.328 in.)
Wear Limit. . . . . . . . . . . 84.70 mm (3.335 in.)
If cylinder bore exceeds wear limit, replace cylinder
procedure.)
If cylinder is rebored, oversize pistons and rings
must be installed. Pistons and rings are available in
0.25 mm (0.010 in.) oversize for all engines and 0.50
mm (0.020 in.) oversize for 4TN82 and M82054A
4TN84(T)(4019).
exceeds specification, replace cylinder block, piston Reboring
or both; or rebore cylinder and install oversize piston NOTE: The cylinder block can be rebored to use
and rings.
oversize pistons and rings. Pistons and
rings are available in 0.25 mm (0.010 in.)
3
Deglazing oversize for all engines and 0.50 mm (0.020
IMPORTANT: If cylinder bores are to be in.) oversize for 4TN82 and
deglazed with crankshaft installed in engine, 4TN84(T)(4019). (See this group for
put clean shop towels over crankshaft to cylinder bore I. D. specifications.)
protect journal and bearing surfaces from any 1. Align center of bore to drill press center.
abrasives.
IMPORTANT: Check stone for wear or damage.
1. Deglaze cylinder bores using a flex-hone with Use a rigid hone with 300 grit stones.
180 grit stones.
2. Adjust hone so lower end is even with lower end
2. Use flex-hone as instructed by manufacturer to of cylinder bore.
3. Adjust rigid hone stones until they contact
IMPORTANT: Do not use gasoline, kerosene or narrowest point of cylinder.
commercial solvents to clean cylinder bores.
4. Coat cylinder with honing oil. Hone should turn
by hand. Adjust if too tight.
cylinder walls.
5. Run drill press at about 250 RPM. Move hone up
and down in order to obtain a 30 - 40°crosshatch
pattern.
using clean white rags and warm soapy water.
no discoloration.
4/7/95 3-39

30 - 40° NOTE: Finish should not be smooth. It should have
a 30 - 40o crosshatch pattern.
mm (0.001 in.) of desired size.
8. Use a flex hone with 180 grit stones for honing to
final size.
9. Check bore for size, taper and out-of-round. (See
IMPORTANT: Do not use solvents to clean
cylinder bore. Solvents will not remove all
metal particles and abrasives produced during
honing.
M52959
3 10.Clean cylinder thoroughly using warm soapy
water until clean white rags show no
discoloration.
3-40 4/7/95
OTHER MATERIALS
Number Name Use
LOCTITE® PRODUCTS
U.S./
Canadian/
LOCTITE No.
TY15130/ John Deere Form-In-Place Seals crankcase extension housing,
NA/ Gasket rear oil seal case and flywheel housing
#395 to engine block.
SERVICE PARTS KITS

3
®LOCTITE is a registeredtrademark of the Loctite Corp.
4/7/95 3-41
BALANCER ASSEMBLY - 4TN82RJK, Oil Strainer

4TN84RJK O-Ring
Replace.
1. Remove oil pan. (See Lubrication System in this
section.)
NOTE: Crankcase extension is removed to show
detail.
2. Align balancer-to-crankshaft timing marks.
IMPORTANT: Rotate crankshaft to find timing
marks or scribe a mark across balancer gear
and crankshaft gear teeth before removing
balancer assembly.
27 N•m (20 lb-ft)
M48309
3
• Align balancer-to-crankshaft timing marks when
3 installing balancer assembly.
Timing Marks
1. Remove nut, drive gear, cap screws and shaft
assemblies.
NOTE: Driven gears are press fit on balancer
shafts.
2. Remove driven gear using a knife-edge puller and
a press.
3. Remove retaining plate.
M48268
necessary.
3. Remove oil strainer. (See Lubrication System in
this section.) NOTE: Shaft bushings cannot be replaced
separately. Replace balancer housing if
4. Remove six mounting cap screws.
necessary.
5. Remove balancer assembly and o-ring.
If drive gear is damaged, check balancer gear on
6. Disassemble and inspect balancer assembly. (See crankshaft for damage. Replace if necessary. (See
Disassembly/Inspection procedures.) CRANKSHAFT - Inspection/Replacement
3-42 4/7/95
Timing Marks
Shaft Bushing Housing Nut
106 N•m (78 lb-ft)
Drive Gear
Driven Gear M48312
Shaft
Retaining Plate 4TN78T, 4TN82RJK, 4TN84RJK
Cap Screw (2) 1. Remove flywheel. (See procedure in this group.)
M8 x 16
M48311
27 N•m (20 lb-ft) 2. Remove oil pan/plate. (See Lubrication System in
this section.)
Assembly is done in the reverse order of 3
disassembly. Cap Screw (2)
4TN78T: M10 x 25
• Install retaining plate on shaft with grooves 4TN82,
toward driven gear. 4TN84: M10 x 20
49 N•m (36 lb-ft)
• Press driven gear on balancer shaft until flush
with beveled edge. Install gear with timing
marks facing away from retainer plate.
Cap Screw (3)
assembly. M8 x 30
26 N•m (226 lb-in.)
• Align driven gear timing marks when installing M48310
balancer shaft assemblies.
John Deere
sealant)
Cap Screw (4) Crankcase Extension

M8 x 120 Housing
27 N•m (20 lb-ft)
Cap Screw (8)

M8 x 50
22 N•m (195 lb-in.)
Cap Screw (14)

27 N•m (20 lb-ft) M82201A
4/7/95 3-43

4TN82RJE, 4TN82ESP,
4TN84(T)(4019)
3
Cap Screw (4)
M8 x 35 49 N•m (36 lb-ft)
3 26 N•m (226 lb-in.)
M82056
John Deere
sealant)
Crankcase Extension
Housing
Cap Screw (2)
M8 x 50
27 N•m (20 lb-ft)
Cap Screw (2)

M8 x 25
22 N•m (195 lb-in.)
M82202A
3-44 4/7/95
CRANKSHAFT REAR OIL SEAL • Replace oil seal using a driver set. Install seal
with lip toward inside of gear housing cover.
Replacement Install seal flush with surface of cover.

• Replace oil seal using a driver set. Install seal, Timing Gear Cover
with lip toward cylinder block. Install seal flush
point, seal can be installed 3 mm (0.120 in.)
farther into oil seal case.
Crankshaft
On 4TN78T, 4TN82RJK, 4TN84RJK: All Front
nine seal case cap screws are M8 x 30 long. Oil Seal
M82203A
Rear Oil Seal

Seal Case-to-Block
3
Cap Screw (6)
M8 X 30 CRANKSHAFT AND MAIN BEARINGS
26 N•m (226 lb-in.)
Oil Seal Case Removal

group.)
3. Remove flywheel housing. (See procedure in this
group.)
4. Remove crankcase extension housing. (See
5. Remove balancer assembly, if equipped. (See
John Deere procedure in this group.)
Form-In-Place
Gasket NOTE: On 4TN82 (970 CUT) and 4TN84 (1070
Seal Case-to-Extension (RTV rubber CUT), crankshaft can be removed without
Cap Screw (3) silicone sealant)
removing timing gear cover mounting plate.
M8 X 35
M82057A
21 N•m (180 lb-in.) 6. Remove timing gear cover mounting plate. (See
Camshaft and Timing Gear Train in this section.)
CRANKSHAFT FRONT OIL SEAL Tests and Adjustments in this section.)
Replacement IMPORTANT: Connecting rod end caps must be

• Remove timing gear cover. (See Camshaft and which they were removed. Note alignment
Timing Gear Train in this section.) marks on caps and rods.
4/7/95 3-45
8. Remove connecting rod cap screws and end caps. 10.Remove main bearing cap screws, caps and cap
thrust bearings.
crankshaft. 11.Remove crankshaft.
IMPORTANT: Main bearing caps must be 12.Remove block thrust bearings and main bearing
installed on the same main bearings from inserts.
which they were removed. 13.Inspect all parts for wear or damage. (See
Crankshaft
Flywheel
3 End
3
Cap Thrust Bearing

Main Bearing Cap
Main Bearing Cap Screw (10)
M82059A
3-46 4/7/95

installation.
IMPORTANT: Do not touch bearing insert locations with arrows pointing toward flywheel
surfaces. Oil and acid from your finger will side of engine.
IMPORTANT: DO NOT use high speed power
1. Install grooved bearing inserts in crankshaft tools or air wrenches to tighten main bearing
bearing bores, aligning tangs with slots in bores. cap screws.
2. Install block thrust bearings with oil grooves 7. Dip entire main bearing cap screws in clean
facing away from engine block. engine oil. Install cap screws and tighten. DO
to align the thrust bearings.
NOTE: Main bearing caps have “raised arrows”
specifications. When tightening, start at center
3
correspond to their location on the engine
beginning with number 1, then 2, etc. The If it does not turn easily, disassemble the parts
main bearing cap at gear train end does not and find the cause.
4/7/95 3-47
Crankshaft
Flywheel
End
Tangs
Cap Thrust Bearing

3 Smooth Bearing Insert
Main Bearing Cap
3 Main Bearing Cap Screw (10)

1
4TN78T: 79 N•m (58 lb-ft)
4TN82, 4TN84(T)(4019): 98 N•m (72 lb-ft)
2
M82059A
IMPORTANT: Connecting rod caps must be NOTE: On 4TN82 (970 CUT) and 4TN84 (1070
installed on the same connecting rods they CUT), crankshaft can be installed without
were removed from. removing timing gear cover mounting plate.
Never reuse connecting rod cap screws, 12.Install timing gear cover mounting plate. (See
replace with new. Camshaft and Timing Gear Train in this section.)
10.Match the connecting rod caps to the rods using 13.Install balancer, if equipped. (See procedure in
alignment marks. Install caps. this group.)
11.Dip entire connecting rod cap screws in clean 14.Install crankcase extension housing. (See
engine oil. Install new cap screws and tighten to procedure in this group.)
specifications. 15.Install flywheel housing. (See procedure in this
group.)
16.Install rear oil seal. (See procedure in this group.)
Specifications:
4TN78T . . . . . . . . . . . . . . . . 39 N•m (29 lb-ft)
4TN82, 4TN84(T)(4019) . . . 47 N•m (35 lb-ft)
3-48 4/7/95
1. Inspect crankshaft gear for chipped or broken Key
teeth. Replace if necessary.
To replace gear:
Crankshaft Gear
puller and a press.
Timing
Mark
CAUTION
DO NOT heat oil over 182° C (360° F). Oil M82060A

2. If equipped, inspect balancer gear on crankshaft
for chipped or broken teeth. Replace if necessary.
with the oil. Heat the oil in a well-ventilated To replace gear: 3
area. Plan a safe handling procedure to avoid - Scribe a mark across crankshaft at location of
burns. timing mark on gear, to aid in assembly.
- Remove gear using a knife-edge puller and a
Heat gear to approximately 150oC (300oF). Install press.
gear with timing mark “A” toward press table. Align - Heat gear to approximately 150°C (300°F).
slot in gear with key in shaft. Press crankshaft into Install new gear with timing mark facing away
gear until gear is tight against crankshaft shoulder. from press table. Align timing mark on gear
with mark on crankshaft made during
disassembly. Press gear onto crankshaft until
gear is tight against crankshaft shoulder.
3. Inspect crankshaft for bend using v-blocks and a
dial indicator. Turn crankshaft slowly and read
0.02 mm (0.0007 in.), replace crankshaft.
Dial Indicator
V-Block M82061A
4/7/95 3-49
4. Measure crankshaft connecting rod journal and If journal diameter is less than wear limit, replace
main bearing journal diameters. Measure several crankshaft or have journals ground undersize by a
places around each journal. qualified machine shop.
If journals are ground, undersize bearing inserts
overhaul, journals may have been ground 0.25 mm (0.010 in.) undersize.
5. Install bearing inserts and main bearing cap on
main bearing. Tighten main bearing cap screws to
Main specifications.
Bearing
Journal
4TN78T . . . . . . . . . . . . . . . . 79 N•m (58 lb-ft)
4TN82,
4TN84(T)(4019) . . . . . . . . . . 98 N•m (72 lb-ft)
6. Measure main bearing diameter.
Connecting
Rod Journal
3 M82062A
Connecting Rod Journal O.D. - 4TN78T:

3
Standard . . . . . . . . . . . . . 42.952 - 42.962 mm
. . . . . . . . . . . . . . . . . . . . . (1.6910 - 1.6914 in.)
Wear Limit. . . . . . . . . . . 42.91 mm (1.689 in.)
Connecting Rod Journal O.D. - 4TN82, M82063

4TN84(T)(4019):
Standard . . . . . . . . . . . . . 47.952 - 47.962 mm
. . . . . . . . . . . . . . . . . . . . . (1.8879 - 1.8883 in.) Main Bearing I.D. - 4TN78T:
Wear Limit. . . . . . . . . . . 47.91 mm (1.886 in.) Standard . . . . . . . . . . . . . . 47.00 - 47.045 mm
. . . . . . . . . . . . . . . . . . . . . . . (1.850 - 1.852 in.)
Main Bearing Journal O.D. - 4TN78T: Wear Limit. . . . . . . . . . 47.10 mm (1.8541 in.)
Standard . . . . . . . . . . . . . 46.952 - 46.962 mm Clearance . . . . . . . . . . . . . 0.16 mm (0.006 in.)
. . . . . . . . . . . . . . . . . . . . . (1.8485 - 1.8489 in.)
Wear Limit. . . . . . . . . . . 46.91 mm (1.847 in.) Main Bearing I.D. - 4TN82, 4TN84(T)(4019):
Standard . . . . . . . . . . . . . . 50.00 - 50.045 mm
Main Bearing Journal O.D. - 4TN82,
4TN84(T)(4019): . . . . . . . . . . . . . . . . . . . . . . . (1.969 - 1.970 in.)
Standard . . . . . . . . . . . . . 46.952 - 46.962 mm Wear Limit. . . . . . . . . . . 50.10 mm (1.972 in.)

. . . . . . . . . . . . . . . . . . . . . (1.9666 - 1.9670 in.) Clearance . . . . . . . . . . . . . 0.16 mm (0.006 in.)
Wear Limit. . . . . . . . . . . 49.90 mm (1.965 in.)
3-50 4/7/95
If bearing diameter exceeds wear limit, replace FLYWHEEL

bearing inserts.
If bearing clearance (bearing I.D. minus crankshaft cap screws. Always install new.
main bearing journal O.D.) exceeds specification,
replace bearing inserts and crankshaft or have • Inspect pilot bushing, if equipped, for wear or
crankshaft journals ground undersize by a qualified damage. Replace if necessary using a driver set.
machine shop and install undersized bearing inserts. Install bushing flush with flywheel surface.
Bearing inserts are available in 0.25 mm (0.010 in.) • Measure flywheel flatness. Place a straight edge
undersize. across flywheel surface opposite of ring gear.
Measure clearance between straight edge and
7. Clean and inspect oil passages in main bearing flywheel surface with a feeler gauge. If
journals, connecting rod journals and main clearance exceeds 0.02 mm (0.0008 in.), replace
bearing bores in cylinder block. flywheel.
8. Inspect crankshaft for cracks or damage. Replace
if necessary.
M35337
Flywheel
Pilot Bushing
(4TN82RJK,
4TN84RJK only)
Flywheel Housing/Plate
Flywheel Mounting
Cap Screw (6)
Replace.
on threads.
83 N•m (61 lb-ft)
M82204A
4/7/95 3-51
FLYWHEEL HOUSING - 4TN78T, NOTE: 4TN84(T)(4019 DF/TF001) engines are

4TN82RJE, 4TN82ESP, 4TN84(T) equipped with a flywheel plate in place of a
(4019 DF/TF005 and 006) housing. (See procedure in this group.)

2. Remove starter.
Housing-to-Block
Cap Screw (6)
M10 x 25
49 N•m (36 lb-ft) Flywheel Housing

Gasket (RTV rubber
Housing-to-Extension silicone sealant)
Cap Screw
4TN78T: (2)
4TN82, 4TN84(T)(4019): (4)
3 4TN78T: M10 x 25
4TN82,
4TN84(T)(4019): M10 x 30
49 N•m (36 lb-ft)
Plug
M82205A
FLYWHEEL PLATE - 4TN82RJK, Mounting Cap Screw (8)

4TN84RJK, 4TN84(T)(4019 DF/TF001) M10 x 20
49 N•m (36 lb-ft) Flywheel Plate
2. Remove starter.
M82206A
3-52 4/7/95

OTHER MATERIALS
Number Name Use
LOCTITE® PRODUCTS
U.S./
Canadian/
LOCTITE No.
NA/ Gasket plate to engine block.
#395 3
#242
3
SERVICE PARTS KITS

4/7/95 3-53
CAMSHAFT
Mounting Cap Screws
M8 X 16
Removal
section.)
group.)
Timing
NOTE: If a magnetic follower holder kit is not Marks
available, turn engine until oil pan is Camshaft
upward, to hold cam followers away from M37836
3 camshaft.
3 NOTE: Due to the odd number of teeth on the idler • Apply clean engine oil on all parts during
group.)
section.)
3-54 4/7/95

Camshaft Gear
Key
Camshaft Gear
3
Side Gap M82067A
Camshaft Side Gap: 3

Thrust Plate
Standard . . . . . . . . . . . . . . . . . 0.05 - 0.20 mm
. . . . . . . . . . . . . . . . . . . . . (0.0020 - 0.0079 in.) M82068A
Wear Limit. . . . . . . . . . . . 0.40 mm (0.016 in.)

if necessary.
To remove/replace gear:
Dial Indicator
puller and a press.
CAUTION
Camshaft
fumes or oil can ignite above 193° C (380° F). Central Bearing
Use a thermometer. Do not allow a flame or Area
with the oil. Heat the oil in a well-ventilated V-Block
burns. M82069A
4/7/95 3-55
If journal diameters are less than wear limit, replace

camshaft.
housing end.
Lobe
Height
Camshaft Bushing
M82070A
Lobe Height:
Standard . . . . . . . . . . . . . 38.635 - 38.765 mm Oil Holes
. . . . . . . . . . . . . . . . . . . . . . . (1.521 - 1.526 in.) M82072
Wear Limit. . . . . . . . . . . 38.40 mm (1.512 in.)

3
If lobe height is less than wear limit, replace Camshaft Bushing I.D.:
camshaft. Standard . . . . . . . . . . . . . 44.990 - 45.055 mm
5. Measure camshaft end and intermediate journal . . . . . . . . . . . . . . . . . . . . . . . (1.771 - 1.774 in.)
3 diameters. Wear Limit. . . . . . . . . . . 45.10 mm (1.776 in.)
Clearance . . . . . . . . . . . . 0.20 mm (0.0079 in.)
Flywheel End If bushing diameter exceeds wear limit, replace
Journal
bushing.
If bushing clearance (bushing I.D. minus camshaft
camshaft or both.
To replace bushing:
Intermediate
Journal Remove bushing using a chisel. Be careful not to
Gear Housing new bushing and cylinder block. Install bushing
End Journal using a driver set.
M82071A
NOTE: Flywheel housing must be removed to
measure camshaft intermediate and
Camshaft Journal O.D.: flywheel end bearing diameters.
Gear Housing and Flywheel Ends 7. Measure intermediate and flywheel end camshaft
Standard . . . . . . . . . . . . . . . 44.92 - 44.95 mm bore diameters using the following procedures:
. . . . . . . . . . . . . . . . . . . . . . . (1.769 - 1.770 in.) • Remove flywheel housing. (See Crankshaft,
Wear Limit. . . . . . . . . . . 44.80 mm (1.764 in.) Main Bearings and Flywheel in this section.)
• Remove plug using a long wooden dowel. Insert
Intermediate wooden dowel through gear housing side.
Standard . . . . . . . . . . . . . . . 44.91 - 44.94 mm
. . . . . . . . . . . . . . . . . . . . . . . (1.768 - 1.769 in.)
Wear Limit. . . . . . . . . . . 44.80 mm (1.764 in.)
3-56 4/7/95
CAM FOLLOWERS
Plug
M35287 removed.
• Measure intermediate and flywheel end block bore to aid in installation.
camshaft bore diameters. 4. Remove cam followers.
Intermediate 6. Apply clean engine oil on all parts during 3
Bore installation.
Inspection
3
Flywheel
End • Inspect cam follower contact surface for
Bore
abnormal wear. Replace if necessary.
M82073
Camshaft Bore I.D.:

Standard . . . . . . . . . . . . . . 45.00 - 45.025 mm
. . . . . . . . . . . . . . . . . . . . . . . (1.772 - 1.773 in.)
Wear Limit. . . . . . . . . . . 45.10 mm (1.776 in.)
Clearance . . . . . . . . . . . . . 0.18 mm (0.007 in.)
block.
If bore clearance (bore I.D. minus camshaft journal Normal Contact
cylinder block or both. Abnormal Contact M82074A

4/7/95 3-57
• Measure cam follower stem diameter.

Pulley Spacer/Plate
If equipped.
Cap Screw (4)

11 N•m (96 lb-in.)
M82207A
M82075A
3. Remove crankshaft pulley cap screw and washer.
4. Remove crankshaft pulley using a two-jaw puller
Cam Follower Stem O.D.: kit.
3 Standard . . . . . . . . . . . . . 11.975 - 11.990 mm 5. Remove tachometer, if equipped.
. . . . . . . . . . . . . . . . . . . . . . . (0.471 - 0.472 in.)
6. 4TN82RJK (970 CUT), 4TN84RJK (1070 CUT):
Wear Limit. . . . . . . . . . . 11.93 mm (0.470 in.) Remove hydraulic pump and steering pump, if
3 If stem diameter is less than wear limit, replace cam equipped. (See procedure in Machine Technical
follower. Manual).
NOTE: It is not necessary to remove auxiliary drive
• Measure cam follower bore diameter in cylinder cover and gasket, if equipped, end cover and
block. o-ring or fuel injection pump gear cover to
remove timing gear cover.
Cam Follower Bore I.D.:
7. Remove 18 mounting cap screws and timing gear
Standard . . . . . . . . . . . . . 12.000 - 12.018 mm cover.
. . . . . . . . . . . . . . . . . . . . . . . (0.472 - 0.473 in.)
Wear Limit. . . . . . . . . . . 12.05 mm (0.474 in.)
• Replace seal washer.
Clearance . . . . . . . . . . . . . 0.10 mm (0.004 in.)
If cam follower bore diameter exceeds wear limit, lb-in.)
replace cylinder block.
• Align pin in crankshaft pulley with hole in
If bore clearance (bore I.D. minus follower stem crankshaft gear. Install crankshaft pulley.
O.D.) exceeds specification, replace cam follower,
TIMING GEAR COVER

Hole
2. Remove fan, spacer/plate, if equipped, and
pulley.
Pin
M35295
3-58 4/7/95
John Deere
Mounting Plate-to-Cover Form-In-Place
Cap Screw (2) Gasket
M8 x 20 (RTV rubber
silicone sealant)
Timing Gear Cover
Cap
End Cover
O-Ring Tachometer is
optional.
Cap Screw (2)

M6 x 12

M8 x 55 3
O-Ring Seal Washer

Replace.
3
Mounting Cap Screw
M8 x 16
Crankshaft Pulley
Clamp
If equipped.
Washer
Gasket
M8 x 45
Cap Screw (4)

M8 x 12
Injection Pump
Crankcase Extension Gear Cover Cap Screw
Housing-to-Cover Apply thread lock and
Cap Screw (2) Mounting Cap Screw (4) sealer (medium strength)
M8 x 25 M8 x 85 to threads.
22 N•m (195 lb-in.) 115 N•m (85 lb-ft) M82208A
IDLER GEAR NOTE: Due to the odd number of teeth on the idler
Removal/Installation gears align, the piston closest to the water
1. Remove timing gear cover. (See procedure in this pump is at TDC on compression stroke.
group.) Number one cylinder is closest to the
flywheel.
Tests and Adjustments in this section.) 3. Rotate crankshaft and align timing marks.
4. Remove two cap screws, shaft and gear.
4/7/95 3-59
5. Inspect all parts for wear or damage. (See If shaft diameter is less than wear limit, replace idler
Inspection/Replacement procedures.) gear shaft.
Installation is done in the reverse order of removal. • Measure idler gear bushing diameter.
Idler Gear (43T) Idler Gear Bushing I.D.:

Standard . . . . . . . . . . . . . . 46.00 - 46.025 mm
. . . . . . . . . . . . . . . . . . . . . . . (1.811 - 1.812 in.)
Idler Gear Shaft Wear Limit. . . . . . . . . . . 46.08 mm (1.814 in.)
Clearance . . . . . . . . . . . . 0.15 mm (0.0059 in.)
bushing.
To replace bushing:
3 Cap Screw (2)
M8 x 45 M82209A If bushing clearance (bushing I.D. minus shaft O.D.)
3 Inspection/Replacement
Idler Gear
Replace if necessary. Bushing
Idler Gear
Shaft
Idler Gear Shaft O.D.:
Standard . . . . . . . . . . . . . 45.950 - 45.975 mm
. . . . . . . . . . . . . . . . . . . . . . . (1.809 - 1.810 in.)
Wear Limit. . . . . . . . . . . 45.93 mm (1.808 in.) M82210A
3-60 4/7/95
John Deere
Form-In-Place Gasket Mounting Cap Screw (4)
(RTV rubber silicone sealant) M8 x 16
25 N•m (220 lb-in.)
Timing Gear Cover

Mounting Plate
Stud (3)
O-Rings
Replace.
M82211A
3
TIMING GEAR COVER MOUNTING

PLATE
this section.)
4. Remove oil pump. (See Lubrication System in
this section.)
5. Remove mounting cap screws and plate.
6. Replace o-rings.
4/7/95 3-61
Lubrication System
OTHER MATERIALS
Number Name Use
LOCTITE® PRODUCTS
U.S./
Canadian/
Loctite No.
TY15130/ John Deere Form-In-Place Seals oil pan to crankcase

#395
TY9375/ John Deere Pipe Sealant 4TN78T and 4TN84T (4019TF001 and
TY9480/ with TEFLON® 005): Apply to threads of plug in oil
filter #592 mounting block.

3-62 4/7/95
Lubrication System
OIL PAN AND STRAINER

John Deere Form-In-Place Gasket Gasket
(RTV rubber silicone sealant) Replace.
4TN78T. . . . . . . . . . . . . . . . . . . . . . . 7.5L (8 qt) Oil Strainer
4TN82RJK . . . . . . . . . . . . . . . . . . 5.3L (5.6 qt)

4TN82RJE/ESP . . . . . . . . . . . . . . . . 5.7L (6 qt)
4TN84RJK . . . . . . . . . . . . . . . . . . 5.3L (5.6 qt) Oil
Pan
4TN84(T)(4019)
4019D/TF001 and 005 . . . . . . . 6.8L (7.1 qt) Cap Screw (2)
M8 x 35
4019D/TF006 . . . . . . . . . . . . . . 9.5L (9.9 qt)
• Tighten all cap screws to 26 N•m (226 lb-in.).
• Fill engine with proper engine oil. (See
SPECIFICATIONS AND GENERAL Cap Screw (20) 3
M8 x 45
Spacer Plate (2)
O-Ring Cap Screw (4) 3

Replace. M8 x 16
4TN82RJE,
4TN82ESP Drain Plug M82213A
Cap Screw
4TN82RJK, 4TN84RJK (1)
4TN78T (2)
M8 x 12
Gasket
Replace.
Oil Strainer
Cap Screw (2)
M8 x 35
O-Ring (4TN78T) John Deere Form-In-Place Gasket

or (RTV rubber silicone sealant)
Copper Washer
(4TN82RJK, 4TN84RJK)
Replace.
Drain Plug Oil Pan/Cover
Cap Screw (20)

M8 x 12 (4TN82RJK, 4TN84RJK)
4TN78T, 4TN82RJK, 4TN84RJK M8 x 25 (4TN78T) M82212A
4/7/95 3-63
Lubrication System
John Deere Form-In-Place Gasket Oil Strainer Gasket

Cap Screw (2)

M8 x 35
4019D/TF006
Oil Pan
(4019D/TF001, 005)
Spacer Plate (2)

M8 x 45 M8 x 50
3 O-Ring
Replace. Cap Screw (4)
Drain Plug M8 x 16
4TN84(T)(4019) M82214A
OIL PUMP
Timing Gear Train in this section.) Oil Pump
(0.010 in.).
3. Remove four mounting cap screws, oil pump and
Oil Pump
gasket. Gasket
Disassembly/Assembly procedures). Mounting Cap Screw
M6 x 25
25 N•m (18 lb-ft)
M82215A
• Gear is press fit on rotor shaft. Remove gear
using a knife edge puller and a press.
NOTE: Safety valve is on 4TN78T and 4TN84T
(4019TF001 and 005) only.
• Coat all parts with clean engine oil.
3-64 4/7/95
Lubrication System
• Install outer rotor with identification mark Rotor Recess - 4TN82, 4TN84(T)(4019):
facing toward rotor shaft assembly. Standard . . . . . . . . . . . . . . . . . 0.03 - 0.09 mm
. . . . . . . . . . . . . . . . . . . . . (0.0011 - 0.0035 in.)
Backing Plate Alignment Pin (2)
Wear Limit. . . . . . . . . . . 0.15 mm (0.0059 in.)
Safety Valve
Non-Adjustable. • Check outer rotor-to-pump body clearance. If
DO NOT Remove. clearance is more than wear limit, replace entire
Pump Body
assembly
Rotor Shaft
Outer Rotor Outer Rotor
Gear
Identification
Mark
Feeler Gauge
Inner Rotor
Body
3
M82216A
M37776
Inspection
Outer Rotor-to-Pump Body Clearance - 4TN78T: 3
• Check rotor shaft outer diameter and the shaft Standard . . . . . . . . . . . . . . . . . 0.09 - 0.16 mm
hole diameter in backing plate. If clearance is
more than wear limit, replace entire assembly . . . . . . . . . . . . . . . . . . . . . (0.0035 - 0.0063 in.)
Rotor Shaft and Plate Clearance: Wear Limit. . . . . . . . . . . 0.25 mm (0.0098 in.)
Standard . . . . . . . . . . . . . . . 0.015 - 0.048 mm
. . . . . . . . . . . . . . . . . . . . . (0.0006 - 0.0035 in.) Outer Rotor-to-Pump Body Clearance - 4TN82,
4TN84(T)(4019):
Wear Limit. . . . . . . . . . . 0.20 mm (0.0078 in.) Standard . . . . . . . . . . . . . . . . . 0.10 - 0.17 mm
• Check rotor recess. If rotors are below face of . . . . . . . . . . . . . . . . . . . . . (0.0039 - 0.0067 in.)
pump housing more than wear limit, replace
rotor assembly. Wear Limit. . . . . . . . . . . 0.25 mm (0.0098 in.)
Feeler Gauge clearance is more than wear limit, replace rotor
Straight Edge assembly.
Feeler Gauge
Inner Rotor
Housing
Outer Rotor M37775
Rotor Recess - 4TN78T:

Standard . . . . . . . . . . . . . . . . . 0.05 - 0.10 mm Outer Rotor M37777
. . . . . . . . . . . . . . . . . . . . . (0.0020 - 0.0039 in.)

Wear Limit. . . . . . . . . . . 0.15 mm (0.0059 in.)
4/7/95 3-65
Lubrication System
Inner-to-Outer Rotor Clearance - 4TN78T: 3. Disconnect coolant hoses.

Standard . . . . . . . . . . . . . . . . . 0.02 - 0.04 mm 4. Remove mounting bolt, oil cooler and o-rings.
. . . . . . . . . . . . . . . . . . . . . (0.0008 - 0.0016 in.) 5. Remove three cap screws, oil filter mounting
Wear Limit. . . . . . . . . . . 0.15 mm (0.0059 in.) block and gasket.
NOTE: See OIL PRESSURE REGULATING VALVE
Inner-to-Outer Rotor Clearance - 4TN82, if service is necessary.
4TN84(T)(4019):
Standard . . . . . . . . . . . . . . . . 0.05 - 0.105 mm necessary.
. . . . . . . . . . . . . . . . . . . . . (0.0019 - 0.0041 in.) NOTE: Oil cooler bypass valve components are not
Wear Limit. . . . . . . . . . . 0.15 mm (0.0059 in.) seviced seperately. Bypass valve and
mounting block are replaced as an
assembly. Remove parts only to inspect for
OIL COOLER - 4TN78T AND 4TN84T wear or damage.
(4019TF001 and 005) 7. Pressure test oil cooler. (See Checks, Tests and
3 NOTE: 4TN84T(4019TF001 and 005):
Approximate cooling system capacity is Installation is done in reverse order of removal.
4.7L (4.9 qt).
• Close drain valve and fill radiator with proper
1. 4TN84T(4019TF001 and 005): Drain cooling coolant to top of filler neck. (See
system. SPECIFICATIONS AND GENERAL
2. Remove oil filter. INFORMATION section.)
Oil Pressure
Regulating Valve
Mounting Block Oil Cooler

By-Pass Valve
O-Rings
Replace.
Gasket
Plug
Apply Pipe Sealant
with TEFLON.
Mounting Stud
Mounting Bolt
30 N•m (22 lb-ft)
Oil Filter
O-Ring
Cap Screw (3)
Oil Cooler M8 x 65
27 N•m (20 lb-ft) M82217A
3-66 4/7/95
Lubrication System
OIL PRESSURE REGULATING OIL PRESSURE REGULATING

VALVE - 4TN78T AND 4TN84T VALVE - 4TN82, 4TN84 (4019DF)
(4019TF001 and 005) AND 4TN84T (4019TF006)
Removal/Installation Removal/Installation
• Inspect all parts for wear or damage. Replace as 1. Remove oil filter.
necessary.
gasket.
Plug NOTE: If adjusting engine oil pressure, retaining

Copper Washer nut need not be removed.
Replace.
3. If adjusting pressure only, remove cap and add
Shims
Spring
NOTE: Valve components are not serviced
Valve individually. Replace complete regulating
valve if any components are defective.
3
4. Inspect all parts for wear or damage. Replace
complete valve if necessary.
5. Check spring free and compressed length.
3
Free Length . . . . . . . . . . . . .46 mm (1.810 in.)
. . . . . . . . . . . . . . . . . . @ 20.5 N (4.6 lb-force)
M82218A
4/7/95 3-67
Lubrication System
Cap
Stake to
valve body.
O-Ring
Replace.
Gasket
Housing
Shims
Retaining Nut
30 N•m (22 lb-ft) Spring
Valve
Oil Filter
Valve Body
3
Cap Screw (3)
M8 x 20
27 N•m (20 lb-ft) M82219A
PISTON COOLING NOZZLES - 4TN78T

AND 4TN84T
Piston
(4019TF001 and 005) Cooling
Nozzle
Replacement
1. Remove oil pan and strainer. (See procedure in
this group.)
• Install nozzle with locating pin in locating hole
Mounting Bolt
of cylinder block. 15 N•m (130 lb-in.) M51580
Locating Pin
M51581
3-68 4/7/95
Cooling System
OTHER MATERIALS
Number Name Use
LOCTITE® PRODUCTS
U.S./
Canadian/
LOCTITE No.
TY9375/ John Deere Pipe Sealant 4TN78T, 4TN82RJE, 4TN82ESP and
TY9480/ with TEFLON® 4TN84(T)(4019): Apply to threads of
#592 plug and nipple in thermostat housing
and pipe plug in water pump housing.

4/7/95 3-69
Cooling System
COOLANT TEMPERATURE SWITCH THERMOSTAT AND HOUSING -

Replacement 4TN78T, 4TN82RJE, 4TN82ESP AND
4TN84(T) (4019)
NOTE: Some engines may also be equipped with a
coolant temperature sender. Sender is
located opposite of switch in thermostat 2. Remove upper radiator hose, if equipped.
3. Disconnect coolant temperature switch/sender
same.
wiring lead(s).
4. Loosen alternator-to-bracket mounting cap screw.
3. Remove switch and washer. to-water pump hose.
4. Test switch. (See Checks, Tests and Adjustments 6. Remove mounting cap screws, housing and
in this section.) gasket.
Installation is done in reverse order of removal. 7. Inspect all parts for wear or damage. Replace as
necessary.
3 Coolant Temperature
Copper 8. Test thermostat. (See Checks, Tests and
Washer Thermostat
Switch Replace. Housing
M82220A
Cap Screw (2)

Gasket Plate M8 x 20
Replace. 20 N•m (180 lb-in.) Cover
Gasket Alternator Slide
Replace. Bracket
Copper Washer Thermostat

Replace. Copper Washer
Gasket Replace.
Replace.
Cap
Cap Screw (2)

M6 x 16 Mounting Cap
9 N•m (78 lb-in.) Gasket Screw
Replace. M8 x 60
26 N•m (226 lb-in.)
Plug Nipple
Apply Pipe Sealant with Apply Pipe Sealant
TEFLON to threads. Housing with TEFLON to threads.
Mounting Cap Screw Mounting Cap Screw Water Pump Hose
M8 x 25 M8 x 50
26 N•m (226 lb-in.) 26 N•m (226 lb-in.) M82221A
3-70 4/7/95
Cooling System
THERMOSTAT - 4TN82RJK AND

Pulley Plate
4TN84RJK 4TN78T, 4TN82RJE, 4TN84RJK Only
Cap Screw
11 N•m (96 lb-in.)
Cap Screw (2)
M8 x 20
20 N•m (180 lb-in.)
Cover
M82294A
Cover
Gasket 4. Remove lower radiator hose, if equipped.
Thermostat 5. Loosen clamps and remove thermostat housing-
to-water pump hose.
6. Remove three mounting cap screws, pump and
Gasket
gasket. 3
M82222A
Water Pump Water Pump Hose
WATER PUMP - 4TN78T, 4TN82RJE,
4TN82ESP AND 4TN84(T) (4019)
2. Remove fan/alternator belt. Gasket
Replace.
3. 4TN78T, 4TN82RJE, 4TN82ESP, 4TN84RJK:
Remove fan, plate, if equipped, and pulley.
4TN84(T) (4019): Remove cooling fan. (See Mounting Cap Screw (3)
procedure in ACCESSORIES - SERIES 220 M8 x 60
M82223A
26 N•m (226 lb-in.)
4/7/95 3-71
Cooling System
Disassembly
1. Apply heat to three plate-to-housing screws.
Remove screws, plate and gasket

15 N•m (134 lb-in.)
Plate
Pipe Plug
Plug Apply Pipe Sealant with
Gasket
Replace.
3 Impeller
Seal Cup and

Ceramic Seal
Replace.
Shaft Seal
Replace.
Water Pump
Housing
Bearing
Shaft
Pulley
Flange M82224A
Two Small Nuts
Pulley Flange
Knife-Edge impeller bore to prevent cap screw from
Puller Set binding.
Water Pump knife-edge puller, a 3/8 in. cap screw and a press.
Housing
M35645
necessary.
3-72 4/7/95
Cooling System

4TN82RJE and 4TN82ESP: Press impeller on
2. Install new shaft seal over impeller side of bearing shaft until top of impeller is 1 mm (0.040
bearing shaft, rubber seal side away from pump in.) below housing.
it stops, using a 25 mm or 1 in. socket and a 4TN78T and 4TN84(T)(4019): Press impeller on
press. bearing shaft until top of impeller is 2 mm (0.080
in.) below housing.
hub facing away from housing. 3
4TN82RJE and 4TN82ESP: Press pulley flange onto
bearing shaft until top of flange is 27 mm (1.060
in.) from top of housing.
4TN78T and 4TN84(T)(4019): Press pulley flange M37905
onto bearing shaft until bottom of flange is 17 mm

(0.670 in.) from top of housing. 6. Install new gasket, plate, three screws, two cap
screws and nuts. Tighten to specifications.
surface of ceramic seal with bare hands. It
4. Install seal cup and ceramic seal in impeller.
4/7/95 3-73
Cooling System
WATER PUMP - 4TN82RJK AND 3. Remove four cap screws, fan, spacer and pulley.
4TN84RJK 4. Remove four mounting cap screws, pump and
gasket.
1. Open engine drain valve to drain coolant. Disassembly/Assembly procedures.)
2. Remove fan/alternator drive belt. Installation is done in the reverse order of removal.
Gasket
Replace. Mounting Cap Screw (3)
M8 x 55
26 N•m (226 lb-in.)
O-Ring Pulley
Replace.
3
Water Pump Fan
Mounting Cap Screw

M8 x 60
26 N•m (226 lb-in.)
Spacer
Cap Screw (4)

M6 x 25
1 N•m (96 lb-in.)1 M82225A
3-74 4/7/95
Cooling System
Disassembly 3. Remove two cap screws, adapter and gasket.

1. Remove thermostat. (See procedure in this 4. Apply heat to six plate-to-housing cap screws.
group.) Remove cap screws, plate and gasket.
2. Remove coolant temperature switch. (See
Plate-to-Housing Cap Screw

9 N•m (78 lb-in.)
Plate
Gasket
Replace.
Plate-to-Housing Cap Screw (5)
M6 x 14 Cap
9 N•m (78 lb-in.)
Shaft Seal 3
Replace.
Copper
Washer
Adapter Replace.
Gasket
Replace.
Impeller
Pulley
Seal Cup and Flange
Ceramic Seal
Replace.
Bearing
Shaft
Water Pump
Housing
M6 x 20
9 N•m (78 lb-in.) M82226A
Two Small Nuts
Pulley Flange
Knife-Edge enough clearance between cap screw and
Puller Set impeller bore to prevent cap screw from
binding.
Water Pump
Housing
M35645
4/7/95 3-75
Cooling System
7. Remove impeller from bearing shaft using a 4. Install seal cup and ceramic seal in impeller.
knife-edge puller, a 3/8 in. cap screw and a press. 5. Install a knife-edge puller around bearing shaft,
8. Remove shaft seal, ceramic seal and seal cup. between pulley flange and pump housing. Place
pump housing, with knife-edge puller down, on a
press table. Install impeller with ceramic seal
necessary.
toward shaft seal.
Assembly 4TN82RJK: Press impeller on bearing shaft until top
of impeller is 1 mm (0.040 in.) below housing.
1. Install bearing shaft into pump housing, long end
down, using a piece of pipe or deep socket and a 4TN84RJK: Press impeller on bearing shaft until top
press. Press shaft into pump housing until bearing of impeller is 2 mm (0.080 in.) below housing.
press.
3
3. Place water pump housing on a press table. M37906
disk. Install pulley flange onto shaft with straight 6. Install new gasket, plate and six cap screws.
hub facing away from housing. Tighten to specifications.
4TN82RJK: Press pulley flange onto bearing shaft 7. Install new gasket, adapter and cap screws.
until top of flange is 27 mm (1.060 in.) from top of Tighten to specifications.
housing.
8. Install coolant temperature switch. (See
4TN84RJK: Press pulley flange onto bearing shaft procedure in this group.)
until bottom of flange is 17 mm (0.670 in.) from
top of housing. 9. Install thermostat. (See procedure in this group.)

3-76 4/7/95
Fuel System

SERVICE PARTS KITS

4/7/95 3-77
Fuel System
FUEL SUPPLY PUMP - IF EQUIPPED
Replacement
NOTE: 4TN78T, 4TN82RJE and 4TN82ESP
engines are not equipped with a fuel supply
pump. Fill Plug
Oil will leak out of fuel injection pump

housing when supply pump is removed.
IMPORTANT: If oil has been drained out of fuel Supply Pump-to-
injection pump housing, add oil as necessary. Filter Hose
Fuel injection pump can become damaged if
operated dry or without proper amount of oil.
Fuel Supply Pump
After fuel supply pump is installed, disconnect
external lube line to fuel injection pump housing. External Lube Line
Tighten mounting bolt to
Remove fill plug and add clean engine oil to 15 N•m (130 lb-in.)
3 housing. Add until oil begins to drip out of lube line
hole (For proper oil specification see M82227
3
Lock Washer (2)
Fill Plug
Packing
Replace.
Mounting Nut (2)

11 N•m (96 lb-in.)
Fuel Supply Pump
M82228A
3-78 4/7/95
Fuel System
FUEL FILTER ASSEMBLY - IF IMPORTANT: Replace all copper washers.

EQUIPPED Damaged or used washers may leak.
NOTE: Fuel filter assemblies will be slightly

different for each engine model
depending on engine application.
4TN84(T) (4019 OEM) shown.
End Cap
Shutoff Valve Mounting Base
Spring O-Ring
O-Ring
Filter
Element
Spring
Shutoff
3
Lever O-Ring
Filter
Mounting Cover
Cap Screw
End Cap Nozzle Leak-Off Hose
(Short) (3)
Retaining
Ring
Fuel Filter-to-
Injection
Pump Hose
Injection Pump
Bleed-Off Hose
* *
Nozzle Leak-Off
Hose (Long)
Fuel Supply *
Pump-to-Filter
Hose
*Copper Washers
Replace. Air Vent
*
Check Valve
*
M82134A
4/7/95 3-79
Fuel System

pump.
cardboard. Protect hands and body from 3. Loosen line clamp(s) and remove fuel injection
high pressure fluids. lines.
If an accident occurs, see a doctor 4. Disconnect hoses to/from fuel filter, if equipped.
3 hours or gangrene may result. Doctors 6. Disconnect fuel shutoff solenoid link.
reference a knowledgable source. Such 7. Note position of timing marks on injection pump
information is available from the Deere & and gear cover mounting plate.
3 Illinois, U.S.A.
8. Remove three mounting nuts.
Fuel Injection Line Fuel Injection

Connectors (4) Lines
Nozzle Leak-Off
Line Clamp(s) Hose
Delivery
Valve (4)
Fuel
Filter-to-Injection
Pump Hose
Fuel Shutoff
Solenoid Link

Lube Line
M82229
3-80 4/7/95
Fuel System
DO NOT attempt to service the injection pump or

governor. If unit is in need of repair, it must be
serviced by a qualified fuel injection repair shop. If
Timing Marks
Installationl
1. Install new o-ring on injection pump.
Mounting
Nut (3) 2. Put injection pump onto back of gear cover
mounting plate. Align key on shaft with keyway
in gear. Be sure to align marks on gears made
M82230 during removal.
9. Remove fan guard, if equipped. 3. Install lock washer and nut. Tighten to
specification.
10.Remove four cap screws, washers, cover and
gasket.
11.Use chalk or paint to mark injection pump gear to
idler gear. Nut and Lock 3
Washer
12.Remove nut and lock washer. M12 Chalk/Paint
90 N•m (66 lb-ft) Marks
Nut and Lock

Washer
Chalk/Paint
Marks M82231
4. Install new gasket, cover, four washers and cap

screws.
5. Install fan guard, if equipped.
M82231
6. Install three mounting nuts. Do not tighten.
13.Pull gear from injection pump shaft using a two 7. Align marks on mounting plate and injection
jaw puller. pump, to same place as when removed, and
tighten mounting nuts to specifications.
Timing Marks
Mounting
Nut (3)
26 N•m (19 lb-ft)
M37794
M82230
14.Remove injection pump and o-ring.
8. Connect fuel shutoff solenoid link.
4/7/95 3-81
Fuel System
10.Install fuel injection lines and tighten line clamp 12.Install external lube line. When installing line,
cap screws. put one copper washer between mounting bolt
IMPORTANT: If oil has been drained out of fuel line and housing.
Fuel injection pump can become damaged if If new injection pump is being installed, check and
operated dry or without proper amount of oil. adjust injection pump static timing. (See Checks,
11.Remove fill plug and add clean engine oil to
external lube line inlet. (For proper oil
specification see SPECIFICATIONS AND
Fuel Injection Line Fuel Injection

3
Nozzle Leak-Off
Line Clamp(s) Hose
3
Delivery
Valve (4)
Fuel
Filter-to-Injection
Pump Hose
Fuel Shutoff
Solenoid Link
Oil Fill Plug
Lube Line-to-Block
Bolt
25 N•m (217 lb-in.)

Lube Line
M82229
3-82 4/7/95
Fuel System

(HOLE-TYPE) Retaining Plate
Hose Clamp
Nut (2) Leak-Off Hose
IMPORTANT: Never steam clean or pour cold 5 N•m
water on injection pump while the pump is (39 lb-in.)
pump. Injection
Nozzle
1. Clean the injection pump lines and area around Ring
Heat
cleaner. Protector
Replace.
CAUTION
Escaping fluid under pressure can penetrate 3
disconnecting hydraulic or other lines. M82092A
pressure. Search for leaks with a piece of If nozzles are stuck in cylinder head:
cardboard. Protect hands and body from
high pressure fluids. • Grind the head of a cap screw so it fits inside a
nut from an old injection line.
If an accident occurs, see a doctor
immediately. Any fluid injected into the skin • Use two nuts to attach a large flat washer to the
must be surgically removed within a few cap screw.
hours or gangrene may result. Doctors • Install assembly onto nozzle and use a puller and
unfamiliar with this type of injury should slide hammer to pull nozzle from cylinder head.
Company Medical Department in Moline, Large Nuts
Illinois, U.S.A. Flat
Washer
NOTE: Nozzles are matched to the cylinders. If Cap Screw
removing more than one nozzle, tag nozzles, Old Injection
according to the cylinder from which it was Line Nut
removed. Injection
Nozzle
2. Loosen fuel injection line connectors-to-nozzles
slightly to release pressure in the fuel system.
M82126
3. Loosen line clamp(s) and remove fuel injection
lines.
4. Remove clamps and leak-off hoses. Adjustments in this section.)
5. Remove nuts and retaining plates. Installation is done in reverse order of removal.
6. Remove injection nozzle, ring and teflon heat
protector. If ring and protector stay in cylinder
from cylinder head.
4/7/95 3-83
Fuel System
Disassembly/Assembly Cross Section

another. Injector
Body
this section.) Fuel Return
Pipe
Shim
3 Injector Body (as required)
Spring
3 Shims (as required)
Spring
Spring Seat Spring Seat

Index Pin (2)
Separator Plate
Separator Plate
Nozzle Valve
Index
Pin (2) Retaining Nut
Nozzle Body
Retaining Nut Nozzle Valve
43 N•m (31 lb-ft)
Nozzle Body
M82093A M37684
3-84 4/7/95
Fuel System

1. Remove anti-corrosive grease from new or performing a slide test. Use the following
reconditioned nozzles by washing them procedure:
IMPORTANT: Never use a steel brush to clean valve in nozzle body.
nozzles as this will distort the spray hole. • Hold nozzle vertical, and pull valve out about
2. Remove carbon from used nozzles, and clean by 1/3 of its engaged length.
washing in diesel fuel. If parts are coated with • Release valve. Valve should slide down to its
hardened carbon or lacquer, it may be necessary seat by its own weight.
Cleaning Kit). Replace nozzle assembly if the valve does not slide
freely to its seat.
3. After removing carbon or lacquer from the 3
nicks or scratches. Nozzle Valve

body. Contact area of separator plate (both parts) Piston Part of
must not be scored or pitted. Use an inspection Nozzle Valve
making the inspection. Nozzle Body
M82095A
Nozzle Contact Index Pin

Surface
Separator
Nozzle Body
M82094A
4/7/95 3-85
Starter
STARTER IDENTIFICATION CHART

The various starters covered in this group are Field Coil Brush (2)
identified by manufacturer and output rating.
To help identify the starters, measure the outside
diameter of the motor.
M82232
3 Manufacturer Rated Output Motor Outside Diameter

Hitachi 0.8 kW N/A
Hitachi 2.0 kW 80 mm (3.150 in.)
3 Nippondenso 1.0 kW 68 mm (2.680 in.)
3-86 4/7/95
Starter
STARTER - HITACHI 0.8 kW 8. Remove brush holder.
Disassembly/Inspection Negative
Brush
Brush Spring
2. Remove two cap screws and two screws from rear
cover.
3. Pry off plastic cap.
4. Remove e-clip, shims and rear cover.
Field
Field Lead
Coil Brush (2) M37875
9. Remove field coil housing from armature/

solenoid assembly.
3
Rear Cover
Cap
E-Clip
3
Shims
M37923
5. Inspect cover bushing for wear or damage.

Field Coil Housing M37876
To replace bushing: 10.Remove two cap screws and pivot bolt, if
Remove bushing using a blind-hole puller set. Install equipped.
new bushing until it bottoms in cover bore using a
11.Remove dust cover.
driver set.
12.Remove solenoid and armature assemblies from
Ream out bushing to 12.50 - 12.53 mm (0.492 -
end frame.
0.493 in.).
Cap
Screw (2) End Frame
Armature
Assembly
Rear Cover
Bushing
M37874

Dust
7. Pry brush springs away and pull negative brushes Cover
up enough to allow spring to hold brush in place. Solenoid Assembly
M37877
4/7/95 3-87
Starter
13.Inspect end frame bushing for wear or damage.

Spring
Solenoid
Shims
Plunger
Clutch Fork
Pivot
M37880
End Frame
Bushing M37830
Assembly
3 14.Slide pinion stopper away from retaining wire
using a piece of pipe or deep socket. Remove
disassembly.
assembly from armature shaft. • After installing clutch assembly, pinion stopper
and retaining wire on armature shaft, use two
3 15.Inspect clutch assembly for wear or damage. pliers to press pinion stopper over retaining
Gear should rotate in one direction only. Replace wire.
if necessary.
Armature
Shaft
Retaining
Wire Retaining
Wire
Pinion
Stopper
Clutch
Assembly
M37831
• When installing solenoid and armature

Pinion Clutch assemblies into end frame, make sure fork pivot
Stopper Assembly seats in notch on clutch fork.
M37879
16.Remove clutch fork pivot, plunger, spring and

shim(s) from solenoid.
necessary.
18.Inspect and test brushes, holder, field coil and
armature. (See Test procedures.)
3-88 4/7/95
Starter

light.
Notch other probe to field coil housing. Be sure the
brush lead is not touching the frame. If there is
continuity, the coil is grounded and the field coil
Fork Pivot housing assembly must be replaced.
Touch one probe of tester to each field coil brush.
M37881
IMPORTANT: When installing rear cover, be Field Coil Brush

brush wires. Press wires inward to clear rear 3
cover.
Test
3
is below minimum.
NOTE: Test brush holder using an ohmmeter or test Field Coil
light. Housing
2. Test brush holder: M82235

Touch one probe of tester to negative brush
holder and other probe to field brush holder. If IMPORTANT: Do not clean armature with
there is continuity, replace the brush holder. solvent. Solvent can damage insulation on
3. Inspect springs for wear or damage. Replace if windings. Use only mineral spirits and a
necessary. brush.
against pole shoes.
Spring (4)
Negative Brush 7. Inspect commutator. Look for roughness, burned
Holder bars, or any material which might cause short
finished.
or test light.
Field Brush Brush Length Touch probes on one commutator bar and
Holder armature shaft. Armature windings are connected
M82234
checked.
4/7/95 3-89
Starter
If test shows continuity, a winding is grounded and STARTER MOTOR - HITACHI 2.0 kW
9. Test for open circuited windings: Disassembly
Touch probes on two different commutator bars.
If test shows no continuity, there is an open circuit
2. Remove rear cover.
and the armature must be replaced.
Commutator Bars
Armature Shaft
3 M82246 Cap Screw (2) Rear Cover
10.Test for short circuited windings using a growler. Screw (2) M82096
3 blade above each slot while slowly rotating 3. Remove field coil brushes from brush holder.
armature.
If coil is shorted, the blade will vibrate on the slot. up enough to allow spring to hold brush in place.
NOTE: A short circuit most often occurs because of 5. Remove brush holder.
Hacksaw Blade
Brush Spring (2)
Armature
Brush Holder
Negative Brush (2)

Growler M82125A
M82097
6. Disconnect wiring lead.

7. Remove field coil housing, armature and seal
ring, if equipped.
3-90 4/7/95
Starter

Spring (4)
Seal Ring
If equipped Negative Brush
Holder
Field Coil
Housing
Field Brush
Holder
Brush
Length
Wiring Lead
M82099 3
Armature
M82098 NOTE: Test field coil using an ohmmeter or test
light.
3
Assembly Touch one probe of tester to field coil brush and
Assembly is done in the reverse order of other probe to field coil housing. Be sure the
disassembly. brush lead is not touching the frame. If there is
continuity, the coil is grounded and the field coil
housing assembly must be replaced.
rear cover.
IMPORTANT: When installing rear cover, be Touch one probe of tester to each field coil brush.
sure field coil brush wires do not touch cover. If there is no continuity, the field coil is open and
Turn brush holder slightly to take up slack in the field coil housing assembly must be replaced.
cover.
Field Coil Brush
Minimum brush length is 9 mm (0.354 in.).
is below minimum.
light. Field Coil
Housing
Touch one probe of tester to negative brush
there is continuity, replace the brush holder.
necessary. M82100
4/7/95 3-91
Starter
IMPORTANT: Do not clean armature with NOTE: A short circuit most often occurs because of
solvent. Solvent can damage insulation on copper dust or filings between two
windings. Use only mineral spirits and a commutator segments.
brush.
6. Inspect armature. Look for signs of dragging the commutator of dust and filings. Check the
against pole shoes. armature again. If the test still indicates a short
circuits between bars. If necessary, clean and Hacksaw Blade
finished.
Armature
or test light.
Touch probes on one commutator bar and
3 armature shaft. Armature windings are connected Growler M82125A
checked.
If test shows continuity, a winding is grounded wear or damage. Replace if necessary.
3 and the armature must be replaced.
9. Test for open circuited windings: Bearings are press fit. Remove bearings using a
Touch probes on two different commutator bars. knife-edge puller set.
If test shows no continuity, there is an open
circuit and the armature must be replaced. IMPORTANT: Install both bearings with sealed
Commutator Bars
Rear Cover Bearing
Housing Bearing
Armature Shaft
M82101

blade above each slot while slowly rotating M82102
armature.
3-92 4/7/95
Starter
STARTER OVERRUNNING CLUTCH - 6. Remove ring, retainer, spring, clutch assembly

HITACHI 2.0 kW and clutch shaft from clutch housing.
Disassembly necessary.
2. Remove two cap screws. Clutch Shaft
3. Remove starter motor assembly.
Clutch Assembly
Wiring Lead
Spring
3
Ring Clutch Housing
Cap Screw (2)
Starter Motor
Assembly Retainer 3
M82096
M82104
4. Remove three cap screws.

5. Separate clutch housing assembly from starter Assembly
housing. Remove gasket.
disassembly.
Gasket Clutch Housing • Apply multipurpose grease to all internal
Assembly
components during assembly.
Starter
• Install retainer with large cupped side toward
Housing clutch assembly.
STARTER SOLENOID - HITACHI

2.0 kW
Cap Screw (3)
Disassembly
M82103 1. Disconnect wiring lead.
2. Remove cap screws.
3. Remove starter solenoid assembly.
4/7/95 3-93
Starter
• Pull clutch shaft away from housing and insert

Wiring Lead clutch arm in starter housing. Push arm in until it
stops.
Clutch Shaft
Clutch Arm
Starter Solenoid
Assembly Cap Screws
M82105
4. Remove clutch arm, clutch arm pivot, plunger M82107

3 and shim(s), if equipped, from solenoid.
necessary.
1.0 kW
3
Solenoid
Disassembly
Plunger
Clutch Arm 2. Remove two cap screws and two screws.
Pivot
Field Lead
Shim(s)
If equipped.
Clutch Arm M82106 O-Ring
Assembly
Screw (2)
disassembly. Rear Cover
M82233
components during assembly. Cap Screw (2)
IMPORTANT: Make sure long end of clutch arm 4. Remove field coil brushes from brush holder.
is installed all the way into starter housing.
Clutch arm must be install on end of clutch
shaft or starter will not operate.
3-94 4/7/95
Starter
Brush Spring
is below minimum.
Brush Holder light.
M36754
7. Remove armature from field coil housing. continuity, replace the brush holder.
8. Remove felt washer and o-ring, if equipped. 3. Inspect springs for wear or damage. Replace if
necessary.
Spring (4)
Negative Brush
3
Felt Washer Holder
Armature
Field Coil Housing
3
O-Ring Brush
M36759 Length
Field Brush
Holder
Assembly M82234

disassembly.
light.
rear cover and felt washer, if equipped.
IMPORTANT: When installing rear cover, be other probe to field coil housing. Be sure the brush
sure field coil brush wires do not touch cover. lead is not touching the frame. If there is continuity,
Turn brush holder slightly to take up slack in the coil is grounded and the field coil housing
brush wires. Press wires inward to clear rear assembly must be replaced.
cover.
4/7/95 3-95
Starter
Field Coil Brush
Commutator Bars
Field Coil
Housing
Armature Shaft
M82236

M82235
3 blade above each slot while slowly rotating
armature.
solvent. Solvent can damage insulation on If coil is shorted, the blade will vibrate on the slot.
windings. Use only mineral spirits and a NOTE: A short circuit most often occurs because of
3 brush. copper dust or filings between two
6. Inspect armature. Look for signs of dragging commutator segments.
against pole shoes. 11.If test indicates short circuited windings, clean
7. Inspect commutator. Look for roughness, burned the commutator of dust and filings. Check the
bars, or any material which might cause short armature again. If the test still indicates a short
circuits between bars. If necessary, clean and circuit, replace the armature.
Hacksaw Blade
finished.
or test light. Armature
Growler
If test shows continuity, a winding is grounded and M82125A

9. Test for open circuited windings: wear or damage. Replace if necessary.
Touch probes on two different commutator bars. If To replace bearings:
the armature must be replaced. Bearings are press fit. Remove bearings using a
3-96 4/7/95
Starter

shaft using a piece of pipe. Clutch Housing-to-
Solenoid Housing
Screws
Rear Cover Bearing
Housing Bearing
M82238
2. Separate clutch housing from solenoid/motor

assembly.
3. Remove plunger spring and gear, if equipped.
Plunger Spring 3
M82237
STARTER GEAR TRAIN AND 3

OVERRUNNING CLUTCH -
NIPPONDENSO 1.0 kW
1. Remove two motor-to-clutch housing cap screws Gear
and two clutch housing-to-solenoid housing Clutch Housing
screws. M82239
Motor-to-Clutch NOTE: Starter is equipped with either a 33 mm

Housing Cap Screws (1.299 in.), 44 mm (1.732 in.) or 44.5 mm
(1.752 in.) drive gear on end of clutch shaft.
different.
6. Remove steel ball.
M82233
4/7/95 3-97
Starter
11.Starter with 33 mm (1.299 in.) drive gear:

Steel Ball
assembly.
Clutch Assembly Starter with 44 mm (1.732 in.) or 44.5 mm (1.752
in.) drive gear: Remove drive gear, spring and clutch
assembly from housing.
Pinion Gear
Clutch Housing
Clutch Assembly
Sarter with 44 or 44.5 mm
(1.732 or 1.752 in.)
drive gear only.
Roller (5)
Drive Gear
Retainer
M82240

3 vice, as shown.
Spring
8. Tighten vise slowly, until drive gear compresses. Retainer
9. Remove retainer and circlip. Circlip
3 M82242
Retainer 12.Remove washer, toothed washer, spring and

clutch shaft.
Circlip
necessary.
Clutch Shaft
Spring
Starter with 44 or 44.5
(1.732 or 1.752 in.)
Drive Gear Shown
M82241
CAUTION Clutch
Toothed Washer
with considerable force if spring is not Large Washer
allowed to extend fully while in vise. M82243
3-98 4/7/95
Starter
Assembly
Contact Plates
disassembly.
• Apply multipurpose grease to bearings, clutch
shaft, springs, pinion gears, retainer, rollers and
steel ball.
assembly. Spring
Plunger
• Install retainer with cupped side away from
clutch assembly.
Copper Washer
STARTER SOLENOID - M82245

NIPPONDENSO 1.0 kW
3
1. Disconnect field lead. Terminal Bolt
2. Remove three screws and clip.

Nut 3
Washer
Field Lead
Clip
Contact Plate
O-Ring
Insulator M36771
Assembly
Screw (3) M82244
disassembly.
4. Remove plunger.
5. Disassemble terminals. Remove parts from each NOTE: The assembly sequence of the left and right
terminal in order shown. terminals is similar. Be sure solenoid
terminal lead is installed between terminal
6. Inspect copper washer and contact plates for bolt and contact plate. Also, be sure smaller
excessive burning or pitting. Clean burnt areas to contact plate is on the left side.
improve electrical contact. Replace contacts or
plunger if necessary. The solenoid is not
serviceable. If defective, replace solenoid
housing assembly.
4/7/95 3-99
Starter

Solenoid Terminal
Lead
Brush Spring (2)
Terminal Bolt
Small Contact
Plate M36771 Brush Holder
Negative Brush (2)

3 1.4 kW M82097

Disassembly equipped.
3 1. Remove two cap screws and two screws. 7. Remove field coil housing, armature and o-ring,
2. Remove rear cover and thrust washer, if if equipped.
equipped. 8. Inspect and test brushes, holder, field coil and
Seal Ring
If equipped
Field Coil
Housing
Thrust
Washer
Cap Screw (2) Rear Cover
Screw (2) M82096

Wiring Lead
up enough to allow spring to hold brush in place. Armature
5. Remove brush holder. M82098
3-100 4/7/95
Starter
Assembly Touch one probe of tester to field coil brush and

Assembly is done in the reverse order of lead is not touching the frame. If there is continuity,
disassembly. the coil is grounded and the field coil housing
• Apply multipurpose grease to bearing cup inside assembly must be replaced.
rear cover. 5. Test for open field coil:
IMPORTANT: When installing rear cover, be Touch one probe of tester to each field coil brush. If
sure field coil brush wires do not touch cover. there is no continuity, the field coil is open and the
Turn brush holder slightly to take up slack in field coil housing assembly must be replaced.
cover. IMPORTANT: Do not clean armature with
Inspection/Test/Replacement windings. Use only mineral spirits and a
brush.
Minimum brush length is 8.5 mm (0.335 in.). 6. Inspect armature. Look for signs of dragging
Replace brush holder or field coil if brush length against pole shoes.
is below minimum. 7. Inspect commutator. Look for roughness, burned
3
NOTE: Test brush holder using an ohmmeter or test circuits between bars. If necessary, clean and
light. touch up with 400 sandpaper. NEVER use emery
finished.
3
continuity, replace the brush holder. Field Coil Brush
necessary.
Spring (4)
Negative Brush Field Coil

Holder Housing
M82100
Field Brush
Holder NOTE: Test armature windings using an ohmmeter
Brush or test light.
Length
M82099 Touch probes on one commutator bar and armature
NOTE: Test field coil using an ohmmeter or test only one commutator bar needs to be checked.
light. If test shows continuity, a winding is grounded and
4. Test for grounded field winding: the armature must be replaced.
4/7/95 3-101
Starter
9. Test for open circuited windings: To replace bearings:

Touch probes on two different commutator bars. If Bearings are press fit. Remove bearings using a
test shows no continuity, there is an open circuit and knife-edge puller set.
Commutator Bars Install new housing bearing tight against shoulder of
Rear Cover Bearing
Housing Bearing

3
10.Test for short circuited windings using a growler. M82102
3 blade above each slot while slowly rotating STARTER GEAR TRAIN AND
armature. SOLENOID - NIPPONDENSO 1.4 kW
copper dust or filings between two 1. Remove two socket head screws, end cap and
commutator segments. shim(s).
End Cap
Hacksaw Blade
Shim(s)
Armature
M37820

Growler M82125A
equipped.
3. Remove two cap screws.
wear or damage. Replace if necessary. 4. Remove starter motor assembly from bearing
housing.
3-102 4/7/95
Starter
8. Remove two cap screws, plunger, spring, shims

and solenoid.
Wiring Lead
End Frame
Shim(s)
Solenoid
Cap
Assembly Cap Screw (2)
M82096
Plunger
Spring
5. Remove three cap screws. M37824
6. Separate end frame assembly from bearing 9. Remove shims from ring gear shaft.
housing. 3
End Cap Screw (3)

Frame
Assembly 3
Shims

10.Remove pivot bolt, clutch fork and clutch

7. Inspect seal and needle bearing for wear or assembly.
11.Inspect shoes on fork for wear or damage.
To replace needle bearing: Replace fork if necessary.
new bearing flush with housing surface using a Shoes
End Frame Clutch
driver set. Assembly
Bearing Housing
Pivot Bolt
Seal
Clutch Fork
M37825
Needle Bearing
M37823
4/7/95 3-103
Starter

flush with face of housing. Clutch
Snap Ring
Spring
Spring Cap
Washer M37829
End Frame
Bushing M37830 Assembly
13.Slide pinion stopper away from retaining wire Assembly is done in the reverse order of
using a piece of pipe or deep socket. Remove disassembly.
retaining wire, pinion stopper, and clutch • After installing clutch assembly, pinion stopper
3 assembly from ring gear shaft. and retaining wire on ring gear shaft, use two
14.Inspect all parts for wear or damage. Replace as pliers to press pinion stopper over retaining
necessary. wire.
3
Clutch Pinion
Assembly Stopper
Retaining Pinion
Wire Stopper
Retaining
Wire
Clutch
Ring Gear Assembly
Shaft
M37831
M37827
15.Remove snap ring, washer, spring cap, and spring

from clutch.
necessary.
3-104 4/7/95
Alternator
ALTERNATOR - KOKOSAN 20A 6. Inspect bearing in coil plate for wear or damage.
Disassembly/Inspection To replace bearing:
1. Remove nut and washers.
press. Install bearing into coil plate until it bottoms
2. Tap on end of shaft with a soft-faced hammer to in bore using a 1 in. socket.
separate flywheel assembly from coil plate
7. Remove wire clamp.
assembly.
8. Remove connector from harness leads.
9. Remove two screws and stator.
Lock Washer 10.Inspect all parts for wear or damage. Replace as
Washer
necessary.
Flywheel Assembly
Wire Clamp
Nut
27 N•m
(20 lb-ft)
Coil plate
3
Screw (2)
Coil Plate Assembly
Long Spacer
Bearing
M82247A Press fit in
coil plate.
Connector Stator
NOTE: Bearing and flywheel are press fit on shaft. M82249A
4. Remove shaft from bearing, short spacer, washer,

flywheel and sheave half, using a press. Assembly
necessary.
disassembly.
Short Spacer
• With sheave half on shaft, press shaft into
flywheel until sheave half bottoms on flywheel
Washer
face.
• With washer and short spacer installed, press
Flywheel new bearing onto shaft until it bottoms on
spacer.
Shaft
Bearing
Press fit on
shaft.
Sheave Half
M82248A

necessary.
4/7/95 3-105
Alternator
VOLTAGE REGULATOR -
HITACHI 25A
Attaching Screw (4)

M5
4 N•m (31 lb-in.)
Stator

Grommet M5
4 N•m (31 lb-in.)
Wire Clamp
Front Frame
End Frame
3 M82108
Replacement 17.Use a soldering gun with at least 120 watt

3 11.Remove three screws and cover. capacity to disconnect five terminals. Replace
voltage regulator.
12.Remove four attaching screws, wire clamp and • If additional solder is needed, use ONLY 60-40
13.Remove four end frame-to-rectifier nuts.
14.Remove two nuts and insulator. ALTERNATOR - HITACHI 25A
Disassembly
16.Remove two screws and insulator. 2. Remove four attaching screws, wire clamp and
grommet.

Terminals
M5
Regulator
Brush
Holder
Screw (2)
M51602
Grommet

Wire Clamp
M82108
3-106 4/7/95
Alternator

Stator Assembly
necessary.
Rotor Assembly M36730 3
Rear Bearing
Screw (3)
2 N•m (16 lb-in.)
Clip Bushing
Rotor
Spacer
Retainer
Nut
Front M14
Front
Frame
Fan
Sheave
Lock
Washer
M82109A
4/7/95 3-107
Alternator

in place.
Insulator
End
Frame Access Hole

3 M5
4 N•m (31 lb-in.) M51595

3 rectifier.
Inspection/Test
Rectifier
Rotor:
Leads (3)
M51605

Assembly
disassembly.
Slip Rings M82110A
(needle movement).
3-108 4/7/95
Alternator

Ohmmeter
this group.)
Rotor Shaft
Slip Rings M82111A

Brushes: Stator:
• Inspect brush holder and brushes for damage. • Inspect stator for defective insulation,
Brushes must slide freely and the springs must discoloration or a burned odor. If any of these
hold the brushes firmly against the slip rings of defects are found, replace stator.
the rotor.
NOTE: Use an ohmmeter that is sensitive to 3
limit line on brushes. Replace brushes as • Touch probes of an ohmmeter to lead wires of
necessary. stator in three possible combinations. Continuity
should read approximately 0.26 ohms. If
Brush Length
Ohmmeter
Rectifier
Voltage
Regulator
Stator
Brushes
M82113A

Ground
Stud Ohmmeter
Brush
Holder
Soldered
Connection
M82112
Stator
M82114A
4/7/95 3-109
Alternator
Rectifier: VOLTAGE REGULATOR -

• Test the diodes by touching probes to ground NIPPONDENSO 35A
• Switch the probes and check each terminal Replacement
again. There should be continuity in only one 1. Remove three attaching screws.
post.
Altaching Screw (3)
• Test the diodes by touching probes to output M5
4 N•m (31 lb-in.)
post.
in either direction. Replace the rectifier assembly if M36725
3 any of the three diodes are defective.
connection. 3. Remove nuts and insulators.
3 NOTE: If additional solder is needed, use ONLY 60-
M5
4 N•m (31 lb-in.)
Soldered
Connection
Nuts and Insulators

M36726

Outer Outer Do not separate stator from front frame.
Terminal Terminals
End
Frame
Output Ground
Post Post M82115
Stator
Front
Frame
M36727
3-110 4/7/95
Alternator
IMPORTANT: Do not heat connections longer IMPORTANT: Do not pry against stator wires.
2. Use a screwdriver to separate rotor assembly
capacity to disconnect terminals. Replace voltage
Stator Assembly
regulator.
Voltage Regulator
Rotor Assembly
Terminals M36730
M36728
3
Rotor Assembly:
rosin-core solder.
ALTERNATOR - NIPPONDENSO 35A 3. Put rotor assembly in a soft-jawed vise. Remove
Disassembly 4. Put front frame on open jaws of vice. Use a soft-
1. Remove three attaching screws. faced hammer to remove rotor and spacer.
Attaching Screw (3) washer and felt washer.
M5
4 N•m (31 lb-in.) 6. Inspect all parts for wear or damage. Replace as
necessary.
M36725
4/7/95 3-111
Alternator
Rear Bearing Fan

Sheave
Screw (3)
Washer
Front
Bearing
Rotor
Spacer
Retainer
3 Nut
M14
Felt Washer
3 Apply multipurpose grease
M82250A
Stator Assembly:
regulator.

M5
4 N•m (31 lb-in.)
Terminals
M36728

M36726
3-112 4/7/95
Alternator

from access hole.
Inspection/Test
Rotor:
M36739
13.Inspect and test brushes, stator and rectifier. (See Replace rotor if test indicates no continuity (no
Inspection/Test procedures.) needle movement).
Assembly
Ohmmeter
disassembly.
3
not evenly spaced. Rotate the rectifier until
the terminal pipes align with the stator
leads.
Rotor Shaft
• Bend the stator lead wires, as necessary, to
obtain an approximate distance of 33.50 mm Slip Rings M82110A
six leads using a soldering gun. • Touch the probes of the ohmmeter to the shaft
(needle movement).
Ohmmeter
Rotor Shaft
Wire
Brushes Slip Rings M82111A
Brushes:
M36748 the rotor.
4/7/95 3-113
Alternator

limit line on brushes. Replace brushes as Insulator
necessary.
• Use an ohmmeter or a test light to check for Brush Holder
should be no continuity. Replace brush holder- Brush
Ground Stud
Brushes Brush Lead
Wire
3
Insulating Washers
M36736
3 • To replace brushes:
M36745
- Melt solder from brush lead connections and - NOTE: If additional solder is needed, use ONLY 60-
remove brushes and springs. 40 rosin-core solder.
- Inspect springs for wear or damage. Replace as
necessary. Stator:
stator wires. Equal continuity readings should be
observed between each pair of leads. If readings
are not equal, replace stator.
M36737
- Push brush lead wire through spring. Insert

spring and brush in brush holder with lead
protruding through hole in brush holder. Make
sure the longest side of brush is on side of brush
holder with raised lip.
- Hold brushes in position so that exposed length
is 13 mm (0.500 in.)
excess length of brush lead wire. M36740
- Be sure insulating washers and insulator are in
place.
3-114 4/7/95
Alternator

Output Post
M36743

M36741 • Switch the probes and check each terminal
Rectifier: direction between each terminal and the ground
post. 3
a printed circuit in the rectifier. A shorted diode would have continuity in both
• Test the three inner terminals using an in either direction. Replace the rectifier assembly if
ohmmeter. Move probes so all terminals are any of the six diodes are defective.
cross checked. Replace the rectifier if test shows
no continuity.
Inner
Terminals Ground
Post
M36744
M36742
VOLTAGE REGULATOR -
NOTE: Each of the three outer terminals on the NIPPONDENSO 40A
direction. Replacement
• Test the diodes by touching probes to output 1. Remove nut and insulator.
post and the three outer terminals. 2. Remove three screws and cover.
post.
4/7/95 3-115
Alternator
Cover Nut
69 N•m (51 lb-ft)
Nut and
Insulator
Sheave
M52470 M52469
3. Remove two screws, brush holder and cover. 4. Remove four screws and straighten stator wire
leads.
3 Regulator Rectifier
Stator Wire
Lead (4)
3
Short
Screw
Brush Holder
and Cover M52472
M52471
IMPORTANT: Make sure to install short screw assembly.
frame and cause damage to the charging 7. Press rotor shaft from end frame.
system. 8. Remove spring washer.
ALTERNATOR - NIPPONDENSO 40A Spring

Washer
Disassembly
1. Remove voltage regulator. (See VOLTAGE
2. Remove nut.
End Frame
3. Remove sheave using a puller set. Assembly
Rotor
Shaft
M52473
3-116 4/7/95
Alternator
9. Remove four screws and retainer. • Touch the probes of an ohmmeter to slip rings.
NOTE: Front bearing is press fit in front frame. needle movement).
necessary. • Touch probes of ohmmeter to the rotor core and
10.Inspect bearing in front frame for wear or Replace rotor if test shows continuity (needle
damage. Replace if necessary. Replace bearing movement).
Rear Bearing
Front Frame
Front Bearing
Screw (4)
2 N•m (16 lb-in.)
Retainer
Rotor Core
Slip Rings
M52474
3
M52475
Brushes:
11.Inspect and test brushes, stator and rectifier. (See
Inspection/Test in this group.) • Inspect brush holder, brushes and springs for
must hold brushes firmly against the slip rings of
Assembly the rotor.
disassembly.
If length is less than wear limit, replace brushes.
Inspection/Test
Rotor:
that rotor assembly and bearing be replaced M52478
as a unit.
• Inspect bearing for wear or damage. Replace Brush Length Specifications
New. . . . . . . . . . . . . . . . . 10.50 mm (0.410 in.)
• Inspect slip rings for dirt build-up, rough spots Wear Limit. . . . . . . . . . . . 4.50 mm (0.170 in.)
or out-of-roundness. If necessary, polish the
surface of the slip rings using No. 00 sandpaper • Check continuity between brush and terminal
or 400-grit silicone carbide paper. Measure outer “A”. Check continuity between brush and
diameter of slip rings. Replace rotor if less than terminal “B”. There should be continuity only at
14 mm (0.550 in.). these points.
4/7/95 3-117
Alternator
Rectifier:
A B NOTE: Set the ohmmeter to the K ohm range.
• Check continuity between output post and each
recheck. There should be continuity in one
direction, but not the other.
M52479 A shorted diode would have continuity in both
Stator: in either direction. Replace the rectifier if any of the
Diode Lead (4)
3 • Check for continuity between each stator lead

and stator body. Replace stator if test indicates
continuity.
To replace stator:
3 - Scribe a mark on housing, at notch in stator, to
Output Post
M52477
aid in installation of a new stator.
- Remove two studs.
Stator
Lead (4)
Stator Body
Stud (2)

Housing
M82251
3-118 4/7/95
Diagnosis
PROBLEM OR


SYMPTOM


uses too much fuel.

noisy, vibrates or
stalls frequently.
or starts hard.
too much oil.

CHECK OR
is incorrect.
level high.
SOLU-
the oil.
TION

● ● ● ● ● ● ●
Replace. 3
Muffler or exhaust manifold leak. ● ● 3
timing incorrect.
● ●
connectors.
warped head.
● ● ● ● ● ●
load.
Test.
● ● ● ● ●
incorrect.
● ● ● ● ● ● ●
leaking.
● ● ● ● ● ● ● ● ●
damaged.
Turbocharger ● ●
4/7/95 3-119
Diagnosis

Conditions:

filter.
- Cooling System
3 Radiator screen free of debris. Clean or replace.
3 Fan belt tight, not glazed or cracked. Replace and adjust belt tension.
intake. tight.
- Air Intake System
Check
filter element.
position.)
3-120 4/7/95
Diagnosis

cable. correctly.
position - engine Adjustments in this section.) Replace 3
Machine TM.
11. Injector ports. Cylinder compression within Perform cylinder compression test. 3
specification.
TM.
Repair Shop.
4/7/95 3-121
VALVE CLEARANCE, CHECK AND Cylinders

ADJUSTMENT 1 2 3 4
Flywheel End
E I E I E I E I
Fan End
Reason:
Equipment:
No. 1 Piston at TDC
• Feeler Gauge T6479AB
Procedure: To adjust valves, loosen nut and turn adjusting screw

1. Remove rocker arm cover. while tightening nut.
2. Remove plug from timing hole on flywheel
housing.
NOTE: “Top Dead Center (TDC)” is the piston at Feeler
its highest point.
3 Gauge
3. Turn crankshaft pulley clockwise until No.1
mark on flywheel housing.
3
TDC Mark on
T6105BF
Flywheel
Index Mark on
Flywheel Housing This puts the piston in No. 4 cylinder at TDC
compression stroke.
7. Measure and adjust valve clearance on the valves
T6469AJ

Cylinders
4. Try to move both No. 1 cylinder rocker arms or 1 2 3 4
E I E I E I E I
push rods.
Flywheel End
Fan End
If rocker arm push rods are not loose, rotate

compression stroke.
No. 4 Piston at TDC
5. Measure and adjust valve clearance on the valves T6479AB
3-122 4/7/95
CONNECTING ROD SIDE PLAY Equipment:

CHECK • PLASTIGAGE®
Reason: Procedure:
the same direction to prevent crankshaft and
Equipment: connecting rod damage.
• Feeler Gauge 1. Remove connecting rod cap.
Procedure: 2. Wipe oil from bearing insert and crankshaft

journal.
between connecting rod cap and crankshaft. 3. Put a piece of PLASTIGAGE, or an equivalent,
PLASTIGAGE M35351
Feeler Gauge
4. Turn crankshaft approximately 30° from bottom
dead center.
M82116A
5. Install connecting rod end cap and original cap
screws. Tighten cap screws to:
Specifications: 4TN78T . . . . . . . . . . . . . . . . 39 N•m (29 lb-ft)
Standard Clearance . . . . . . . . 0.20 - 0.40 mm 4TN82, 4TN84(T)(4019) . . . 47 N•m (35 lb-ft)
. . . . . . . . . . . . . . . . . . . . . (0.0079 - 0.0157 in.)
6. Remove cap screws and connecting rod cap.
Wear Limit. . . . . . . . . . . 0.55 mm (0.0217 in.)
Results: on either the bearing insert or crankshaft
journal.
• If side play exceeds wear limit, replace
connecting rod and connecting rod cap. 7. Use the graduation marks on the envelope to
compare the width of the flattened
PLASTIGAGE at its widest point.
CLEARANCE CHECK the graduation marks indicates the bearing
Reason: which side of the envelope is used.
4/7/95 3-123
9. Remove PLASTIGAGE. 3. Zero the dial indicator.

Graduation Marks
on Envelope
Flattened
PLASTIGAGE M82117A
Specifications:
. . . . . . . . . . . . . . . . . . . . . (0.0015 - 0.0035 in.)
3 Dial Indicator
Wear Limit. . . . . . . . . . . 0.16 mm (0.0063 in.)
Crankshaft M82118A
Results: Specifications:
3 • If clearance exceeds wear limit, replace bearing Standard Clearance . . . . . . 0.090 - 0.271 mm
inserts. . . . . . . . . . . . . . . . . . . . . . . . (0.004 - 0.011 in.)
®PLASTIGAGE is a registered trademark of the DANA Wear Limit. . . . . . . . . . . 0.33 mm (0.0129 in.)
Corporation.
Results:
CRANKSHAFT, END PLAY CHECK • If end play exceeds wear limit, replace thrust
bearings.
Reason:
To determine proper side clearance between CRANKSHAFT MAIN BEARING,
crankshaft and engine block. CLEARANCE CHECK
Equipment: Reason:
• Dial Indicator To measure oil clearance between main bearing and

crankshaft journal.
NOTE: Crankshaft end play can be measured at • PLASTIGAGE®

front end or rear end of crankshaft.
Procedure is performed from the rear end. Procedure:
The flywheel is removed to show detail. IMPORTANT: Main bearing caps must be
1. Fasten dial indicator to engine and position installed on the same main bearing and in the
indicator tip on end of crankshaft. same direction to prevent crankshaft and main
bearing damage.
IMPORTANT: Do not use excessive force when
moving crankshaft to avoid damaging 1. Remove main bearing cap.
bearings. 2. Wipe oil from bearing insert and crankshaft
2. Push crankshaft toward rear as far as possible. journal.
3-124 4/7/95
3. Put a piece of PLASTIGAGE, or an equivalent, Specifications:

along the full length of the bearing insert Standard Clearance . . . . . . 0.038 - 0.090 mm
. . . . . . . . . . . . . . . . . . . . . (0.0015 - 0.0035 in.)
Wear Limit. . . . . . . . . . . 0.06 mm (0.0063 in.)
Results:
PLASTIGAGE
inserts.
ration.
VALVE LIFT CHECK

M35382
Reason:
cap screws to:
4TN78T . . . . . . . . . . . . . . . . 79 N•m (58 lb-ft)
followers, and/or push rods. 3
4TN82, 4TN84(T)(4019) . . . 98 N•m (72 lb-ft) Equipment:
5. Remove cap screws and main bearing cap. • Dial Indicator
3
Procedure:
on either the bearing insert or crankshaft
journal. 1. Adjust valve clearance. (See procedure in this
group.)
compare the width of the flattened 2. Remove rocker arm cover. (See Cylinder Head,
PLASTIGAGE at its widest point. Valves and Manifolds in this section.)
7. Determine main bearing clearance. The number 3. Fasten dial indicator to engine and position
within the graduation marks indicates the bearing indicator tip on valve retainer. Valve must be
clearance in inches or millimeters depending on fully closed and rocker arm must move freely.
which side of the envelope is used. 4. Zero the dial indicator.
8. Remove PLASTIGAGE. 5. Manually turn crankshaft pulley clockwise (from
fan end).
Graduation Marks should be 8.8 mm (0.350 in.).
on Envelope
Flattened
PLASTIGAGE
M82119AE
4/7/95 3-125
Procedure:
indicator tip on end of camshaft.
3. Push camshaft toward the rear as far as possible.
5. Pull camshaft forward as far as possible.
T6333DT
Results:
3 Cylinder Head, Valves and Manifolds in this
section.)
3 CAMSHAFT END PLAY CHECK M37512
Reason:
Specifications:
To determine proper side clearance between Standard Clearance . . . . . . . . 0.05 - 0.20 mm
camshaft gear end journal and thrust plate.
. . . . . . . . . . . . . . . . . . . . . (0.0020 - 0.0079 in.)
Equipment: Wear Limit. . . . . . . . . . . . 0.40 mm (0.016 in.)
• Dial Indicator Results:
and replace thrust plate. (See Camshaft and
3-126 4/7/95
TIMING GEAR BACKLASH, CHECK Specifications - 4TN78T:

Standard Backlash
Reason: Crankshaft Gear-to-Oil
To check for wear between meshing gears, resulting Pump Gear. . . . . . . . . . . . . 0.11 - 0.19 mm
in excessive noise and poor engine performance. . . . . . . . . . . . . . . . . . . (0.0043 - 0.0075 in.)
All Except Crankshaft Gear-to-Oil
Equipment: Pump Gear. . . . . . . . . . . . . 0.04 - 0.12 mm
• Dial Indicator . . . . . . . . . . . . . . . . . . (0.0016 - 0.0047 in.)
Wear Limit. . . . . . . . . . . 0.20 mm (0.0079 in.)
Procedure: Specifications - 4TN82, 4TN84(T)(4019):
1. Measure backlash between meshing gears. Standard Backlash . . . . . . . . . 0.04 - 0.12 mm
. . . . . . . . . . . . . . . . . . . . . (0.0016 - 0.0047 in.)
Wear Limit. . . . . . . . . . . 0.20 mm (0.0079 in.)
Results:
• If backlash exceeds wear limit, replace meshing 3
gears as a set:
Pump Gear AND/OR Idler Gear, Fuel Injection 3
Pump Gear.

4/7/95 3-127


3 must be surgically removed within a few Procedure 1:
3 information is available from the Deere &
instructions.
. . . . . . . . . . . . . . . . . . . . . . . . . (2843 ± 70 psi)
Reason:
opening pressure.
3-128 4/7/95

Assembly

Container
M35913 3
psi).
Test fuel injection nozzle leakage following the
Nozzle Tester manufacturer's instructions. 2. Listen for “chatter” sound and watch spray
3
pattern.
Results:
Slow Hand
. . . . . . . . . . . . . . . . . . . . . . . . . Spray Pattern
instructions.
4/7/95 3-129
Procedure:
Correct
Proper Spray
CAUTION
Angle

2. Heat and stir the water. Observe opening action
Poor
specifications.
3 3. Remove thermostat and observe its closing action

as it cools.
3 Thermometer
M82121A
Results:

Results:
• Thermometer
• Glass Container
• Heating Unit
3-130 4/7/95
COOLANT TEMPERATURE SWITCH 2. Suspend sender and a thermometer in a container

TEST of water.
To determine operating temperature of sender. temperature should be 107 - 113° C (225 -
235°F).
Equipment:
• Thermometer
Ohmmeter
• Glass Container Probes
• Heating Unit
• Ohmmeter
Procedure:
CAUTION 3
Coolant
DO NOT allow switch or thermometer to rest Temperature
Switch M82123A
when heating water. Either may rupture if 3
overheated. Results:
4/7/95 3-131
STARTER NO-LOAD AMP Specifications:

DRAW/RPM TEST Maximum Starter Amperage
Reason: Hitachi 0.8 kW. . . . . . . 60 Amps at 7000 rpm
Hitachi 2.0 kW. . . . . . 110 Amps at 4500 rpm
To determine if starter is binding or has excessive
amperage draw under no load. Nippondenso 1.0 kW. . 90 Amps at 3000 rpm
Nippondenso 1.4 kW. . 90 Amps at 3500 rpm
Equipment:
Minimum Starter RPM
Hitachi 0.8 kW. . . . . . . . . . . . . . . . . . . . . 7000
• JT05719 Hand-Held Digital Tachometer Hitachi 2.0 kW. . . . . . . . . . . . . . . . . . . . . 4500
• Jumper Cables Nippondenso 1.0 kW. . . . . . . . . . . . . . . . 3000
• Jumper Wire Nippondenso 1.4 kW. . . . . . . . . . . . . . . . 3500
Procedure:
Results:
1. Mount starter in a vise.
3 NOTE: Check that battery is fully charged and of not turn, replace solenoid.
proper size to ensure accuracy of test. • If pinion gear engages and motor doesn't turn,
2. Connect jumper cables to a 12 volt battery. repair or replace starter motor.
3 3. Connect positive (+) cable to solenoid battery • If starter engages and runs but amperage is more
terminal on starter. than specifications, repair or replace starter.
4. Connect negative (-) cable to starter body. • If rpm is less than specification, with battery
5. Attach Current Gun to positive cable.
or less to prevent starter damage.
3-132 4/7/95
JT05712 Current Gun
Jumper Wire
3
All Except Nippondenso 1.0 kW M82149A
JT05712 Current Gun
Jumper Wire
Nippondenso 1.0 kW M82150A
4/7/95 3-133

ADJUSTMENT - 4TN78T Index Mark on
TDC Mark
on Flywheel Flywheel Housing
Reason:
Equipment:
• Timing Tool (No. 1 fuel injection line cut off at
first bend) M82253A

5. Prime pump to fill it with fuel. 1 L (1.06 qt) of
fuel is more than adequate.
Procedure:
6. Hold throttle lever in run position.
correct. Once timing is set, it will not normally 7. Turn flywheel clockwise (as viewed from the
3 change during the life of the engine, unless it flywheel end) until tip of Timing Tool has
was altered. become MOIST with solid fuel.
Check and adjust timing only as the last 8. Check timing mark on flywheel. The index mark
option. Check fuel, fuel supply system, must line up with the 14° mark on flywheel.
3 injectors, air intake system and cylinder
compression before continuing. Flywheel

flywheel end, is counterclockwise. The
flywheel.
1. Remove the number one fuel injection line. TDC Mark on
Flywheel
2. Install timing tool (number one fuel line cut off at
first bend).
Timing Tool
Index Mark
on Flywheel
Housing
T6530AB
M82254A
3. Remove rubber plug from flywheel housing.

No. 1 cylinder top dead center (TDC) mark aligns
with the index mark on the flywheel housing.
3-134 4/7/95
Specifications: Procedure:
Injection Pump Timing. . . . . . . . . .14° BTDC IMPORTANT: Injection pump timing should be
. . . . . . . . . . . . . . . (Before Top Dead Center) correct. Once timing is set, it will not normally
Engine Crankshaft change during the life of the engine, unless it
Position. . . . . . . . . . . . . . . . . . . No.1 Cylinder was altered.
. . . . . . . . . . . . . on TDC Compression Stroke Check and adjust timing only as the last
Per 1° Of Rotation. . . . . . 2.88 mm (0.110 in.)
Timing Lines On Pump
Mounting Plate . . . . . . . . . . . . . . . .2.5° Apart NOTE: If injection pump has been removed from
engine without disturbing engine crankshaft
and pump shaft, perform Step 1 only.
Results:
Otherwise, perform the entire timing
• If timing is not according to specifications, procedure.
loosen pump mounting bolts and turn pump
1. 4TN82: Align arrow or line on injection pump
flange with the sixth mark (line) on timing gear 3
mounting plate.
tested by a diesel injection service shop. 4TN84(T)(4019): Align arrow or line on
• If timing is OK: injection pump flange between third and fourth 3
marks (lines) on timing gear mounting plate.
- Install rubber plug in flywheel housing.

ADJUSTMENT - 4TN82 AND
4TN84(T)(4019)
Reason: 4TN82
M82255A
Equipment:
first bend)
4TN84(T)(4019)
M82256A
4/7/95 3-135
NOTE: Normal rotation, as viewed from the 6. Prime pump to fill it with fuel. 1 L (1.06 qt) of
flywheel end, is counterclockwise. The fuel is more than adequate.
7. Hold throttle lever in run position.
flywheel.
8. Turn flywheel clockwise (as viewed from the
2. Remove the number one fuel injection line.
flywheel end) until tip of Timing Tool has
3. Install timing tool (number one fuel line cut off at become MOIST with solid fuel.
first bend).
9. Check timing mark on flywheel. The index mark
must line up with injection pump timing mark on
Timing Tool flywheel. See specifications.
25°
Injection Pump Flywheel
20°
Timing Marks
15°
TDC Mark on
3 Flywheel
1
T6530AB
4. Remove rubber plug from flywheel housing, if

3 equipped.
No. 1 cylinder top dead center (TDC) mark aligns Index Mark
with the index mark on the flywheel housing/ on Flywheel
plate. Housing
TDC Mark
on Flywheel
M82373A
1
Specifications:
Index Mark on Injection Pump Timing Mark
Flywheel
Housing/Plate 4TN82 (970 CUT, 675 SSL,
T6530AC 3325/65 GM) . . . . . . . . . . . . . .15° ± 1° BTDC
4TN84
(1070 CUT) . . . . . . . . . . . .15° ± 1° BTDC
(4019D OEM) . . . . . . . . . .16° ± 1° BTDC
4TN84T (4019T OEM)
4019TF001 and 005 . . . . . .15° ± 1° BTDC
4019TF006 . . . . . . . . . . . . .12° ± 1° BTDC
Engine Crankshaft
Position. . . . . . . . . . . . . . . . . . . . . . No. 1 Cylinder
. . . . . . . . . . . . . . . . on TDC Compression Stroke
3-136 4/7/95
• If timing is not according to specifications, Applied Force . . . . . . . . . . .98 N (22 lb-force)
loosen pump mounting bolts and turn pump Deflection . . . . . 10 - 15 mm (0.400 - 0.600 in.)
Results:
• If deflection is not within specifications:
nuts.
- Install rubber plug in flywheel housing, if
- Apply force to FRONT alternator housing
equipped.
- Tighten cap screws/nuts.
ENGINE OIL COOLER LEAKAGE
FAN/ALTERNATOR DRIVE BELT TEST - 4TN78T AND 4TN84T
ADJUSTMENT (4019TF001 and 005) 3
Reason: Reason:
and alternator. To prevent shortened belt and bearing
Inspect oil cooler for leaks. 3
life. Procedure:
Equipment: 1. Plug one end of coolant inlet or outlet passage.
• JDG529 or JDST28 Belt Tension Gauge 2. Apply regulated air pressure of 206 - 483 kPa
(30 - 70 psi) to other end.
• Straight Edge
3. Dip oil cooler into water and check for leaks.
Procedure: Optional test:
If a leak did not appear, use a hot water bath to
1. Check belt tension between fan and alternator
possibly open crack(s).
using Belt Tension Gauge and a straight edge.
Results:
• Repair leak(s) or replace oil cooler if necessary.
Belt Deflection
M54014
4/7/95 3-137
FUEL SHUTOFF SOLENOID 5. Turn plunger rod in or out of knuckle until

ADJUSTMENT knuckle and link holes line up. Turn out two
the solenoid bottoms out before the linkage.
Reason:
To ensure that fuel shutoff solenoid retracts fully,
switch is turned ON. Also check that linkage
returns completely to the STOP position when
key switch is turned OFF.
Procedure:
1. Loosen lock nut.
Plunger
Link
body.
4. Move link toward solenoid until it stops
Knuckle
3 Lock Nut
M82141
3-138 4/7/95
Operational Tests
RADIATOR, BUBBLE TEST • If air escapes from air cleaner, check for worn
intake valve.
Reason: • If air escapes from engine oil fill, check for worn
To determine if compression pressure is leaking piston rings.
from cylinder.
COOLING SYSTEM, PRESSURE TEST
Equipment:
• JDG560 Adapter Reason:
Procedure:
1. With coolant at proper level and radiator cap Equipment:
tight, run engine for 5 minutes to bring to • D05104ST Cooling System Pressure Pump
operating temperature.
bottom of tank.
3
2. Apply pressure according to specifications.
leak:
3. Check for leaks throughout cooling system.
- Remove injection nozzles. 3
Cooling System
- Move piston to bottom of stroke with intake Pressure Pump
adapter.
into cylinder:
T6333AW
4TN78T, 4TN82RJK,
4TN84RJK, 4TN82RJE,
4TN82ESP . . . . . . . . . . . . . 2448 kPa (355 psi)
Specifications - 4TN78T, 4TN82RJK,
4TN84(T)(4019) . . . . . . . . . 2158 kPa (313 psi) 4TN84RJK, 4TN84(T)(4019):
- Check for bubbles in recovery tank or air Maximum Pressure . . . . . . . . . 97 kPa (14 psi)
escaping from muffler, air cleaner or oil fill Minimum Pressure
opening. after 15 Seconds . . . . . . . . . 88 kPa (12.8 psi)
- Repeat for each cylinder.
Specifications - 4TN82RJE, 4TN82ESP:
Results: Maximum Pressure . . . . . . . . . 69 kPa (10 psi)
• If bubbles are present, check for cracks in Minimum Pressure
cylinder head and block. Check for damaged after 15 Seconds . . . . . . . . . . . . 55 kPa (8 psi)
head gasket.
exhaust valve.
4/7/95 3-139
Operational Tests
Results: Results:
parts as necessary.
cause. Perform RADIATOR BUBBLE TEST. Reason:
Equipment:
Reason:
Test radiator cap for operating in correct pressure
range. • JDG560 Adapter
3 Procedure:
Equipment:
• D05104ST Cooling System Pressure Pump 1. Run engine for 5 minutes to bring to operating
3 • JDG692 Radiator Pressure Test Kit (Adapters)
Procedure: this section.)
1. Install radiator cap on pressure pump. 3. Remove heat protector from end of injector and
install on Adapter.
open according to specifications.
and tighten nuts to 4.5 N•m (39 lb-in.)
5. Hold fuel shut-off knob in shut-off position.
Cooling System
Pressure Pump 6. Crank engine for three seconds with starter.
Specifications:
4TN78T, 4TN82RJK, 4TN84RJK,
4TN84(T)(4019) . . . . . . . . . . 88 kPa (12.8 psi)
4TN82RJE, 4TN82ESP . . . . . . 55 kPa (8 psi) JDG560 Adapter
JT01682 Compression
T6333EU
Gauge Assembly
3-140 4/7/95
Operational Tests
Specifications: IMPORTANT: Do not run if no pressure

Minimum Compression Pressure present.
4TN78T, 4TN82RJK, 4. Start engine. If pressure reading is below 69 kPa
4TN84RJK, 4TN82RJE, (10 psi), STOP ENGINE.
4TN82ESP . . . . . . . . . . . . . 2448 kPa (355 psi) 5. Run engine approximately five minutes to heat
4TN84(T)(4019) . . . . . . . . . 2158 kPa (313 psi) oil, then check oil pressure at fast and/or slow
idle.
Maximum Difference Between
Cylinders . . . . . . . . . . . . . . . . . . . 490 kPa (71 psi)
NOTE: Pressure listed is for 300 m (1000 ft) above JT05577 Pressure Gauge
sea level. For naturally aspirated engines,
reduce specification an additional 4% for
each 300 m (1000 ft) of altitude. For turbo
charged engines, reduce specification an
additional 3.6% (4TN78T) or 3%
(4TN84T)(4019T) for each additional 300 m
(1000 ft) of altitude.
JT03017 Hose Assembly 3
Results:
approximately two teaspoons of clean engine oil 3
test.
rings and cylinder walls for wear or damage.
retest, check for leaking valves, valve seats or Connector
T6471FB
Reason:
Specifications - 4TN78T:
To determine if engine bearings or lubrication
system components are worn. Idle Speed
Fast . . . . . . . . . . . . . . . . . . . . . . 2750 ± 25 rpm
Equipment:
Slow . . . . . . . . . . . . . . . . . . . . . . 800 ± 25 rpm
• JT03017 Hose Assembly Engine Oil Pressure
• JT05577 Pressure Gauge (100 psi) Fast Idle . . . . . . . . . .345 ± 48 kPa (50 ± 7 psi)
• JT05487 Connector (4TN78T) Slow Idle. . . . . . . . . . . . . . . . . 214 kPa (31 psi)
• JT03349 Connector (All Except 4TN78T)
Specifications - 4TN82RJE:
Procedure: Idle Speed
1. Remove oil pressure sender. Fast . . . . . . . . . . . . . . . . . . . . . . . . . . 2800 rpm
2. Install Connector. Slow . . . . . . . . . . . . . . . . . . . . . 1000 ± 50 rpm
3. Connect Hose Assembly and Pressure Gauge. Engine Oil Pressure . . . . . . . . . . . . 294 - 440 kPa
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(43 - 64 psi)
4/7/95 3-141
Operational Tests
Specifications - 4TN82ESP: filter element. Install main filter element and

Idle Speed cover.
Fast . . . . . . . . . . . . . . . . . . . . . . 2875 ± 25 rpm 5. Pressurize air intake system between 34 - 69 kPa
Slow . . . . . . . . . . . . . . . . . . . . . . 900 ± 25 rpm (5 - 10 psi). If air intake system cannot be
Engine Oil Pressure . . . . . . . . . . . . 294 - 392 kPa
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (43 - 57 psi)
Specifications - 4TN82RJK, 4TN84RJK:
Fast Idle Speed IMPORTANT: When reinstalling starting aid
4TN82RJK . . . . . . . . . . . . . . .2750 - 2800 rpm
against intake air flow.
4TN84RJK . . . . . . . . . . . . . . .2850 - 2900 rpm
Engine Oil Pressure . . . . . . . . . . . . 365 ± 69 kPa
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (53 ± 10 psi)
3 Specifications - 4TN84(T)(4019):
Low Idle Speed
Industrial . . . . . . . . . . . . . . . . . . . . . 1300 rpm
Generator. . . . . . . . . . . . . . . . . . . . . 1200 rpm
3 Engine Oil Pressure . . . . . . . . . . 147 kPa (21 psi)
M82124
Results:
inspect oil pressure regulating valve parts for Results:
wear or damage. Add or remove shims as • Find leaks and repair or replace parts as
necessary. (See Lubrication System in this necessary.
section.)
• If oil pressure does not increase, see “Engine FUEL SUPPLY PUMP PRESSURE
Has Low Oil Pressure” in Diagnosis group. TEST - IF EQUIPPED
NOTE: 4TN78T, 4TN82RJE and 4TN82ESP
AIR INTAKE SYSTEM LEAKAGE TEST engines are not equipped with a fuel supply
pump.
Reason:
Check for leaks in air intake system. Reason:
Equipment:
• Air Pressure Regulator Equipment:
Procedure:
and install test fitting. • JT03115 Gauge w/Male Quick Coupler (0 - 150
psi)
hose and fitting from air cleaner.
4. Put large plastic bag into and over end of main
3-142 4/7/95
Operational Tests
1. Disconnect supply pump-to-filter hose. 1. Disconnect fuel supply line and return line at fuel
tank.
2. Install Hose Fitting, Coupler and Gauge.
3. Pull fuel shut-off cable out and crank engine IMPORTANT: Fuel return line MUST extend
using the starter. Do not run starter for more than below fuel level in fuel tank before performing
10 seconds at a time. Gauge should read more this test. Fill fuel tank if necessary.
than 29 kPa (4.3 psi). 2. Drain all fuel from the system, including fuel
JT03115 Gauge w/Male 3. Plug end of fuel return hose.
Quick Coupler
JT01609 Female Quick
Coupler
leaks.
3
Results:
Fuel Filter necessary. 3
Supply BLEED FUEL SYSTEM
Pump-to
Filter Hose IMPORTANT: Modification or alteration of the
M82145A
Results: obligation.
• If pressure is below specification, repair or All engines are equipped with an automatic air
replace fuel supply pump. venting system which makes the fuel system self-
bleeding.
FUEL DRAIN BACK TEST • Assure that all fuel line connections are securely
tightened.
Reason: • Add fuel to fuel tank.
Determines if air is entering the fuel system at • Crank engine to allow fuel system to bleed itself.
4/7/95 3-143
4TN100 ENGINE
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4
Cylinder Head, Valves and Manifolds . . . . . . . . . . . . . . . . 4-8
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
Starter (Nippondenso 1.4 kW) . . . . . . . . . . . . . . . . . . . . . 4-70
Alternator (Hitachi 25A) . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
Checks, Tests and Adjustments. . . . . . . . . . . . . . . . . . . . 4-83
Operational Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97
Section 4
4
Specifications
ENGINE SPECIFICATIONS - 4TN100

Rocker Arm Cover Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.)
Rocker Arm Assembly
Push Rod Bend
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.) or Less
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.)
Push Rod Length
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178.25 - 178.75 mm (7.018 - 7.037 in.)
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 mm (0.002 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.50 - 18.52 mm (0.728 - 0.729 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.60 mm (0.732 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.46 - 18.48 mm (0.727 - 0.728 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.35 mm (0.722 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.) or Less
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.) 4
First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft)
Second. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 N•m (72 lb-ft)
Final . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 N•m (116 lb-ft)
Valve Seat Width (Exhaust Valve)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.02 - 2.33 mm (0.079 - 0.089 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.73 mm (0.108 in.)
Valve Seat Width (Intake Valve)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.38 - 1.62 mm (0.054 - 0.064 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12 mm (0.084 in.)
Valve Face
Exhaust Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Intake Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
Valve Recession
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm (0.008 - 0.016 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.80 mm (0.071 in.)
Valve Stem O.D. (Exhaust Valve)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.94 - 8.96 mm (0.3520 - 0.3528 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.90 mm (0.3504 in.)
Valve Stem O.D. (Intake Valve)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.96 - 8.98 mm (0.3528 - 0.3535 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.90 mm (0.3504 in.)
Valve Guides
Valve Guide Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.50 mm (0.453 in.)
Valve Guide I.D.
4/7/95 4-1
Specifications

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.00 - 9.02 mm (0.354 - 0.355 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10 mm (0.358 in.)
Valve Springs
Maximum Spring Tension . . . . . . . . . . . . . . . . . . . . . . . 41.50 mm (1.634 in.) at 12.6 N (5.7 lb force)
Spring Free Length
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 mm (1.693 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.50 mm (1.673 in.)
Exhaust Manifold
Intake Manifold
Valve Seat Angles
Valve Seat Surface
Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
4 Connecting Rod Bearing I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09 mm (0.004 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 - 60.042 mm (2.3622 - 2.3639 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.10 mm (2.3661 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.090 - 0.125 mm (0.0035 - 0.0049 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.0079 in.)
Oil Ring
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.030 - 0.065 mm (0.0012 - 0.0026 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.035 - 0.070 mm (0.0014 - 0.0028 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Piston Ring End Gap
Compression Rings
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 - 0.40 mm (0.0098 - 0.0157 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.0591 in.)
Oil Ring
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 - 0.50 mm (0.0118 - 0.0197 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.0591 in.)
Piston Pin
Bore I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.022 mm (0.0009 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.00 - 34.011 mm (1.3386 - 1.3390 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.02 mm (1.3393 in.)
Bushing I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.061 mm (0.0024 in.)
4-2 4/7/95
Specifications
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.03 - 34.05 mm (1.3398 - 1.3406 in.)

Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.10 mm (1.3425 in.)
Pin O.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.989 - 34.00 mm (1.3381 - 1.3386 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.90 mm (1.3346 in.)
Piston O.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100.15 - 100.18 mm (3.943 - 3.944 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100.05 mm (3.939 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.895 - 99.925 mm (3.9329 - 3.9341 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.79 mm (3.9287 in.)
Cylinder Bore I.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100.25 - 100.28 mm (3.947 - 3.948 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100.45 mm (3.955 in.)
Deglazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 40° Cross-Hatch Pattern
Reboring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 40° Cross-Hatch Pattern
Standard Size Bore
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.41 mm (0.016 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100.00 - 100.03 mm (3.9370 - 3.9382 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100.15 mm (3.9429 in.)
4
Extension-to-Block (M12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 N•m (65 lb-ft)
Extension-to-Block (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.)
Extension-to-Gear Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (180 lb-in.)
Flywheel Housing-to-Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft)
Crankshaft Front Oil Seal Depth . . . . . . . . . . . . . . . . . . . . . 3.18 mm (0.125 in.) Below Surface of Cover
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59.952 -59.964 mm (2.3603 - 2.3608 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59.90 mm (2.3583 in.)
Crankshaft and Main Bearings - Continued
Main Bearing Cap Screw Torque
Initial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 N•m (100 lb-ft)
Final . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 N•m (145 lb-ft)
Main Bearing I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09 mm (0.004 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.00 - 60.042 mm (2.3622 - 2.3639 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.10 mm (2.3661 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69.952 - 69.964 mm (2.7540 - 2.7545 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69.90 mm (2.7520 in.)
4/7/95 4-3
Specifications
Flywheel
Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 N•m (145 lb-ft)
Camshaft
Bore I.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.00 - 57.03 mm (2.2441 - 2.2453 in.)
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.12 mm (0.005 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.10 mm (2.2480 in.)
Bushing Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 mm (0.062 in.)
Bushing I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.14 mm (0.006 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.98 - 57.05 mm (2.2433 - 2.2461 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.10 mm (2.2480 in.)
Camshaft Side Gap
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.29 mm (0.0114 in.)
End Journal O.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.91 - 56.94 mm (2.2406 - 2.2417 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.80 mm (2.2362 in.)
Intermediate Journal O.D.
4 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.89 - 56.92 mm (2.2398 - 2.2409 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.80 mm (2.2362 in.)
Lobe Height
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.435 - 48.565 mm (1.9069 - 1.9120 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.20 mm (1.897 in.)
Maximum Camshaft Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.0020 in.)
Cam Followers
Bore I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.052 mm (0.0020 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.249 - 14.270 mm (0.5610 - 0.5618 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.30 mm (0.5630 in.)
Cam Followers - Continued
Stem O.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.218 - 14.233 mm (0.5598 - 0.5604 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.17 mm (0.5579 in.)
Timing Gear Cover
Fan Mounting Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 N•m (47 lb-ft)
Fan Spacer-to-Water Pump Socket-Head Cap Screw Torque . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.)
Idler Gear
Bushing I.D.
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.075 mm (0.0030 in.)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.00 - 46.025 mm (1.8110 - 1.8120 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.09 mm (1.8146 in.)
Shaft O.D.
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.95 - 45.975 mm (1.8091 - 1.8100 in.)
4-4 4/7/95
Specifications
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.9 mm (1.8071 in.)

Timing Gear Housing
Extension-to-Gear Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (180 lb-in.)
Gear Housing-to-Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (220 lb-in.)
Oil Strainer Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.)
Oil Pan Mounting Cap Screw Torque
Oil Pan-to-Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (226 lb-in.)
Oil Pan-to-Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (180 lb-in.)
Oil Pump
Inner-to-Outer Rotor Maximum Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
Maximum Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
Maximum Outer Rotor Recess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
Outer Rotor-to-Pump Housing Maximum Clearance . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
Rotor Shaft Assembly-to-Housing Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . 6 N•m (53 lb-in.)
Rotor Shaft O.D.-to-Housing I.D. Maximum Clearance . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
Oil Cooler
Adapter-to-Housing Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (18 lb-ft)
Oil Cooler-to-Housing Nut Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft)
Oil Cooler By-Pass Valve Spring
4
Compressed Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 mm (1.450 in.) @ 3.75 N (0.840 lb force)
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 mm (2.480 in.)
Oil Pressure Regulating Valve Spring
Compressed Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 mm (1.970 in.) @ 5.40 N (1.200 lb force)
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 mm (2.010 in.)
Piston Cooling Nozzle Mounting Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (130 lb-in.)
Thermostat Cover Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (180 lb-in.)
Water Pump
Adapter Fitting-to-Housing Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 N•m (199 lb-in.)
Adapter-to-Plate Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 N•m (91 lb-in.)
Fan Mounting Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 N•m (47 lb-ft)
Fan Spacer-to-Pump Socket-Head Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . 11 N•m (96 lb-in.)
Impeller-to-Pump Housing Clearance . . . . . . . . . . . . . . . . . . . . . . . 0.30 - 1.10 mm (0.012 - 0.043 in.)
Fuel Supply Pump
External Lube Line Inlet Mounting Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (130 lb-in.)
Fuel Injection Pump
External Lube Line Inlet Mounting Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (130 lb-in.)
4/7/95 4-5
Specifications
Starter Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 mm (0.335 in.)
Alternator
Rotor Assembly
Rotor-to-Stator Assembly Attaching Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (31 lb-in.)
Stator Assembly
End Frame-to-Rectifier Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (31 lb-in.)
Camshaft End Play
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.29 mm (0.0114 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.45 mm (0.0177 in.)
4 Coolant Temperature Sender Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . 107 - 133° C (225 - 235° F)
Thermostat
Begin Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71° C (160° F)
Fully Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85° C (184° F)
Checks, Tests and Adjustments - Continued
Crankshaft End Play
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.29 mm (0.0114 in.)
Main Bearing Cap Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 N•m (145 lb-ft)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09 mm (0.0040 in.)
Fan/Alternator Drive Belt
Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 15 mm (0.400 - 0.600 in.)
Chatter and Spray Pattern at 20100 ± 490 kPa (2915 ± 71 psi) Pressure
Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum 5 Seconds at 18100 kPa (2625 psi)
Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19615 kPa (2850 psi)
Injection Pump Static Timing
Distance on Outer Surface of Flywheel per 1° of Rotation . . . . . . . . . . . . . . . . 3.5 mm (0.130 in.)
Timing Lines on Pump Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2° Apart
4-6 4/7/95
Specifications
Starter, No-Load Amp Draw/RPM

Maximum Starter Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 amps at 3500 rpm
Minimum Starter RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3500
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.0098 in.)
Valve Lift Intake and Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 mm (0.256 in.)
Operational Tests
Cooling System
Maximum Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 kPa (14 psi)
Minimum Pressure After 15 Seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 kPa (12.8 psi)
Cylinder Compression Pressure
Compression Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2942 kPa (427 psi)
Engine Oil Pressure
Fast Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2375 ± 50 rpm
Oil Pressure Fast Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .343 - 441 kPa (50 - 64 psi)
Oil Pressure Slow Idle (Minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 kPa (14 psi)
Slow Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900 ± 50 rpm
Fuel Supply Pump Pressure (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 kPa (31 psi)
4
Radiator Cap
Valve Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 kPa (12.8 psi)
4/7/95 4-7

JT07092 Valve Guide Knurler (9 mm)
Use to knurl inside diameter of valve guides.

JT07091 Valve Guide Reamer (9 mm)

Use to ream out new valve guides.
OTHER MATERIALS
Number Name Use
LOCTITE® PRODUCTS
U.S./
Canadian/
LOCTITE No.
4 TY9375/
TY9480/
John Deere Pipe Sealant
with TEFLON®
Apply to threads of fitting on top of
cylinder head.
#592
SERVICE PARTS KITS


4-8 4/7/95
ROCKER ARM COVER
Oil Fill Cap
O-Ring
Cap Screw (10)

M8 x 25
26 N•m (226 lb-in.)
Gasket
Crankcase Breather
Tube
4
M82020A
4/7/95 4-9
ROCKER ARM ASSEMBLY IMPORTANT: Install rocker arm support, with

alignment cap screw on rocker arm shaft, with
Removal/Installation and raised letter “F” facing toward other supports.
Install remaining rocker arm supports on
Disassembly/Assembly rocker arm shaft with raised letter “F” facing
1. Remove rocker arm cover. (See procedure in this away from support with alignment cap screw.
group.) • Adjust valve clearance. (See Checks, Tests and
• Inspect all parts for wear or damage. (See Adjustments in this section.)
• Lubricate all parts with clean oil during
assembly.
Alignment Cap Screw
Rocker Arm Shaft
4
Rocker Arm
Shaft Spring
Mounting
Nut (2)
Mounting Cap 26 N•m
Screw (6) (226 lb-in.)
Push Rod
26 N•m
Adjusting (226 lb-in.)
Screw
Rocker Arm Support

M82021A
4-10 4/7/95

• Measure outer diameter of rocker arm shaft. Standard . . . . . . . . . . . . . . . 18.50 - 18.52 mm
. . . . . . . . . . . . . . . . . . . . . . . (0.728 - 0.729 in.)
Wear Limit. . . . . . . . . . . 18.60 mm (0.732 in.)
Clearance . . . . . . . . . . . . . 0.06 mm (0.002 in.)
wear limit.
parts.
M35262

Standard . . . . . . . . . . . . . . . 18.46 - 18.48 mm
. . . . . . . . . . . . . . . . . . . . . . . (0.727 - 0.728 in.)
Length
Wear Limit. . . . . . . . . . . 18.35 mm (0.722 in.)
Replace rocker arm shaft if less than wear limit. 4
Feeler
supports.
M82023A
Push Rod Length:

Standard . . . . . . . . . . . . . 178.25 - 178.75 mm
. . . . . . . . . . . . . . . . . . . . . . . (7.018 - 7.037 in.)
Push Rod Bend:

Wear Limit. . . . . . . . . . . . 0.30 mm (0.012 in.)
M82022A
4/7/95 4-11
CYLINDER HEAD AND VALVES NOTE: Fitting must be removed to remove mounting
cap screw.
procedures in this group.)
Install gasket as shown.
section.)
4. Remove fuel injection nozzles. (See Fuel System
in this section.)
Mounting Cap
Fitting Screw (18)
Apply Pipe Sealant Dip entire cap
with TEFLON to threads. screw in
clean engine oil
before
4 installing.
Flywheel
Oil Passage
Cylinder Head
Gasket
M82024A
4-12 4/7/95
6. Tighten mounting cap screws, in the sequence Disassembly/Assembly

shown, in three stages of gradually-increasing
torque. • Compress valve springs using a valve spring
compressor.
IMPORTANT: Cylinder head mounting cap • Intake and exhaust valve guides are press fit.
screws must be checked for proper torque Remove guides only if replacement is necessary.
after 50 hours of engine operation. (See Inspection/Replacement procedures.)
Exhaust Manifold Side Inspection/Replacement procedures.)

IMPORTANT: Do not reuse stem seals if
Flywheel Side
18 12 10 3 1 5 7 13 15 removed. Used seals will leak.

• Apply clean engine oil on intake and exhaust
valve stems during assembly.
16 14 8 6 2 4 9 11 17 NOTE: If new valves are installed, measure valve
recession. (See Inspection/Replacement
Intake Manifold Side procedures.)
M82025A

Torque Specifications:
First . . . . . . . . . . . . . . . . . . . 49 N•m (36 lb-ft) 4
Second . . . . . . . . . . . . . . . . . 98 N•m (72 lb-ft)
Final . . . . . . . . . . . . . . . . . 157 N•m (116 lb-ft)

Seal (8)
Replace
Short
Stud (8) Retainer (8)
Exhaust Valve
Guide (4) Valve Spring (8)
Lifting
Bracket (2)
Intake Valve Guide (4)
Long Stud (2)

Cap Screw (4)
M10 x 20
Exhaust Valve
Intake Valve M82026A
4/7/95 4-13
of carbon or dirt.
Cylinder Head:
• Measure cylinder head flatness. Place a straight-
diagonal. Measure clearance between straight Valve Seat
edge and combustion surface with a feeler Width
gauge.
M82029A
Valve Seat Width:

Intake Valve:
Standard . . . . . . . . . . . . . . . . . 1.38 - 1.62 mm
M82027A . . . . . . . . . . . . . . . . . . . . . . . (0.054 - 0.064 in.)
Wear Limit. . . . . . . . . . . . 2.12 mm (0.084 in.)
4
Straight-Edge Exhaust Valve:
Standard . . . . . . . . . . . . . . . . . 2.02 - 2.23 mm
. . . . . . . . . . . . . . . . . . . . . . . (0.079 - 0.089 in.)
Feeler Gauge Wear Limit. . . . . . . . . . . . 2.73 mm (0.108 in.)
If necessary, grind valve seats to meet specifications.
(See GRIND VALVE SEATS procedure.)
M82028A • Check valve for out-of-round, bent or warped
Replace valve if necessary.
Cylinder Head Distortion:
Wear Limit. . . . . . . . . . . . 0.20 mm (0.008 in.)
If distortion exceeds the wear limit, resurface or
make cylinder head flat; but do not remove more
than 0.20 mm (0.008 in.).
If cylinder head was resurfaced:
• Measure piston-to-cylinder head clearance. (See
procedure in this group.) M35307
• Measure valve recession. (See procedure in this

group.)
4-14 4/7/95
• If valve faces are worn, burned or pitted, grind

valves to proper face angle. If valve face margin Valve Recession
is less than 0.51mm (0.020 in.) after grinding,
replace valve.
Valve Face
Valve Angle
Cylinder
Face
Exhaust: 45° Head
Margin
Intake: 30°
Depth
Gauge
M82030A
• Measure valve stem diameter at two locations

wear limit.
M82032A
4
40 mm 60 mm
(1.570 in.) (2.360 in.) Valve Recession:
Standard . . . . . . . . . . . . . . . . . 0.20 - 0.40 mm
. . . . . . . . . . . . . . . . . . . . . . . (0.008 - 0.016 in.)
Wear Limit. . . . . . . . . . . . 1.80 mm (0.071 in.)
Valve Guides:
• Clean valve guides using a valve guide brush.
• Measure valve guide inside diameter.
Valve Guide I.D.:
M82031A Standard . . . . . . . . . . . . . . . . . 9.00 - 9.02 mm
. . . . . . . . . . . . . . . . . . . . . . . (0.354 - 0.355 in.)
Valve Stem O.D.: Wear Limit. . . . . . . . . . . . 9.10 mm (0.358 in.)
Intake Valve: If diameter exceeds wear limit, knurl or replace
Standard . . . . . . . . . . . . . . . . . 8.96 - 8.98 mm guide.
. . . . . . . . . . . . . . . . . . . . . (0.3528 - 0.3535 in.) If diameter is less than wear limit, determine guide-
Wear Limit: . . . . . . . . . . 8.90 mm (0.3504 in.) to-stem clearance (guide diameter minus stem
diameter).
Exhaust Valve:
Standard . . . . . . . . . . . . . . . . . 8.94 - 8.96 mm
than 0.20 mm (0.008 in.), knurl valve guide using
. . . . . . . . . . . . . . . . . . . . . (0.3520 - 0.3528 in.) JT07092 Knurler.
Wear Limit. . . . . . . . . . . 8.90 mm (0.3504 in.)
• Measure valve recession using a depth gauge. valve guide.
• Replace valve guides using JDE118 Valve Guide
exceeds wear limit.
Driver.
4/7/95 4-15
Intake and exhaust valve guides are different. The • Measure spring inclination. Replace spring if
exhaust valve guide has two grooves and the intake measurement exceeds specification.
valve guide has one. Install valve guides with
grooves upward. Push valve guides down until top of
valve guides are 11.50 mm (0.453 in.) from top of
cylinder head.
Ream inside diameter of valve guides using
JT07091 Valve Guide Reamer.
Spring Inclination
1.20mm (0.047 in.)
Square Gauge
Free Length
Intake Valve Guide Exhaust Valve Guide
4 M82033A
M82035A
Valve Springs: • Measure spring tension. Replace spring if

• Measure spring free length. Replace spring if
41.50 mm (1.634 in.)

at 12.6 N
(5.7 lb-force)
Spring
Tension
Tester
M82034A
Spring Free Length:

Standard . . . . . . . . . . . . . . .43 mm (1.693 in.) M82036A
Wear Limit. . . . . . . . . . . 42.50 mm (1.673 in.)
4-16 4/7/95
EXHAUST MANIFOLD
NOTE: Turbocharger removal/installation
procedures are similar to unit used on
Series 220 Engines. Follow procedures used
in ACCESSORIES - SERIES 220 POWER
UNIT ENGINES section. Service
procedures are also similar.
1. Remove turbocharger, if equipped. (See
POWER UNIT ENGINES section).
Cap Screw (4) EXHAUST MANIFOLD

M8 x 50 WITH TURBOCHARGER
26 N•m (226 lb-in.) Stud (4)
Cap Screw (4)

M8 x 40
26 N•m (226 lb-in.) Stud (4)
Cap Screw
M8 x 110 4
26 N•m (226 lb-in.)
Exhaust
Manifold
Gasket
Gasket
Cap Screw (3)

Exhaust M8 x 70
Manifold 26 N•m (226 lb-in.)
Cap Screw (4)
M8 x 40
EXHAUST MANIFOLD
26 N•m (226 lb-in.)
WITHOUT TURBOCHARGER M82037A
4/7/95 4-17
INTAKE MANIFOLD
procedures found in ACCESSORIES - SERIES
220 POWER UNIT ENGINES section.
ENGINES section.)
2. Remove two fuel filter assembly mounting cap
screws.
3. Remove dipstick tube.
NOTE: Before placing intake manifold on engine,
install one M8 x 70 cap screw in manifold at
position shown.
Cap Screw (4)

M8 x 15
4 Cover Gasket
Gasket
Cap Screw
M8 x 115
26 N•m (226 lb-in.)
Intake Manifold

M8 x 70 M8 x 20
26 N•m (226 lb-in.) 26 N•m (226 lb-in.) M82038A
4-18 4/7/95
GRIND VALVE SEATS 6. Lap valves. (See procedure in this group.)

surface, which may result in leaks or valve/
seat failure. Valve seats should be ground and Lower Seat
lapped. Surface 70°
NOTE: LIGHTLY grind valve seats for a few Upper

Valve
seconds only to avoid excessive valve seat Seat Seat
width. Surface
Seat
1. Grind intake valve seat using a 30° seat grinder 15°
Width
and exhaust valve seat using a 45° seat grinder.
Follow tool manufacturers instructions.
Cylinder
Head
M82040A
Seat Grinder
or seats cannot be reconditioned, replace valves and 4
cylinder head.
LAP VALVES
NOTE: Use a rubber type lapping tool for valves
M82039A without a lapping tool groove slit.
If seat does not make proper contact, lap the valve
2. Measure valve seat width after grinding. into the seat:
3. If seat is too wide after grinding, grind lower seat 1. Apply small amount of fine lapping compound to
surface using a 70° seat grinder until seat width is face of valve.
close to specifications.
2. Turn valve to lap valve to seat.
4. Grind upper seat surface using a 15° seat grinder
until seat width is narrowed to specifications. 3. Lift valve from seat every 8 to 10 strokes. Lap
until a uniform ring appears around the surface of
5. If valve seats are ground, measure valve recession the valve face.
and check contact pattern between the seat and
valve with bluing dye. 4. Wash all parts in solvent to remove lapping
compound. Dry parts.
4/7/95 4-19
5. Check position of lap mark on valve face. Lap 3. Slowly turn crankshaft one complete revolution.
specification.
Lapping Tool
M82041A
MEASURE PISTON-TO-CYLINDER
HEAD CLEARANCE M82042A
4 1. Place three 10 mm (0.400 in.) long pieces of 1.50

mm (0.060 in.) diameter soft wire in three If clearance is less than 0.71 - 0.89 mm (0.028 -
positions on the flat part of the piston head. 0.035 in.), replace cylinder head.
2. Install cylinder head and old gasket. Install
sequence to specified torque. (See CYLINDER
this group.)
4-20 4/7/95
SERVICE PARTS KITS

• Connecting Rod Cap Screws
4/7/95 4-21
Removal
cause damage to piston if ridge is not removed. Piston and
4. If necessary, remove ridge from top of cylinder Connecting Rod
Inserts
Note alignment marks on each part. Connecting
Rod Cap
4 7. Remove two cap screws, connecting rod cap and
bearing inserts.
Connecting Rod
matched. Pistons must be installed in the

• Never reuse connecting rod cap screws, Replace
installing piston.
from which it was removed, with piston size
mark on top of piston toward camshaft.
4-22 4/7/95
IMPORTANT: Do not touch bearing insert 7. Install cylinder head. (See Cylinder Head, Valves
surfaces. Oil and acid from your finger will and Manifolds in this section.)
3. Install bearing inserts on connecting rod and rod System in this section.)
cap, aligning tangs with grooves.
IMPORTANT: Connecting rod caps must be Disassembly
installed on the same connecting rods they IMPORTANT: Pistons must be installed on the
were removed from. same connecting rod they were removed from.
4. Match the connecting rods to caps using • Put a mark on each piston and connecting rod to
alignment marks. Install caps. aid in assembly.
5. Dip entire connecting rod cap screws in clean • Piston pin bushing is press fit in connecting rod.
engine oil. Install new cap screws and tighten to Remove bushing only if replacement is
specifications. necessary. (See Inspection/Replacement
6. If a new piston and connecting rod were installed, procedures.)
stamp a number corresponding to the cylinder • Inspect all parts for wear or damage. Replace as
number on the connecting rod cap and connecting necessary. (See Inspection/Replacement
rod. procedures.)
1st Compression Ring 4
Piston Size 2nd Compression Ring

Mark
Camshaft Flywheel
Side Side Oil Ring with
Coil Expander
Piston
Groove
Piston Pin
Connecting Rod
Tangs Cap Alignment Snap Ring
Mark
Connecting Rod
Cap Screw Piston Pin Bushing
Dip in clean
Groove engine oil.
98 N•m (69 lb-ft)
Connecting Rod
M82043A
M82044A
4/7/95 4-23
Assembly
assembly. Expander

Ring
Oil Ring
size mark opposite connecting rod “punched” Expander
alignment mark. If a new connecting rod is used, Ends
assemble piston to connecting rod with piston
size mark on same side as connecting rod bearing
insert groove.
Piston Pin
M82046A
Piston
Piston
Size 5. Install second compression ring, with chamfer
Mark toward top of piston, in middle groove. Turn ring
until gap is 120o away from oil ring gap.
6. Install first compression ring, with
4 manufacturer's mark “R” (near ring gap) toward
Piston Pin
top of piston, in top groove. Turn ring until gap
is 120o away from second ring gap.
2nd Compression
Ring
Snap Ring
Rod Mark
1st Compression
Ring
2nd 120°
Compression 120°
Bearing Insert Groove M82045A Ring 120°
3. Install oil ring expander in bottom ring groove of

piston with ends above either end of piston pin. Oil Ring

M82047A
4-24 4/7/95
Inspection/Replacement 5. With rings installed on piston, measure piston

ring groove clearance. Measure several places
1. Inspect all parts for wear or damage. Replace as around each piston.
necessary.
2. Measure crankshaft connecting rod journal
diameter. (See Crankshaft, Main Bearings and
Flywheel in this section.)
3. Install connecting rod cap and bearing inserts on
connecting rod. Install old connecting rod cap
screws and tighten to 93 N•m (69 lb-ft).
M35360
Piston Ring Groove Clearance:

First Compression Ring:
Standard . . . . . . . . . . . . . . . 0.090 - 0.125 mm 4
. . . . . . . . . . . . . . . . . . . . . (0.0035 - 0.0049 in.)
Wear Limit. . . . . . . . . . . 0.20 mm (0.0079 in.)
Second Compression Ring:

M82048A
Standard . . . . . . . . . . . . . . . 0.035 - 0.070 mm
. . . . . . . . . . . . . . . . . . . . . (0.0014 - 0.0028 in.)
Wear Limit. . . . . . . . . . . 0.15 mm (0.0059 in.)
Connecting Rod Bearing I.D.:
Standard . . . . . . . . . . . . . . . . 60 - 60.042 mm Oil Ring:
. . . . . . . . . . . . . . . . . . . . . (2.3622 - 2.3639 in.) Standard . . . . . . . . . . . . . . . 0.030 - 0.065 mm
Wear Limit. . . . . . . . . . 60.10 mm (2.3661 in.) . . . . . . . . . . . . . . . . . . . . . (0.0012 - 0.0026 in.)
If bearing diameter exceeds wear limit, replace If clearance exceeds wear limit, replace rings or
bearing inserts. piston.
If bearing clearance (bearing I.D. minus crankshaft 6. Measure piston ring end gap. Push ring into
journal O.D.) exceeds specification, grind crankshaft cylinder bore, using a piston, until ring is
connecting rod journals and install undersized approximately 30 mm (1.181 in.) from bottom of
bearing inserts, or replace bearing inserts and cylinder bore.
crankshaft.
4/7/95 4-25
End Gap
Cylinder
Bore
Measuring Positions
Piston
Ring
Approx.
4 30 mm
(1.181 in.)
End Gap M82049A M82050A
Piston Ring End Gap: Piston Pin O.D.:

Compression Rings: Standard . . . . . . . . . . . . . . 33.989 - 34.00 mm
Standard . . . . . . . . . . . . . . . . . 0.25 - 0.40 mm . . . . . . . . . . . . . . . . . . . . . (1.3381 - 1.3386 in.)
. . . . . . . . . . . . . . . . . . . . . (0.0098 - 0.0157 in.) Wear Limit. . . . . . . . . . 33.90 mm (1.3346 in.)
Wear Limit. . . . . . . . . . . 1.50 mm (0.0591 in.) If pin diameter is less than wear limit, replace pin.
Oil Ring: 8. Measure piston pin bore diameter in piston.
Standard . . . . . . . . . . . . . . . . . 0.30 - 0.50 mm
. . . . . . . . . . . . . . . . . . . . . (0.0118 - 0.0197 in.)
Wear Limit. . . . . . . . . . . 1.50 mm (0.0591 in.)
at six places.
M37683
4-26 4/7/95
Piston Pin Bore I.D.: Piston pin bushing is press fit. Replace bushing
Standard . . . . . . . . . . . . . . 34.00 - 34.011 mm using a driver set. When installing bushing, make
. . . . . . . . . . . . . . . . . . . . . (1.3386 - 1.3390 in.)
connecting rod.
Wear Limit. . . . . . . . . . 34.02 mm (1.3393 in.)
10.Measure piston diameter perpendicular to piston
Clearance . . . . . . . . . . . 0.022 mm (0.0009 in.) pin bore 25.50 mm (1.004 in.) from bottom of
If piston pin bore exceeds wear limit, replace piston. piston.
If bore clearance (bore I.D. minus pin O.D.) exceeds NOTE: If engine has had a previous major
specification, replace piston, piston pin or both. overhaul, oversize pistons and rings may
9. Measure piston pin bushing diameter in have been installed. Pistons and rings are
connecting rod. available in 0.25 mm (0.010 in.) oversize.
M82052A
M82051A
Piston O.D.:
Standard Size Piston:
Piston Pin Bushing I.D.:
Standard . . . . . . . . . . . . . 99.895 - 99.925 mm
Standard . . . . . . . . . . . . . . . 34.03 - 34.05 mm . . . . . . . . . . . . . . . . . . . . . (3.9329 - 3.9341 in.)
. . . . . . . . . . . . . . . . . . . . . (1.3398 - 1.3406 in.)
Wear Limit. . . . . . . . . . 99.79 mm (3.9287 in.)
Wear Limit. . . . . . . . . . 34.10 mm (1.3425 in.)
Clearance . . . . . . . . . . . 0.061 mm (0.0024 in.) 0.25 mm (0.010 in.) Oversize Piston:
If bushing diameter exceeds wear limit, replace Standard . . . . . . . . . . . . . 100.15 - 100.18 mm
bushing. . . . . . . . . . . . . . . . . . . . . . . . (3.943 - 3.944 in.)
If bushing clearance (bushing I.D. minus pin O.D.) Wear Limit. . . . . . . . . . 100.05 mm (3.939 in.)
exceeds specification, replace bushing, piston pin or If piston diameter is less than wear limit, install a
both. new piston.
in this group.)
4/7/95 4-27
CYLINDER BORE If cylinder bore exceeds wear limit, replace cylinder

Inspection procedure.)
If cylinder is rebored, oversize pistons and rings
Measure cylinder bore diameter at three positions;
must be installed. Pistons and rings are available in
top, middle and bottom. At these three positions,
0.25 mm (0.010 in.) oversize.
measure in both directions; along crankshaft center
line and direction of crankshaft rotation. If clearance (cylinder bore I.D. minus piston O.D.)
exceeds specification, replace cylinder block, piston
NOTE: If engine has had a previous major or both; or rebore cylinder and install oversize piston
overhaul, oversize pistons and rings may and rings.
Deglazing
Top Position
deglazed with crankshaft installed in engine,
put clean shop towels over crankshaft to
protect journal and bearing surfaces from any
abrasives.
Middle Position
1. Deglaze cylinder bores using a flex-hone with
180 grit stones.
4 Bottom Position
2. Use flex-hone as instructed by manufacturer to
IMPORTANT: Do not use gasoline, kerosene or
Direction of commercial solvents to clean cylinder bores.
Crankshaft Rotation Solvents will not remove all abrasives from
cylinder walls.
Direction of 3. Remove excess abrasive residue from cylinder
Crankshaft walls using a clean dry rag. Clean cylinder walls
Centerline using clean white rags and warm soapy water.
no discoloration.
M82053A
Cylinder Bore I.D.:

Standard Size Bore:
Standard . . . . . . . . . . . . . 100.00 - 100.03 mm
. . . . . . . . . . . . . . . . . . . . . (3.9370 - 3.9382 in.)
Wear Limit . . . . . . . . 100.15 mm (3.9429 in.)
Clearance . . . . . . . . . . . . . 0.41 mm (0.016 in.)
0.25 mm (0.010 in.) Oversize Bore:

M82054A
Standard . . . . . . . . . . . . . 100.25 - 100.28 mm
. . . . . . . . . . . . . . . . . . . . . . . (3.947 - 3.948 in.)
Wear Limit. . . . . . . . . . 100.45 mm (3.955 in.)
4-28 4/7/95
Reboring NOTE: Measure bore when cylinder is cool.
NOTE: The cylinder block can be rebored to use 6. Stop press and check cylinder diameter.
0.25 mm (0.010 in.) oversize pistons and NOTE: Finish should not be smooth. It should have
rings. (See this group for cylinder bore I. D. a 30 - 40o crosshatch pattern.
specifications.)
1. Align center of bore to drill press center. mm (0.001 in.) of desired size.
IMPORTANT: Check stone for wear or damage. 8. Use a flex hone with 180 grit stones for honing to
Use a rigid hone with 300 grit stones. final size.
2. Adjust hone so lower end is even with lower end 9. Check bore for size, taper and out-of-round. (See
of cylinder bore. Inspection procedures.)
3. Adjust rigid hone stones until they contact IMPORTANT: Do not use solvents to clean
narrowest point of cylinder. cylinder bore. Solvents will not remove all
4. Coat cylinder with honing oil. Hone should turn metal particles and abrasives produced during
by hand. Adjust if too tight. honing.
5. Run drill press at about 250 RPM. Move hone up 10.Clean cylinder thoroughly using warm soapy
and down in order to obtain a 30 - 40°crosshatch water until clean white rags show no
pattern. discoloration.
4
30 - 40°
M52959
4/7/95 4-29
OTHER MATERIALS
Number Name Use
LOCTITE® PRODUCTS
U.S./
Canadian/
LOCTITE No.
TY15130/ John Deere Form-In-Place Seals crankcase extension housing and
NA/ Gasket rear oil seal case to engine block.
#395
SERVICE PARTS KITS

• Flywheel Mounting Cap Screws
4-30 4/7/95
CRANKCASE EXTENSION HOUSING

3. Remove oil dipstick and tube, if equipped.
NOTE: 4TN100LFB shown. 4TN100RJF is not
equipped with an oil dipstick tube.
Cap Screw (4)

M8 x 25 49 N•m (36 lb-ft)
21 N•m (180 lb-in.)
M82056
4
Oil Dipstick
Cap Screw Intake

M10 x 16 Manifold
Oil Dipstick John Deere

Tube Form-In-Place Gasket
O-Ring
Cap Screw (2)

M8 X 70
26 N•m (226 lb-in.) Cap Screw (4)
M8 x 35
21 N•m (180 lb-in.)
Cap Screw (6)

M12 X 85 Washer (6) Crankcase Extension
88 N•m (65 lb-ft) M82055A
Housing
4/7/95 4-31
CRANKSHAFT REAR OIL SEAL • Replace oil seal using a driver set. Install seal
with lip toward inside of gear housing cover.
Replacement Install seal 3.18 mm (0.125 in.) below surface of
cover.
• Replace oil seal using a driver set. Install seal,
with lip toward cylinder block. Install seal flush Timing Gear Cover
Rear Oil Seal

Seal Case-to-Block
Cap Screw (5)
M8 X 25
Crankshaft
26 N•m (226 lb-in.)
Front
Oil Seal
Oil Seal Case
M82058A
CRANKSHAFT AND MAIN BEARINGS

4
Removal
John Deere group.)
Form-In-Place
Gasket 3. Remove flywheel housing. (See procedure in this
Seal Case-to-Extension (RTV rubber group.)
Cap Screw (3) silicone sealant)
M8 X 25 4. Remove crankcase extension housing. (See
21 N•m (180 lb-in.) M82057A
5. Remove timing gear housing. (See Camshaft and
CRANKSHAFT FRONT OIL SEAL
Replacement
• Remove timing gear cover. (See Camshaft and IMPORTANT: Connecting rod end caps must be
Timing Gear Train in this section.) installed on the same connecting rods from
marks on caps and rods.
4-32 4/7/95
7. Remove connecting rod cap screws and end caps. 9. Remove main bearing cap screws, caps and cap
thrust bearings.
crankshaft. 10.Remove crankshaft.
IMPORTANT: Main bearing caps must be 11.Remove block thrust bearings and main bearing
installed on the same main bearings from inserts.
which they were removed. 12.Inspect all parts for wear or damage. (See
Crankshaft
Flywheel
End
Cap Thrust Bearing

Main Bearing Cap
M82059A
4/7/95 4-33

installation.
IMPORTANT: Do not touch bearing insert locations with arrows pointing toward flywheel
surfaces. Oil and acid from your finger will side of engine.
IMPORTANT: DO NOT use high speed power
1. Install grooved bearing inserts in crankshaft tools or air wrenches to tighten main bearing
bearing bores, aligning tangs with slots in bores. cap screws.
2. Install block thrust bearings with oil grooves 7. Dip entire main bearing cap screws in clean
facing away from engine block. engine oil. Install cap screws and tighten. DO
to align the thrust bearings.
NOTE: Main bearing caps have “raised arrows”
correspond to their location on the engine specifications. When tightening, start at center
If it does not turn easily, disassemble the parts
4 beginning with number 1, then 2, etc. The
and find the cause.
main bearing cap at gear train end does not
4-34 4/7/95
Crankshaft
Flywheel
End
Tangs
Cap Thrust Bearing

Smooth Bearing Insert
Main Bearing Cap

4
Dip in clean engine oil. 1
Initial: 136 N•m (100 lb-ft)
Final: 196 N•m (145 lb-ft)
2
M82059A
IMPORTANT: Connecting rod caps must be 12.Install timing gear housing. (See Camshaft and
installed on the same connecting rods they Timing Gear Train in this section.)
were removed from.
13.Install crankcase extension housing. (See
Never reuse connecting rod cap screws, procedure in this group.)
replace with new.
14.Install flywheel housing. (See procedure in this
10.Match the connecting rod caps to the rods using group.)
alignment marks. Install caps. 15.Install rear oil seal. (See procedure in this group.)
11.Dip entire connecting rod cap screws in clean
engine oil. Install new cap screws and tighten to
98 N•m (69 lb-ft).
4/7/95 4-35
Inspection/Replacement Heat gear to approximately 150o C (300o F). Install

gear with timing mark “A” toward press table. Align
1. Inspect gear for chipped or broken teeth. Replace slot in gear with key in shaft. Press crankshaft into
if necessary. gear until gear is tight against crankshaft shoulder.
To replace gear:
puller and a press. Key
Crankshaft Gear
CAUTION
DO NOT heat oil over 182° C (360° F). Oil Timing
Mark
area. Plan a safe handling procedure to avoid M82060A
burns.
2. Inspect crankshaft for bend using v-blocks and a
4 dial indicator. Turn crankshaft slowly and read
0.02 mm (0.0007 in.), replace crankshaft.
Dial Indicator
V-Block
M82061A
4-36 4/7/95
3. Measure crankshaft connecting rod journal and 4. Install bearing inserts and main bearing cap on
main bearing journal diameters. Measure several main bearing. Tighten main bearing cap screws to
places around each journal. 196 N•m (145 lb-ft).
NOTE: If engine has had a previous major 5. Measure main bearing diameter.
Main
Bearing
Journal
M82063
Connecting
Rod Journal
M82062A Main Bearing I.D.:
Standard . . . . . . . . . . . . . . 60.00 - 60.042 mm
Connecting Rod Journal O.D.: . . . . . . . . . . . . . . . . . . . . . (2.3622 - 2.3639 in.)
Standard . . . . . . . . . . . . . 59.952 - 59.964 mm Wear Limit. . . . . . . . . . 60.10 mm (2.3661 in.)
4
. . . . . . . . . . . . . . . . . . . . . (2.3603 - 2.3608 in.) Clearance . . . . . . . . . . . . . 0.09 mm (0.004 in.)
Wear Limit. . . . . . . . . . 59.90 mm (2.3583 in.) If bearing diameter exceeds wear limit, replace
bearing inserts.
Main Bearing Journal O.D.:
Standard . . . . . . . . . . . . . 69.952 - 69.964 mm main bearing journal O.D.) exceeds specification,
. . . . . . . . . . . . . . . . . . . . . (2.7540 - 2.7545 in.) replace bearing inserts and crankshaft or have
Wear Limit. . . . . . . . . . 69.90 mm (2.7520 in.) crankshaft journals ground undersize by a qualified
If journal diameter is less than wear limit, replace
undersize.
qualified machine shop.
6. Clean and inspect oil passages in main bearing
If journals are ground, undersize bearing inserts
journals, connecting rod journals and main
0.25 mm (0.010 in.) undersize. bearing bores in cylinder block.
7. Inspect crankshaft for cracks or damage. Replace
if necessary.
4/7/95 4-37
FLYWHEEL
• Inspect pilot bearing, if equipped, for wear or
Install bearing flush with flywheel surface.
across flywheel surface opposite of ring gear.
Measure clearance between straight edge and
flywheel surface with a feeler gauge. If M35337
clearance exceeds 0.02 mm (0.0008 in.), replace

flywheel.
Flywheel
Pilot Bearing
(4TN100RJF only)
4 Flywheel
Flywheel Mounting
Cap Screw (6)
Replace.
on threads.
196 N•m (145 lb-ft)
M82064A
4-38 4/7/95
FLYWHEEL HOUSING
2. Remove starter.
Housing-to-Block
Cap Screw (8) Flywheel
M10 X 25
49 N•m (36 lb-ft)
Plug
Housing-to-Extension Cap Screw (4)

M10 X 30
49 N•m (36 lb-ft) M82065A
4/7/95 4-39

OTHER MATERIALS
Number Name Use
LOCTITE® PRODUCTS
U.S./
Canadian/
LOCTITE No.
NA/ Gasket housing to engine block.
#395
4 TY9477/ (Medium Strength) cap screw.
#242
SERVICE PARTS KITS

4-40 4/7/95
CAMSHAFT
Mounting Cap Screws (2)
M8 X 16 Camshaft
Removal
section.)
group.)
NOTE: If a magnetic follower holder kit is not
available, turn engine until oil pan is
upward, to hold cam followers away from Timing Marks
M82066
camshaft.
NOTE: Due to the odd number of teeth on the idler • Apply clean engine oil on all parts during 4
group.)
section.)
4/7/95 4-41

Camshaft Gear
Key
Camshaft Gear
Side Gap M82067A
4 Camshaft Side Gap:

Thrust Plate
Standard . . . . . . . . . . . . . . . . . 0.05 - 0.20 mm
. . . . . . . . . . . . . . . . . . . . . (0.0020 - 0.0079 in.) M82068A
Wear Limit. . . . . . . . . . . 0.29 mm (0.0114 in.)

if necessary.
To remove/replace gear:
Dial Indicator
puller and a press.
CAUTION
Camshaft
fumes or oil can ignite above 193° C (380° F). Central Bearing
Use a thermometer. Do not allow a flame or Area
with the oil. Heat the oil in a well-ventilated V-Block
burns. M82069A
4-42 4/7/95
If journal diameters are less than wear limit, replace

camshaft.
housing end.
Lobe
Height
Camshaft Bushing
M82070A
Lobe Height:
Standard . . . . . . . . . . . . . 48.435 - 48.565 mm Oil Holes
. . . . . . . . . . . . . . . . . . . . . (1.9069 - 1.9120 in.) M82072
Wear Limit. . . . . . . . . . . 48.20 mm (1.897 in.)

If lobe height is less than wear limit, replace Camshaft Bushing I.D.:
camshaft. Standard . . . . . . . . . . . . . . . 56.98 - 57.05 mm
5. Measure camshaft end and intermediate journal . . . . . . . . . . . . . . . . . . . . . (2.2433 - 2.2461 in.)
diameters. Wear Limit. . . . . . . . . . 57.10 mm (2.2480 in.)
4
Clearance . . . . . . . . . . . . . 0.14 mm (0.006 in.)
Flywheel End If bushing diameter exceeds wear limit, replace
Journal
bushing.
To replace bushing:
Remove bushing using a chisel. Be careful not to
new bushing and cylinder block. Install bushing 1.6
Intermediate mm (0.062 in.) below surface of cylinder block
Journal using a driver set.
Gear Housing If bushing clearance (bushing I.D. minus camshaft
End Journal journal O.D.) exceeds specification, replace bushing,
M82071A
camshaft or both.
NOTE: Flywheel housing must be removed to
Camshaft Journal O.D.: measure camshaft intermediate and
Gear Housing and Flywheel Ends: flywheel end bearing diameters.
Standard . . . . . . . . . . . . . . . 56.91 - 56.94 mm 7. Measure intermediate and flywheel end camshaft
. . . . . . . . . . . . . . . . . . . . . (2.2406 - 2.2417 in.) bore diameters using the following procedures:
Wear Limit. . . . . . . . . . 56.80 mm (2.2362 in.) • Remove flywheel housing. (See Crankshaft,
Main Bearings and Flywheel in this section.)
Intermediate: • Remove plug using a long wooden dowel. Insert
wooden dowel through gear housing side.
Standard . . . . . . . . . . . . . . . 56.89 - 56.92 mm
. . . . . . . . . . . . . . . . . . . . . (2.2398 - 2.2409 in.)
Wear Limit. . . . . . . . . . 56.80 mm (2.2362 in.)
4/7/95 4-43
CAM FOLLOWERS
Plug
M35287 removed.
• Measure intermediate and flywheel end block bore to aid in installation.
camshaft bore diameters. 4. Remove cam followers.
Intermediate 6. Apply clean engine oil on all parts during
Bore installation.
4 Inspection
Flywheel
End • Inspect cam follower contact surface for
Bore
abnormal wear. Replace if necessary.
M82073
Camshaft Bore I.D.:

Standard . . . . . . . . . . . . . . . 57.00 - 57.03 mm
. . . . . . . . . . . . . . . . . . . . . (2.2441 - 2.2453 in.)
Wear Limit. . . . . . . . . . 57.10 mm (2.2480 in.)
Clearance . . . . . . . . . . . . . 0.12 mm (0.005 in.)
block.
If bore clearance (bore I.D. minus camshaft journal Normal Contact
cylinder block or both. Abnormal Contact M82074A

4-44 4/7/95
• Measure cam follower stem diameter. 3. Remove cap screw and washer.
4. Remove crankshaft pulley using a two-jaw puller
kit.
5. Remove key.
Pulley
Spacer
M82075A
Cam Follower Stem O.D.:

Standard . . . . . . . . . . . . . 14.218 - 14.233 mm
. . . . . . . . . . . . . . . . . . . . . (0.5598 - 0.5604 in.)
Wear Limit. . . . . . . . . . 14.17 mm (0.5579 in.)
Socket-Head
If stem diameter is less than wear limit, replace cam Cap Screw (4) 4
follower. M8 x 50
11
in.)N•m (96 lb- Cap Screw (4)
• Measure cam follower bore diameter in cylinder M10 x 20
block. Apply thread lock and
Fan sealer (medium strength)
to threads.
Cam Follower Bore I.D.: 65 N•m (47 lb-ft)
Standard . . . . . . . . . . . . . 14.249 - 14.270 mm M82076A
. . . . . . . . . . . . . . . . . . . . . (0.5610 - 0.5618 in.)
Wear Limit. . . . . . . . . . 14.30 mm (0.5630 in.) NOTE: It is not necessary to remove auxiliary drive
cover and gasket, end cover and o-ring or
Clearance . . . . . . . . . . . 0.052 mm (0.0020 in.) fuel injection pump gear cover to remove
If cam follower bore diameter exceeds wear limit, timing gear cover.
replace cylinder block. 6. Remove 18 mounting cap screws and timing gear
If bore clearance (bore I.D. minus follower stem cover.
O.D.) exceeds specification, replace cam follower, Installation is done in the reverse order of removal.
• Replace seal washer.
TIMING GEAR COVER • Tighten all mounting cap screws to 26 N•m (226
lb-in.).
Removal/Installation • Adjust fan/alternator drive belt tension. (See
2. Remove fan, spacer and pulley.
4/7/95 4-45
Mounting Cap Screw Gasket

M8 x 45 Auxiliary Drive Cover
Mounting Cap Screw Mounting Cap Screw (2)

M8 x 75 M8 x 50
Mounting Plate Cap Screw (2)

M8 x 20
Mounting Cap Screw

M8 x 45
O-Ring
End Cover
Cap Screw (2)
M8 x 20
Mounting Cap Screws

M8 x 45
Mounting Cap Screws
John Deere
M8 x 75
Form-In-Place
4 Gasket
(RTV
Mounting Cap Screw
M8 x 45
rubber silicone
sealant) Key
Crankshaft Pulley
Timing Gear Washer

Cover
Mounting Cap
Screw Injection Pump
M8 x 45 Gear Cover Cap Screw
Seal Washer M8 x 20
Cap Screw
Replace
Mounting Cap Apply thread lock and
Screw Mounting Cap sealer (medium strength)
M8 x 75 Screw (3) to threads.
Mounting Cap M8 x 45 Mounting Cap 115 N•m (85 lb-ft)
Screw Screw (2)
M8 x 40 M8 x 90 M82077A
IDLER GEAR NOTE: Due to the odd number of teeth on the idler
Removal/Installation gears are aligned, the piston closest to the
1. Remove timing gear cover. (See procedure in this water pump is at TDC on compression
group.) stroke. Number one cylinder is closest to the
flywheel.
Tests and Adjustments in this section.) 3. Rotate crankshaft and align timing marks.
4. Remove two cap screws, shaft and gear.
4-46 4/7/95
5. Inspect all parts for wear or damage. (See If bushing diameter exceeds wear limit, replace
Inspection/Replacement procedures.) bushing.
Installation is done in the reverse order of removal. To replace bushing:
Idler Gear (51T)
Idler Gear Shaft
Idler Gear
Bushing
Idler Gear
Shaft
Cap Screw (2)

M8 x 45 M82078A
M82079A
4
TIMING GEAR HOUSING
Idler Gear Shaft O.D.: 2. Remove idler gear. (See procedure in this group.)
Standard . . . . . . . . . . . . . . 45.95 - 45.975 mm 3. Remove fuel injection pump. (See Fuel System in
. . . . . . . . . . . . . . . . . . . . . (1.8091 - 1.8100 in.) this section.)
Wear Limit. . . . . . . . . . . 45.9 mm (1.8071 in.) 4. Remove mounting cap screws and housing.
If shaft diameter is less than wear limit, replace idler Installation is done in the reverse order of removal.
gear shaft.

Standard . . . . . . . . . . . . . . 46.00 - 46.025 mm
. . . . . . . . . . . . . . . . . . . . . (1.8110 - 1.8120 in.)
Wear Limit. . . . . . . . . . 46.09 mm (1.8146 in.)
Clearance . . . . . . . . . . . 0.075 mm (0.0030 in.)
4/7/95 4-47
John Deere
Timing Gear
Housing
Mounting Cap Screw

M8 x 45
25 N•m (220 lb-in.)
4 Mounting Cap Screw (4)

M8 x 35 Mounting Cap Screw (5)
21 N•m (180 lb-in.) M8 x 20
25 N•m (220 lb-in.) M82080A
AUXILIARY DRIVE GEAR - IF

EQUIPPED Auxiliary
Drive Gear
Remove timing gear cover. (See procedure in this
group.)
NOTE: Bearings are slip fit in timing gear housing Ball
and cover and press fit on drive gear ends. Bearing
Inspect all parts for wear or damage. Replace as

necessary.
M82081
4-48 4/7/95
Lubrication System
OTHER MATERIALS
Number Name Use
LOCTITE® PRODUCTS
U.S./
Canadian/
LOCTITE No.
TY15130/ John Deere Form-In-Place Seals oil pan to crankcase

#395
TY9375/ John Deere Pipe Sealant Apply to threads of plug in oil cooler.
TY9480/ with TEFLON®
#592

4/7/95 4-49
Lubrication System
OIL PAN AND STRAINER • Replace all O-rings and copper washers, if
equipped.
Removal/Installation • Fill engine with proper engine oil. (See
• Approximate crankcase oil capacity is 12.7L
(13.4 qt.).
Drain Plug
Assembly
(4TN100LFB)
Copper Washer (2)

Replace
4 Cap Screw (4)
M8 x 30
21 N•m (180 lb-in.) Drain Plug
(4TN100RJF)
O-Ring
(4TN100RJF)
Replace
O-Ring
Replace
John Deere
Form-In-Place Gasket Oil Strainer Tube
sealant)
Cap Screw with

Lock Washer (2)
M8 x 16
26 N•m (226 lb-in.)
Oil Pan Cap Screw (2)
M8 x 16
Cap Screw (4) Cap Screw (18) 26 N•m (226 lb-in.)
M8 x 30 M8 x 85
21 N•m (180 lb-in.) 26 N•m (226 lb-in.) M82082A
4-50 4/7/95
Lubrication System
OIL PUMP • Coat all parts with clean engine oil.

• Install outer rotor with identification mark
Removal/Installation facing toward rotor shaft assembly.
Safety Valve
Housing Non-Adjustable.
2. Check oil pump gear backlash. Replace entire oil Outer Rotor
Do not remove.
(0.010 in.). Cap Screws
M6 x 25
3. Remove idler shaft and gear. (See Camshaft and 6 N•m (53 lb-in.)
4. Remove two mounting cap screws, oil pump and
gasket.
Disassembly/Assembly procedures).
Identification
Mounting Cap Screw Mark
M8 x 16 Rotor Shaft
Oil Pump Oil Pump Cap Screw (2)
Gasket 25 N•m (18 lb-ft) Assembly
M6 x 16
6 N•m (53 lb-in.)
M51574
4
Inspection
• Check rotor shaft outer diameter and the shaft
hole diameter in housing. If clearance is more
than 0.20 mm (0.008 in.), replace entire
assembly.
Housing Rotor Shaft Assembly

Mounting Cap Screw
M8 x 50
25 N•m (18 lb-ft) M51568
• Do not remove gear to remove cap screws. Do
not disassemble rotor shaft assembly other than
M51570
shown. If any parts are worn or damaged,
replace as an assembly.
4/7/95 4-51
Lubrication System
• Check outer rotor recess. If outer rotor is below

face of pump housing more than 0.25 mm
(0.010 in.), replace entire assembly. Feeler Gauge
Inner Rotor
Feeler Gauge
Straight Edge
Outer Rotor M51573
Housing
Outer Rotor M51571

OIL COOLER
• Check outer rotor-to-pump housing clearance. If this section.)
clearance is more than 0.25 mm (0.010 in.), • Replace O-ring, copper washer and gaskets.
replace entire assembly. Damaged or used parts will leak.
• Pressure test oil cooler. (See Checks, Tests and
Adjustments section.)
4 Outer Rotor
NOTE: Oil cooler adapter is slip fit on water pump
with an O-ring seal.
Feeler Gauge
Water Pump
Housing
M51572

clearance is more than 0.25 mm (0.010 in.),
replace entire assembly. O-Ring
Oil Cooler
Adapter M51577
4-52 4/7/95
Lubrication System
Cap Screw (10) Oil Cooler

M8 x 50 Housing
24 N•m (18 lb-ft)
Gasket
Plug
Copper
Washer Oil Cooler
Flange Nut (4) Gasket (2)

49 N•m (36 lb-ft)
Gasket
Adapter Cap Screw
M8 x 25
Cap Screw (8)
24 N•m (18 lb-ft)
M8 x 35
24 N•m (18 lb-ft)
Cap Screw
Oil Cooler
M8 x 20 4
Cap Screw (3) 24 N•m (18 lb-ft)
By-Pass Valve
M8 x 20 Plug
Oil Pressure 24 N•m (18 lb-ft) Apply Pipe Sealant
Regulating Valve M82083A
with TEFLON.
NOTE: See OIL COOLER BY-PASS VALVE and

OIL PRESSURE REGULATING VALVE
if service is necessary.
Copper
OIL COOLER BY-PASS VALVE Washer
NOTE: Oil cooler is removed to show detail. Plug

• Inspect parts for wear or damage. Check spring Valve
free and compressed lengths. Replace parts as Spring
necessary.
M51578
• Replace copper washer. A used washer may
leak.
Free Length . . . . . . . . . . . . .63 mm (2.480 in.)
. . . . . . . . . . . . . . . . . @ 3.75N (0.840 lb force)
4/7/95 4-53
Lubrication System
OIL PRESSURE REGULATING VALVE PISTON COOLING NOZZLES

NOTE: Oil cooler is removed to show detail.
Replacement
• Inspect parts for wear or damage. Check spring
free and compressed lengths. Replace parts as 1. Remove oil pan and strainer. (See procedure in
necessary. this group.)
• Install nozzle with locating pin in locating hole
of cylinder block.
Piston
Cooling
Shim Nozzle
If equipped
Plug
Valve
Spring
Copper
Washer M51579 Mounting Bolt
15 N•m (130 lb-in.) M51580
• Replace copper washer. A used washer may

4 leak.
NOTE: Valve assembly may or may not be equipped
with shims. Locating Pin
Free Length . . . . . . . . . . . . 51 mm (2.010 in.).
. . . . . . . . . . . . . . . . . @ 5.40N (1.200 lb force)
M51581
4-54 4/7/95
Cooling System
OTHER MATERIALS
Number Name Use
LOCTITE® PRODUCTS
U.S./
Canadian/
LOCTITE No.
TY9375/ John Deere Pipe Sealant Apply to threads of coolant temperature
TY9480/ with TEFLON® sender, heater hose fitting and adapter
#592 fitting.
TY9370/ Thread Lock and Sealer Apply to threads of fan-to-spacer
TY9477/ (Medium Strength) cap screws.
#242
® TEFLON is a registered trademark of the Du Pont Company.

4/7/95 4-55
Cooling System
COOLANT TEMPERATURE SENDER

• Replace copper washer. Cap Screw (4)
M6 x 14
• Test sender. (See Checks, Tests and Adjustments 20 N•m (180 lb-in.)
in this section.)
Cover
• Apply Pipe Sealant with TEFLON, or equivalent
to threads of sender. Cover
Gasket
Thermostat
Coolant Temperature
Sender
Copper
Washer Gasket
Water Pump M82084A
4 THERMOSTAT
• Replace gaskets. M82085A

4-56 4/7/95
Cooling System
WATER PUMP 5. Remove four socket head cap screws, spacer and
pulley.
Removal/Installation 6. Remove five mounting cap screws, pump and
gasket.
3. Remove alternator slide bracket-to-water pump
cap screw.
• Replace gasket and o-ring.
4. Remove four cap screws and fan.
Alternator Slide Bracket

Gasket
Cap Screw
M8 x 20

M8 x 65
O-Ring 26 N•m (226 lb-in.)
Pulley
Fan 4
Water Pump Spacer
Cap Screw (4)

M10 x 20
Socket-Head Apply thread lock and
Cap Screw (4) sealer (medium strength)
M8 x 50 to threads.
11 N•m (96 lb-in.) 65 N•m (47 lb-ft)
M82086A
4/7/95 4-57
Cooling System
Disassembly 3. Remove two screws, adapter and gasket.

1. Remove thermostat. (See procedure in this 4. Remove two M8 cap screws and nuts.
group.) 5. Apply heat to six plate-to-housing screws.
2. Remove coolant temperature sender. (See Remove screws, plate and gasket.
Heater Hose Fitting

Adapter-to-Plate Screw (2) Apply Pipe Sealant with
Plate
15 N•m (134 lb-in.)
Adapter Fitting
Gasket Apply Pipe Sealant with
TEFLON to threads.
Nut (2) 23 N•m (199 lb-in.)
Cap
4
Copper
Washer
Adapter
Plug
15 N•m (130 lb-in.)
Gasket
Cap Screw (2)
M8 x 60
15 N•m (134 lb-in.)
Pulley
Impeller Flange
Seal Cup Ceramic

Seal
Shaft Seal
Water Pump Bearing

Housing Shaft
M82087A
4-58 4/7/95
Cooling System
6. Apply extreme heat to pulley flange. Remove IMPORTANT: Support pump housing on
flange using a knife-edge puller set and two small bearing shaft only. DO NOT support on
nuts. housing or damage to housing will occur.
hub facing away from housing. Press pulley
Two Small Nuts flange onto bearing shaft until bottom of flange is
Pulley Flange
Knife-Edge
11 mm (0.433 in.) from top of housing.
Puller Set
Water Pump must be clean and dry.
Housing
M35645
4. Install seal cup and ceramic seal in impeller.
5. Install a knife-edge puller around bearing shaft,
7. Place water pump assembly on a press table. between pulley flange and pump housing. Place
Install supports under water pump housing, pump housing, with knife-edge puller down, on a
staying clear of impeller. Press bearing shaft press table. Install impeller with ceramic seal
assembly through water pump housing using a toward shaft seal. Press impeller on bearing shaft
piece of pipe or a deep socket. until shaft end is flush with impeller ID surface
OR clearance between impeller and pump
IMPORTANT: Impeller bore is tapered. When housing is 0.30 - 1.10 mm (0.012 - 0.043 in.). 4
impeller bore to prevent cap screw from Bearing Shaft End
Clearance
binding. Specification
knife-edge puller, a 3/8 in. cap screw and a press.
necessary. Impeller ID
Assembly M51567
NOTE: Replace shaft seal, ceramic seal, seal cup, 6. Install new gasket, plate, six screws, two cap
gaskets and copper washer. screws and nuts.
1. Install bearing shaft into pump housing, long end 7. Install new gasket, adapter and screws.
down, using a piece of pipe or deep socket and a
8. Install coolant temperature sender. (See
press. Press shaft into pump housing until bearing
9. Install thermostat. (See procedure in this group.)
press.
4/7/95 4-59
Fuel System

SERVICE PARTS KITS

4-60 4/7/95
Fuel System
FUEL SUPPLY PUMP

NOTE: Oil will leak out of fuel injection pump
housing when shaft or pump body is
removed.
• Inspect all parts for wear or damage. Replace as Fill Plug
necessary.
Replace all o-rings and copper washers. Damaged or
used parts will leak.
Fuel Supply Pump
• Replace seal if necessary. Remove seal using a
blind-hole puller set. Install seal, lips toward
holder, flush with pump body.
• Install holder into pump body with small hole in
holder toward bottom of pump body.
Fuel injection pump can become damaged if External Lube Line
operated dry or without proper amount of oil. Tighten mounting bolt to
15 N•m (130 lb-in.)
After fuel supply pump is installed, disconnect
M82089
external lube line to fuel injection pump housing. 4
Remove fill plug and add clean engine oil to
housing. Add until oil begins to drip out of lube line
hole (For proper oil specification see
4/7/95 4-61
Fuel System
Supply Pump-to-
Filter Hose
Hose Clamp
Cover
Fitting
Copper
Washer Hand Primer
Assembly
Fitting
Copper
Washer
O-Ring Gasket Retaining
Wire
Spring (2)
Roller
Valve (2)
Shaft
Lock Washer (3) Washer (2)
4
Mounting Nut (3) Seal
Holder Slide Pivot (2)
11 N•m (96 lb-in.)
Pump
Shaft Body
Plunger
Spring
Copper
Plug Washer M82088A
4-62 4/7/95
Fuel System
FUEL FILTER ASSEMBLY

End Cap Nozzle Leak-Off Bleed Valve Rubber Washer

Nozzle Leak-Off Hose (Long) *
Hose (Short) (3)
Bleed Valve
* *
Mounting Cap
Screw (2) *
To
** Fuel Tank
Mounting
Bracket
Fuel Filter 4
Fuel Supply
Pump-to-Filter Hose Fuel Filter-to-Injection
Pump Hose
Injection Pump
Bleed-Off Hose
*Copper Washers
Replace
Air Vent
*
Check Valve From
Fuel Tank M82090A
4/7/95 4-63
Fuel System

pump.
cardboard. Protect hands and body from 3. Loosen line clamp and remove fuel injection
high pressure fluids. lines.
If an accident occurs, see a doctor 4. Disconnect hoses to/from fuel filter.
hours or gangrene may result. Doctors 6. Scribe an alignment mark across injection pump
unfamiliar with this type of injury should and gear case housing.
4 Illinois, U.S.A.
Line Clamp Injection Pump Bleed-Off-to-Filter Hose
Fuel Injection Line Fuel Injection Fuel Supply Pump-to-Filter Hose

Fuel
Filter-to-Injection
Pump Hose
Oil Filler Neck

Assembly and Gasket
Delivery
Valve (4)
Mounting Cap
Screws
Cap Screw (2)
Alignment Mark
Mounting Cap Screw External

Lube Line Mounting Cap Screw (3) M82091
4-64 4/7/95
Fuel System
7. Remove two cap screws, oil filler neck assembly

and gasket. Gear Case Housing
Injection Pump Gear
8. Use chalk or paint to mark injection pump gear to
O-Ring
notch on gear case housing.
Alignment Mark Notch
Injection Pump Gear Case Injection Pump

Housing
M51585
Injection Pump
Notch Gear 5. Install new gasket, oil filler neck assembly and
two cap screws.
M51583
7. Install fuel injection lines and tighten line clamp
9. Remove six mounting cap screws, injection pump cap screws.
and o-ring.
DO NOT attempt to service the injection pump or injection pump housing, add oil as necessary.
governor. If unit is in need of repair, it must be Fuel injection pump can become damaged if
serviced by a qualified fuel injection repair shop. If operated dry or without proper amount of oil. 4
8. Remove fill plug and add clean engine oil to
Installation external lube line inlet. (For proper oil
1. Install new o-ring on injection pump. specification see SPECIFICATIONS AND
2. Put injection pump onto gear case housing. Align
mark, made on injection pump gear during 9. Install external lube line. When installing line,
removal, with notch on housing. put one copper washer between mounting bolt
3. Install six mounting cap screws. Do not tighten. line and housing.
4. Align marks on housing and injection pump, If new injection pump is being installed, check and
made during removal, and tighten mounting cap adjust injection pump static timing. (See Checks,
screws. Tests and Adjustments in this section.)
4/7/95 4-65
Fuel System
Line Clamp Injection Pump Bleed-Off-to-Filter Hose
Fuel Injection Fuel Supply Pump-to-Filter Hose

Lines
Fuel
Filter-to-Injection
Pump Hose
Oil Filler Neck

Assembly and Gasket
Oil Fill
Plug
Mounting Cap Screws
M8 x 90
27 N•m (20 lb-ft)
Lube Line-to-Block
Bolt
25 N•m (217 lb-in.) Cap Screw (2)
M8 x 25
External Lube
Line Inlet Alignment Mark
Tighten Mounting Bolt
to 15 N•m (130 lb-in.) Mounting Cap Screw External Mounting Cap Screw (3)
M8 x 16 Lube Line M8 x 25
27 N•m (20 lb-ft) 27 N•m (20 lb-ft)
M82091

(HOLE-TYPE)
CAUTION
Removal/Installation Escaping fluid under pressure can penetrate
IMPORTANT: Never steam clean or pour cold hazard by relieving pressure before
water on injection pump while the pump is disconnecting hydraulic or other lines.
running or warm. Doing so can damage the Tighten all connections before applying
pump. pressure. Search for leaks with a piece of
1. Clean the injection pump lines and area around cardboard. Protect hands and body from
the pump using a parts cleaning solvent or steam high pressure fluids.
cleaner. If an accident occurs, see a doctor
must be surgically removed within a few
Illinois, U.S.A.
4-66 4/7/95
Fuel System
NOTE: Nozzles are matched to the cylinders. If

removing more than one nozzle, tag nozzles, Large Nuts
according to the cylinder from which it was Flat
Washer
removed. Cap Screw
2. Loosen fuel injection line connectors-to-nozzles Old Injection
slightly to release pressure in the fuel system. Line Nut
3. Loosen line clamp and remove fuel injection Injection

Nozzle
lines.
4. Remove clamps and leak-off hoses.
M82126
5. Remove nuts and retaining plates.
6. Remove injection nozzle, ring and teflon heat 7. Test injection nozzles. (See Checks, Tests and
protector. If ring and protector stay in cylinder Adjustments in this section.)
from cylinder head. Disassembly/Assembly
Retaining Plate parts for each nozzle separate from one
Hose Clamp
another.
Nut (2)
5 N•m
Leak-Off Hose Cleaning/Inspection procedures.) 4
(39 lb-in.)
Injection this section.)
Nozzle
Ring
Heat
Protector
Replace.
Injector Body
M82092A Shims (as required)
If nozzles are stuck in cylinder head:

Spring
• Grind the head of a cap screw so it fits inside a
nut from an old injection line. Spring Seat
• Use two nuts to attach a large flat washer to the Separator Plate
cap screw. Nozzle Valve
Index
• Install assembly onto nozzle and use a puller and Pin (2)
slide hammer to pull nozzle from cylinder head. Nozzle Body
Retaining Nut
43 N•m (31 lb-ft)
M82093A
4/7/95 4-67
Fuel System
Cross Section 1. Remove anti-corrosive grease from new or

reconditioned nozzles by washing them
Injector IMPORTANT: Never use a steel brush to clean

Body nozzles as this will distort the spray hole.
2. Remove carbon from used nozzles, and clean by
washing in diesel fuel. If parts are coated with
hardened carbon or lacquer, it may be necessary
Fuel Return
Pipe Cleaning Kit).
nicks or scratches.
Shim body. Contact area of separator plate (both parts)
(as required) must not be scored or pitted. Use an inspection
making the inspection.
Spring
4 for wear. If contact surface is more than 0.10 mm
Spring Seat
Index Pin (2) Nozzle Contact Index Pin
Surface
Separator Plate Separator
Retaining Nut
Nozzle Body
Nozzle Valve
Nozzle Body
M37684
M82094A

4-68 4/7/95
Fuel System

performing a slide test. Use the following
procedure:
valve in nozzle body.
• Hold nozzle vertical, and pull valve out about
1/3 of its engaged length.
• Release valve. Valve should slide down to its
seat by its own weight.
Replace nozzle assembly if the valve does not slide
freely to its seat.
Nozzle Valve
Piston Part of
Nozzle Valve
Nozzle Body
4
M82095A
4/7/95 4-69
Starter (Nippondenso 1.4 kW)
STARTER MOTOR 8. Inspect and test brushes, holder, field coil and
Disassembly
1. Remove two cap screws and two screws. Seal Ring
If equipped
2. Remove rear cover and thrust washer, if
equipped. Field Coil
Housing
Thrust
Washer
Wiring Lead
Cap Screw (2) Rear Cover Armature
M82098
Screw (2) M82096
4
3. Remove field coil brushes from brush holder. Assembly
4. Pry brush springs away and pull negative brushes Assembly is done in the reverse order of
up enough to allow spring to hold brush in place. disassembly.
5. Remove brush holder. • Apply multipurpose grease to bearing cup inside
rear cover.
Field Coil Brush (2) IMPORTANT: When installing rear cover, be
cover.
Brush Spring (2)
is below minimum.
Brush Holder NOTE: Test brush holder using an ohmmeter or test

light.
Negative Brush (2) 2. Test brush holder:
M82097
6. Disconnect wiring lead and relay leads, if continuity, replace the brush holder.
equipped. 3. Inspect springs for wear or damage. Replace if
7. Remove field coil housing, armature and o-ring, necessary.
if equipped.
4-70 4/7/95

Spring (4) solvent. Solvent can damage insulation on
brush.
Negative Brush 7. Inspect armature. Look for signs of dragging
Holder against pole shoes.
finished.
Field Brush NOTE: Test armature windings using an ohmmeter
Holder
or test light.
Brush
Length 9. Test for grounded windings:
M82099
light. If test shows continuity, a winding is grounded and
the armature must be replaced. 4
necessary. 10.Test for open circuited windings:
5. Test for grounded field winding: Touch probes on two different commutator bars. If
Touch one probe of tester to field coil brush and the armature must be replaced.
the coil is grounded and the field coil housing Commutator Bars
Field Coil Brush
Field Coil
Housing
M82100
4/7/95 4-71

Put armature in a growler and hold a hacksaw Rear Cover Bearing
armature. Housing Bearing

armature again. If the test still indicates a short M82102
Hacksaw Blade
SOLENOID
Armature
1. Remove two socket head screws, end cap and
shim(s).
4
Growler M82125A
End Cap
To replace bearings: Shim(s)

side toward armature. M37820

equipped.
3. Remove two cap screws.
4. Remove starter motor assembly from bearing
housing.
4-72 4/7/95
8. Remove two cap screws, plunger, spring, shims

and solenoid.
Wiring Lead
End Frame
Shim(s)
Solenoid
Cap
Assembly Cap Screw (2)
M82096
Plunger
Spring
5. Remove three cap screws. M37824
6. Separate end frame assembly from bearing 9. Remove shims from ring gear shaft.
housing.
End Cap Screw (3)

Frame
Assembly 4
Shims

10.Remove pivot bolt, clutch fork and clutch

7. Inspect seal and needle bearing for wear or assembly.
11.Inspect shoes on fork for wear or damage.
To replace needle bearing: Replace fork if necessary.
new bearing flush with housing surface using a Shoes
End Frame Clutch
driver set. Assembly
Bearing Housing
Pivot Bolt
Seal
Clutch Fork
M37825
Needle Bearing
M37823
4/7/95 4-73
Replace bushing using a driver set. Install bushing 16.Inspect all parts for wear or damage. Replace as
flush with face of housing. necessary.
Clutch
Snap Ring
Spring
Spring Cap
End Frame Washer
Bushing M37830 M37829
13.Slide pinion stopper away from retaining wire

using a piece of pipe or deep socket. Remove Assembly
retaining wire, pinion stopper, and clutch Assembly is done in the reverse order of
assembly from ring gear shaft. disassembly.
14.Inspect all parts for wear or damage. Replace as • After installing clutch assembly, pinion stopper
necessary. and retaining wire on ring gear shaft, use two
4 pliers to press pinion stopper over retaining
Clutch Pinion wire.
Assembly Stopper
Retaining
Wire
Retaining Pinion
Ring Gear Stopper
Wire
Shaft
M37827 Clutch
Assembly
15.Remove snap ring, washer, spring cap, and spring M37831
from clutch.
4-74 4/7/95
Alternator (Hitachi 25A)
VOLTAGE REGULATOR
Attaching Screw (4)

M5
4 N•m (31 lb-in.)
Stator

Grommet M5
4 N•m (31 lb-in.)
Wire Clamp
Front Frame
End Frame
M82108
Replacement 7. Use a soldering gun with at least 120 watt

capacity to disconnect five terminals. Replace
1. Remove three screws and cover. voltage regulator.
2. Remove four attaching screws, wire clamp and • If additional solder is needed, use ONLY 60-40 4
4. Remove two nuts and insulator. ALTERNATOR
Disassembly
6. Remove two screws and insulator. 2. Remove four attaching screws, wire clamp and
grommet.

Terminals
M5
Regulator
Brush
Holder
Screw (2)
M51602
Grommet

Wire Clamp
M82108
4/7/95 4-75

Stator Assembly
necessary.
Rotor Assembly M36730
4 Rear Bearing
Screw (3)
2 N•m (16 lb-in.)
Clip Bushing
Rotor
Spacer
Retainer
Nut
Front M14
Front
Frame
Fan
Sheave
Lock
Washer
M82109A
4-76 4/7/95

in place.
Insulator
End
Frame Access Hole

M5
4 N•m (31 lb-in.) M51595

rectifier. 4
Inspection/Test
Rectifier
Rotor:
Leads (3)
M51605

Assembly
disassembly.
Slip Rings M82110A
(needle movement).
4/7/95 4-77

Ohmmeter
this group.)
Rotor Shaft
Slip Rings M82111A

Brushes: Stator:
• Inspect brush holder and brushes for damage. • Inspect stator for defective insulation,
Brushes must slide freely and the springs must discoloration or a burned odor. If any of these
hold the brushes firmly against the slip rings of defects are found, replace stator.
the rotor.
limit line on brushes. Replace brushes as • Touch probes of an ohmmeter to lead wires of
necessary. stator in three possible combinations. Continuity
4 should read approximately 0.26 ohms. If
Brush Length
Ohmmeter
Rectifier
Voltage
Regulator
Brushes Stator
M82113A

Ground
Stud
Brush
Holder
Soldered
Connection
M82112
4-78 4/7/95

Ohmmeter directions. An open diode would have no continuity
in either direction. Replace the rectifier assembly if
any of the six diodes are defective.
connection.
Stator
M82114A
Rectifier: Soldered
Connection
post.
• Test the diodes by touching probes to output
post and the three outer terminals. Outer
4
Outer
• Switch the probes and check each terminal Terminal Terminals
post. Output Ground
Post Post M82115
4/7/95 4-79
Diagnosis
PROBLEM OR


SYMPTOM


uses too much fuel.

noisy, vibrates or
stalls frequently.
or starts hard.
too much oil.

CHECK OR
is incorrect.
level high.
SOLU-
the oil.
TION

● ● ● ● ● ● ●
Replace.
4 Muffler or exhaust manifold leak. ● ●
timing incorrect.
● ●
connectors.
warped head.
● ● ● ● ● ●
load.
Test.
● ● ● ● ●
incorrect.
● ● ● ● ● ● ●
leaking.
● ● ● ● ● ● ● ● ●
damaged.
Turbocharger ● ●
4-80 4/7/95
Diagnosis

Conditions:

filter.
- Cooling System
Fan belt tight, not glazed or cracked. Replace and adjust belt tension. 4
intake. tight.
- Air Intake System
Check
filter element.
position.)
4/7/95 4-81
Diagnosis

cable. correctly.
9. Intake and Cold engine valve clearance of Check and adjust. (See Checks, Tests
exhaust valves. 0.30 mm (0.012 in.). and Adjustments in this section.)
Machine TM.
4 11. Injector ports. Minimum compression of 2942 kPa Perform cylinder compression test.
(Key in START (427 psi) with a 588 kPa (85 psi) (See Operational Tests in this section.)
position.) maximum difference between
cylinders.
12. Flywheel and Minimum cranking rpm - 300 rpm. See Starter Amp Draw Test in
starter. ELECTRICAL section of Machine
TM.
Repair Shop.
14. Injection pump Slow idle at 900 + 50 rpm. Fast idle at See Slow Idle and Fast Idle
idle settings. 2375 + 50 rpm. Adjustments in ENGINE section of
15. Oil pressure Minimum oil pressure at 900 rpm is Test engine oil pressure. (See
sender port. 98 kPa (14 psi). Operational Tests in this section.)
(Engine at Opening temperature 71°C (160°F) or
operating 85°C (184°F).
temperature.)
4-82 4/7/95
VALVE CLEARANCE CHECK AND

ADJUSTMENT
Cylinders
Reason: 1 2 3 4
Flywheel End
E I E I E I E I
Fan End
Equipment:
• Feeler Gauge
No. 1 Piston at TDC
Procedure: T6479AB
1. Remove rocker arm cover.

2. Remove plug from timing hole on flywheel until clearance is 0.30 mm (0.012 in.). Hold screw
housing. while tightening nut.
its highest point.
3. Turn crankshaft pulley clockwise until No.1 Feeler
cylinder TDC mark on flywheel aligns with index Gauge
mark on flywheel housing.
4
TDC Mark on
Flywheel
Index Mark on T6105BF

Flywheel Housing
This puts the piston in No. 4 cylinder at TDC
compression stroke.
T6469AJ
push rods.
Cylinders
If rocker arm push rods are not loose, rotate 1 2 3 4
flywheel one revolution (360°). If both rocker arm E I E I E I E I
Flywheel End

Fan End
compression stroke.
No. 4 Piston at TDC
T6479AB
4/7/95 4-83
CONNECTING ROD SIDE PLAY Equipment:

CHECK • PLASTIGAGE®
Reason: Procedure:
the same direction to prevent crankshaft and
Equipment: connecting rod damage.
• Feeler Gauge 1. Remove connecting rod cap.
Procedure: 2. Wipe oil from bearing insert and crankshaft

journal.
between connecting rod cap and crankshaft. 3. Put a piece of PLASTIGAGE, or an equivalent,
PLASTIGAGE M35351
Feeler Gauge
4. Turn crankshaft approximately 30° from bottom
dead center.
M82116A
5. Install connecting rod end cap and original cap
screws. Tighten cap screws to 118 N•m (87 lb-
Specifications: ft).
Standard Clearance . . . . . . . . 0.20 - 0.40 mm 6. Remove cap screws and connecting rod cap.
. . . . . . . . . . . . . . . . . . . . . (0.0079 - 0.0157 in.)
Wear Limit. . . . . . . . . . . 0.45 mm (0.0177 in.) on either the bearing insert or crankshaft
journal.
Results:
• If side play exceeds wear limit, replace compare the width of the flattened
connecting rod and connecting rod cap. PLASTIGAGE at its widest point.
CONNECTING ROD BEARING the graduation marks indicates the bearing
CLEARANCE CHECK clearance in inches or millimeters depending on
Reason:
4-84 4/7/95
9. Remove PLASTIGAGE. 3. Zero the dial indicator.

Graduation Marks
on Envelope
Flattened
PLASTIGAGE M82117A
Specifications:
. . . . . . . . . . . . . . . . . . . . . (0.0014 - 0.0035 in.) Dial Indicator
Wear Limit. . . . . . . . . . . 0.15 mm (0.0059 in.)
Crankshaft M82118A
• If clearance exceeds wear limit, replace bearing Standard Clearance . . . . . . 0.132 - 0.223 mm 4
inserts. . . . . . . . . . . . . . . . . . . . . . (0.0052 - 0.0088 in.)
®PLASTIGAGE is a registered trademark of the DANA Wear Limit. . . . . . . . . . . 0.29 mm (0.0114 in.)
Corporation.
Results:
CRANKSHAFT END PLAY CHECK • If end play exceeds wear limit, replace thrust
bearings.
Reason:
To determine proper side clearance between CRANKSHAFT MAIN BEARING
crankshaft and engine block. CLEARANCE CHECK
Equipment: Reason:
• Dial Indicator To measure oil clearance between main bearing and
crankshaft journal.
Procedure:
NOTE: Crankshaft end play can be measured at Equipment:
front end or rear end of crankshaft. • PLASTIGAGE®
Procedure is performed from the rear end.
The flywheel is removed to show detail. Procedure:
IMPORTANT: Main bearing caps must be
indicator tip on end of crankshaft.
installed on the same main bearing and in the
IMPORTANT: Do not use excessive force when same direction to prevent crankshaft and main
moving crankshaft to avoid damaging bearing damage.
bearings. 1. Remove main bearing cap.
2. Push crankshaft toward rear as far as possible. 2. Wipe oil from bearing insert and crankshaft
journal.
4/7/95 4-85
3. Put a piece of PLASTIGAGE, or an equivalent, Results:

inserts.
ration.
VALVE LIFT CHECK

PLASTIGAGE
Reason:
M35382
Equipment:
• Dial Indicator
cap screws to 196 N•m (145 lb-ft). Procedure:
5. Remove cap screws and main bearing cap. 1. Adjust valve clearance. (See procedure in this
group.)
on either the bearing insert or crankshaft 2. Remove rocker arm cover. (See Cylinder Head,
4 journal. Valves and Manifolds in this section.)
6. Use the graduation marks on the envelope to 3. Fasten dial indicator to engine and position
compare the width of the flattened indicator tip on valve retainer. Valve must be
PLASTIGAGE at its widest point. fully closed and rocker arm must move freely.
7. Determine main bearing clearance. The number 4. Zero the dial indicator.
within the graduation marks indicates the bearing 5. Manually turn crankshaft pulley clockwise (from
clearance in inches or millimeters depending on fan end).
8. Remove PLASTIGAGE. full open position. Valve lift (intake and exhaust)
Graduation Marks
on Envelope
Flattened
PLASTIGAGE
M82119AE
Specifications: T6333DT

. . . . . . . . . . . . . . . . . . . . . (0.0014 - 0.0037 in.)
Wear Limit. . . . . . . . . . . 0.09 mm (0.0040 in.)
4-86 4/7/95
Results: 4. Zero the dial indicator.

• If valve lift is less than specification, remove and 5. Pull camshaft forward as far as possible.
section.)
CAMSHAFT END PLAY CHECK
Reason:
camshaft gear end journal and thrust plate.
M37512
Equipment:
• Dial Indicator Specifications:
Standard Clearance . . . . . . . . 0.05 - 0.20 mm
Procedure: . . . . . . . . . . . . . . . . . . . . . (0.0020 - 0.0079 in.)
1. Remove timing gear cover. (See Camshaft and Wear Limit. . . . . . . . . . . 0.29 mm (0.0114 in.)
2. Fasten dial indicator to engine and position Results: 4
indicator tip on end of camshaft. • If end play exceeds wear limit, remove camshaft
3. Push camshaft toward the rear as far as possible. and replace thrust plate. (See Camshaft and
4/7/95 4-87
TIMING GEAR BACKLASH CHECK Specifications:

Standard Backlash . . . . . . . . . 0.08 - 0.16 mm
Reason: . . . . . . . . . . . . . . . . . . . . . (0.0031 - 0.0063 in.)
Results:
Equipment:
• If backlash exceeds wear limit, replace meshing
• Dial Indicator gears as a set:
Idler Gear, Camshaft Gear, Crankshaft Gear AND/
Procedure: OR Idler Gear, Fuel Injection Pump Gear, Oil Pump
1. Measure backlash between meshing gears. Gear.

Idler Gear-to-Oil Pump Gear
M82120A
4-88 4/7/95


instructions. 4
Opening Pressure . . . . .19615 kPa (2850 psi)
Reason:
Results:
To determine opening pressure, leakage, chatter and
spray pattern of the fuel injection nozzle. • If pressure reading does not meet specification,
opening pressure.
4/7/95 4-89

Assembly

Container
M35913

psi).
4 Test fuel injection nozzle leakage following
Nozzle Tester manufacturer's instructions.
the
2. Listen for “chatter” sound and watch spray
pattern.
Results:
Slow Hand
. . . . . . . . . . . . . . . . . . . . . . . . . Spray Pattern
instructions.
4-90 4/7/95
Procedure:
Correct
Proper Spray
CAUTION
Angle

2. Heat and stir the water. Observe opening action
Poor
specifications.
as it cools.
Thermometer 4
M82121A
Results:

Results:
• Thermometer
• Glass Container
• Heating Unit
4/7/95 4-91
COOLANT TEMPERATURE SENDER 2. Suspend sender and a thermometer in a container

TEST of water.
To determine operating temperature of sender. temperature should be 107-113° C (225-235° F).
Equipment:
• Thermometer Ohmmeter
Probes
• Glass Container
• Heating Unit
• Ohmmeter
Procedure:
CAUTION Coolant
Temperature
Sender M82123A
DO NOT allow sender or thermometer to
rest against the side or bottom of glass
4 container when heating water. Either may Results:
4-92 4/7/95
STARTER NO-LOAD AMP 5. Attach Current Gun to positive cable.

DRAW/RPM TEST IMPORTANT: Complete this test in 20 seconds
Reason: or less to prevent starter damage.
To determine if starter is binding or has excessive 6. Use a jumper wire to briefly connect positive (+)
amperage draw under no load. starter terminal to solenoid terminal “S”. Starter
Equipment: 7. Read and record starter amperage and rpm.
Specifications:
• JT05719 Photo Tachometer
Maximum Starter
• Jumper Cables
Amperage. . . . . . . . . . . .90 amps at 3500 rpm
• Jumper Wire
Minimum Starter RPM . . . . . . . . . . . . . 3500
Procedure:
1. Mount starter in a vise. Results:
NOTE: Check that battery is fully charged and of not turn, replace solenoid.
proper size to ensure accuracy of test.
• If pinion gear engages and motor doesn't turn,
2. Connect jumper cables to a 12 volt battery. repair or replace starter motor.
3. Connect positive (+) cable to solenoid battery • If starter engages and runs but amperage is more 4
terminal on starter. than specifications, repair or replace starter.
4. Connect negative (-) cable to starter body. • If rpm is less than specification, with battery
JT05719 Tachometer
JT05712 Current Gun
Jumper Wire
Negative (-) Jumper Cable
Positive (+) Jumper Cable
LV066AE
4/7/95 4-93

ADJUSTMENT TDC Mark
on Flywheel
Reason:
1
Equipment: Index Mark on
Flywheel Housing
first bend) T6530AC

5. Operate hand operated primer pump to fill
injection pump with fuel.
Procedure:
6. Hold throttle lever in RUN position.
correct. Once timing is set, it will not normally 7. Turn flywheel clockwise (as viewed from
change during the life of the engine, unless it flywheel end) until tip of Timing Tool has
was altered. become MOIST with solid fuel. This is the point
of injection timing at which the pump is set.
option. Check fuel, fuel supply system, 8. Check timing mark on flywheel. The index mark
4 injectors, air intake system and cylinder must line up with the 16° mark on flywheel.
flywheel end, is counterclockwise. The
flywheel. Flywheel 16° Flywheel
Injection Pump
Timing Marks 12°
1. Remove the number one fuel injection line.
TDC Mark on
2. Install timing tool (number one fuel line cut off at Flywheel
first bend).
1
Timing Tool
Index Mark
on Flywheel
Housing
T6530AB
3. Remove rubber plug from flywheel housing.

4. Turn crankshaft pulley in either direction until the T6471CS
No. 1 cylinder top dead center (TDC) mark aligns

with the index mark on the flywheel housing.
4-94 4/7/95
Specifications:
Injection Pump Timing. . . . . . . . . .16° BTDC
Engine Crankshaft
Position. . . . . . . . . . . . . . . . . . . No.1 Cylinder
. . . . . . . . . . . . . on TDC Compression Stroke
Belt Deflection
Per 1° Of Rotation. . . . . . . 3.5 mm (0.130 in.)
Timing Lines On Pump M54014
Mounting Plate . . . . . . . . . . . . . . . . . 2° Apart
• If timing is not according to specifications, Applied Force . . . . . . . . . . .98 N (22 lb-force)
loosen pump mounting bolts and turn pump Deflection . . . . . 10 - 15 mm (0.400 - 0.600 in.)
from block to advance timing. Recheck timing. Results:
• If timing did not change, remove pump and have • If deflection is not within specifications:
- Loosen both alternator mounting cap screws.
4
- Install rubber plug in flywheel housing. only (near the belt) until tension is correct.
- Remove timing tool. - Tighten cap screws.
ENGINE OIL COOLER LEAKAGE
FAN/ALTERNATOR DRIVE BELT TEST
ADJUSTMENT
Reason:
Reason: Inspect oil cooler for leaks.
and alternator. To prevent shortened belt and bearing Procedure:
life. 1. Plug one end of coolant inlet or outlet passage.
Equipment: 2. Apply regulated air pressure of 206 - 483 kPa (30
- 70 psi) to other end.
• JDG529 or JDST28 Belt Tension Gauge
3. Dip oil cooler into water and check for leaks.
• Straight Edge
4. Optional test: If a leak did not appear, use a hot
Procedure: water bath to possibly open crack(s).
1. Check belt tension between fan and alternator Results:

using Belt Tension Gauge and a straight edge.
• Repair leak(s) or replace oil cooler if necessary.
4/7/95 4-95
Operational Tests
RADIATOR BUBBLE TEST COOLING SYSTEM PRESSURE TEST
Reason: Reason:
To determine if compression pressure is leaking Inspect cooling system for leaks.
from cylinder.
Equipment:
Equipment:
• JDG560 Adapter
Procedure:
Procedure:
2. Apply 97 kPa (14 psi) maximum pressure.
tight, run engine for 5 minutes to bring to
operating temperature. 3. Check for leaks throughout cooling system.
3. Check for bubbles coming from overflow hose at
Cooling System
bottom of tank. Pressure Pump
leak:
4 - Remove injection nozzles.
T6333AW
- Move piston to bottom of stroke with intake
- Connect hose from compressed air source Specifications:
(2942 kPa (427 psi) maximum) to adapter.
Minimum pressure
- Check for bubbles in recovery tank or air after 15 seconds . . . . . . . . . . 88 kPa (12.8 psi)
escaping from muffler, air cleaner or oil fill
opening. Results:
- Repeat for each cylinder. • Pressure should hold to specifications. If pressure
decreases, check for leaks. Repair leaks or replace
Results: parts as necessary.
• If bubbles are present, check for cracks in • If pressure test still indicates leakage after all
cylinder head and block. Check for damaged
head gasket. external leaks have been stopped, a defective head
exhaust valve. cause. Perform RADIATOR BUBBLE TEST.
• If air escapes from air cleaner, check for worn

intake valve.
• If air escapes from engine oil fill, check for worn
piston rings.
4-96 4/7/95
Operational Tests
RADIATOR CAP PRESSURE TEST Procedure:

1. Run engine for 5 minutes to bring to operating
Reason: temperature. Shut off engine.
Test radiator cap for operating in correct pressure 2. Remove injection nozzles. (See Fuel System in
range. this section.)
3. Remove heat protector from end of injector and
Equipment:
install on Adapter.
Procedure: and tighten nuts to 4.5 N•m (39 lb-in.).
1. Install radiator cap on pressure pump. 5. Hold fuel shut-off knob in shut-off position.
2. Apply pressure. Pressure valve in cap should 6. Crank engine for five seconds with starter.
open at 88 kPa (12.8 psi).
Cooling System
Pressure Pump
Results:
JDG560 Adapter
• If cap leaks, retighten and test again. Replace cap
JT01682 Compression
if pressure is not within specification. Gauge Assembly
T6333EU
CYLINDER COMPRESSION Specifications:

PRESSURE TEST
Compression Pressure . . . 2942 kPa (427 psi)
Reason: Maximum Difference Between
Cylinders . . . . . . . . . . . . . . . . 588 kPa (85 psi)
cylinder walls and valves. NOTE: Pressure listed is for 300 m (1000 ft) above
sea level. Reduce specification an
Equipment: additional 3.6% for each additional 300 m
(1000 ft) of altitude.
• JDG560 Adapter Results:
approximately two teaspoons of clean engine oil
test.
4/7/95 4-97
Operational Tests

rings and cylinder walls for wear or damage.
JT05577 Pressure Gauge
retest, check for leaking valves, valve seats or
Reason: JT03017 Hose Assembly

system components are worn.
Equipment:
• JT03017 Hose Assembly
• JT05577 Pressure Gauge (100 psi)
Procedure: JT05487 Connector
4 1. Remove oil pressure sender.

2. Install connector. T6471FB
3. Connect Hose Assembly and Pressure Gauge.

IMPORTANT: Do not run if no pressure Specifications:
present.
Fast Idle . . . . . . . . . . . . . . . . . . .2375 ±50 rpm
4. Start engine. If pressure reading is below 69 kPa Slow Idle. . . . . . . . . . . . . . . . . . . .900 ±50 rpm
5. Run engine approximately five minutes to heat Engine Oil Pressure:
oil, then check oil pressure at fast and slow idle.
Fast Idle . . . . . . .343 - 441 kPa (50 - 64 psi)
Slow Idle (Minimum) . . . . . 98 kPa (14 psi)
Results:
section.)
Has Low Oil Pressure” in Diagnosis group.
4-98 4/7/95
Operational Tests
AIR INTAKE SYSTEM LEAKAGE TEST FUEL SUPPLY PUMP PRESSURE

TEST
Reason:
Check for leaks in air intake system. Reason:
Equipment:
• Air Pressure Regulator Equipment:
Procedure:
• JT03115 Gauge w/Male Quick Coupler (0 - 150
and install test fitting.
psi)
hose and fitting from air cleaner. Procedure:
3. Remove air cleaner cover and main filter element. 1. Disconnect supply pump-to-filter hose.
4. Put large plastic bag into and over end of main 2. Install Hose Fitting, Coupler and Gauge.
filter element. Install main filter element and
cover. 3. Pull fuel shut-off cable out and crank engine
using the starter. Do not run starter for more than
5. Pressurize air intake system between 34 - 69 kPa 10 seconds at a time. Gauge should read more
(5 - 10 psi). If air intake system cannot be than 216 kPa (31 psi). 4
cleaner to intake manifold or turbocharger, if JT03115 Gauge w/Male
equipped, and check for leaks. Quick Coupler
IMPORTANT: When reinstalling starting aid JT01609 Female Quick

Coupler
against intake air flow. JT03274 Hose Fitting
Supply
Pump-to
Filter Hose Fuel Filter
T6471CU
M82124
Results:
Results:
• If pressure is below specification, repair or
• Find leaks and repair or replace parts as replace fuel supply pump.
necessary.
4/7/95 4-99
Operational Tests
FUEL DRAIN BACK TEST 2. Drain all fuel from the system, including fuel
Reason: separator, if equipped.
Determines if air is entering the fuel system at 3. Plug end of fuel return hose.
connections, allowing fuel to siphon back to tank. 4. Pressurize fuel system at fuel supply line, to a
Procedure:
1. Disconnect fuel supply line and return line at fuel and connections in the fuel system and inspect for
tank. leaks.
IMPORTANT: Fuel return line MUST extend
Results:
below fuel level in fuel tank before performing
this test. Fill fuel tank if necessary. • Find leaks and repair or replace parts as
necessary.
4-100 4/7/95
Operational Tests
4/7/95 4-101
ACCESSORIES
SERIES 220
POWER UNIT
ENGINES
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Intake and Exhaust Systems . . . . . . . . . . . . . . . . . . . . . . 10-5
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39 10
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-43
Engine Tune-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44
Operational Tests and Adjustments . . . . . . . . . . . . . . . . 10-47
Dealer Fabricated Tools . . . . . . . . . . . . . . . . . . . . . . . . . 10-62
Section 10
10
Specifications
ENGINE ACCESSORIES SPECIFICATIONS

Turbocharger
Rotor Shaft Axial Play
Without Waste Gate (RHB3)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.022 - 0.053 mm (0.0008 - 0.0021 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.07 mm (0.0028 in.)
With Waste Gate (RHB5)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.06 mm (0.0012 - 0.0024 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09 mm (0.0035 in.)
Rotor Shaft Radial Play
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.061 - 0.093 mm (0.0024 - 0.0037 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.12 mm (0.0047 in.)
With Waste Gate (RHB5)
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08 - 0.13 mm (0.0031 - 0.0051 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.17 mm (0.0067 in.)
Thrust Bearing-to-Center Housing Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 N•m (9 lb-in.)
Seal Plate-to-Center Housing Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 N•m (9 lb-in.)
Compressor Wheel Lock Nut Torque
RHB3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 N•m (9 lb-in.)
RHB5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 N•m (17 lb-in.)
Center Housing-to-Turbine Housing Cap Screw Torque
RHB3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 N•m (108 lb-in.)
RHB5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 N•m (247 lb-in.)
Center Housing-to-Compressor Housing Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . .4 N•m (39 lb-in.)
Turbine Wheel/Shaft Deflection
RHB3 10
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 mm (0.00008)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.005 mm (0.00019)
RHB5
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 mm (0.00039)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.011 mm (0.00043)
Turbine Shaft O.D.
RHB3
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.257 - 6.263 mm (0.2463 - 0.2466 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.250 mm (0.2461 in.)
RHB5
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.99 - 8.00 mm (0.3146 - 0.3150 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.980 mm (0.3142 in.)
Shaft Seal Ring Groove Width
RHB3
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.038 - 1.062 mm (0.0409 - 0.0418 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.070 mm (0.0421 in.)
RHB5
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.250 - 1.280 mm (0.0492 - 0.0504 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.290 mm (0.0508 in.)
Oil Thrower Seal Ring Groove Widths
Small End
RHB3
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.82 - 0.83 mm (0.0323 - 0.0327 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.84 mm (0.0331 in.)
4/7/95 10-1
Specifications
Oil Thrower Seal Ring Groove Widths, Small End - continued

RHB5
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.02 - 1.03 mm (0.0402 - 0.0406 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 mm (0.0437 in.)
Large End
RHB3
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.02 - 1.03 mm (0.0402 - 0.0406 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.04 mm (0.0409 in.)
RHB5
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22 - 1.23 mm (0.0480 - 0.0484 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.31 mm (0.0516 in.)
Seal Plate I.D.s
Side Without Slot
RHB3
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.968 - 8.00 mm (0.3137 - 03150 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.015 mm (0.3156 in.)
RHB5
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.00 - 10.02 mm (0.3937 - 0.3945 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.05 mm (0.3957 in.)
Side With Slot
RHB3
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.987 - 10.025 mm (0.3932 - 0.3947 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.04 mm (0.3953 in.)
RHB5
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.40 - 12.42 mm (0.4882 - 0.4890 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.45 mm (0.4902 in.)
10 Thrust Bushing Shoulder Length
RHB3
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.632 - 3.642 mm (0.1430 - 0.1434 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.650 mm (0.1437 in.)
RHB5
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.04 - 4.05 mm (0.1591 - 0.1594 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.07 mm (0.1602 in.)
Thrust Bearing Thickness
RHB3
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.59 - 3.61 mm (0.1413 - 0.1421 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.58 mm (0.1409 in.)
RHB5
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.99 - 4.01 mm (0.1571 - 0.1579 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.98 mm (0.1567 in.)
Journal Bearing I. D.
RHB3
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.275 - 6.285 mm (0.2470 - 0.2474 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.290 mm (0.2476 in.)
RHB5
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.01 - 8.03 mm (0.3154 - 0.3161 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.04 mm (0.3165 in.)
Journal Bearing O.D.
RHB3
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.940 - 9.946 mm (0.3913 - 0.3916 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.930 mm (0.3909 in.)
10-2 4/7/95
Specifications
Journal Bearing O. D. - continued

RHB5
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.32 - 12.33 mm (0.4850 - 0.4854 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.31 mm (0.4846 in.)
Seal Ring Surface I.D.
RHB3
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.00 - 11.018 mm (0.4331 - 0.4338 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.03 mm (0.4343 in.)
RHB5
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.00 - 15.02 mm (0.5906 - 0.5913 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.05 mm (0.5925 in.)
Journal Bearing Surface I.D.
RHB3
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.995 - 10.005 mm (0.3935 - 0.3939 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.01 mm (0.3941 in.)
RHB5
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.40 - 12.41 mm (0.4882 - 0.4886 in.)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.42 mm (0.4890 in.)
Fan/Alternator Belt
Applied Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 N (22 lb-force)
Belt Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 15 mm (0.400 - 0.600 in.)
Glow Plug Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.35 - 1.65 ohms
Coolant Temperature Sender Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110° C (230° F)
Operational Tests and Adjustments
Radiator Bubble Test
Maximum Air Pressure Into Cylinder 10
3009 (3TNA72). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2455 kPa (356 psi)
3011 (3TNC78), 3014 (3TN84), 4019 (4TN84). . . . . . . . . . . . . . . . . . . . . . . . 2158 kPa (313 psi)
Cooling System
Maximum Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 kPa (14 psi)
Minimum Pressure after 10 Seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 kPa (12.8 psi)
Radiator Cap
Valve Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 kPa (12.8 psi)
Cylinder Compression Pressure - 3009
Compression Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2455 kPa (356 psi)
Maximum Difference Between Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490 kPa (71 psi)
Cylinder Compression Pressure - 3011, 3014, 4019
Compression Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2158 kPa (313 psi)
Maximum Difference Between Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490 kPa (71 psi)
Engine Oil Pressure
Low Idle Speed
Industrial Application
All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1300 rpm
Generator Application
3009 (3TNA72). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1300 rpm
3011 (3TNC78), 3014 (3TN84), 4019 (4TN84). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200 rpm
Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 kPa (21 psi)
Air Intake System Holding Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 - 69 kPa (5 - 10 psi)
Fuel Supply Pump Pressure (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 kPa (4.3 psi)
Fuel System Holding Pressure (maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 kPa (15 psi)
4/7/95 10-3
Specifications
Slow Idle Speed

All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1300 rpm
3009 (3TNA72). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1300 rpm
3011 (3TNC78), 3014 (3TN84), 4019 (4TN84). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200 rpm
Fast Idle Speed - 3009
Industrial Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3300 rpm
Generator Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3800 rpm
Fast Idle Speed - 3011, 3014 and 4019
Industrial Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3300 rpm
Generator Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1900 rpm
Fuel Shutoff Solenoid
Maximum Pull-in Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Amps for 1/2 second
Maximum Hold-In Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 amp continuous
Starter
Amp Draw/RPM
3009 (3TNA72). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Amps at 300 rpm
3011 (3TNC78) and 3014 (3TN84) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 Amps at 300 rpm
4019 (4TN84) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 0 Amps at 1100 rpm
No-Load Amp Draw RPM
3009 (3TNA72). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Amps at 7000 rpm
3011 (3TNC78) and 3014 (3TN84) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Amps at 3000 rpm
4019 (4TN84) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Amps at 3500 rpm
Regulated Amperage
Fast Idle Speed
10 Industrial Application
All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3300 rpm
3009 (3TNA72). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3800 rpm
3011 (3TNC78), 3014 (3TN84), 4019 (4TN84). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1900 rpm
Minimum Regulated Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 amps
Unregulated Amperage
Fast Idle Speed
All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3300 rpm
3009 (3TNA72). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3800 rpm
3011 (3TNC78), 3014 (3TN84), 4019 (4TN84). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1900 rpm
Minimum Regulated Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 amps
Regulated Voltage
Fast Idle Speed
All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3300 rpm
3009 (3TNA72). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3800 rpm
3011 (3TNC78), 3014 (3TN84), 4019 (4TN84). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1900 rpm
Regulated Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2 - 14.7 VDC
10-4 4/7/95
Intake and Exhaust Systems

NOTE: Order tools according to information given in the U.S. SERVICE-GARD® Catalog or in the
*DFRG1 Extended Indicator Tip (RHB3)

Attach to a dial indicator gauge to check radial play of turbocharger rotor shaft.
*DFRG2 Extended Indicator Tip (RHB5)

Attach to a dial indicator gauge to check radial play of turbocharger rotor shaft.
OTHER MATERIALS
Number Name Use
LOCTITE® PRODUCTS
U.S./
Canadian/
LOCTITE No.
TY9370/ Thread Lock and Sealer Apply to threads of turbocharger thrust
TY9477/ (Medium Strength) bearing and seal plate mounting screws.
#242
TY15130/ John Deere Form-In-Place Seals turbocharger seal plate and

NA/ Gasket compressor housing to center housing.
#395 10
* Fabricated tool, dealer made. (See Dealer Fabricated Tools in this section for instruction to make tools.)
4/7/95 10-5
AIR CLEANER - 3009 (3TNA72)

Inspection
Isolator Pad (2)
Mounting
Bracket
Rain Cap
Collar
Flywheel End Seal Washer
Element
Air Cleaner Housing

10 Hose Clamp (2)
Air Cleaner-to-Intake
Manifold Hose
M82182A
10-6 4/7/95
AIR CLEANER - 3011(3TNC78), 3014

(3TN84) AND 4019D (4TN84)
Inspection
Isolator Pad (2) Primary Element
Mounting Bracket
Rain Cap
Secondary Safety
Element (Optional)
Hose Clamp (2)
Air Cleaner Dust Pan Assembly

Housing
Baffle
10
Seal Washer
Flywheel End
Air Cleaner-to-Intake
Manifold Hose
M82183AE
4/7/95 10-7
AIR CLEANER - 4019T (4TN84T)

Inspection
Isolator Pad (2)
Mounting Bracket Primary Element
Rain Cap
Secondary Safety
Element (Optional)
Large Hose Clamp (2)
10 Dust Pan Assembly
Baffle
Air Cleaner-to-
Turbocharger Hose Seal Washer
Small Hose
Clamp (2)
Flywheel End
Turbocharger-to-Intake
Manifold Hose
M82184AE
10-8 4/7/95
MUFFLER - 3009 (3TNA72)

Removal/Installation CAUTION
Muffler may be hot. Allow muffler to cool
before removing. A hot muffler can cause
serious burns.
Muffler
Mounting
Nut (4)
Gasket
Fan Side
10
Mounting
Nut (2)
Adapter
Gasket
M82188AE
4/7/95 10-9
MUFFLER - 3011 (3TNC78), 3014

(3TN84) AND 4019D (4TN84)
CAUTION
serious burns.
Muffler
Mounting
Nut (4)
Fan Side
10
Gasket
M82127AE
10-10 4/7/95
MUFFLER - 4019T (4TN84T)

Removal/Installation CAUTION
serious burns.
Gasket
Muffler
Mounting
Nut (4) Support
Bracket Fan Side
10
Cap Screw (2)
M8 x 18
Cap Screw (2)
M8 x 22
M82128AE
4/7/95 10-11
EXTENDING TURBOCHARGER LIFE Oil levels and pressure should always be closely
monitored. All worn hoses and lines should be
Turbochargers are designed to last the life of the replaced. The turbo oil supply line should be
engine, but, because they operate at such high checked frequently to make sure it is not kinked or
speeds (100,000 rpm or more); a moments bent. It should always be replaced with a line of
carelessness can cause them to fail in seconds. equal size, length and strength.
The major causes of turbocharger failures are The easiest way to damage a turbo is through
attributed to: improper start-up and shutdown procedures. Always
- Lack of lube oil (quick starts and hot idle the engine for at least 30 seconds (no load) after
shutdowns) start-up and before shutdown. Warming the engine
up before applying a load allows oil pressure to
- Oil contamination build up and lines to fill with oil.
- Ingestion of foreign objects Idling the engine before shutdown allows the engine
- Restricted oil drainage and turbo to cool. “Hot” shutdowns can cause the
turbo to fail. After high-speed operation the turbo
- Low oil level will continue to rotate long after the engine has been
- Operation on excessive side slopes shut off and oil pressure has dropped to zero. This
will cause heat to build up and create possible
- Abnormally high exhaust temperatures bearing damage. It can also cause carbon and
varnish deposits to form.
Lack of Lube Oil
Oil not only lubricates the turbo's spinning shaft and
Oil Contamination
bearings, it also carries away heat. When oil flow A second cause of turbo failure is contaminated oil.
stops or is reduced, heat is immediately transferred It can be caused by a worn or damaged oil filter or
from the hot turbine wheel to the bearings, which are not changing the lube oil at recommended intervals.
10 also heating up because of the increased friction due Expecting the oil filter to remove dirt, sand, metal
to the lack of oil. This combination causes the turbo chips, ect. from the oil before they reach the engine
shaft temperature to increase rapidly. or turbocharger can be a costly mistake.
Contaminated oil may completely bypass the engine
If oil flow does not increase and the process
oil filter if; the oil filter or oil cooler is clogged, the
continues, bearings will fail. Once the bearings fail
filter is improperly installed, or the oil is thick
(which can happen in seconds) seals, shaft, turbine
during cold weather.
and compressor wheels can also be damaged.
The principle causes of turbo bearing lubrication
problems are low oil pressure, a bent, plugged or
undersized oil lube supply line, plugged or restricted
oil galleries in the turbo, or improper machine start-
up and shutdown procedures.
10-12 4/7/95
Four good ways of avoiding oil contamination are: There are two primary reasons for restricted
drainage:
- Always inspect the engine thoroughly during
a major overhaul. Look especially for any - A blocked drain tube, due to either damage or
sludge or debris left in lube oil galleries. a buildup of sludged oil.
- Change lube oil at recommended intervals. - High crankcase pressure, due to restricted
Analysis of oil samples at filter change crankcase breather or excessive engine
periods can help identify potentially harmful blowby.
contaminants in the oil. Periodically check both the turbocharger oil drain
- Clean the area around the oil fill cap before tube and engine breather tube for damage or
adding oil. restriction. Correction of these conditions lead to
longer turbo life.
- Use a clean container when adding oil.
Abnormally High Exhaust
Injestion of Foreign Objects Temperatures
The third cause of turbo damage is the injestion of A fifth cause of turbocharger damage is abnormally
foreign objects. Foreign objects or particles can be high exhaust temperatures. Elevated exhaust
injested and cause damage to the turbo on both temperatures cause choking of oil which can lead to
compressor and turbine sides. This is easy to avoid. bearing failure. Extreme over-temperature operation
On the compressor side, foreign objects usually take can cause wheel burst.
the form of dust, sand, or shreds of air cleaner There are two basic causes of over-temperature:
element that enter through improperly installed air
cleaner elements. Leaky air inlet piping (loose - Restricted air flow.
clamps or torn rubber joints) or torn pleats in dry- - Overpowering the engine.
type air cleaner elements also create problems. In either case the engine has more fuel than available
air for proper combustion. This overfueled condition
10
The result is erosion of compressor blades that can
cause the delicately balanced wheel to wobble. leads to elevated exhaust temperatures.
IMPORTANT: Whenever an internal engine Causes of restricted air flow can include damaged
failure (valve, valve seat, piston) occurs, a inlet piping, clogged air filters, excessive exhaust
thorough inspection of the turbocharger restriction, or operation at extreme altitudes.
MUST BE performed before returning engine Overpowering generally is due to improper fuel
to service. delivery or injection timing. If overtemperature
operation has been identified, an inspection of the
air inlet and exhaust systems should be performed.
Restricted Oil Drainage Also check the fuel delivery and timing.
A fourth cause of turbocharger damage is restricted
lube oil drainage. The lubricating oil carries away
heat generated by friction of the bearings and from
the hot exhaust gases. If drainage back to the sump
is impeded, the bearings will overheat with damage
that will ultimately lead to failure.
4/7/95 10-13
TURBOCHARGER - YANMAR (RHB3 IMPORTANT: When cleaning turbocharger, do

and RHB5) not spray directly into compressor or turbine
housings. If inspection is required, do not
Removal clean exterior of turbocharger prior to
removal. Cleaning can remove evidence of a
NOTE: Model number RHB5 is equipped with a potential failure mode.
waste gate system. Removal/installation
procedures are the same for both. Model 2. Remove air cleaner-to-turbocharger hose and
RHB3 turbocharger is shown. clamps.
1. Remove muffler. (See procedure in this group.) 3. Remove turbocharger-to-intake manifold hose
and clamps.
4. Remove lube line clamp cap screw.
CAUTION 5. Remove lube line mounting cap screw and two
copper washers.
Turbocharger may be hot. Allow 6. Remove two oil drain line cap screws.
turbocharger to cool before removing. A hot Disconnect line and remove o-ring.
turbocharger can cause serious burns.
7. Remove three nuts, turbocharger and gasket.
Lube Line Mounting

Cap Screw and Washers
10 Turbocharger-to-Intake
Manifold Hose
Air Cleaner-to-
Turbocharger Hose
Turbocharger Lube Line Clamp

Oil Drain Line
Cap Screws Cap Screw
M82185
10-14 4/7/95
8. Diagnose the cause of failure, if necessary. (See Rotor Shaft Axial Play Check
TURBOCHARGER FAILURE ANALYSIS.)
1. Fasten dial indicator to turbine housing and
9. Inspect turbocharger. (See TURBOCHARGER position indicator tip on end of rotor shaft at
SEVEN-STEP INSPECTION.) turbine housing end.
10.Check rotor shaft axial and radial play. (See 2. Move rotor shaft in axial direction. Record
Rotor Shaft Axial and Radial Play Check measurement.
procedures.)
11.Disassemble and inspect all parts for wear or
damage, if necessary. (See Disassembly Magnetic Base
procedures.) Turbine Housing
Installation
Dial
1. Prelube turbocharger: Fill oil inlet or drain port Indicator
with clean oil and turn rotating assembly (by
hand) to properly lubricate bearings.
Axial Direction
2. Install new gasket, turbocharger and three nuts.
3. Install new o-ring and connect oil drain line.
Install and tighten two mounting cap screws.
4. Install two new copper washers and lube line
mounting cap screw.
M82186A
5. Install lube line clamp cap screw.
6. Install turbocharger-to-intake manifold hose and Axial Play Specifications:
clamps. Without Waste Gate (RHB3) 10
7. Install air cleaner-to-turbocharger hose and Standard . . . . . . . . . . . . . . . 0.022 - 0.053 mm
clamps. . . . . . . . . . . . . . . . . . . . . . (0.0008 - 0.0021 in.)
8. Install muffler. (See procedure in this group.) Wear Limit. . . . . . . . . . . 0.07 mm (0.0028 in.)
IMPORTANT: A new or repaired turbocharger
does not have an adequate oil supply for With Waste Gate (RHB5)
immediate start-up of engine. Perform the Standard . . . . . . . . . . . . . . . . . 0.03 - 0.06 mm
following steps to prevent damage to . . . . . . . . . . . . . . . . . . . . . (0.0012 - 0.0024 in.)
turbocharger bearings.
Wear Limit. . . . . . . . . . . 0.09 mm (0.0035 in.)
9. Push the throttle lever to the “STOP” position or If axial play is not within specifications, disassemble
disconnect fuel shutoff solenoid connector, if and inspect all components for wear or damage. (See
equipped. Disassembly procedures.)
10.Crank engine over with starter until oil pressure
gauge needle registers within the “GREEN” zone
of pressure gauge. DO NOT crank engine longer
than 30 seconds at a time to avoid damaging the
starter.
4/7/95 10-15
Rotor Shaft Radial Play Check Radial Play Specifications:

1. Attach DFRG1 or DFRG2 Extended Indicator
Tip to Dial Indicator gauge. Standard . . . . . . . . . . . . . . . 0.061 - 0.093 mm
. . . . . . . . . . . . . . . . . . . . . (0.0024 - 0.0037 in.)
2. Fasten dial indicator to bottom of turbocharger
mounting flange. Insert extended indicator tip Wear Limit. . . . . . . . . . . 0.12 mm (0.0047 in.)
through oil drain opening and position tip on
rotor shaft. With Waste Gate (RHB5)
3. Hold both turbine and compressor wheels and Standard . . . . . . . . . . . . . . . . . 0.08 - 0.13 mm
move rotor shaft in radial direction. Record . . . . . . . . . . . . . . . . . . . . . (0.0031 - 0.0051 in.)
measurement. Wear Limit. . . . . . . . . . . 0.17 mm (0.0067 in.)
If radial play is not within specifications, disassem-
ble and inspect all components for wear or damage.
(See Disassembly procedures.)
Dial Indicator
Magnatic Base
DFRG1 or DFRG2
10 Extended Indicator Tip Mounting Flange
Oil Drain
Compressor Wheel Turbine Wheel
Radial
Direction
Oil Inlet
M82187A
10-16 4/7/95
Disassembly
NOTE: Model number RHB5 is equipped with a Compressor
Alignment Marks Housing
waste gate system. Service procedures are
the same for both unless noted otherwise.
Model RHB5 turbocharger is illustrated
throughout service procedures.
1. Remove circlip and disconnect rod.
2. Remove clamps and hose.
3. Remove two cap screws, waste gate actuator and
spacer(s), if equipped. Lock Plate (4)
Oil Inlet Port Spacer(s)

Cap Screw (4)
M5 x 10
M82159
Circlip
7. Scribe alignment marks across turbine housing

and center housing to aid in assembly.
Hose
and Clamps 8. Remove four cap screws, lock plates and turbine
housing.
Waste Gate
Actuator M82158 Turbine Housing
10
Alignment
Marks
4. Scribe alignment marks across compressor
housing and center housing to aid in assembly.
5. Remove four cap screws and lock plates.
IMPORTANT: Be careful when removing
compressor housing. Damage to compressor
wheel blades can occur.
6. Tap on compressor housing with a plastic
hammer to remove from center housing.
Lock Plate (4)

Cap Screw (4)
M6 x 10 (RHB3)
M8 x 10 (RHB5)
M82160
4/7/95 10-17
NOTE: Lock nut has left-hand threads. 14.Insert two existing M5 cap screws (compressor
housing-to-center housing cap screws) into
9. Remove lock nut and compressor wheel.
threaded holes and pull out seal plate.
Holes
Compressor
Wheel
Lock Nut
M4 (RHB3)
M5 (RHB5)
M82161
Seal Plate Assembly
Mounting Screw (RHB3: 2)
10.Remove turbine wheel/shaft and heat protector. M3 x 12 (RHB5: 3)
Replace.
11.Remove seal ring.
M82163
15.Remove oil thrower assembly from seal plate.

16.Remove seal rings.
10
Large Seal Ring
Heat Protector Replace.
Small Seal Ring

Replace.
Oil Thrower
Turbine
Wheel/Shaft Seal Ring
Replace.
Seal Plate
M82164
M82162
17.Remove thrust bearing mounting screws.
12.Model RHB3: Tap two holes in seal plate using a 18.Remove thrust bearing, thrust bushing and
5 mm, 0.80 thread tap. journal bearing.
13.Remove seal plate mounting screws.
10-18 4/7/95
Assembly
1. If removed, install two new retaining rings into
center housing with “open end” of rings facing
toward oil outlet port.
2. Coat journal bearing with clean engine oil and
Journal Bearing install in center housing.
Thrust Bearing
Retaining Rings
Thrust Bushing
Mounting Screw
(RHB3: 2)
(RHB5: 4)
M3 x 7
Replace. Journal Bearing
M82165
19.Remove retaining ring and journal bearing from

turbine side.
Retaining Ring
NOTE: There are two retaining rings inside center M82166
housing. Remove only if replacement is
necessary. 3. Install turbine side retaining ring with beveled
edge toward journal bearing and with “open end”
in direction shown. 10
Oil Inlet Port End
Retaining Ring
Journal Bearing
Match Up Contact
Surface
Viewed from Compressor Side (RBH3)

Viewed from Turbine Side (RBH5) M82167A
Retaining Ring 4. Install new seal ring on turbine shaft.

Replace. M82166
5. Install heat protector and turbine wheel/shaft with

“open end” of seal ring facing toward oil inlet
necessary. (See Inspection procedures.)
port. Turbine wheel/shaft should “snap” into
place.
4/7/95 10-19
9. Position seal rings on oil thrower as shown and

insert thrower into seal plate. Oil thrower should
“snap” into place.
Oil Inlet Port
Large Seal Ring

Heat Protector
Small Seal Ring
Oil Thrower
Turbine
Wheel/Shaft Seal Ring
Seal Plate
M82164
M82162
Seal
Plate
6. Coat journal bearing and thrust bushing with
clean engine oil and install in center housing.
7. Install thrust bearing and mounting screws.
10
45°
Slot
Thrust Bearing Viewed from Seal Plate Side Without Slot
M82169A
Journal Bearing 10.Clean mating surfaces of center housing and seal

Thrust Bushing
plate assembly using Clean and Cure Primer.
Mounting Screw (RHB3: 2) 11.Install seal plate assembly with slot toward oil
M3 x 7 (RHB5: 4) outlet port.
Apply thread lock and sealer
(medium strength) to threads. 12.Install mounting screws.
1 N•m (9 lb-in.)
M82168
8. Install new seal rings on oil thrower.
10-20 4/7/95
Turbine Housing
Alignment
Marks
Slot Seal Plate

Assembly
Oil Outlet Port
Lock Plate (4)

Mounting Screw (RHB3: 2) Cap Screw (4)
M3 x 12 (RHB5: 4) RHB3: M6 x 10
John Deere 12 N•m (108 lb-in.)
Apply thread lock and sealer RHB5: M8 x 10
Form-In-Place (medium strength) to threads.
Gasket 28 N•m (247 lb-in.)
(RTV rubber silicone 1 N•m (9 lb-in.)
sealant) M82160
M82170
16.Clean mating surfaces of center housing and

NOTE: Lock nut has left-hand threads. compressor housing using Clean and Cure
Primer. Apply a coat of John Deere Form-In-
13.Install compressor wheel and lock nut.
Place Gasket (RTV rubber silicone sealant) on
compressor housing.
17.Install compressor housing. 10
18.Align marks made during disassembly and install
lock plates and cap screws.
Compressor
Wheel
Compressor
Alignment Marks Housing
Lock Nut
RHB3: M4
1 N•m (9 lb-in.)
RHB5: M5
2 N•m (17 lb-in.)
Lock Plate (4)

M82161
14.Install turbine housing.

Cap Screw (4)
15.Align marks made during disassembly and install
M5 x 10
lock plates and cap screws. 4 N•m (39 lb-in.)
M82159
4/7/95 10-21
19.Install spacer(s), if equipped, waste gate actuator RHB5

and two cap screws. Tighten cap screws to 4 N•m Standard . . . . . . . . . . . . . 0.010 mm (0.00039)
(39 lb-in.).
Wear Limit. . . . . . . . . . . . 0.011 mm (0.00043)
20.Install hose and clamps.
If variation is more than wear limit, replace wheel/
21.Connect rod and install circlip. shaft.
22.Prelube turbocharger: Fill oil inlet or drain port 3. Measure turbine shaft diameter and seal ring
with clean oil and turn rotating assembly (by groove width.
hand) to properly lubricate bearings.
Oil Inlet Port Shaft Seal Ring

Spacer(s) Groove Width
Circlip
Turbine Shaft O.D.

Hose
and Clamps M82172A
Turbine Shaft O.D.:

Waste Gate RHB3
Actuator M82158
Standard . . . . . . . . . . . . . . . 6.257 - 6.263 mm
. . . . . . . . . . . . . . . . . . . . . (0.2463 - 0.2466 in.)
10 Inspection Wear Limit. . . . . . . . . . 6.250 mm (0.2461 in.)
necessary. RHB5
2. Inspect turbine wheel/shaft for bend using v- Standard . . . . . . . . . . . . . . . . . 7.99 - 8.00 mm
block and a dial indicator. Turn wheel/shaft . . . . . . . . . . . . . . . . . . . . . (0.3146 - 0.3150 in.)
slowly and read variation on indicator.
Wear Limit. . . . . . . . . . 7.980 mm (0.3142 in.)
Dial Indicator Shaft Seal Ring Groove Width:

RHB3
Standard . . . . . . . . . . . . . . . 1.038 - 1.062 mm
. . . . . . . . . . . . . . . . . . . . . (0.0409 - 0.0418 in.)
Wear Limit. . . . . . . . . . 1.070 mm (0.0421 in.)
V-Block
RHB5
M82171A
Standard . . . . . . . . . . . . . . . 1.250 - 1.280 mm
. . . . . . . . . . . . . . . . . . . . . (0.0492 - 0.0504 in.)
Wear Limit. . . . . . . . . . 1.290 mm (0.0508 in.)
Turbine Wheel/Shaft Deflection:
RHB3 If turbine shaft diameter is less than wear limit,
replace turbine wheel/shaft and journal bearings.
Standard . . . . . . . . . . . . . 0.002 mm (0.00008)
Wear Limit. . . . . . . . . . . . 0.005 mm (0.00019) If ring groove width is greater than wear limit,
replace turbine wheel/shaft.
10-22 4/7/95
4. Measure seal ring groove widths in oil thrower.
Seal Ring Groove Seal Ring Groove Seal Plate

Width (Large End) Width (Small End)
Seal Ring Surface Seal Ring Surface

I.D. (Large) I.D. (Small)
Oil Thrower
M82173A Slot M82174A
Oil Thrower Seal Ring Groove Widths: Seal Plate I.D.s:

Small End Side Without Slot
RHB3 RHB3
Standard . . . . . . . . . . . . . . . . . 0.82 - 0.83 mm Standard . . . . . . . . . . . . . . . . 7.968 - 8.00 mm
. . . . . . . . . . . . . . . . . . . . . (0.0323 - 0.0327 in.) . . . . . . . . . . . . . . . . . . . . . (0.3137 - 0.3150 in.)
RHB5 RHB5
Standard . . . . . . . . . . . . . . . . . 1.02 - 1.03 mm Standard . . . . . . . . . . . . . . . 10.00 - 10.02 mm
. . . . . . . . . . . . . . . . . . . . . (0.0402 - 0.0406 in.) . . . . . . . . . . . . . . . . . . . . . (0.3937 - 0.3945 in.)
Wear Limit. . . . . . . . . . . 1.11 mm (0.0437 in.) Wear Limit. . . . . . . . . . 10.05 mm (0.3957 in.) 10
Large End Side With Slot
RHB3 RHB3
Standard . . . . . . . . . . . . . . . . . 1.02 - 1.03 mm Standard . . . . . . . . . . . . . . 9.987 - 10.025 mm
. . . . . . . . . . . . . . . . . . . . . (0.0402 - 0.0406 in.) . . . . . . . . . . . . . . . . . . . . . (0.3932 - 0.3947 in.)
RHB5 RHB5
. . . . . . . . . . . . . . . . . . . . . (0.0480 - 0.0484 in.) . . . . . . . . . . . . . . . . . . . . . (0.4882 - 0.4890 in.)
If either ring groove width is greater than wear limit, If either inside diameter is less than wear limit,
replace oil thrower. replace seal plate.
5. Measure inside diameters (seal ring surfaces) of 6. Measure length of thrust bushing shoulder.
seal plate.
4/7/95 10-23
Journal Bearing I.D.:

RHB3
Standard . . . . . . . . . . . . . . . 6.275 - 6.285 mm
. . . . . . . . . . . . . . . . . . . . . (0.2470 - 0.2474 in.)
Wear Limit. . . . . . . . . . 6.290 mm (0.2476 in.)
RHB5
Thrust Bushing
Standard . . . . . . . . . . . . . . . . . 8.01 - 8.03 mm
Shoulder Length . . . . . . . . . . . . . . . . . . . . . (0.3154 - 0.3161 in.)
Thrust Bushing Shoulder Length: Journal Bearing O.D.:

RHB3 RHB3
. . . . . . . . . . . . . . . . . . . . . (0.1430 - 0.1434 in.) . . . . . . . . . . . . . . . . . . . . . (0.3913 - 0.3916 in.)
Wear Limit. . . . . . . . . . 3.650 mm (0.1437 in.) Wear Limit. . . . . . . . . . 9.930 mm (0.3909 in.)
RHB5 RHB5
. . . . . . . . . . . . . . . . . . . . . (0.1591 - 0.1594 in.) . . . . . . . . . . . . . . . . . . . . . (0.4850 - 0.4854 in.)
If shoulder length is more than wear limit, replace If inside diameter is more than wear limit, replace
10 thrust bushing. both journal bearings and turbine wheel/shaft.
7. Measure thrust bearing thickness. If outside diameter is less than wear limit, replace
both journal bearings, turbine wheel/shaft and center
Thrust Bearing Thickness: housing.
RHB3 9. Inspect center housing for cracks or damage.
Standard . . . . . . . . . . . . . . . . . 3.59 - 3.61 mm Measure inside diameters (seal ring surface and
. . . . . . . . . . . . . . . . . . . . . (0.1413 - 0.1421 in.) journal bearing surfaces) of center housing.
Wear Limit. . . . . . . . . . . 3.58 mm (0.1409 in.)
RHB5
Standard . . . . . . . . . . . . . . . . . 3.99 - 4.01 mm
. . . . . . . . . . . . . . . . . . . . . (0.1571 - 0.1579 in.)
Wear Limit. . . . . . . . . . . 3.98 mm (0.1567 in.)
Seal Ring
If bearing thickness is less than wear limit, replace Surface I.D.
thrust bearing.
8. Measure outside and inside diameters of journal
bearings.
Journal Bearing
Surface I.D.s M82176A
10-24 4/7/95
Seal Ring Surface I.D.: Journal Bearing Surface I.D.:

RHB3 RHB3
Standard . . . . . . . . . . . . . . 11.00 - 11.018 mm Standard . . . . . . . . . . . . . . 9.995 - 10.005 mm
. . . . . . . . . . . . . . . . . . . . . (0.4331 - 0.4338 in.) . . . . . . . . . . . . . . . . . . . . . (0.3935 - 0.3939 in.)
RHB5 RHB5
. . . . . . . . . . . . . . . . . . . . . (0.5906 - 0.5913 in.) . . . . . . . . . . . . . . . . . . . . . (0.4882 - 0.4886 in.)
If seal ring surface diameter is more than wear limit,
replace center housing.
If journal bearing surface diameters are more than
wear limit, replace center housing, journal bearings
and turbine wheel/shaft.
10
4/7/95 10-25
TURBOCHARGER FAILURE ANALYSIS
Problem Possible Cause Suggested Remedy

Compressor Housing Inlet Defects
Foreign Object Damage Objects left in intake system. Disassemble and inspect intake system
for foreign objects.
Inspect engine for internal damage.
Leaking and/or defective intake Inspect air intake system connections
system. and air cleaner. Repair or replace as
necessary.
Inspect air intake related engine
components.
Compressor Wheel Rub Failure of journal bearings and/ Determine if engine and/or operator
or thrust bushing and bearing. contributed to lack of lubrication,
contaminated lubrication, excessive
temperature, or debris generating
engine failure in progress.
Manufacturing defects. Correct as required. (See Disassembly
and Inspection procedures in this
group.)
Compressor Housing Outlet Defects
10 Oil and/or Dirt in Housing Restricted air intake system. Inspect and clean air cleaner.
Prolonged periods of low RPM Check with operator to confirm
engine idling. conditions. (See Operators manual.)
Defective seal ring on oil Repair as necessary. (See
thrower or defective seal Disassembly and Inspection in this
around seal plate. group.
Restricted oil drain line. Inspect and clear oil drain line as
required.
Turbine Housing Inlet Defects
Oil in Housing Internal engine failure. Inspect and repair engine as required.
Oil leaking from turbine shaft Repair as necessary. (See
seal ring. Disassembly and Inspection in this
group.)
Internal Walls Deteriorated Excessive operating Check for restricted air intake.
temperature.
Check engine for overfueling.
Check injection pump timing.
10-26 4/7/95
Problem Possible Cause Suggested Remedy

Turbine Housing Outlet Defects
Turbine Wheel Rub Failure of journal bearings and/ Determine if engine and/or operator
or thrust bushing and bearing. contributed to lack of lubrication,
contaminated lubrication, excessive
temperature, or debris generating
engine failure in progress.
Manufacturing defect. Correct as required. (See Disassembly
and Inspection procedures in this
Leaking air intake system.
group.)
Foreign Object Damage Internal engine failure. Inspect and repair engine as required.
Objects left in intake system. Disassemble and inspect air intake
system. (See AIR CLEANER in this
group.)
Leaking air intake system. Correct as required.
Oil and/or Excessive Carbon Internal engine failure. Verified by oil in turbine housing.
Correct as required.
Turbine shaft seal ring failure. Inspect for excessive heat from
overfueling and/or restricted air intake.
Verify with operator to run engine
Prolonged periods of low RPM under load or a higher RPM. (See
engine idling. Operator’s manual). 10
Inspect and clean oil drain line as
Restricted oil drain line. required.
Engine Center Housing and Joint Defects
Leaks from Casting Defective casting. Replace turbocharger.
Leaks from Joints Loose attaching screws. Tighten to specifications. (See
Assembly procedures in this group.)
Defective heat shield or Inspect and repair as required. (See
deteriorated sealant. Disassembly and Assembly
procedures in this group.)
Internal Center Housing Defects
Excessive Carbon Build-up in Hot engine shut-down. Review proper operation with operator
Housing or on Shaft as shown in Operator’s manual.
Excessive operating Restricted air intake; Overfueling or
temperature. mistimed engine.
Restricted oil drain line. Inspect and clean oil drain lines as
required.
Operating engine at high Idle engine for a few minutes to allow
speeds & loads immediately oil to reach bearings before applying
after start-up. heavy loads.
4/7/95 10-27
TURBOCHARGER SEVEN-STEP
INSPECTION
Compressor Wheel
The following inspection procedure is recommended
for systematic failure analysis of a suspected failed
turbocharger. This procedure will help to identify
when a turbocharger has failed, and why it has
failed, so the primary cause of the failure can be
corrected.
Proper diagnosis of a non-failed turbocharger is
important for two reasons. First, identification of a RG4523
non-failed turbocharger will lead to further
investigation and repair of the cause of a
NOTE: You will need a good light source for this
performance complaint.
check.
Second, proper diagnosis eliminates the unnecessary
3. Check compressor inlet for wheel rub on the
expense incurred when a non-failed turbocharger is
housing (arrow). Look very closely for any score
replaced.
marks on the housing itself and check the tips of
The seven recommended inspection steps, which are the compressor wheel blades for damage.
explained in detail on the following pages, are:
- Compressor Housing Inlet and Compressor
Wheel
- Compressor Housing Outlet
- Turbine Housing Inlet
- Turbine Housing Outlet and Turbine Wheel
10 - External Center Housing and Joints
- Internal Center Housing
- Turbo Bench Test
NOTE: To enhance the turbocharger inspection, an RG4524
inspection sheet (Form No. DS-2280
available from Distribution Service Center) Compressor Housing Outlet
can be used that lists the inspection steps in
the proper order and shows potential failure 1. Check compressor housing outlet. The outlet
modes for each step. Check off each step as should be clean and free of dirt or oil.
you complete the inspection and record any 2. Mark it on your checklist if dirt or oil is found
details or problems obtained during and continue the inspection.
inspection. Retain this with the work order
for future reference.
Compressor Housing Inlet and

Compressor Wheel
1. Check compressor inlet and wheel for foreign
object damage.
NOTE: Foreign object damage may be extensive or
minor. In either case, the source of the
foreign object must be found and corrected
to eliminate further damages. Model RHB5
Compressor
2. Mark findings on your checklist and continue the Housing Outlet M82154
inspection.
10-28 4/7/95
Turbine Housing Inlet 2. Inspect the wheel blades and housing for
evidence of wheel rub (arrow). Wheel rub can
1. Check the turbine housing inlet port for oil in bend the tips of the blades with the housing
housing, excessive carbon deposit or erosion of showing wear or damage.
walls.
NOTE: If the inlet is wet with oil or has excessive
carbon deposits, an engine problem is likely.
Wall erosion (cracking or missing pieces),
indicate excessive exhaust temperature.
Turbine Housing
Inlet Port
RG4528
External Center Housing and Joints

1. Visually check the outside of the center housing,
all connections to the compressor housing, and
turbine housing for oil.
M82155
NOTE: If oil is present, make sure it is not coming
Model RHB5
from a leak at the oil supply or return line.
Turbine Housing Outlet and Turbine
Wheel 10
1. Use a flashlight to look up inside the turbine Center Housing
housing outlet and check blades for foreign
object damage.
Turbine
Housing
Outlet
Model RHB5
M82157
Internal Center Housing

Blades
1. Using a flashlight, look through the oil return
Model RHB5 hole to check the condition of the shaft and/or
M82156 bearings. There should not be excess carbon
deposits on the shaft or in the housing.
4/7/95 10-29
Oil Return Hole
Model RHB5 M82155
Model RHB5 M82157

2. Excessive “blueing” or “coking” of oil along the
complete length of the shaft indicates a possible 3. Pull up on the compressor end of the shaft and
lack of lubrication caused by an engine failure, or press down on the turbine end while rotating
improper operation, such as hot shutdowns. shaft. Neither the compressor wheel nor the
turbine wheel should contact the housing at any
Turbine Wheel/Shaft point.
NOTE: There will be some “play” because the
bearings inside the center housing are free
floating.
10
RG4531
Turbo Bench Test

1. Mount the turbocharger in a vise.
2. Rotate the shaft, using both hands, to check
rotation and clearance. The shaft should turn
freely, however, there may be a slight amount of
drag.
M82157
10-30 4/7/95
4. Check shaft endplay by moving the shaft back NOTE: These diagnostic procedures will allow you
and forth while rotating. There will be some to determine the condition of the
endplay but not to the extent that the wheels turbocharger. If the turbocharger has failed,
contact the housings. analysis of your inspection notes should
direct you to the specific areas of the engine
to correct the problems causing the
turbocharger failure.
(See TURBOCHARGER FAILURE
ANALYSIS.) It is not unusual to find that a
turbocharger has not failed. If your
turbocharger passes all the inspections, the
problem lies somewhere else.
IMPORTANT: Before you finalize your
conclusion that the turbocharger has not
failed, it is strongly recommended to check
rotor shaft axial and radial play. (See
procedures in this group.) These procedures
are not required if a failure mode has already
M82157 been identified.
10
4/7/95 10-31
Cooling System
RADIATOR
Fan
Upper Radiator Hose
Removal/Inspection Guard
c CAUTION
Explosive release of fluids from pressurized
cooling system can cause serious burns.
Shut off engine. Only remove filler cap when Fan
cool enough to touch with bare hands. Slowly Shroud
loosen cap to first stop to relieve pressure
before removing completely.
NOTE: Approximate cooling system capacity is: Lower

Radiator
3009 ................ 3.5 L (3.7 qt) Hose
3011 ................ 3.7 L (3.9 qt)
3014 ................ 4.0 L (4.2 qt)
4019 ................ 4.7 L (4.9 qt)
1. Remove radiator cap and open drain valve to
drain cooling system. Drain Hose
2. Remove fan guard. M82129
Drain Valve
3. Remove four fan shroud mounting cap screws,
10 6. Support bottom of radiator and remove four
and place shroud over fan.
mounting cap screws.
4. Remove upper and lower radiator hoses.
7. Remove radiator.
5. Disconnect drain hose.
CAUTION
Reduce compressed air to less than 210 kPa
(30 psi) when using for cleaning purposes.
Clear area of bystanders, guard against
flying chips, and wear personal protection
equipment including eye protection.
10-32 4/7/95
Cooling System
8. Check radiator for debris lodged in fins. Clean

radiator using compressed air or pressure washer.
Alternator Mount/
9. Inspect radiator for bent fins, cracks and damaged Lift Bracket
seams. Repair as necessary.
Fan Guard
Fan Shroud
Radiator Mounting
Cap Screws Flange Nut M82131
M82130
Installation 10
Installation Installation is done in the reverse order of removal.
Installation is done in the reverse order of removal. • Install fan with blade curve facing AWAY from
engine.
• Close drain valve and fill radiator with proper
coolant to top of filler neck. (See • Adjust belt tension. (See procedure in this
SPECIFICATIONS AND GENERAL group.)
• Start engine and allow it to reach proper
operating temperature. Check radiator, hoses
and connections for leaks. Adjust coolant level
in recovery tank.
Fan Blade
Curve
COOLING FAN
Removal
1. Remove fan guard, if equipped. Engine
2. Loosen alternator mount/lift bracket cap screws
and flange nut.
3. Remove four fan shroud mounting cap screws, if
equipped, and move shroud toward engine. M82132
4. Remove four cap screws, fan and spacer, if

equipped.
4/7/95 10-33
Cooling System
FAN/ALTERNATOR BELT Adjustment

Replacement 1. Use JDG529 or JDST28 Belt Tension Gauge and
a straight edge to check belt deflection between
1. Remove fan guard, if equipped. fan and alternator pulleys.
2. Loosen alternator mount/lift bracket cap screws
and flange nut.
3. Replace belt.
4. Adjust belt tension. (See Adjustment procedure.)
Belt Deflection
Alternator Mount/
Lift Bracket
M54014
Specifications:
Applied Force . . . . . . . . . . .98 N (22 lb-force)
Belt Deflection . . . . . . . . . . . . . . . . 10 - 15 mm
. . . . . . . . . . . . . . . . . . . . . . . (0.400 - 0.600 in.)
Fan Guard If deflection is not according to specifications:
- Loosen alternator mounting cap screws and
10 nut.
Fan/Alternator Belt
- Tighten cap screws and nut.
Flange Nut M82131
10-34 4/7/95
Fuel System
FUEL FILTER ASSEMBLY - 3009

(3TNA72)
IMPORTANT: Replace all copper and rubber
washers. Damaged or used washers may leak.
Nut (3)

(Short) (2)
Bleed Valve
Rubber Washer
* *
Bleed Screw
10
(Long)
Shutoff Rubber Washer

Valve
To Fuel Tank
Mounting Base
Spring
O-Ring
Shutoff
* Lever
Filter Element
*
Spring
O-Ring
Fuel Supply
Pump-to-Filter
Hose
Filter Cover
Fuel Filter-to- Retaining Ring

*Copper Washers Injection Pump
Replace. Hose
M82133A
4/7/95 10-35
Fuel System
FUEL FILTER ASSEMBLY - 3011

(3TNC78), 3014 (3TN84) AND 4019
(4TN84)
IMPORTANT: Replace all copper and rubber
washers. Damaged or used washers may leak.
End Cap
Shutoff Valve Mounting Base

Spring O-RIng
O-Ring
Shutoff
Lever Filter
Element
Spring
Mounting O-Ring
Cap Screw
Filter
Cover
End Cap
Retaining (Short) (2 or 3)
10 Ring
Fuel Filter-
to-Injection
Fuel Supply Pump Hose
Pump-to-Filter
Hose
* * Injection Pump
Bleed-Off Hose
Nozzle Leak-Off
Hose (Long)
*Copper Washers
Replace.
Air Vent Check Valve *
* M82134A
10-36 4/7/95
Fuel System
FUEL SUPPLY PUMP - 3009 (3TNA72)

Copper Washer (4)

Replace.
Fuel Supply
Pump
Gasket
Fuel Supply-to- Mounting Screw (2)

Pump Hose Lock Washer (2)
10
M82135A
4/7/95 10-37
Fuel System
FUEL SUPPLY PUMP - 3011 (3TNC78),

3014 (3TN84) AND 4019 (4TN84)
Lock Washer (2)
Mounting Nut (2)

Packing
Fuel Supply Pump
10
Fuel Supply-to-Pump Hose
M82136A
10-38 4/7/95
Electrical System
GLOW PLUGS - IF EQUIPPED AIR HEATER - IF EQUIPPED

Removal/Installation Removal/Installation
1. Remove air cleaner assembly. (See Intake and 1. Remove air intake hose.
Exhaust System in this section.)
2. Disconnect wiring leads and remove glow plug.
3. Scribe a mark across heater and intake manifold
3. Test glow plugs. (See Test procedure.) to aid in installation.
Installation is done in the reverse order of removal. 4. Remove four cap screws, heater and gasket.
Wiring Leads
Air Heater
Glow Plug
Wiring Lead
M81237
M82137
Test
NOTE: Test glow plug using an ohmmeter.
Touch one probe of tester to glow plug terminal and 10
the other probe to body. If resistance is not within
1.35 - 1.65 ohms, replace glow plug.
Teminal
Body
M46296
4/7/95 10-39
Electrical System
INSTRUMENT PANEL
Mount Bracket (2)

Mounting Screw (4) Red Warning Lamp (3)
Water Temperature
Spacer (4) Oil Pressure
Charge
Isolator (4)
Instrument
Panel
Blue Warning Lamp
Preheat
Key Switch
Tachometer Cable
Cap (2)
Optional: Oil Pressure Guage
Water Temperature Gauge
10
Tachometer
Timer
M82138A
10-40 4/7/95
Electrical System
OIL PRESSURE SWITCH Test

Replacement Equipment:
• Thermometer
• Glass Container
• Heating Unit
Oil Pressure Switch
• Ohmmeter
Procedure:
Wiring Lead
M82139
CAUTION
DO NOT allow sender or thermometer to
COOLANT TEMPERATURE SENDER rest against the side or bottom of glass
Replacement rupture if overheated.
IMPORTANT: Replace copper washer. 1. Connect lead wires from ohmmeter probes, to
Damaged or used washer may leak. sender terminal and body.
2. Suspend sender and a thermometer in a container
of water.
3. Heat and stir the water. Observe water 10
Copper Washer temperature when continuity occurs. If continuity
Replace. does not occur at 110° C (230° F), replace
sender.
Coolant Temperature Thermometer

Sender Ohmmeter
Wiring Lead Probes
M82140
Coolant
Temperature Sender
M82123A
4/7/95 10-41
Electrical System
FUEL SHUTOFF SOLENOID

Replacement
NOTE: 3011 (3TNC78), 3014 (3TN84), 4019
(4TN84) shown. 3009 (3TNA72) is similar.
• Ajust. (See Operational Tests and Adjustments
in this section.)
Clip and Washer

Wire Connector
M82141
10
10-42 4/7/95
Miscellaneous
RADIATOR MOUNT - IF EQUIPPED

• Inspect isolators for cracks, wear or damage.
Support Rod
3009
Left Hand
Support Pillar
Isolator (2)
Support Rod 10
3011,
3014 4019
Support Rod Right Hand Support Pillar
Support Bracket
Engine Foot (2) Side Support Plate (2) M82142A
4/7/95 10-43
Engine Tune-Up
GENERAL TUNE-UP ALTITUDE COMPENSATION

RECOMMENDATIONS GUIDELINES
The following services are recommended each time High elevations may affect engine performance. As
a tune-up is performed: a general rule, these guidelines will apply:
• Change oil and filter. (See Operator's Manual.)
Naturally Aspirated Engines
• Replace fuel filter and clean sediment bowl.
(See Fuel System in this section.) Four percent power reduction per 300 m (1000 ft)
rise in elevation above sea level. Engine may have to
• Clean crankcase vent tube. (See this group.) be defueled when a substantial percentage of
• Check air intake system. Replace air cleaner operating time occurs at 1500 m (5000 ft) or higher.
elements. (See Operator's Manual)
Turbocharged Engines
• Check exhaust system. (See this group.)
Three percent power reduction per 300 m (1000 ft)
• Check and service engine cooling system. (See
rise in elevation above sea level. Engine may have to
this group.)
be defueled when a substantial percentage of
• Check electrical system. (See this group.) operating time occurs at 2250 m (7500 ft) or higher.
• Check fuel injection system. Check engine/ If engine required less fuel for acceptable
injection pump timing: check and adjust speed performance at higher elevation, contact your local
advance, clean injection nozzles and adjust authorized fuel injection pump repair station for
injection nozzle opening pressure. (See Fuel service.
System in the appropriate ENGINE section.)
• Check engine oil pressure. Adjust if necessary. PRELIMINARY ENGINE TESTING
(See Operational Tests and Adjustments in this
Before tuning up an engine, determine whether a
10 section.)
tune-up will restore operating efficiency. When there
• Check engine valve clearance. Adjust if is doubt, the following preliminary tests will help to
necessary. (See Checks, Tests and Adjustments determine if the engine can be tuned-up. Choose
in the appropriate ENGINE section.) from the following procedures only those necessary
• Check engine speeds. Adjust if necessary. (See to restore the unit.
Operational Tests and Adjustments in this 1. After engine has stopped for several hours,
section.) carefully loosen crankcase drain plug and watch
• Check engine performance on dynamometer. for any water to seep out. A few drops could be
(See Operational Tests and Adjustments in this due to condensation, but any more than this
section.) would indicate problems which require engine
repairs rather than just a tune-up.
10-44 4/7/95
Engine Tune-Up
2. With engine stopped, inspect engine coolant for AIR INTAKE SYSTEM
an oil film. With engine running, inspect coolant
for air bubbles. (See Radiator Bubble Test in Check
Operational Tests and Adjustments in this
1. Replace air cleaner filter element(s).
section.) Either condition would indicate
problems which require engine repairs rather than 2. Check condition of air intake hose(s). Replace
just a tune-up. any hose that is cracked, split, or otherwise in
poor condition.
3. Perform a dynamometer test and record power
output. (See Operational Tests and Adjustments 3. Check hose clamps for tightness. Replace any
in this section.) Repeat dynamometer test after clamp that cannot be properly tightened. This
tune-up, so power output before and after tune-up will help prevent dust from entering the air intake
can be compared. system which could cause serious engine
damage.
4. Perform compression test. (See Operational Tests
EXHAUST SYSTEM
CRANKCASE VENTILATION SYSTEM Check
Check 1. Inspect exhaust system for leaks or restrictions.
Check manifold for cracks. Repair or replace as
1. Inspect crankcase ventilation system for
necessary.
restrictions. Lack of ventilation causes sludge to
form in engine crankcase. This can lead to
clogging of oil passages, filters and screens, COOLING SYSTEM
resulting in serious engine damage.
2. Clean crankcase vent hose with solvent and Check and Service
compressed air if restricted. 1. Remove any trash that has accumulated on the 10
3. 3009 (3TNA72): Remove rocker arm cover and radiator.
clean crankcase ventilator. 2. Visually inspect entire cooling system for leaks
3011 (3TNC78), 3014 (3TN84) and 4019 (4TN84): or damage. Repair or replace as necessary.
Remove and clean crankcase ventilator assembly. 3. Remove and check thermostat. (See Cooling
System in the appropriate ENGINE section.)
Ventilator Assembly
CAUTION
Vent Hose Do not drain coolant until the coolant
temperature is below operating temperature.
Always loosen drain cock slowly to relieve
any excess pressure.
4. Drain cooling system by opening drain cocks on

RG6589 radiator and engine block.
All Except 3009 (3TNA72) Shown
4/7/95 10-45
Engine Tune-Up
5. Close drain cocks and fill cooling system with FAN/ALTERNATOR BELT
clean water.
6. Run engine until it reaches operating temperature Inspection
(about 10 minutes) to stir up possible rust or Check condition of fan/alternator belt and replace if
sediment. cracked, frayed or excessively worn. Check belt
7. Stop engine and immediately drain the water tension and adjust as necessary. (See Cooling System
before rust and sediment settle. in this section.)
8. Close drain cocks and fill the cooling system with

a good commercial radiator cleaner and water. ELECTRICAL SYSTEM
Follow the instructions with the cleaner.
Check
9. After cleaning the cooling system, fill with water
to flush the system. Run the engine about 10 1. Clean battery and cables with a damp cloth. If
minutes, then drain out flushing water. corrosion is present, remove it and wash the
terminals with a solution of ammonia or baking
IMPORTANT: Air must be expelled from soda in water. Then flush area with clean water.
cooling system when system is refilled. Loosen
2. Coat battery terminals and connectors with
coolant temperature sender or plug in
petroleum jelly mixed with baking soda to retard
thermostat housing to allow air to escape when
corrosion.
filling system. Retighten sender or plug when
all the air has been expelled. 3. Test battery. If battery is not near full charge, try
to find out why.
10.Fill cooling system with coolant. (See
SPECIFICATIONS AND GENERAL 4. On low-maintenance batteries, check level of
INFORMATION section.) electrolyte in each cell of battery. If water is
needed, use clean, mineral-free water.
11.Run engine until it reaches operating
10 temperature. This mixes solution uniformly and If water must be added to batteries more often than
circulates it through the entire system. The every 250 hours, alternator may be overcharging.
normal engine coolant temperature range is 70° -
80° C (160° - 180° F). NOTE: Water cannot be added to maintenance-free
batteries.
NOTE: Coolant level should be approximately 19 5. If battery appears to be either undercharged or
mm (3/4 in.) below bottom of radiator filler overcharged, check alternator and charging
neck. circuit.
12.After running engine, check coolant level and 6. Check tension of fan/alternator drive belt. (See
entire cooling system for leaks. FAN/ALTERNATOR BELT-Adjustment in
13.Check system for holding pressure. (See Cooling Cooling System in this section.)
System Pressure Test in Operational Tests and 7. Check operation of starting motor and gauges.
10-46 4/7/95
DYNAMOMETER TEST 2. Operate engine at one-half load until coolant and

crankcase oil temperatures are up to normal.
NOTE: High elevations may affect engine
performance. (See ALTITUDE 3. Run engine at fast idle.
COMPENSATION GUIDELINES in 4. Gradually increase load on engine until speed is
Engine Tune-up in this section.) reduced to rated speed rpm.
1. Connect engine to dynamometer using 5. Read horsepower on dynamometer.
manufacturer's instructions.
6. Compare readings taken with power rating level
for your engine application listed in the following
chart.
DYNAMOMETER TEST SPECIFICATIONS
Injection
Pump Pump
Engine Option Assembly Governor Rated Fast Idle Power Rating*
Model Code Part Number Regulation Speed (rpm) (rpm) kW (BHP)
3009DF001 1601 RG60070 STD 3000 3300 15.4 (20.7)

3009DF005 1601 RG60070 STD 3000 3300 15.4 (20.7)
3009DF007 1601 RG60132 3-5% 3600 3800 14.2 (19.0)
3011DF001 1601 RG60187 STD 3000 3300 20.2 (27.1)
3011DF005 1601 RG60187 STD 3000 3300 20.2 (27.1)
10
3011DF006 1601 RG60464 3-5% 1800 1900 13.0 (17.4)
3014DF001 1601 RG60269 STD 3000 3300 24.9 (33.5)
3014DF005 1601 RG60269 STD 3000 3300 24.9 (33.5)
3014DF006 1601 RG60293 3-5% 1800 1900 16.0 (21.5)
4019DF001 1601 RG60330 STD 3000 3300 33.4 (44.8)
4019DF005 1601 RG60330 STD 3000 3300 33.4 (44.8)
4019DF006 1601 RG60410 3-5% 1800 1900 22.0 (29.5)
4019TF001 1601 RG60425 STD 3000 3300 40.3 (54.0)
4019TF005 1601 RG60425 STD 3000 3300 40.3 (54.0)
4019TF006 1601 RG60459 3-5% 1800 1900 27.2 (36.5)
*Industrial Intermittent Gross or Generator Standby Net.
4/7/95 10-47
RADIATOR BUBBLE TEST • If air escapes from muffler, check for worn
exhaust valve.
Reason: • If air escapes from air cleaner, check for worn
To determine if compression pressure is leaking intake valve.
from cylinder. • If air escapes from engine oil fill, check for worn
piston rings.
Equipment: COOLING SYSTEM PRESSURE TEST
• JDG560 Adapter
Reason:
Procedure: Inspect cooling system for leaks.
tight, run engine for 5 minutes to bring to Equipment:
operating temperature. • D05104ST Cooling System Pressure Pump
Procedure:
3. Check for bubbles coming from overflow hose at
bottom of tank. 1. Remove cap and attach pressure pump to radiator.
If bubbles are present, isolate source of compression 2. Apply 97 kPa (14 psi) maximum pressure.
leak: 3. Check for leaks throughout cooling system.
- Remove injection nozzles.
cylinder to be tested. Cooling System
Pressure Pump
10 - Move piston to bottom of stroke with intake
adapter.
into cylinder: T6333AW
3009 (3TNA72) . . . . . . . . . 2455 kPa (356 psi)

3011 (3TNC78), Specifications:
3014 (3TN84), Minimum Pressure
after 10 seconds . . . . . . . . . . 88 kPa (12.8 psi)
4019 (4TN84) . . . . . . . . . . . 2158 kPa (313 psi)
- Check for bubbles in recovery tank or air Results:
escaping from muffler, air cleaner or oil fill • Pressure should hold to specifications. If
opening. pressure decreases, check for leaks. Repair leaks
- Repeat for each cylinder. or replace parts as necessary.
• If pressure test still indicates leakage after all
Results: external leaks have been stopped, a defective
head gasket, cracked block, or cylinder head
• If bubbles are present, check for cracks in
may be the cause. Perform RADIATOR BUBBLE
cylinder head and block. Check for damaged
TEST.
head gasket.
10-48 4/7/95
RADIATOR CAP PRESSURE TEST 3. Remove injection nozzles. (See Fuel System in
the appropriate ENGINE section.)
Reason: 4. Install Adapter and Compression Gauge
Test radiator cap for operating in correct pressure Assembly.
range. 5. Disconnect fuel shutoff solenoid connector.
6. Crank engine for five seconds with starter.
Equipment:
JT01682 Compression
Procedure: Gauge Assembly
1. Install radiator cap on pressure pump.
open at 88 kPa (12.8 psi).
Cooling System
Pressure Pump
JDG472 Adapter
M82143

Specifications:
10
Compression Pressure . . . 2455 kPa (356 psi)
Results:
Maximum Difference
• If cap leaks, retighten and test again. Replace Between Cylinders . . . . . . . . 490 kPa (71 psi)
cap if pressure is not within specification.
sea level. Reduce specification an
CYLINDER COMPRESSION additional four percent for each additional
PRESSURE TEST - 3009 (3TNA72) 300 m (1000 ft) of altitude.
Reason: Results:
To determine the condition of the pistons, rings, • If pressure reading is below specification, squirt
cylinder walls and valves. approximately two teaspoons of clean engine oil
Equipment: test.
• JT01682 Compression Gauge Assembly • If pressure increases significantly, check piston,
• JDG472 Adapter rings and cylinder walls for wear or damage.
Procedure: retest, check for leaking valves, valve seats or
1. Run engine for 5 minutes to bring to operating
2. Remove air cleaner assembly. (See Intake and
Exhaust System in this section.)
4/7/95 10-49
CYLINDER COMPRESSION Specifications:

PRESSURE TEST - 3011 (3TNC78), Compression Pressure . . . 2158 kPa (313 psi)
3014 (3TN84) AND 4019 (4TN84) Maximum Difference
Between Cylinders . . . . . . . . 490 kPa (71 psi)
Reason:
sea level. For naturally aspirated engines,
reduce specification an additional four
percent for each additional 300 m (1000 ft)
Equipment: of altitude. For turbocharged engines,
• JT01682 Compression Gauge Assembly reduce specification an additional three
percent for each additional 300 m (1000 ft)
• JDG560 Adapter of altitude.
Procedure: Results:
1. Run engine for 5 minutes to bring to operating • If pressure reading is below specification, squirt
temperature. Shut off engine. approximately two teaspoons of clean engine oil
2. Remove air cleaner assembly. (See Intake and into cylinders through injector ports and repeat
Exhaust System in this section.) test.
3. Remove injection nozzles. (See Fuel System in • If pressure increases significantly, check piston,
the appropriate ENGINE section.) rings and cylinder walls for wear or damage.
4. Remove heat protector from end of injector and • If pressure does not increase significantly after
install on Adapter. retest, check for leaking valves, valve seats or
10 5. Install Adapter and Compression Gauge
and tighten nuts to 4.5 N•m (39 lb-in.) ENGINE OIL PRESSURE TEST
6. Disconnect fuel shutoff solenoid connector.
Reason:
7. Crank engine for five seconds with starter.
8. Record pressure reading for each cylinder. system components are worn.
Equipment:
• JT03017 Hose Assembly
• JT05577 Pressure Gauge (100 psi)
Procedure:
1. Remove oil pressure sender.
2. Install Connector.
JDG560 Adapter 3. Connect Hose Assembly and Pressure Gauge.
IMPORTANT: Do not run engine if no pressure
JT01682 Compression present.
Gauge Assembly T6333EU
10-50 4/7/95
4. Start engine. If pressure reading is below 69 kPa AIR INTAKE SYSTEM LEAKAGE TEST
5. Run engine approximately five minutes to heat Reason:
oil, then check oil pressure at low idle. Check for leaks in air intake system.
Equipment:
• Air Pressure Regulator
Procedure:
JT05577 1. Remove air cleaner restriction indicator, if
Pressure equipped, and install test fitting.
Gauge
JT03349 Connector hose and fitting from air cleaner.
4. Put large plastic bag into and over end of main
filter element. Install main filter element and
cover.
JT03017 5. Pressurize air intake system within 34 - 69 kPa (5
Hose Assembly - 10 psi). If air intake system cannot be
M82144 6. Spray soap solution over all connections from air
equipped, and check for leaks. 10
Specifications:
Low Idle Speed
All . . . . . . . . . . . . . . . . . . . . . . . . . . . 1300 rpm
3009 (3TNA72) . . . . . . . . . . . . . . . . 1300 rpm
3011 (3TNC78), 3014 (3TN84),
4019 (4TN84) . . . . . . . . . . . . . . . . . . 1200 rpm
M82124
Engine Oil Pressure . . . . . . . . . . 147 kPa (21 psi)
Results: Results:
• If oil pressure is not within specifications, • Find leaks and repair or replace parts as
inspect oil pressure regulating valve parts for necessary.
necessary. (See Lubrication System in the
appropriate ENGINE section.)
Has Low Oil Pressure” in Diagnosis in the
appropriate ENGINE section.
4/7/95 10-51
FUEL SUPPLY PUMP PRESSURE FUEL DRAIN BACK TEST

TEST
Reason:
Reason:
Determines if air is entering the fuel system at
Equipment:
Procedure:
1. Disconnect fuel supply line and return line at fuel
• JT01609 Female Quick Coupler tank.
• JT03115 Gauge w/Male Quick Coupler (0 - 150 IMPORTANT: Fuel return line MUST extend
psi) below fuel level in fuel tank before performing
this test. Fill fuel tank if necessary.
Procedure:
2. Drain all fuel from the system, including fuel
1. Disconnect supply pump-to-filter hose. supply pump, injection pump, filter(s) and water
2. Install Hose Fitting, Coupler and Gauge. separator, if equipped.
3. Disconnect fuel shutoff solenoid connector. 3. Plug end of fuel return hose.
4. Crank engine using the starter. Do not run starter 4. Pressurize fuel system, at fuel supply line, to a
for more than 10 seconds at a time. Gauge should maximum pressure of 103 kPa (15 psi).
read more than 29 kPa (4.3 psi). 5. Apply liquid soap and water solution to all joints
JT03315 Gauge w/Male leaks.
Quick Coupler
10 Results:
JT01609 Female • Find leaks and repair or replace parts as
Quick Coupler
necessary.
BLEED FUEL SYSTEM - 3009
(3TNA72)
Reason:
Supply Any time the fuel system has been opened up for
Pump-to- service (lines disconnected or filters removed), it
Filter Hose
will be necessary to bleed air from the system.
Fuel Filter
Procedure:
M82145A
IMPORTANT: Modification or alteration of the
Results: nozzles in any way not approved by the
• If pressure is below specification, repair or obligation.
replace fuel supply pump.
1. Turn fuel filter shutoff valve to “OPEN” position.
2. Loosen both air bleed screws on fuel filter base.
10-52 4/7/95
9. When fuel appears at injectors, tighten line nuts.

Air Bleed 10.Start engine. If engine does not start, repeat bleed
Screws procedure.
Shutoff Valve
RG6594
3. Turn ignition switch to “ON” position.

4. Operate hand primer lever of fuel supply pump RG6597
until fuel flows free of air bubbles. Tighten bleed
screws.
BLEED FUEL SYSTEM - 3011
(3TNC78), 3014 (3TN84) AND 4019
(4TN84)
IMPORTANT: Modification or alteration of the
obligation.
All engines are equipped with an automatic air
10
RG6595 venting system which makes the fuel system self-
bleeding.
5. Loosen bleed screw on injection pump. Operate
hand primer and tighten bleed screw when fuel • Assure that all fuel line connections are securely
flows free of air bubbles. tightened.
6. Start engine. If engine does not start after several • Add fuel to fuel tank.
attempts, proceed with steps 7 through 10. • Crank engine to allow fuel system to bleed itself.
SLOW IDLE SPEED ADJUSTMENT
Reason:
To achieve proper slow idle rpm setting. Provides
adequate rpm to keep engine running smoothly
without stalling.
Equipment:
RG6596 • JT05719 Hand-Held Digital Tachometer
7. Loosen all three injector line nuts using a 17 mm

wrench. Be sure not to loosen bottom nut of
injector.
8. Crank engine over with starter.
4/7/95 10-53
1. Start engine and run for five minutes. • JT05719 Hand-Held Digital Tachometer
2. Visually check that injection pump throttle lever
is against slow idle stop screw. Procedure:
3. Check engine speed at flywheel using the Digital NOTE: Make sure air cleaner is clean and not
Tachometer. restricted. Clean or replace air cleaner
element(s) as necessary.
1. Start engine and run for five minutes.
2. Push against injection pump throttle lever to
insure it is against fast idle stop screw.
Nut 3. Check engine speed at flywheel using the Digital
Tachometer.
Idling Adjustment
Screw
Screw
Control Lever Nut
Sealed Wire
M82146A
Specifications:
Industrial Application M55700
10
All . . . . . . . . . . . . . . . . . . . . . . . . . . . 1300 rpm
Specifications:
Generator Application Industrial Application . . . . . . . . . . 3300 rpm
3009 (3TNA72) . . . . . . . . . . . . . . . . 1300 rpm Generator Application . . . . . . . . . . 3800 rpm
3011 (3TNC78), 3014 (3TN84),
4019 (4TN84) . . . . . . . . . . . . . . . . . . 1200 rpm Results:
NOTE: Some adjustment can be made without
Results: removing sealed wire. Attempt to make the
• If slow idle rpm is not according to adjustment before removing wire.
specifications, loosen nut and turn screw. After • If fast idle rpm is not according to specifications,
adjustment, tighten nut. loosen nut and turn screw until fast idle speed is
correct. After adjustment, tighten nut.
FAST IDLE SPEED ADJUSTMENT - • If engine still does not meet fast idle
3009 (3TNA72) specifications, have pump inspected by a diesel
injection service.
Reason:
To achieve proper fast idle rpm setting. Provides
proper speed for PTO operation and insures that
engine is running at proper rpm's for peak
performance.
10-54 4/7/95
FAST IDLE SPEED ADJUSTMENT - FUEL SHUTOFF SOLENOID

3011 (3TNC78), 3014 (3TN84) AND AMPERAGE TEST
4019 (4TN84)
Reason: Reason:
To achieve proper fast idle rpm setting. Provides To test condition of fuel shutoff solenoid windings
proper speed for PTO operation and insures that and check for fuel pump linkage binding creating
engine is running at proper rpm's for peak excessive current draw.
performance.
Equipment:
Equipment:
• JT05719 Hand-Held Digital Tachometer
NOTE: Make sure air cleaner is clean and not 1. Test system ground connections and battery.
restricted. Clean or replace air cleaner 2. Perform circuit tests to ensure voltage at
element(s) as necessary. solenoid.
1. Start engine and run for five minutes. 3. Attach current gun to white wire of fuel shutoff
2. Push against injection pump throttle lever to solenoid.
insure it is against fast idle stop screw. 4. Set current gun for DC current.
3. Check engine speed at flywheel using the Digital 5. Turn key switch ON.
Tachometer. Maximum pull-in amperage should be 50
amps for 1/2 second.
6. Move current gun to red wire.
Nut Maximum hold-in amperage should be 1 amp 10
continuous.
Maximum Speed
Adjustment Screw
Fuel Shutoff
Solenoid
Control Lever
JT05712
M82147A
Current Gun
Specifications:
Industrial Application . . . . . . . . . . 3300 rpm
Generator Application . . . . . . . . . . 1900 rpm M82148A
Results:
Results:
• If fast idle rpm is not according to specifications,
loosen nut and turn screw until fast idle speed is • If readings do not meet specifications, check for
correct. After adjustment, tighten nut. binding linkage and adjust as needed or replace
solenoid.
• If engine still does not meet fast idle
specifications, have pump inspected by a diesel
injection service.
4/7/95 10-55
FUEL SHUTOFF SOLENOID STARTER AMP DRAW/RPM TEST

ADJUSTMENT
Reason:
Reason: To determine the amperage required to crank the
To ensure that fuel shutoff solenoid retracts fully, engine and check starter motor operation under load.
enough to allow full rack travel. Equipment:
• JT05685 Battery Load Tester
Procedure:
• JT05719 Hand-Held Digital Tachometer
1. Loosen lock nut.
IMPORTANT: Turn load knob fully
counterclockwise before making connections.
body. NOTE: Engine should be at normal operating
temperature when performing this test for
4. Move link toward solenoid until it stops. an accurate amperage reading.
5. Turn plunger rod in or out of knuckle until
knuckle and link holes line up. Turn out two Procedure:
1. Turn load knob fully counterclockwise.
the solenoid bottoms out before the linkage.
2. Connect Battery Load Tester to battery.
switch is turned ON. Also check that linkage 3. Disconnect fuel shutoff solenoid connector.
returns completely to the STOP position when 4. Check system ground connections. Be sure
key switch is turned OFF. battery is fully charged.
10 5. Crank engine. Read and record voltage at meter.
6. Use Tachometer to read and record cranking rpm.
Plunger
Link
7. Turn key switch to OFF position. Adjust load
knob until battery voltage is the same as when
engine is cranking.
8. Read amperage on meter.
Lock Nut
Knuckle Specifications:
M82141 3009 (3TNA72) . . . . . . 200 Amps at 300 rpm
3011 (3TNC78) and
3014 (3TN84) . . . . . . . . 230 Amps at 300 rpm
4019 (4TN84) . . . . . . . 350 Amps at 1100 rpm
9. Turn load knob fully counterclockwise.
Results:
• If amp reading is not to specification, or to
specification but rpm is low, perform STARTER
NO-LOAD AMP DRAW/RPM TEST.
10-56 4/7/95
STARTER NO-LOAD AMP DRAW/RPM 4. Connect negative (-) cable to starter body. Attach
TEST Current Gun to positive (+) cable.
Reason: or less to prevent starter damage.
To determine condition of starter. 5. Use a jumper wire to briefly connect positive (+)
starter terminal to solenoid.
Equipment:
6. Measure starter amperage and rpm.
• JT05719 Hand-Held Digital Tachometer Specifications:
3009 (3TNA72) . . . . . . 60 Amps at 7000 rpm
Procedure: 3011 (3TNC78) and
1. Remove starter from engine. 3014 (3TN84) . . . . . . . . 90 Amps at 3000 rpm
4019 (4TN84) . . . . . . . . 90 Amps at 3500 rpm
NOTE: Check that battery is fully charged and of
proper size to ensure accuracy of test.
Results:
2. Connect jumper cables to battery.
• If starter amps or rpm are not to specification,
3. Connect positive (+) cable to positive (battery) repair or replace starter.
terminal on starter.
JT05719 Hand-Held JT05712 Current Gun 10

Digital Tachometer
Jumper Wire
3009 and 4019 M82149A
4/7/95 10-57
JT05712 Current Gun

JT05719 Hand-Held
Digital Tachometer
Jumper Wire
3011 and 3014 M82150A
10 STARTER SOLENOID TEST 5. Connect jumper wire between terminals.

• Starter runs: Replace solenoid.
Reason:
• Starter does not run: Check battery cables then
To determine if starter solenoid or starter motor is replace starter.
defective.
Equipment:
• Jumper Wire Large Terminals
Procedure:
1. Disconnect fuel shutoff solenoid connector. Starter Solenoid
Terminal
2. Disconnect single wire connector from starter
solenoid.
3. Connect jumper wire to positive (+) battery Connector
M82151
terminal and briefly jump to starter solenoid

terminal. 3011 and 4019 Shown
• Starter runs: Solenoid is good.

• Starter does not run: Go to step 4. REGULATED AMPERAGE TEST
4. Remove rubber boots from starter solenoid large Reason:
terminals.
To determine regulated charging output of the
alternator.
10-58 4/7/95
Equipment: Fast Idle Speed Specifications:

• JT05712 Current Gun Industrial Application
• JT05685 Battery Load Tester All . . . . . . . . . . . . . . . . . . . . . . . . . . . 3300 rpm
Procedure: 3009 (3TNA72) . . . . . . . . . . . . . . . . 3800 rpm
1. Turn load knob of Battery Tester fully out 3011 (3TNC78), 3014 (3TN84),
(counterclockwise) before connecting to battery. 4019 (4TN84) . . . . . . . . . . . . . . . . . . 1900 rpm
2. Connect Battery Tester to battery. 5. Turn load knob in until voltage read on the tester
3. Attach Current Gun to alternator red wire. Set voltage scale is 11 volts and read amperage on
Current Gun for DC current. Current Gun. Minimum regulated amperage
should be 35 amps.
IMPORTANT: Perform this test quickly to
prevent damage to battery tester. DO NOT Results:
apply full load to battery for more than 10
seconds. • If reading is less than specifications, verify
voltage at the alternator regulator terminal and
4. Start and run engine at fast idle (full throttle). good alternator ground. If voltage and ground
are OK, perform UNREGULATED
AMPERAGE TEST to determine if alternator or
voltage regulator is defective.
JT05685 Battery Load Tester 10

JT05712 Current Gun
M82152A
4/7/95 10-59
UNREGULATED AMPERAGE TEST Results:

• If reading is less than specifications, verify
Reason: voltage at the alternator regulator terminal and
To determine charging output of the alternator stator. good alternator ground. If voltage and ground
are OK, replace the alternator.
Equipment: • If reading meets the specification, replace the
regulator.
REGULATED VOLTAGE TEST
Procedure:
1. Attach Current Gun to alternator red wire. Set Reason:
Current Gun for DC current. To determine regulated voltage output of the
IMPORTANT: Perform this test quickly to alternator regulator.
prevent damage to battery. DO NOT apply full
load to battery for more than 10 seconds. Equipment:
2. Start and run engine at fast idle (full throttle). • Voltmeter
Fast Idle Speed Specifications: Procedure:

Industrial Application 1. Remove surface charge from battery by placing a
small load on the battery for 15 seconds.
All . . . . . . . . . . . . . . . . . . . . . . . . . . . 3300 rpm
Generator Application 2. Set voltmeter to DC volts scale.
3009 (3TNA72) . . . . . . . . . . . . . . . . 3800 rpm 3. Connect meter red lead to positive (+) battery
terminal.
10 3011 (3TNC78), 3014 (3TN84),
4019 (4TN84) . . . . . . . . . . . . . . . . . . 1900 rpm 4. Connect meter black lead to negative (-) battery
terminal.
3. Insert a Phillips screwdriver through hole in rear
cover of alternator, to ground the regulator to the 5. Start and run engine at fast idle (full throttle).
rear cover. Read amperage on current gun.
Minimum regulated amperage should be 35 Fast Idle Speed Specifications:
amps. Industrial Application
All . . . . . . . . . . . . . . . . . . . . . . . . . . . 3300 rpm
JT05712 Generator Application
Current Gun
3009 (3TNA72) . . . . . . . . . . . . . . . . 3800 rpm
3011 (3TNC78), 3014 (3TN84),
4019 (4TN84) . . . . . . . . . . . . . . . . . . 1900 rpm
6. Read meter several times during five minutes of
running time. Regulated voltage should be
within 12.2 - 14.7 VDC.
Hole IMPORTANT: Do not allow the battery voltage
M82153A
to exceed 15.5 volts or the battery and
charging system will be damaged.
10-60 4/7/95
Results:
• If the DC voltage stays below the minimum
specification, verify voltage at the alternator
regulator terminal and good alternator ground. If
voltage and ground are OK, perform
UNREGULATED AMPERAGE TEST to
determine if alternator or voltage regulator is
defective.
• If the DC voltage goes above the maximum
specification, replace the regulator.
10
4/7/95 10-61
Dealer Fabricated Tools
DFRG1 EXTENDED INDICATOR TIP (RHB3)
Ø3 mm (0.1181 in.)
R10 mm
(0.3937 in.)
R5 mm (0.1968 in.)
6 mm (0.236 in.)
M 2.6
P 0.45 1 mm (0.0393 in.)
8 mm 30 mm 10 mm 20 mm
(1.180 in.) (0.3937 in.) (0.787 in.)
(0.3149 in.)
M82177A
Extended indicator tip is used to check radial play of Material required:

turbocharger rotor shaft. Attach extended tip to a
Extended indicator tip from a local supplier.
dial indicator gauge.
Approximately 0.118 in. dia. x 3 in. long. Heat and
bend to size shown.
10
10-62 4/7/95
DFRG2 EXTENDED INDICATOR TIP

(RHB5)
Ø5 mm (0.1968 in.)
R10 mm
(0.3937 in.)
R5 mm (0.1968 in.)
7 mm (0.2755 in.)
M 2.6
P 0.45 1 mm (0.0393 in.)
8 mm 40 mm 10 mm 15 mm
(1.5748 in.) (0.3937 in.) (0.5905 in.)
(0.3149 in.)
M82177A
Extended indicator tip is used to check radial play of Material required:

turbocharger rotor shaft. Attach extended tip to a
Extended indicator tip from a local supplier.
dial indicator gauge.
Approximately 0.197 in. dia. x 3 in. long. Heat and
bend to size shown. 10
4/7/95 10-63
10
10-64 4/7/95
ENGINE, AIR INTAKE
AND FUEL SYSTEM
Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1

Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-4
20
Section 20
20
Component Location
INTRODUCTION While most parts in the TN Series Engines are

identical and interchangeable with Series 220
This section provides an overview of the compact Engines, specifications are not always the same.
three and four cylinder in-line diesel engines used in General appearance, repair procedures, and
John Deere Grounds Care and Industrial products. operation of sub-systems are similar and often even
These compact engines are also available as OEM identical.
stand-alone power packs.
There are two “types” of engines; Indirect Injection -
The TN Series diesel engines are offered as base 3TN66 and 3TNA72 (3009) and Direct Injection -
engines only and are mainly used in tractor All except 3TN66 and 3TNA72 (3009).
applications.
The following is a complete engine listing with the
The Series 220 diesel engines are offered as OEM approximate horsepower ratings:
units with three different configurations available. A
base industrial engine, an industrial power unit, and NOTE: The TN Series horsepower ratings are
a generator drive unit. Features on the power units averages as a result of the numerous tractor
include an air cleaner kit, muffler, radiator kit and applications for each engine.
instrument panel.
NOTE: The Series 220 engines are NOT repower
engines for tractor application.
TN Series Engines
Model Number kW (hp) Rating
3TN6611.9 (16) SAE Net @ 3200 rpm
3TNA7216.4 (22) SAE Net @ 3600 rpm
3TN7517.9 (24) SAE Net @ 3200 rpm
3TN7817 (23) SAE Net @ 2500 rpm
3TN8221.4 (28.7) SAE Net @ 2800 rpm
3TNA8217.2 (24) SAE Net @ 2600 rpm
3TN8420.9 (28) SAE Net @ 2600 rpm 20
4TN78T29 (39) SAE Net @ 2650 rpm
4TN8228.9 (38.8) SAE Net @ 2800 rpm
4TN8428.7 (38.5) SAE Net @ 2600 rpm
4TN10041 (55) SAE Net @ 2200 rpm
Series 220 Engines (OEM)

Intermittent Gross Power,
Model (Engine) kW (hp) @ 3000 rpm
3009 (3TNA72). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.4 (20.7)
3011 (3TNC78). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.2 (27.1)
3014 (3TN84) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.9 (33.5)
4019D (4TN84). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.4 (44.8)
4019T (4TN84T). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.3 (54)
4/7/95 20-1
Component Location
20
INDIRECT INJECTION (IDI) ENGINE COMPONENTS

M82000A
20-2 4/7/95
Component Location
20
DIRECT INJECTION (DI) ENGINE COMPONENTS

M82001A
4/7/95 20-3
Theory of Operation
ENGINE BALANCER OPERATION - However, the forces are not entirely cancelled.
4TN82 and 4TN84 During each 45° segment of crankshaft rotation, the
No. 1 piston and connecting rod moves a different
distance than the No. 2 piston and connecting rod.
Function:
Since the crankshaft throws move at equal speed, the
To minimize engine vibrations resulting from parts moving farther must also move faster. As
unbalanced movements. engine speeds increase and/or parts get heavier,
vibrations resulting from the unbalanced movements
NOTE: TN Series 4TN82 and 4TN84 engines are may become objectionable.
fitted with balancer shafts, because the
engines are used as rigid-mount, structural To minimize these vibrations the engines have a
members. Series 220 OEM 4019D (4TN84) balancer assembly mounted to the block, below the
and 4019T (4TN84T) engines are “loose” crankshaft. It is driven by a gear on the crankshaft.
engines and do not have balancer shafts. The balancer has two shafts, counter-rotating, with
These engines may be “soft” mounted if balancing weights, turning at double crankshaft
vibration is a concern. RPM.
The balancer weights are timed to the crankshaft so
Theory of Operation: that when No. 1 piston travels downward from TDC
In-line 4 cylinder engines with crankshaft throws to horizontal crankshaft position, the balancer
180° apart have some unbalanced forces of the weights both move upward. The weights are then
reciprocating parts. Most of these forces are offset positioned so they can move downward as the No. 2
by parts moving in opposite directions. piston moves up from horizontal crankshaft position
to TDC.
20
20-4 4/7/95
4/7/95
16MM
2 CYL
1 CYL
TDC
50MM
9MM 77MM 86MM
70MM
36MM
BDC
45° 90°
135°
1 2 3 4 5
ENGINE BALANCER OPERATION - 4TN82 and 4TN84
M82002A
Theory of Operation
20-5
20
Theory of Operation
COOLING SYSTEM OPERATION From the block, coolant is then directed through the
cylinder head, and into thermostat housing. With the
Function: thermostat open, 82° C (180° F), warm engine
coolant passes through the housing into the top of
The coolant pump circulates coolant through the the radiator where it is circulated to dissipate heat.
cooling system, drawing hot coolant from the engine
block, circulating it through the radiator for cooling. When coolant system pressure exceeds 48 kPa (7
psi), a valve in the radiator cap opens to allow
coolant to discharge into the coolant recovery tank.
Theory of Operation:
When temperature is reduced, a vacuum is produced
The pressurized cooling system includes the
in the radiator and coolant is drawn back out of the
radiator, water pump, fan and thermostat.
coolant recovery tank through a valve in the radiator
During the warm-up period, the thermostat remains cap.
closed and coolant is directed through a by-pass tube
3TN84UJ, 4TN78T, 4TN84T (4019T) and 4TN100
to the suction side of the coolant pump. The coolant
are equipped with an oil cooler. The oil cooler is
then circulates through the cylinder block providing
used to help reduce the temperature of engine oil.
a fast warm-up period.
Pressurized oil enters the oil cooler and passes
Once the engine has reached operating temperature, through a network of tubing surrounded by engine
the thermostat opens and coolant is pumped from coolant. Heat transfers from the oil to the coolant,
the bottom of the radiator via the lower radiator hose thus reducing oil temperature.
into the cylinder block. Here it circulates through the
A coolant temperature sender senses critical coolant
block and around the cylinders.
temperature and sends a signal to an indicator light
and/or gauge in the instrument panel.
20
20-6 4/7/95
Theory of Operation
Thermostat
Cylinder Head
Coolant
Recovery
Tank
By-Pass
Tube
Cylinder Block
Radiator
Coolant
Pump
Oil Cooler
COOLING SYSTEM OPERATION

M82003A
20
4/7/95 20-7
Theory of Operation
CRANKCASE BREATHER OPERATION - 3TN66, 3TNA72 (3009) and 4TN100
Oil Filler Cap
Valve Cover Nut
Breather Pipe
Joint Fitting
Breather Tube
Valve Cover
Baffle Gasket
Baffle Breather
Deflector
20 Valve Cover Gasket
CRANKCASE BREATHER OPERATION - 3TN66, 3TNA72 (3009) and 4TN100

M82004A
Function: Theory of Operation:

Vents crankcase fuel and water vapor out of engine During normal engine operation, unburned fuel
without losing engine oil, controls the pressurization vapors and water vapors, tend to contaminate the
of the crankcase. crankcase. Most of these vapors are expelled by the
exchange of air which is controlled by the breather.
The crankcase is slightly pressurized by the leakage
of compression around the pistons. The air is
circulated by the movement of the pistons.
20-8 4/7/95
Theory of Operation
CRANKCASE BREATHER OPERATION - ALL EXCEPT 3TN66, 3TNA72

(3009) and 4TN100
Oil Filler Cap

Cap
Valve Cover Nut
Plate
O-Ring
Deflector
Breather Tube
Valve Cover
20
Valve Cover O-Ring
CRANKCASE BREATHER OPERATION - ALL EXCEPT

3TN66, 3TNA72 (3009) and 4TN100 M82005A
Function: Theory of Operation:

Vents crankcase fuel and water vapor out of engine During normal engine operation, unburned fuel
without losing engine oil, controls the pressurization vapors and water vapors tend to contaminate the
of the crankcase. crankcase. Most of these vapors are expelled by the
exchange of air which is controlled by the breather.
The crankcase is slightly pressurized by the leakage
of compression around the pistons. The air is
circulated by the movement of the pistons.
4/7/95 20-9
Theory of Operation
AIR CLEANER OPERATION - 3009 (3TNA72)
Rain Cap
Air Cleaner Seal Washer

Collar Housing
Metal Shield Element
Unloader Valve
AIR CLEANER OPERATION - 3009 (3TNA72)

M82006AE
Function: Most of the dust is separated from the air by

centrifugal force that causes heavy dust particles to
20 Air cleaner filters air needed for combustion. enter the opening at the top of the unloader valve.
The remaining air enters the element.
The dirt that is deposited in the unloader valve is
Air enters the air cleaner inlet and is directed into removed by the rubber diaphragm at the base of
the side of a metal shield. This starts a high-speed unloader valve. When the engine is running, a
centrifugal motion of air which continues around the pulsing action is created in the intake system by each
element until it reaches the far end of the air cleaner intake stroke of engine. This pulsing action causes
housing, to an unloader valve. the rubber diaphragm to open and close, thus
emptying the unloader valve.
20-10 4/7/95
Theory of Operation
AIR CLEANER OPERATION - 3011 (3TNC78), 3014 (3TN84), 4019D (4TN84)

and 4019T (4TN84T)
Primary
Element
Fins
Rain Cap
Secondary
Safety Element
Seal Washer Dust Pan

Air Cleaner Assembly
Housing
To Intake
Manifold
Baffle
AIR CLEANER OPERATION - 3011 (3TNC78),

3014 (3TN84), 4019D (4TN84) AND 4019T (4TN84T)
M82007AE
Function: Most of the dust is separated from the air by

Air cleaner filters air needed for combustion.
centrifugal force that causes the heavy dust particles
to enter the opening at the top of the dust pan
20
assembly. The remaining air enters the primary
Theory of Operation: element, then secondary safety element to cylinder
Air enters the air cleaner inlet and is forced into a head.
high-speed centrifugal motion by fins on the primary Remove the baffle to empty dust pan assembly.
element. When the air reaches the end of the air Dust pan should be emptied daily.
cleaner housing, the dirt passes through a slot in top
of the dust pan assembly.
4/7/95 20-11
Theory of Operation
TURBOCHARGER OPERATION - Engine oil under pressure from the engine

4TN78T, 4TN84T (4019T) and 4TN100 lubrication system is pumped through passages in
the bearing housing and directed to the bearings.
Function: The turbocharger contains two floating bearings that
have clearance between the bearing O.D. and
To force more air into the engine cylinders to allow
housing wall as well as a clearance between the
the engine to efficiently burn more fuel, thereby
bearing I.D. and the shaft O.D.
producing more power.
These clearances are lubricated by the oil supply and
Theory of Operation: the bearings are protected by a cushion of oil.
The turbocharger provides additional air to burn The pressure-free oil drains by gravity from the
more fuel and produce more power without center housing to the engine crankcase.
increasing the size of the engine. In the thinner air of The turbocharger may be equipped with a waste
high altitudes, the turbocharger turbine wheel may gate. If the turbocharger goes above specified
turn as fast as 186,000 rpm to maintain power. pressure, a diaphragm sensing inlet pressure from
Exhaust gases from the engine pass through a the compressor, opens a waste gate valve to allow
turbine housing, causing a shaft to rotate before the excess exhaust gases to bypass the turbine. The
exhaust gas is discharged. waste gate valve limits boost pressure at high rpm to
prevent damage to the engine.
A compressor wheel, also mounted on the shaft,
rotates in the compressor housing. Inlet air is drawn
into the housing, where it is compressed and
delivered to engine cylinders.
20
20-12 4/7/95
Theory of Operation
Shaft
Turbine Housing
Oil Inlet
To Muffler From Air Cleaner
Compressor Wheel
Oil
Outlet To Intake
Manifold Compressor Housing
Floating Bearings
From
Turbine Wheel Center
Exhaust
Manifold Housing
TURBOCHARGER OPERATION - 4TN78T, 4TN84T (4019T) AND 4TN100

M82008A
From Air Cleaner

Turbine
Compressor Turbocharger
20
Waste To Muffler
Gate
Valve
Diaphram
Intake
Manifold Exhaust
Manifold
Cylinder
M82019A
4/7/95 20-13
Theory of Operation
LUBRICATION SYSTEM OPERATION Lube oil holes in main bearing oil grooves are
provided to direct oil to the camshaft bearings.
Function: A drilled passage from the rear camshaft bearing
A full pressure system lubricates engine parts with through the cylinder block and cylinder head
clean oil. supplies lubricating oil to the rocker arm shaft. The
hollow shaft distributes oil to the rocker arms,
NOTE: Safety valve and oil cooler are on 3TN84UJ, tappets and valves.
4TN78T, 4TN84T (4019T) and 4TN100
Oil passages direct from the main oil galley, through
engines only.
external oil lines, route lubricating oil to the fuel
injection pump and turbocharger, if equipped.
Piston cooling nozzles are on 4TN78T,
4TN84T (4019T) and 4TN100 engines only. An oil pressure switch activates an indicator light to
alert the operator to shut down the engine if oil
Theory of Operation: pressure drops below a specification.
The pressure lubrication system consists of a A safety valve (by-pass) (3TN84UJ, 4TN78T,
positive displacement gear-driven pump, oil 4TN84T (4019T), 4TN100 only) is located in the oil
strainer, full flow oil filter, oil pressure regulating pump housing. Should the difference between the
valve and an electrical pressure warning switch. pressure in the main oil galley and oil pump become
Some models are also equipped with an oil cooler, excessive, this valve would open and let oil bypass
safety valve and piston cooling nozzles. the filter and oil cooler to reach the main galley
faster. This valve has a permanent setting which
The pump draws lubrication oil from the oil pan cannot be changed.
through a strainer and a suction tube. The oil is then
pumped through an oil passage to the oil filter, oil
cooler, if equipped, and through the engine block
main oil galley.
From the main oil galley, oil is forwarded under
pressure to the crankshaft main bearing journals,
idler gear shaft and piston cooling nozzles, if
20 equipped. Drilled cross-passages in the crankshaft
distribute the oil from the main bearings to
connecting rod bearings.
20-14 4/7/95
4/7/95
By-Pass Valve
By-Pass Valve Fuel Injection Pump
Oil Filter Oil Cooler Oil Pressure

Regulating Valve
Safety Valve Engine Block Main Oil Galley
Piston
Cooling Nozzle
Oil Pump Idler
Gear Shaft Camshaft Bearing Crank Journal
Idler Valve Rocker

Oil Strainer Crank Pin Piston Turbocharger
Gear Face Arm Shaft
Valve
Rocker Arm
Tappet Valve
Oil Pan
LUBRICATION SYSTEM OPERATION
M82009A
Theory of Operation
20-15
20
Theory of Operation
OIL FILTER OPERATION
By-Pass
Valve
OIL FILTER OPERATION

M53983
Function: The oil filter is equipped with a bypass valve to

ensure adequate engine lubrication if the filter is
Filters contaminates from the oil between oil/filter
clogged or oil viscosity is too heavy to properly flow
20 changes.
through the filter. Bypass valve opens at 96 kPa (14
psi) pressure differential.
Pressurized oil is directed from the oil pump to the
oil filter. Oil flows through the filter element to the
main oil galley and to the engine components.
20-16 4/7/95
Theory of Operation
OIL PRESSURE REGULATING VALVE OPERATION
Engine
Filtered
Oil-to-Main Oil
Galley
Poppet Spring
Filtered
Oil-to-Crankcase
Filter Mounting Base
OIL PRESSURE REGULATING VALVE OPERATION

M53993
Function: The oil pressure regulating valve is set to maintain a

pressure of 294 - 440 kPa (43 - 64 psi).
Regulates engine oil pressure.
NOTE: All pressure regulating valves operate the 20
Theory of Operation: same. The most common mounting location
The oil pressure regulating valve is located in the oil is shown. 4TN100 valve is located in the oil
filter mounting base stud. Filtered oil passes through cooler housing and 4TN78T and 4TN84T
the pressure regulating valve to the main oil galley. (4019T) valve is located in oil filter and
cooler mounting bracket.
If oil pressure is higher than the valve is set for, a
poppet spring is overcome, opening the relief valve.
When opened, a passage is opened to route oil back
to the crankcase.
4/7/95 20-17
Theory of Operation
OIL COOLER OPERATION - 3TN84UJ, The coolant, its temperature now reduced, enters the
4TN78T, 4TN84T (4019T) AND 4TN100 oil cooler and passes over the warmer tubing. Heat
transfers from the oil to the coolant, thus reducing
NOTE: 4TN78T and 4TN84T (4019T) is shown. Oil oil temperature. Oil then flows into the engine block
cooler assembly on 3TN84UJ and 4TN100 main oil galley through the filter bracket.
engines is different in shape, but operation
The oil cooler keeps the maximum oil temperature
is the same.
below 115° C (175° F).
Function: The oil filter bracket on 4TN78T and 4TN84T
(4019T) (cooler housing on 4TN100), contains a by-
The oil cooler helps reduce the temperature of pass valve for the oil cooler. If the oil cooler would
engine oil. become plugged, pressure would build to exceed the
spring force, opening the valve and directing oil to
Theory of Operation: the engine block, by-passing the oil cooler.
After passing through the oil filter, pressurized oil The oil filter bracket also contains an oil pressure
enters the oil cooler and passes through a network of regulating valve. See OIL PRESSURE
tubing surrounded by engine coolant. Prior to REGULATING VALVE OPERATION.
entering the oil cooler, the engine coolant passes
through the radiator, which transfers much of the
coolant's heat into the surrounding air.
20
20-18 4/7/95
Theory of Operation
Oil Cooler By-Pass Valve Oil Pressure

Regulating Valve
To Main Oil Galley

Oil Cooler To Crankcase
From Oil Pump
Oil Filter Bracket
Oil Filter
Oil Filter Bracket
Oil Cooler
Oil Filter 20
OIL COOLER OPERATION - 3TN84UJ, 4TN78T,

4TN84T (4019T) AND 4TN100
M82010AE
4/7/95 20-19
Theory of Operation
PISTON COOLING NOZZLE Theory of Operation:

OPERATION - 4TN78T, 4TN84T Lube oil from the engine block main oil galley
(4019T) and 4TN100 passes a check valve in the nozzle mounting bolt,
then flows through a small steel pipe creating a jet
Function: spray. This jet spray coats the underside of the
piston, cooling the piston as a whole.
Cooling nozzles direct lube oil to underside of
pistons to lower piston temperature and thermal The check valve's opening pressure is factory set at
load. Cooling the pistons also reduces thermal 148 - 245 kPa (21.5 - 35.5 psi).
expansion and carbon deposits in the piston ring The oil spray amount is 21.3 L/min (5.6 gal/min) at
grooves. an oil pressure of 343 kPa (50 psi).
20
20-20 4/7/95
Theory of Operation
Piston
Jet Spray
Engine Block
Main Oil Galley
Check Valve
Nozzle
Mounting Bolt
Piston Cooling
Nozzle
PISTON COOLING NOZZLE OPERATION - 4TN78T,

4TN84T (4019T) AND 4TN100
M82011A
20
4/7/95 20-21
Theory of Operation
FUEL SYSTEM OPERATION The injection nozzle prevents flow until high
pressure is reached, opening the valve and spraying
NOTE: On 3TNA72 (3009) IDI engine, fuel supply atomized fuel into the combustion chamber.
pump is part of the engine (attached to fuel Injection lines have trapped fuel whenever injection
injection pump) for OEM application only. is not taking place.
On 3TN82, 3TN78, 4TN78T and some 3TN66 and 3TNA72 (3009) (IDI engine): A small
4TN82 DI engines, the fuel supply pump is amount of fuel leaks past the nozzle valve to
separate from the engine. lubricate the fuel injection nozzle. This leakage is
then returned to the fuel tank.
Function: All except 3TN66 and 3TNA72 (3009) (DI engine):
A small amount of fuel leaks past the nozzle valve to
Fuel system supplies fuel to injection nozzles.
lubricate the fuel injection nozzle. This leakage
combines with excess fuel from the injection pump
Theory of Operation: and is returned to tank.
Fuel supply pump draws fuel from a vented fuel tank Any air in the fuel system is bled out with return fuel
through a water separator and directs fuel through a to the fuel tank.
fuel filter to the fuel gallery of an injection pump.
The injection pump meters fuel as determined by the
governor and delivers it at high pressure to the
injection nozzles.
20
20-22 4/7/95
4/7/95
Return Fuel
Air Vent
Fuel Tank Fuel Tank

Fuel Water Fuel
Water Supply Separator Supply Fuel Filter
Separator Fuel Filter
Pump Pump
Return Fuel Fuel Fuel Fuel Fuel

Nozzles Pump Nozzles Pump
Local Procurement Engine Local Procurement Engine
IDI Engine - 3TN66 and 3TNA72 (3009) DI Engine - All Except 3TN66 and 3TNA72 (3009)
FUEL SYSTEM OPERATION
M82012A
Theory of Operation
20-23
20
Theory of Operation
FUEL INJECTION PUMP OPERATION When the plunger is in the downward position,
filtered medium pressure fuel from the fuel supply
Function: pump flows through the fuel inlet fitting, to the fuel
gallery. Fuel flows from the fuel gallery through the
Injection pump regulates fuel flow from fuel supply inlet orifice and fills the plunger area.
pump to injectors.
Whenever the plunger is in the downward position,
the delivery valve is held closed against the valve
seat, by spring pressure and trapped fuel pressure. In
this position, fuel flow to the fuel injection line and
Bottom of Plunger Stroke: nozzle is blocked.
The fuel injection pump is a variable-displacement,
in-line plunger-type pump. It is located on the right
side of the engine. The pump is driven by a camshaft
which turns at one-half engine speed.
20
20-24 4/7/95
Theory of Operation
Fuel Injection Line
Fuel Inlet Fitting
Spring
Delivery Valve
Valve Seat
Fuel Gallery
Inlet Orifice
Barrel
Plunger
Control Sleeve Control Rack
Roller Tappet
Camshaft
Medium Pressure Fuel
Trapped Fuel
20
FUEL INJECTION PUMP OPERATION (BOTTOM OF PLUNGER STROKE)
M82013AE
4/7/95 20-25
Theory of Operation
Theory of Operation - Continued: As the plunger continues moving upward, the

plunger helix aligns with the inlet orifice. The
Top of Plunger Stroke: pressure in the plunger area is higher than the
pressure in the fuel gallery. This causes fuel to flow
When the roller tappet is moved up by the camshaft, from the plunger area, through the plunger helix and
the inlet orifice is blocked by the plunger. Fuel in the inlet orifice to the fuel gallery.
plunger area is compressed and forced against the
delivery valve. Fuel flow through the inlet orifice causes pressure in
the plunger area to decrease. With pressure equal on
When fuel pressure is high enough to overcome the both sides of the delivery valve, spring force closes
spring, the delivery valve is lifted upward off the the delivery valve and stops the fuel flow to injection
valve seat. High pressure fuel flows past the delivery nozzle.
valve to the fuel injection line and then to the fuel
injection nozzle. The delivery valve is held open A governor-operated control rack is connected to the
only when the fuel pressure in the plunger area is control sleeve and plunger to regulate the quantity of
greater than the delivery valve spring pressure. fuel delivery to the nozzles. The control sleeve turns
the plunger and increases or decreases the amount of
plunger movement before the plunger helix and inlet
orifice are aligned.
20
20-26 4/7/95
Theory of Operation
Fuel Injection Line
Fuel Inlet Fitting
Spring
Delivery Valve
Valve Seat
Fuel Gallery
Inlet Orifice
Plunger Helix
Barrel
Plunger
Control Sleeve Control Rack
Roller Tappet
Camshaft
High Pressure Fuel
Medium Presure Fuel

20
FUEL INJECTION PUMP OPERATION (TOP OF PLUNGER STROKE)
M82014AE
4/7/95 20-27
Theory of Operation
GOVERNOR OPERATION The flyweights are mounted on the injection pump

camshaft. The flyweights move the thrust sleeve in
Function: and out with changes in engine RPM. The thrust
sleeve works against a button on the governor lever.
Governor maintains a set engine speed under The governor lever is connected to the injection
varying loads. pump control rack by the fuel control link. The
governor spring connects the tension lever assembly
Theory of Operation: to the throttle lever.
The injection pump governor is a mechanical NOTE: Due to the variety and number of tractor
centrifugal flyweight type. On 3TN66 and 3TNA72 applications, information on all horsepower
(3009) (IDI) engines, it is contained in a housing ratings for TN Series engines are not
mounted to the timing gear case and is serviced available. Refer to individual machine
separately from the injection pump. On all except Technical manual for proper horsepower
3TN66 and 3TNA72 (3009) (DI) engines, the ratings.
governor is assembled to the injection pump and
serviced with the pump. Governor internal
components and operation are similar.
Series 220 Engines (OEM)

Model NET Power kW (hp) @Rated rpm
3009DF001. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continuous . . . . . . . . . . . . . 12.8 (17.1) @ 3000
3009DF005. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intermittent . . . . . . . . . . . . . 14.2 (19.0) @ 3000
3009DF007. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator . . . . . . . . . . . . . . 14.2 (19.0) @ 3600
3011DF001. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continuous . . . . . . . . . . . . . 16.9 (22.7) @ 3000
3011DF005. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intermittent . . . . . . . . . . . . . 18.8 (25.2) @ 3000
20 3011DF006. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator . . . . . . . . . . . . . . 10.2 (13.7) @ 1800
3014DF001. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continuous . . . . . . . . . . . . . 21.3 (28.6) @ 3000
3014DF005. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intermittent . . . . . . . . . . . . . 23.5 (31.5) @ 3000
3014DF006. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator . . . . . . . . . . . . . . 12.9 (17.3) @ 1800
4019DF001. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continuous . . . . . . . . . . . . . 28.1 (37.7) @ 3000
4019DF005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intermittent . . . . . . . . . . . . . 30.9 (41.4) @ 3000
4019DF006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator . . . . . . . . . . . . . . 18.7 (25.0) @ 1800
4019TF001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continuous . . . . . . . . . . . . . 34.4 (46.1) @ 3000
4019TF005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intermittent . . . . . . . . . . . . . 37.8 (50.7) @ 3000
4019TF006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator . . . . . . . . . . . . . . 24.6 (33.0) @ 1800
20-28 4/7/95
Theory of Operation
High Idle Stop
Torque Spring Capsule
Throttle Shaft
Governor Spring
Fuel Control Lever
Tension Lever
Throttle Lever
Fuel Control Link
Control Rack
Low Idle Stop
Governor Lever Assembly

Thrust Sleeve
Enrichment Spring
20
Flyweights
GOVERNOR OPERATION
M54070
4/7/95 20-29
Theory of Operation
Theory of Operation - Continued: The forces generated by the flyweights against the
governor lever overcome governor spring tension,
Starting: pushing the rack to the right. This reduces fuel
delivery to an amount that will maintain the RPM
When the key switch is turned to “ON”, a fuel established by the speed control lever setting.
solenoid pulls the shutoff lever to the “RUN”
position. This permits the governor spring to move When the key is turned “OFF”, the fuel control
the tension lever, pulling the control rack left. The solenoid is de-energized. The spring on the shutoff
enrichment spring extends, pulling the rack an lever rotates the shaft so the high spot moves the
additional amount to give starting fuel delivery. governor lever to the right, pushing the rack to a
“NO” fuel position, stopping the engine.
After the engine starts as speed increases,
centrifugal force moves the flyweights outward
forcing the thrust sleeve against the button on the
governor lever. The enrichment spring compresses
and remains compressed while the engine is
running.
20
20-30 4/7/95
Theory of Operation
Governor Spring
Tension Lever
Starting Fuel Delivery

Max. Fuel
Min. Fuel
Shutoff Lever
Governor Lever
Enrichment Spring
20
GOVERNOR OPERATION - STARTING
M48495
4/7/95 20-31
Theory of Operation
Theory of Operation - Continued: Additional load would further reduce the flyweight
force permitting the governor spring to pull tension
High Idle, Maximum Torque: lever against the torque spring, compressing it and
moving the rack to the maximum torque fuel
When a load is applied, decreasing engine speed, the delivery.
flyweight force is reduced against the governor
lever. The spring can then pull the lever assembly A high idle adjusting screw and low idle screw,
and the rack to increase fuel delivery and bring RPM provide stops for the speed control lever.
back up to preset speed.
20
20-32 4/7/95
Theory of Operation
High Idle Screw
Governor Spring
Torque Spring
Max. Fuel
Min. Fuel
Low Idle Screw
Governor Lever
20
GOVERNOR OPERATION - HIGH IDLE, MAXIMUM TORQUE
M48496
4/7/95 20-33
Theory of Operation
INDIRECT INJECTION NOZZLE High pressure fuel from the pump flows through an
OPERATION (PINTLE TYPE) - inlet passage to the pintle valve. When pressure
3TN66 and 3TNA72 (3009) against the valve increases above spring tension, the
valve is lifted off its seat, permitting fuel to be
forced through a nozzle body orifice in an atomized
Function: form into the precombustion chamber.
Injection nozzle injects fuel in an atomized form A small amount of fuel leaks past the pintle valve to
into a precombustion chamber. lubricate valve and body, then flows through a return
passage to return lines and tank.
The pintle valve is shim adjustable to regulate the
The pintle type nozzle is used on indirect injection opening pressure.
engines 3TN66 and 3TNA72 (3009). It is different
from the hole-type nozzle in that it is threaded into
the cylinder head.
The fuel injection nozzle has an inward opening
pintle-type valve.
20
20-34 4/7/95
Theory of Operation
Fuel Inlet Passage

Return Connector
Return Line
Injector Body
Fuel Return Passage
Shim
Spring
Nozzle Fitting
Spring Seat
Pintle Separator Plate

(Valve) 20
Nozzle Body
High Pressure Fuel

Orifice
Return Fuel
Valve Seat
INDIRECT INJECTION NOZZLE OPERATION (PINTLE TYPE)
M82015AE
4/7/95 20-35
Theory of Operation
DIRECT INJECTION NOZZLE High pressure fuel from the injection pump flows
OPERATION (HOLE TYPE) - ALL through a fuel inlet passage. Pressure builds beneath
EXCEPT 3TN66 and 3TNA72 (3009) the nozzle valve. When the fuel pressure reaches
specified pressure it overcomes the nozzle spring
tension. The nozzle valve retracts into the nozzle
Function: body and fuel is injected into the engine.
Injection nozzle injects fuel in an atomized form The nozzle valve is automatically pushed down by
into the combustion chamber. the nozzle spring and closed after fuel is injected.
Theory of Operation: Leakage (return fuel) flows from between the nozzle
valve and nozzle body to the hole on top of the
The hole type nozzle is used on direct injection nozzle spring through the return pipe and back into
engines 3TN75 and larger. It is different from the the fuel tank.
pintle type nozzle in that it is held in the cylinder
head by a retaining bracket instead of being The nozzle valve is shim adjustable to regulate the
threaded. opening pressure.
20
20-36 4/7/95
Theory of Operation
Return Pipe
Shim
Spring
Retainer
Dowel Pin
Seat 20
Nozzle Valve
Nozzle Body Nozzle Nut
Injection Holes
Nozzle Valve Seat

High Pressure Fuel
Return Fuel
DIRECT INJECTION NOZZLE OPERATION (HOLE TYPE)
M82016A
4/7/95 20-37
Theory of Operation
PRECOMBUSTION CHAMBER At 16° BTDC crankshaft rotation, injection of fuel

OPERATION (INDIRECT INJECTION) - begins. The injection nozzle sprays atomized fuel
3TN66 and 3TNA72 (3009) into the precombustion chamber turbulent air. Heat
from the compressed air ignites the fuel, increasing
pressure in the precombustion chamber forcing the
Function: burning mixture into the cylinder where it mixes
The precombustion chamber is a small turbulent with the air in the piston swirl cup.
area where the fuel is injected, mixed with a limited Expansion for the burning mixture forces the piston
amount of air, and the start of ignition takes place. down on its power stroke.
Theory of Operation: When starting a cold engine, compression pressure
may not provide enough heat to ignite the fuel when
A precombustion chamber is located in the cylinder injected into a cold precombustion chamber. An
head with a small opening into the cylinder. electrically operated glow plug is installed into the
As the piston comes up on the compression stroke, precombustion chamber to provide added heat to
some of the air is forced through the opening into ignite the fuel as it is injected. The glow plugs are
the precombustion chamber. The opening is shaped energized during starting, and also may be pre-
to direct this air flow into a turbulent action as it is heated by turning key switch counterclockwise and
being compressed and heated. holding for up to 30 seconds.
20
20-38 4/7/95
Theory of Operation
Injection Nozzle Glow Plug
Intake Valve Exhaust Valve
Precombustion Chamber
Cylinder
Swirl Cup
Combustion 20
PRECOMBUSTION CHAMBER OPERATION

(INDIRECT INJECTION)
M82017AE
4/7/95 20-39
Theory of Operation
COMBUSTION CHAMBER At 16° BTDC crankshaft rotation, fuel is injected by

OPERATION (DIRECT INJECTION) - the multi-hole injection nozzle. The swirling action
ALL EXCEPT 3TN66 and 3TNA72 of the air thoroughly mixes the atomized fuel and air
for complete burning, as the piston travels into the
(3009) power stroke.
Function: When starting a cold engine, compression of
ambient temperature air may not provide enough
The combustion chamber is an area where the fuel is heat for ignition. To aid cold temperature starting, an
injected, mixed with a limited amount of air, and the electrically operated heater element is located at the
start of ignition takes place. intake manifold inlet. The heater is energized during
starting and also may be pre-heated by turning key
Theory of Operation: switch counterclockwise and holding for up to 30
A swirl cup is formed in the head of the piston. As seconds.
the piston travels upward on its compression stroke,
the shape of the cup causes the air to swirl as it is
compressed and heated.
20
20-40 4/7/95
Theory of Operation
Injection Nozzle
Intake Valve Exhaust Valve
Combustion Chamber
Piston Swirl Cup
20
High Pressure Fuel
COMBUSTION CHAMBER OPERATION (DIRECT INJECTION)
M82018AE
4/7/95 20-41
ELECTRICAL SYSTEM
SERIES 220
POWER UNIT ENGINES
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-1

Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-2
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-4
21
Section 21
21
Electrical System
INTRODUCTION
This section provides component location and schematics of the electrical system used on OEM stand-alone
power packs.
The Series 220 diesel engines are offered as OEM units with two different power unit configurations
available for each model. Features on the power units include an air cleaner kit, muffler, radiator kit and
instrument panel.
The following is a complete engine listing of all Series 220 Power Units:
Power Unit Engine

Model Number Model Number Description
3009DF005 3TNA72 Industrial Power Unit
3009DF007 3TNA72 3600 rpm gen-set Power Unit
3011DF005 3TNC78 Industrial Power Unit

3011DF006 3TNC78 1800 rpm gen-set Power Unit
3014DF005 3TN84 Industrial Power Unit

3014DF006 3TN84 1800 rpm gen-set Power Unit
4019DF005 4TN84 Industrial Power Unit

4019DF006 4TN84 1800 rpm gen-set Power Unit
4019TF005 4TN84T Industrial Power Unit

4019TF006 4TN84T 1800 rpm gen-set Power Unit
21
4/7/95 21-1
Component Location
Instrument Panel
Air Heater Coolant
(Glow Plugs on Temperature Sensor
3009D Engine) Optional.
Oil Pressure Switch

Additional Oil Pressure
Sensor is Optional.
RG6604
21
Alternator
Starter
RG6605
ENGINE ELECTRICAL COMPONENTS
21-2 4/7/95
Component Location
Preheat Indicator
Coolant Temperature Gauge Oil Pressure Gauge
Optional. Optional. Charge Indicator
Oil Pressure Indicator
Coolant
Temperature
Indicator
Key Switch
Preheat Timer
M82178A
INSTRUMENT PANEL COMPONENTS
21
4/7/95 21-3
Schematics
LEGEND FOR ELECTRICAL SCHEMATIC - 3009 POWER UNIT

B1 - Oil Pressure Switch
B2 - Coolant Temperature Switch
D1 - Preheat Timer
D2 - Fuel Shutoff Solenoid Timer
F1 - 30-amp Fuse
G1 - 12-volt Battery
G2 - Alternator
H1 - Preheat Indicator
H2 - Charge Indicator
H3 - Oil Pressure Indicator
H4 - Coolant Temperature Indicator
K1 - Fuel Injection Relay
M1 - Starter
R1 - Glow Plugs
S1 - Battery Switch
S2 - Key Switch
V1 - Diode
X1 - 4-Wire Connector, at Preheat Timer
X2 - 10-Wire Connector, Main Harness-to-Instrument Panel
X3 - 3-Wire Connector, at Fuel Shutoff Solenoid
X4 - 1-Wire Bullet Connector, at Oil Pressure Switch
X5 - 1-Wire Connector, at Starter
X6 - 2-Wire Connector, at Alternator
X7 - 1-Wire Bullet Connector, at Coolant Temperature Switch
21 X8 - 1-Wire Connector, Fuel Injection Relay-to-Fuse
X9 - 1-Wire Connector, at Fuel Injection Relay-to-Shutoff Solenoid
X10 - 2-Wire Connector, at Fuel Injection Relay
X11 - 1-Wire Bullet Connector, Preheat Indicator Positive Lead
X12 - 1-Wire Bullet Connector, Preheat Indicator Negative Lead
X13 - 1-Wire Bullet Connector, Charge Indicator Positive Lead
X14 - 1-Wire Bullet Connector, Charge Indicator Negative Lead
X15 - 1-Wire Bullet Connector, Oil Pressure Indicator Positive Lead
X16 - 1-Wire Bullet Connector, Oil Pressure Indicator Negative Lead
X17 - 1-Wire Bullet Connector, Collant Temperature Indicator Positive Lead
X18 - 1-Wire Bullet Connector, Collant Temperature Indicator Negative Lead
X19 - 4-Wire Connector, at Fuel Shutoff Solenoid Timer
Y1 - Fuel Shutoff Solenoid
21-4 4/7/95
Schematics
21
4/7/95 21-5
Schematics
21
M82179AE
21-6 4/7/95
Schematics
21
M82179AF
4/7/95 21-7
Schematics
LEGEND FOR ELECTRICAL SCHEMATIC - 3011, 3014 AND 4019 POWER UNITS
B1 - Oil Pressure Switch
B2 - Coolant Temperature Switch
D1 - Preheat Timer
D2 - Fuel Shutoff Solenoid Timer
F1 - 10-amp Fuse
G1 - 12-volt Battery
G2 - Alternator
H1 - Preheat Indicator
H2 - Charge Indicator
H3 - Oil Pressure Indicator
H4 - Coolant Temperature Indicator
M1 - Starter
R1 - Air Heater
S1 - Battery Switch
S2 - Key Switch
X1 - 4-Wire Connector, at Preheat Timer
X3 - 3-Wire Connector, at Fuel Shutoff Solenoid
X4 - 1-Wire Bullet Connector, at Oil Pressure Switch
X5 - 1-Wire Connector, at Starter
X6 - 2-Wire Connector, at Alternator
X7 - 1-Wire Bullet Connector, at Coolant Temperature Switch
X8 - 1-Wire Bullet Connector, Preheat Indicator Positive Lead
X9 - 1-Wire Bullet Connector, Preheat Indicator Negative Lead
21 X10 - 1-Wire Bullet Connector, Charge Indicator Positive Lead
X11 - 1-Wire Bullet Connector, Charge Indicator Negative Lead
X12 - 1-Wire Bullet Connector, Oil Pressure Indicator Positive Lead
X13 - 1-Wire Bullet Connector, Oil Pressure Indicator Negative Lead
X14 - 1-Wire Bullet Connector, Coolant Temperature Indicator Positive Lead
X15 - 1-Wire Bullet Connector, Coolant Temperature Indicator Negative Lead
Y1 - Fuel Shutoff Solenoid
21-8 4/7/95
Schematics
21
4/7/95 21-9
Schematics
21
M82180AE
21-10 4/7/95
Schematics
21
M82180AF
4/7/95 21-11
Schematics
LEGEND FOR ELECTRICAL SCHEMATIC - OPTIONAL EQUIPMENT

B3 - Coolant Temperature Sender
B4 - Oil Pressure Sender
P1 - Coolant Temperature Gauge
P2 - Oil Pressure Gauge
X20 - 1-Wire Bullet Connector, at Coolant Temperature Sender
X21 - 1-Wire Bullet Connector, at Oil Pressure Sender
21
21-12 4/7/95
Schematics
21
M82181AE
4/7/95 21-13
Schematics
21
21-14 4/7/95
Index
A Alternator - 3TNA72 (430 LGT, 670 CUT, 755/56

CUT, F925/35 FM) (Nippondenso 35A)
Air Cleaner Operation Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 1-125
3009 (3TNA72). . . . . . . . . . . . . . . . . . . . . 20-10 Disassembly . . . . . . . . . . . . . . . . . . . . . . . 1-123
3011 (3TNC78), 3014 (3TN84), Test/Inspection . . . . . . . . . . . . . . . . . . . . . 1-125
4019D (4TN84), 4019T (4TN84T) . . . . . 20-11 Alternator - 3TNA72 (455 LGT, 755/56 CUT,
Air Cleaner, Inspection 3009 OEM) (Nippondenso 40A)
3009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 1-129
3011, 3014, 4019D . . . . . . . . . . . . . . . . . . . 10-7 Disassembly . . . . . . . . . . . . . . . . . . . . . . . 1-128
4019T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 Inspection/Test . . . . . . . . . . . . . . . . . . . . . 1-129
Air Heater, Removal/Installation . . . . . . . . . . 10-39 Alternator - 3TNA72 (670 CUT, 15 EX)
Air Intake System, Check . . . . . . . . . . . . . . . . 10-45 (Kokosan 20A)
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 1-122
Air Intake System, Leakage Test
Disassembly/Inspection . . . . . . . . . . . . . . 1-122
3009, 3011, 3014, 4019 . . . . . . . . . . . . . . 10-51
3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . 1-155 Alternator - 3TNA82, 3TN84 (870 CUT)
3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-137 (Kokosan 20A)
3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-137 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 2-102
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-99 Disassembly/Inspection . . . . . . . . . . . . . . 2-102
4TN78T, 4TN82, 4TN84(T) (4019) . . . . . 3-142 Alternator - 4TN100 (Hitachi 25A)
Alternator - 3TN66 (375 SSL, 330/332 LGT, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
F915 FM) (Kokosan 20A) Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 4-75
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 1-122 Inspection/Test . . . . . . . . . . . . . . . . . . . . . . 4-77
Disassembly/Inspection . . . . . . . . . . . . . . 1-122 Alternator - 4TN78T (Hitachi 25A)
Alternator - 3TN66 (655 CUT) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-108
(Nippondenso 35A) Disassembly . . . . . . . . . . . . . . . . . . . . . . . 3-106
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 1-125 Inspection/Test . . . . . . . . . . . . . . . . . . . . . 3-108
Disassembly . . . . . . . . . . . . . . . . . . . . . . . 1-123 Alternator - 4TN82, 4TN84RJK
Test/Inspection . . . . . . . . . . . . . . . . . . . . . 1-125 (Nippondenso 35A)
Alternator - 3TN66 (655 CUT) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-113
(Nippondenso 40A) Disassembly . . . . . . . . . . . . . . . . . . . . . . . 3-111
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 1-129 Inspection/Test . . . . . . . . . . . . . . . . . . . . . 3-113
Disassembly . . . . . . . . . . . . . . . . . . . . . . . 1-128 Alternator - 4TN82ESP/RJE, 4TN84(T) (4019)
Inspection/Test . . . . . . . . . . . . . . . . . . . . . 1-129 (Nippondenso 40A)
Alternator - 3TN75 (855/56 CUT), 3TN82 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-117
(575 SSL), 3TNA82, 3TN84 (870 CUT, 955 CUT) Disassembly . . . . . . . . . . . . . . . . . . . . . . . 3-116
(Nippondenso 35A) Inspection/Test . . . . . . . . . . . . . . . . . . . . . 3-117
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 2-110 Alternator - 4TN82RJK, 4TN84RJK
Disassembly . . . . . . . . . . . . . . . . . . . . . . . 2-108 (Kokosan 20A)
Inspection/Test . . . . . . . . . . . . . . . . . . . . . 2-110 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-105 I
Alternator - 3TN75, 3TNC78 (3011), 3TN82 Disassembly/Inspection . . . . . . . . . . . . . . 3-105
(575 SSL), 3TN84 (955 CUT, 3014 OEM) Altitude Compensation Guidelines . . . . . . . . . 10-44
(Nippondenso 40A) Amperage Test - 3009, 3011, 3014, 4019
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 2-114 Regulated . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
Disassembly . . . . . . . . . . . . . . . . . . . . . . . 2-113 Unregulated. . . . . . . . . . . . . . . . . . . . . . . . 10-60
Inspection/Test . . . . . . . . . . . . . . . . . . . . . 2-114
Auxiliary Drive Gear
Alternator - 3TN78, 3TN82 (30 EX)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
(Hitachi 25A)
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 2-105
Disassembly . . . . . . . . . . . . . . . . . . . . . . . 2-103
Inspection/Test . . . . . . . . . . . . . . . . . . . . . 2-105
4/7/95 Index-1
Index
B Component Location
Engine Components - Direct Injection . . . . 20-3
Balancer Assembly - 4TN82RJK, 4TN84RJK Engine Components - Indirect Injection . . . 20-2
Disassembly/Assembly . . . . . . . . . . . . . . . . 3-42 Engine Electrical Components . . . . . . . . . . 21-2
Removal/Installation . . . . . . . . . . . . . . . . . . 3-42 Instrument Panel Components . . . . . . . . . . 21-3
Basic Engine Specifications . . . . . . . . . . . . . . . . G-4 Connecting Rod Check - 3TN66, 3TNA72 (3009)
Bearing Clearance. . . . . . . . . . . . . . . . . . . 1-136
C Side Play . . . . . . . . . . . . . . . . . . . . . . . . . . 1-136
Connecting Rod Check - 3TN75, 3TN78,
Cam Followers - 3TN66, 3TNA72 (3009) 3TNC78 (3011)
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 1-60 Bearing Clearance. . . . . . . . . . . . . . . . . . . 2-120
Removal/Installation . . . . . . . . . . . . . . . . . . 1-59 Side Play . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120
Cam Followers - 3TN75, 3TN78, 3TNC78 (3011) Connecting Rod Check - 3TN82, 3TNA82,
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58 3TN84 (3014)
Removal/Installation . . . . . . . . . . . . . . . . . . 2-58 Bearing Clearance. . . . . . . . . . . . . . . . . . . 2-120
Cam Followers - 3TN82, 3TNA82, 3TN84 (3014) Side Play . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58 Connecting Rod Check - 4TN100
Removal/Installation . . . . . . . . . . . . . . . . . . 2-58 Bearing Clearance. . . . . . . . . . . . . . . . . . . . 4-84
Cam Followers - 4TN100 Side Play . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44 Connecting Rod Check - 4TN78T, 4TN82,
Removal/Installation . . . . . . . . . . . . . . . . . . 4-44 4TN84(T) (4019)
Cam Followers - 4TN78T, 4TN82, Bearing Clearance. . . . . . . . . . . . . . . . . . . 3-123
4TN84(T) (4019) Side Play . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57 Coolant Temperature Sender
Removal/Installation . . . . . . . . . . . . . . . . . . 3-57 Replacement . . . . . . . . . . . . . . . . . . . . . . . 10-41
Camshaft - 3TN66, 3TNA72 (3009) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41
End Play Check. . . . . . . . . . . . . . . . . . . . . 1-139 Coolant Temperature Sender - 4TN100
Inspection/Replacement . . . . . . . . . . . . . . . 1-57 Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4-56
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 1-56 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-92
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-56
Coolant Temperature Sensor - 3TN66,
Camshaft - 3TN75, 3TN78, 3TNC78 (3011)
3TNA72 (3009)
End Play Check. . . . . . . . . . . . . . . . . . . . . 2-123
Replacement . . . . . . . . . . . . . . . . . . . . . . . . 1-84
Inspection/Replacement . . . . . . . . . . . . . . . 2-56
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-144
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55 Coolant Temperature Switch - 3TN75, 3TN78,
3TNC78 (3011)
Camshaft - 3TN82, 3TNA82, 3TN84 (3014)
Replacement . . . . . . . . . . . . . . . . . . . . . . . . 2-70
End Play Check. . . . . . . . . . . . . . . . . . . . . 2-123
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-128
I Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-55 Coolant Temperature Switch - 3TN82, 3TNA82,
3TN84 (3014)
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
Camshaft - 4TN100 Replacement . . . . . . . . . . . . . . . . . . . . . . . . 2-70
End Play Check. . . . . . . . . . . . . . . . . . . . . . 4-87 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-128
Inspection/Replacement . . . . . . . . . . . . . . . 4-42 Coolant Temperature Switch - 4TN78T, 4TN82,
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-41 4TN84(T) (4019)
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41 Replacement . . . . . . . . . . . . . . . . . . . . . . . . 3-70
Camshaft - 4TN78T, 4TN82, 4TN84(T) (4019) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-131
End Play Check. . . . . . . . . . . . . . . . . . . . . 3-126 Cooling Fan
Inspection/Replacement . . . . . . . . . . . . . . . 3-55 Installation . . . . . . . . . . . . . . . . . . . . . . . . 10-33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-54 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
Combustion Chamber Operation
(Direct Injection). . . . . . . . . . . . . . . . . . . . . . . 20-40
Index-2 4/7/95
Index
Cooling System Crankshaft and Main Bearings - 4TN78T, 4TN82,

Check and Service . . . . . . . . . . . . . . . . . . 10-45 4TN84(T) (4019)
Flushing and Servicing . . . . . . . . . . . . . . . . G-13 Inspection/Replacement . . . . . . . . . . . . . . . 3-49
Theory of Operation . . . . . . . . . . . . . . . . . . 20-6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
Cooling System, Pressure Test Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
3009, 3011, 3014, 4019 . . . . . . . . . . . . . . 10-48 Crankshaft Front Oil Seal
3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . 1-152 3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . . 1-46
3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-134 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . 2-46
3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-134 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . 2-46
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-96 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
4TN78T, 4TN82, 4TN84(T) (4019) . . . . . 3-139 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . . 3-45
Crankcase Breather Operation Crankshaft Main Bearing, Clearance Check
3TN66, 3TNA72 (3009), 4TN100 . . . . . . . 20-8 3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . 1-138
All Except 3TN66, 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-122
3TNA72 (3009), 4TN100 . . . . . . . . . . . . . . 20-9 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-122
Crankcase Extension Housing 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85
3TN75, 3TNC78 (3011 OEM), 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . 3-124
3TN82 (575 SSL), 3TN84 Crankshaft Rear Oil Seal
(955 CUT, 3014 OEM) . . . . . . . . . . . . . . . . 2-44 3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45
3TN78 (25 EX), 3TN82 (30 EX), 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . 2-45
3TNA82 (770 CUT), 3TN84 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . 2-45
(870 CUT). . . . . . . . . . . . . . . . . . . . . . . . . . 2- 44 3TNA72 (15 EX, 670 CUT,
3TNA72 (15 EX and 3009 OEM). . . . . . . . 1-44 3009 OEM) . . . . . . . . . . . . . . . . . . . . . . . . . 1-45
3TNA72 (670 CUT) . . . . . . . . . . . . . . . . . . 1-43 3TNA72 (430 LGT, 455 LGT,
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 755/56 CUT, F925/35 FM) . . . . . . . . . . . . . 1-45
4TN78T, 4TN82RJK, 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
4TN84RJK . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . . 3-45
4TN82RJE, 4TN82ESP, Crankshaft, End Play Check
4TN84(T) (4019) . . . . . . . . . . . . . . . . . . . . 3-44 3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . 1-137
Crankcase Ventilation System, Check . . . . . . 10-45 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-121
Crankshaft and Main Bearings - 3TN66, 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-121
3TNA72 (3009) 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85
Inspection/Replacement . . . . . . . . . . . . . . . 1-49 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . 3-124
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 1-47 Cylinder Bore - 3TN66, 3TNA72 (3009)
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46 Deglazing . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40
Crankshaft and Main Bearings - 3TN75, 3TN78, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40
3TNC78 (3011) Reboring . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41
Inspection/Replacement . . . . . . . . . . . . . . . 2-49 Cylinder Bore - 3TN75, 3TN78, 3TNC78 (3011)
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-47 Deglazing . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 I
Crankshaft and Main Bearings - 3TN82, 3TNA82, Reboring . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
3TN84 (3014) Cylinder Bore - 3TN82, 3TNA82, 3TN84 (3014)
Inspection/Replacement . . . . . . . . . . . . . . . 2-49 Deglazing . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-47 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46 Reboring . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Crankshaft and Main Bearings - 4TN100 Cylinder Bore - 4TN100
Inspection/Replacement . . . . . . . . . . . . . . . 4-36 Deglazing . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32 Reboring . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
4/7/95 Index-3
Index
Cylinder Bore - 4TN78T, 4TN82,

4TN84(T) (4019)
E
Deglazing . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 Electrical Component Location
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-2
Reboring . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 Instrument Panel . . . . . . . . . . . . . . . . . . . . . 21-3
Cylinder Head and Valves - 3TN66, Electrical Schematic
3TNA72 (3009) 3009 Power Unit . . . . . . . . . . . . . . . . . . . . . 21-4
Disassembly/Assembly . . . . . . . . . . . . . . . . 1-23 3011, 3014 and 4019 Power Units . . . . . . . 21-8
Inspection/Replacement . . . . . . . . . . . . . . . 1-24 Optional Equipment . . . . . . . . . . . . . . . . . 21-12
Removal/Installation . . . . . . . . . . . . . . . . . . 1-21 Electrical System, Check . . . . . . . . . . . . . . . . 10-46
Cylinder Head and Valves - 3TN75, 3TN78, Engine Application Chart
3TNC78 (3011) Industrial Equipment. . . . . . . . . . . . . . . . . . . G-3
Disassembly/Assembly . . . . . . . . . . . . . . . . 2-22 Lawn and Grounds Care Equipment. . . . . . . G-2
Inspection/Replacement . . . . . . . . . . . . . . . 2-23 OEM Application . . . . . . . . . . . . . . . . . . . . . G-3
Removal/Installation . . . . . . . . . . . . . . . . . . 2-21
Engine Balancer Operation . . . . . . . . . . . . . . . . 20-4
Cylinder Head and Valves - 3TN82, 3TNA82,
Engine Coolant
3TN84 (3014)
Recommendations. . . . . . . . . . . . . . . . . . . . . G-9
Disassembly/Assembly . . . . . . . . . . . . . . . . 2-22
Specifications . . . . . . . . . . . . . . . . . . . . . . . G-10
Removal/Installation . . . . . . . . . . . . . . . . . . 2-21 Engine Oil Pressure, Test
3009, 3011, 3014, 4019 . . . . . . . . . . . . . . 10-50
Cylinder Head and Valves - 4TN100
3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . 1-154
3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-136
3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-136
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-98
Cylinder Head and Valves - 4TN78T, 4TN82, 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . 3-141
4TN84(T) (4019) Engine Serial Number Plate
Disassembly/Assembly . . . . . . . . . . . . . . . . 3-22 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1
Inspection/Replacement . . . . . . . . . . . . . . . 3-23 Serial Number Information . . . . . . . . . . . . . . G-1
Engine Specifications
Cylinder, Compression Pressure Test
3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
3009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-49 3TNA72 (3009). . . . . . . . . . . . . . . . . . . . . . . 1-8
3011, 3014, 4019 . . . . . . . . . . . . . . . . . . . 10-50 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . . 2-1
3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . 1-153 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . . 2-8
3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-135 4TN78T. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-135 4TN82, 4TN84(T) (4019) . . . . . . . . . . . . . . . 3-8
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4TN78T, 4TN82, 4TN84(T) (4019) . . . . . 3-140
Engine, Clean . . . . . . . . . . . . . . . . . . . . . . . . . . G-17
D Exhaust Manifold
I Dealer Fabricated Tools 3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
DFRG1 Extended Indicator Tip . . . . . . . . 10-62 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . 2-26
DFRG2 Extended Indicator Tip . . . . . . . . 10-63 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . 2-26
Diagnosis 3TNA72 (3009). . . . . . . . . . . . . . . . . . . . . . 1-28
3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . 1-132 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-117 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . . 3-26
3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-117 Exhaust System, Check. . . . . . . . . . . . . . . . . . 10-45
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81
4TN78T, 4TN82, 4TN84(T) (4019) . . . . . 3-120 F
Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . G-8
Fan/Alternator Belt
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 10-34
Dynamometer Test - 3009, 3011, Replacement . . . . . . . . . . . . . . . . . . . . . . . 10-34
3014, 4019 . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-47
Index-4 4/7/95
Index
Fan/Alternator Drive Belt, Adjustment Fuel Filter Assembly

3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . 1-150 3009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-132 3011, 3014 and 4019. . . . . . . . . . . . . . . . . 10-36
3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-132 3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . . 1-93
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-95 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . 2-79
4TN78T, 4TN82, 4TN84(T) (4019) . . . . . 3-137 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . 2-79
Fan/Alternator Drive Belt, Inspection . . . . . . 10-46 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63
4TN78T, 4TN82, 4TN84(T) (4019) . . . . . . 3-79
Fast Idle Speed Adjustment
3009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-54 Fuel Injection Nozzles - 3TN66, 3TNA72 (3009)
3011, 3014, 4019 . . . . . . . . . . . . . . . . . . . 10-55 Cleaning/Inspection . . . . . . . . . . . . . . . . . 1-111
Cross Section . . . . . . . . . . . . . . . . . . . . . . 1-111
Flywheel Disassembly/Assembly . . . . . . . . . . . . . . . 1-110
3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . . 1-52 Removal/Installation . . . . . . . . . . . . . . . . . 1-109
3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . 2-51 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-142
3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . 2-51
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38 Fuel Injection Nozzles - 3TN75, 3TN78,
4TN78T, 4TN82, 4TN84(T) (4019) . . . . . . 3-51 3TNC78 (3011)
Cleaning/Inspection . . . . . . . . . . . . . . . . . . 2-85
Flywheel Housing Cross Section . . . . . . . . . . . . . . . . . . . . . . . 2-84
3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-54 Disassembly/Assembly . . . . . . . . . . . . . . . . 2-84
3TN78, 3TNC78 (3011), 3TN82, Removal/Installation . . . . . . . . . . . . . . . . . . 2-83
3TN84 (3014) . . . . . . . . . . . . . . . . . . . . . . . 2-52 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-125
3TNA72 (15 EX, 3009 OEM) . . . . . . . . . . 1-53
3TNA72 (All Except 15 EX and Fuel Injection Nozzles - 3TN82, 3TNA82,
3009 OEM) . . . . . . . . . . . . . . . . . . . . . . . . . 1-54 3TN84 (3014)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39 Cleaning/Inspection . . . . . . . . . . . . . . . . . . 2-85
4TN78T, 4TN82RJE, 4TN82ESP, Cross Section . . . . . . . . . . . . . . . . . . . . . . . 2-84
4TN84(T) (4019) . . . . . . . . . . . . . . . . . . . . 3-52 Disassembly/Assembly . . . . . . . . . . . . . . . . 2-84
Flywheel Plate Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-125
3TN75, 3TNC78 (3011), 3TNA82,
3TN84 (3014) . . . . . . . . . . . . . . . . . . . . . . . 2-53 Fuel Injection Nozzles - 4TN100
4TN82RJK, 4TN84RJK, Cleaning/Inspection . . . . . . . . . . . . . . . . . . 4-68
4TN84(T) (4019) . . . . . . . . . . . . . . . . . . . . 3-52 Cross Section . . . . . . . . . . . . . . . . . . . . . . . 4-68
Fuel Control and Governor Linkage - Removal/Installation . . . . . . . . . . . . . . . . . . 4-66
3TN66 and Later 3TNA72 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 1-107
Disassembly . . . . . . . . . . . . . . . . . . . . . . . 1-106 Fuel Injection Nozzles - 4TN78T, 4TN82,
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 1-108 4TN84(T) (4019)
Installation . . . . . . . . . . . . . . . . . . . . . . . . 1-105 Cleaning/Inspection . . . . . . . . . . . . . . . . . . 3-85
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 1-105 Cross Section . . . . . . . . . . . . . . . . . . . . . . . 3-84
Fuel Control and Governor Linkage - Removal/Installation . . . . . . . . . . . . . . . . . . 3-83 I
Early 3TNA72 (430 LGT) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-128
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 1-104
Installation . . . . . . . . . . . . . . . . . . . . . . . . 1-101 Fuel Injection Pump - 3TN66, 3TNA72 (3009)
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-99 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 1-95
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-94
Fuel Drain Back Test
3009, 3011, 3014, 4019 . . . . . . . . . . . . . . 10-52 Fuel Injection Pump - 3TN75, 3TN78,
3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . 1-156 3TNC78 (3011)
3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-138 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-81
3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-138 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-100 Static Timing Adjustment . . . . . . . . . . . . . 2-131
4TN78, 4TN82, 4TN84(T) (4019) . . . . . . 3-143
4/7/95 Index-5
Index
Fuel Injection Pump - 3TN82, 3TNA82, Fuel Supply Pump - 3TN75, 3TNC78 (3011),
3TN84 (3014) 3TNA82, 3TN84 (3014)
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-81 Pressure Test . . . . . . . . . . . . . . . . . . . . . . . 2-137
Static Timing Adjustment . . . . . . . . . . . . . 2-131 Fuel Supply Pump - 3TNA72 (670 CUT, 3009 OEM)
Fuel Injection Pump - 4TN100 Pressure Test . . . . . . . . . . . . . . . . . . . . . . . 1-155
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-65 Replacement . . . . . . . . . . . . . . . . . . . . . . . . 1-92
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64 Fuel Supply Pump - 4TN100
Static Timing Adjustment . . . . . . . . . . . . . . 4-94 Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . 4-99
Fuel Injection Pump - 4TN78T, 4TN82, Removal/Installation . . . . . . . . . . . . . . . . . . 4-61
4TN84(T) (4019) Fuel Supply Pump - 4TN82, 4TN84(T) (4019)
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-81 Pressure Test . . . . . . . . . . . . . . . . . . . . . . . 3-142
Fuel Injection Pump Camshaft - Fuel System Operation . . . . . . . . . . . . . . . . . . 20-22
3TN66 and Later 3TNA72
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1-98 Fuel System, Bleed
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 1-98 3009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 1-98 3011, 3014, 4019 . . . . . . . . . . . . . . . . . . . 10-53
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 1-98 3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . 1-156
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-97 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-138
3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-138
Fuel Injection Pump Camshaft - 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . 3-143
Early 3TNA72 (430 LGT)
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1-97
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 1-96 G
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 1-97 General Tune-Up Recommendations . . . . . . . 10-44
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 1-96
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-96 Glow Plugs
Removal/Installation . . . . . . . . . . . . . . . . . 10-39
Fuel Injection Pump Operation . . . . . . . . . . . 20-24 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39
Fuel Injection Pump Static Timing Adjustment Governor Operation . . . . . . . . . . . . . . . . . . . . 20-28
3TN66 and Later 3TNA72 . . . . . . . . . . . . 1-148
4TN78T. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-134 Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-9
4TN82, 4TN84(T) (4019) . . . . . . . . . . . . . 3-135
Early 3TNA72 (430 LGT) . . . . . . . . . . . . 1-147 I
Fuel Shutoff Solenoid Idler Gear - 3TN66 and Later 3TNA72
Replacement . . . . . . . . . . . . . . . . . . . . . . . 10-42 Inspection/Replacement . . . . . . . . . . . . . . . 1-66
Fuel Shutoff Solenoid - 3009, 3011, 3014, 4019 Removal/Installation . . . . . . . . . . . . . . . . . . 1-66
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 10-56 Idler Gear - 3TN75, 3TN78, 3TNC78 (3011)
Amperage Test . . . . . . . . . . . . . . . . . . . . . 10-55 Inspection/Replacement . . . . . . . . . . . . . . . 2-61
I Fuel Shutoff Solenoid, Adjustment Removal/Installation . . . . . . . . . . . . . . . . . . 2-61
3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . 1-151 Idler Gear - 3TN82, 3TNA82, 3TN84 (3014)
3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-133 Inspection/Replacement . . . . . . . . . . . . . . . 2-61
3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-133 Removal/Installation . . . . . . . . . . . . . . . . . . 2-61
4TN78T, 4TN82, 4TN84(T) (4019) . . . . . 3-138
Idler Gear - 4TN100
Fuel Supply Pump - 3009 Inspection/Replacement . . . . . . . . . . . . . . . 4-47
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . 10-52 Removal/Installation . . . . . . . . . . . . . . . . . . 4-46
Idler Gear - 4TN78T, 4TN82, 4TN84(T) (4019)
Fuel Supply Pump - 3011, 3014, 4019 Inspection/Replacement . . . . . . . . . . . . . . . 3-60
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . 10-52 Removal/Installation . . . . . . . . . . . . . . . . . . 3-59
Idler Gear - Early 3TNA72 (430 LGT)
Index-6 4/7/95
Index
Injection Nozzle Operation Oil Pressure Regulating Valve

Hole Type . . . . . . . . . . . . . . . . . . . . . . . . . 20-36 3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-80
Pintle Type . . . . . . . . . . . . . . . . . . . . . . . . 20-34 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . 2-68
Instrument Panel - 3009, 3011, 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . 2-68
3014, 4019 . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40 3TN84 (955 CUT) . . . . . . . . . . . . . . . . . . . 2-67
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
Intake Manifold 4TN78T, 4TN84T (4019TF001, 005). . . . . 3-67
3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29 4TN82, 4TN84 (4019DF),
3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . 2-27 4TN84T (4019TF006) . . . . . . . . . . . . . . . . 3-67
3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . 2-27 Early 3TNA72 (430 LGT) . . . . . . . . . . . . . 1-81
3TNA72 (3009). . . . . . . . . . . . . . . . . . . . . . 1-29 Later 3TNA72. . . . . . . . . . . . . . . . . . . . . . . 1-82
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Theory of Operation . . . . . . . . . . . . . . . . . 20-17
4TN78T, 4TN82, 4TN84(T) (4019) . . . . . . 3-26
Oil Pressure Switch, Replacement . . . . . . . . . 10-41
Oil Pump - 3TN66 and Later 3TNA72
L Disassembly/Assembly . . . . . . . . . . . . . . . . 1-79
Lubrication System Operation . . . . . . . . . . . . 20-14 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 1-80
M Oil Pump - 3TN75, 3TN78, 3TNC78 (3011)
Muffler, Removal/Installation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
3009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9 Removal/Installation . . . . . . . . . . . . . . . . . . 2-65
3011, 3014, 4019D . . . . . . . . . . . . . . . . . . 10-10
4019T . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11 Oil Pump - 3TN82, 3TNA82, 3TN84 (3014)
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
O Removal/Installation . . . . . . . . . . . . . . . . . . 2-65
Oil Cooler - 3TN84 (955 CUT) Oil Pump - 4TN100
Leakage Test . . . . . . . . . . . . . . . . . . . . . . . 2-133 Disassembly/Assembly . . . . . . . . . . . . . . . . 4-51
Removal/Installation . . . . . . . . . . . . . . . . . . 2-67 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
Oil Cooler - 4TN100 Removal/Installation . . . . . . . . . . . . . . . . . . 4-51
Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . 4-52 Oil Pump - 4TN78T, 4TN82, 4TN84(T) (4019)
Removal/Installation . . . . . . . . . . . . . . . . . . 4-52 Disassembly/Assembly . . . . . . . . . . . . . . . . 3-64
Oil Cooler - 4TN8T, 4TN84T (4019TF001, 005) Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
Leakage Test . . . . . . . . . . . . . . . . . . . . . . . 3-137 Removal/Installation . . . . . . . . . . . . . . . . . . 3-64
Removal/Installation . . . . . . . . . . . . . . . . . . 3-66 Oil Pump - Early 3TNA72 (430 LGT)
Oil Cooler By-Pass Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 1-77
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 1-76
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-75
Oil Cooler Operation . . . . . . . . . . . . . . . . . . . 20-18
Oil Filter Operation. . . . . . . . . . . . . . . . . . . . . 20-16 P I
Oil Pan and Strainer
3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-72 Piston and Connecting Rod - 3TN66, 3TNA72
3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . 2-64 (3009)
3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . 2-64 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-73 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 1-34
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50 Inspection/Replacement . . . . . . . . . . . . . . . 1-36
4TN78T, 4TN82, 4TN84(T) (4019) . . . . . . 3-63 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
4/7/95 Index-7
Index
Piston and Connecting Rod - 3TN75, 3TN78, Radiator Mount - If Equipped. . . . . . . . . . . . . 10-43
3TNC78 (3011) Radiator, Bubble Test
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34 3009, 3011, 3014, 4019 . . . . . . . . . . . . . . 10-48
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 2-33 3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . 1-152
Inspection/Replacement . . . . . . . . . . . . . . . 2-35 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-134
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-32 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-134
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . 3-139
Piston and Connecting Rod - 3TN82, 3TNA82, 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-96
3TN84 (3014) Regulated Voltage Test
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34 3009, 3011, 3014, 4019 . . . . . . . . . . . . . . 10-60
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Inspection/Replacement . . . . . . . . . . . . . . . 2-35 Rocker Arm Assembly - 3TN66, 3TNA72 (3009)
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-32 Disassembly/Assembly . . . . . . . . . . . . . . . . 1-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Piston and Connecting Rod - 4TN100
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Rocker Arm Assembly - 3TN75, 3TN78,
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 4-23 3TNC78 (3011)
Inspection/Replacement . . . . . . . . . . . . . . . 4-25 Disassembly/Assembly . . . . . . . . . . . . . . . . 2-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Removal/Installation . . . . . . . . . . . . . . . . . . 2-19
Piston and Connecting Rod - 4TN78T, 4TN82, Rocker Arm Assembly - 3TN82, 3TNA82, 3TN84
4TN84(T) (4019) (3014)
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 Disassembly/Assembly . . . . . . . . . . . . . . . . 2-19
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 3-32 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Inspection/Replacement . . . . . . . . . . . . . . . 3-34 Removal/Installation . . . . . . . . . . . . . . . . . . 2-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Rocker Arm Assembly - 4TN100
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Disassembly/Assembly . . . . . . . . . . . . . . . . 4-10
Piston Cooling Nozzles Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54 Removal/Installation . . . . . . . . . . . . . . . . . . 4-10
4TN78T, 4TN84T (4019TF001, 005). . . . . 3-68 Rocker Arm Assembly - 4TN78T, 4TN82,
Theory of Operation . . . . . . . . . . . . . . . . . 20-20 4TN84(T) (4019)
Piston-to-Cylinder Head Clearance Disassembly/Assembly . . . . . . . . . . . . . . . . 3-19
3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . . 1-31 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . 2-29 Removal/Installation . . . . . . . . . . . . . . . . . . 3-19
3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . 2-29 Rocker Arm Cover
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . . 1-18
4TN78T, 4TN82, 4TN84(T) (4019) . . . . . . 3-29 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . 2-18
Precombustion Chamber Operation 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . 2-18
(Indirect Injection) . . . . . . . . . . . . . . . . . . . . . 20-38 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
I Preliminary Engine Testing . . . . . . . . . . . . . . 10-44
4TN78T, 4TN82, 4TN84(T) (4019) . . . . . . 3-18
R S
Radiator Slow Idle Speed Adjustment
Installation . . . . . . . . . . . . . . . . . . . . . . . . 10-33 3009, 3011, 3014, 4019 . . . . . . . . . . . . . . 10-53
Removal/Inspection . . . . . . . . . . . . . . . . . 10-32 Specifications
Radiator Cap, Pressure Test Engine Accessories . . . . . . . . . . . . . . . . . . . 10-1
3009, 3011, 3014, 4019 . . . . . . . . . . . . . . 10-49 Starter - 3TN66 (Hitachi 0.8 kW)
3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . 1-153
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 1-114
3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-135
Disassembly/Inspection . . . . . . . . . . . . . . 1-113
3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-135
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-115
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97
4TN78T, 4TN82, 4TN84(T) (4019) . . . . . 3-140
Index-8 4/7/95
Index
Starter - 3TNA72 (3009 OEM) (Hitachi 0.8 kW) Starter Motor - 3TN78, 3TN82 (30 EX)
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 1-114 (Hitachi 2.0 kW)
Disassembly/Inspection . . . . . . . . . . . . . . 1-113 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-115 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 2-87
Starter - 4TN78T (Hitachi 0.8 kW) Inspection/Test/Replacement . . . . . . . . . . . 2-87
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88 Starter Motor - 3TN82 (575 SSL)
Disassembly/Inspection . . . . . . . . . . . . . . . 3-87 (Nippondenso 1.4 kW)
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97
Starter Gear Train and Overrunning Clutch - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 2-96
3TN75, 3TNC78 (3011), 3TNA82, 3TN84 Inspection/Test/Replacement . . . . . . . . . . . 2-97
(870 CUT, 955 CUT) (Nippondenso 1.0 kW) Starter Motor - 3TNA72 (All Except 3009 OEM)
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95 (Nippondenso 1.0 kW)
Disassembly/Inspection . . . . . . . . . . . . . . . 2-93 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 1-117
Starter Gear Train and Overrunning Clutch - Disassembly . . . . . . . . . . . . . . . . . . . . . . . 1-116
3TNA72 (All Except 3009 OEM) Inspection/Test/Replacement . . . . . . . . . . 1-117
(Nippondenso 1.0 kW) Starter Motor - 3TNA82, 3TN84
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 1-120 (870 CUT, 3014 OEM) (Nippondenso 1.2 kW)
Disassembly/Inspection . . . . . . . . . . . . . . 1-119 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91
Starter Gear Train and Overrunning Clutch - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 2-91
3TNA82, 3TN84 (870 CUT, 3014 OEM) Inspection/Test/Replacement . . . . . . . . . . . 2-92
(Nippondenso 1.2 kW) Starter Motor - 4TN100
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
Disassembly/Inspection . . . . . . . . . . . . . . . 2-93 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 4-70
Starter Gear Train and Overrunning Clutch - Inspection/Test/Replacement . . . . . . . . . . . 4-70
4TN82RJK, 4TN84RJK (Nippondenso 1.0 kW) Starter Motor - 4TN82ESP, 4TN84(T) (4019)
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99 (Nippondenso 1.4 kW)
Disassembly/Inspection . . . . . . . . . . . . . . . 3-97 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-101
Starter Gear Train and Solenoid - 3TN82 (575 SSL) Disassembly . . . . . . . . . . . . . . . . . . . . . . . 3-100
(Nippondenso 1.4 kW) Inspection/Test/Replacement . . . . . . . . . . 3-101
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 2-101 Starter Motor - 4TN82RJE (Hitachi 2.0 kW)
Disassembly/Inspection . . . . . . . . . . . . . . . 2-99 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-91
Starter Gear Train and Solenoid - 4TN100 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 3-90
(Nippondenso 1.4 kW) Inspection/Test/Replacement . . . . . . . . . . . 3-91
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74 Starter Motor - 4TN82RJK, 4TN84RJK
Disassembly/Inspection . . . . . . . . . . . . . . . 4-72 (Nippondenso 1.0 kW)
Starter Gear Train and Solenoid - 4TN82ESP, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-95
4TN84(T) (4019) (Nippondenso 1.4 kW) Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 3-94
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 3-104 Inspection/Test/Replacement . . . . . . . . . . . 3-95
Disassembly/Inspection . . . . . . . . . . . . . . 3-102 Starter Overrunning Clutch - 3TN78, I
Starter Identification Chart 3TN82 (30 EX) (Hitachi 2.0 kW)
3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . 2-86 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90
3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . 2-86 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 2-89
4TN78T, 4TN82, 4TN84(T) (4019) . . . . . . 3-86 Starter Overrunning Clutch - 4TN82RJE
Starter Motor - 3TN75, 3TNC78 (3011), (Hitachi 2.0 kW)
3TNA82, 3TN84 (870 CUT, 955 CUT) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93
(Nippondenso 1.0 kW) Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 3-93
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91 Starter Solenoid - 3TN75, 3TNC78 (3011),
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 2-91 3TNA82, 3TN84 (870 CUT, 955 CUT)
Inspection/Test/Replacement . . . . . . . . . . . 2-92 (Nippondenso 1.0 kW)
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96
Disassembly/Inspection . . . . . . . . . . . . . . . 2-95
4/7/95 Index-9
Index
Starter Solenoid - 3TN78, 3TN82 (30 EX) Thermostat and Housing - 3TN78, 3TN82 (30 EX),
(Hitachi 2.0 kW) 3TN84 (955 CUT, 3014 OEM)
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90 Opening Test. . . . . . . . . . . . . . . . . . . . . . . 2-127
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 2-90 Thermostat Replacement . . . . . . . . . . . . . . 2-70
Starter Solenoid - 3TNA72 (All Except 3009 OEM) Thermostat and Housing - 4TN78T, 4TN82RJE,
(Nippondenso 1.0 kW) 4TN82ESP, 4TN84(T) (4019)
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 1-121 Opening Test. . . . . . . . . . . . . . . . . . . . . . . 3-130
Disassembly/Inspection . . . . . . . . . . . . . . 1-121 Thermostat Replacement . . . . . . . . . . . . . . 3-70
Starter Solenoid - 3TNA82, 3TN84 Timing Gear Backlash, Check
(870 CUT 3014 OEM) (Nippondenso 1.2 kW) 3TN66 and Later 3TNA72 . . . . . . . . . . . . 1-141
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-123
Disassembly/Inspection . . . . . . . . . . . . . . . 2-95 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-123
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88
Starter Solenoid - 4TN82RJE (Hitachi 2.0 kW) 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . 3-127
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94 Early 3TNA72 (430 LGT) . . . . . . . . . . . . 1-140
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 3-93 Timing Gear Cover
Starter Solenoid - 4TN82RJK, 4TN84RJK 3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-60
(Nippondenso 1.0 kW) 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . 2-59
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . 2-59
Disassembly/Inspection . . . . . . . . . . . . . . . 3-99 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
Starter Solenoid, Test 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . . 3-58
3009, 3011, 3014, 4019 . . . . . . . . . . . . . . 10-58 Early 3TNA72 (430 LGT) . . . . . . . . . . . . . 1-62
Later 3TNA72. . . . . . . . . . . . . . . . . . . . . . . 1-63
Starter, AMP Draw/RPM Test
3009, 3011, 3014, 4019 . . . . . . . . . . . . . . 10-56 Timing Gear Cover Mounting Plate
3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . 2-62
Starter, No-Load AMP Draw/RPM Test 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . 2-62
3009, 3011, 3014, 4019 . . . . . . . . . . . . . . 10-57 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . . 3-61
Starter, No-Load Amp Draw/RPM Test Timing Gear Housing
3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . 1-145 3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-67
3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-129 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-129 Early 3TNA72. . . . . . . . . . . . . . . . . . . . . . . 1-68
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-93 Later 3TNA72. . . . . . . . . . . . . . . . . . . . . . . 1-69
4TN78T, 4TN82, 4TN84(T) (4019) . . . . . 3-132 Torque Values
Stub Shaft Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-15
3TN66 (330/332 LGT, F915 FM). . . . . . . . 1-51 Unified Inch . . . . . . . . . . . . . . . . . . . . . . . . G-16
3TNA72 (430 LGT, F925/35 FM) . . . . . . . 1-51 Troubleshooting Chart
3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . 1-131
T 3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-116
Thermostat - 3TN66, 3TNA72 (3009) 3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-116
Opening Test. . . . . . . . . . . . . . . . . . . . . . . 1-144 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
I Replacement . . . . . . . . . . . . . . . . . . . . . . . . 1-84 4TN78T, 4TN82, 4TN84(T) (4019) . . . . . 3-119
Thermostat - 3TN75, 3TNC78 (3011), Turbocharger
3TN82 (575 SSL), 3TNA82, 3TN84 (870 CUT) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
Opening Test. . . . . . . . . . . . . . . . . . . . . . . 2-127 Disassembly . . . . . . . . . . . . . . . . . . . . . . . 10-17
Replacement . . . . . . . . . . . . . . . . . . . . . . . . 2-71 Disconnect Oil Inlet Line . . . . . . . . . . . . . . G-17
Extending Life . . . . . . . . . . . . . . . . . . . . . 10-12
Thermostat - 4TN100 Failure Analysis . . . . . . . . . . . . . . . . . . . . 10-26
Opening Test. . . . . . . . . . . . . . . . . . . . . . . . 4-91 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4-56 Installation . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Thermostat - 4TN78T, 4TN82, 4TN84(T) (4019) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
Opening Test. . . . . . . . . . . . . . . . . . . . . . . 3-130 Rotor Shaft Axial Play Check. . . . . . . . . . 10-15
Thermostat - 4TN82RJK, 4TN84RJK Rotor Shaft Radial Play Check . . . . . . . . . 10-16
Replacement . . . . . . . . . . . . . . . . . . . . . . . . 3-71 Seven-Step Inspection. . . . . . . . . . . . . . . . 10-28
Theory of Operation . . . . . . . . . . . . . . . . . 20-12
Index-10 4/7/95
Index
V W
Valve Clearance, Check and Adjustment Water Pump - 3TN66
3TN66 and Later 3TNA72 . . . . . . . . . . . . 1-135 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1-87
3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-119 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 1-86
3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-119 Removal/Installation . . . . . . . . . . . . . . . . . . 1-85
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83 Water Pump - 3TN75, 3TNC78 (3011),
4TN78T, 4TN82, 4TN84(T) (4019) . . . . . 3-122 3TN82 (575 SSL), 3TNA82, 3TN84 (870 CUT)
Early 3TNA72 (430 LGT) . . . . . . . . . . . . 1-134 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76
Valve Lift Check Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 2-75
3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . 1-138 Removal/Installation . . . . . . . . . . . . . . . . . . 2-74
3TN75, 3TN78, 3TNC78 (3011) . . . . . . . 2-122 Water Pump - 3TN78, 3TN82 (30 EX),
3TN82, 3TNA82, 3TN84 (3014) . . . . . . . 2-122 3TN84 (955 CUT, 3014 OEM)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
4TN78T, 4TN82, 4TN84(T) (4019) . . . . . 3-125 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 2-72
Valve Seats, Grind Removal/Installation . . . . . . . . . . . . . . . . . . 2-71
3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . . 1-30 Water Pump - 3TNA72
3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . 2-28 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1-90
3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . 2-28 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 1-89
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Removal/Installation . . . . . . . . . . . . . . . . . . 1-88
4TN78T, 4TN82, 4TN84(T) (4019) . . . . . . 3-28
Water Pump - 4TN100
Valves, Lap Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
3TN66, 3TNA72 (3009) . . . . . . . . . . . . . . . 1-30 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 4-58
3TN75, 3TN78, 3TNC78 (3011) . . . . . . . . 2-29 Removal/Installation . . . . . . . . . . . . . . . . . . 4-57
3TN82, 3TNA82, 3TN84 (3014) . . . . . . . . 2-29
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Water Pump - 4TN78T, 4TN82RJE, 4TN82ESP,
4TN78T, 4TN82, 4TN84(T) (4019) . . . . . . 3-28 4TN84(T) (4019)
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
Voltage Regulator, Replacement (Hitachi 25A) Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 3-72
3TN78, 3TN82 (30 EX) . . . . . . . . . . . . . . 2-103 Removal/Installation . . . . . . . . . . . . . . . . . . 3-71
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75
4TN78T. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-106 Water Pump - 4TN82RJK, 4TN84RJK
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76
Voltage Regulator, Replacement Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 3-75
(Nippondenso 35A) Removal/Installation . . . . . . . . . . . . . . . . . . 3-74
3TN66 (655 CUT) . . . . . . . . . . . . . . . . . . 1-122
3TN75, (855/56 CUT), 3TN82
(575 SSL), 3TNA82, 3TN84
(870 CUT, 955 CUT) . . . . . . . . . . . . . . . . 2-107
3TNA72 (430 LGT, 670 CUT,
755/56 CUT, F925/35 FM) . . . . . . . . . . . . 1-122
4TN82, 4TN84RJK. . . . . . . . . . . . . . . . . . 3-110 I
Voltage Regulator, Replacement
(Nippondenso 40A)
3TN66 (655 CUT) . . . . . . . . . . . . . . . . . . 1-128
3TN75, 3TNC78 (3011),
3TN82 (575 SSL),
3TN84 (955 CUT, 3014 OEM). . . . . . . . . 2-112
3TNA72 (455 LGT, 755/56 CUT,
3009 OEM) . . . . . . . . . . . . . . . . . . . . . . . . 1-128
4TN82ESP/RJE, 4TN84(T) (4019) . . . . . 3-115
4/7/95 Index-11
Index
Index-12 4/7/95
John Deere Series 220 CTM3 (10AUG93)
Diesel Engines

JD220 Dieselengine

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John Deere Series 220

Each section will be identified with a symbol, letter

3TN66, 3TNA72 (3009) 1

3TN75, 3TN78, 3TNC78 (3011),

4TN78T, 4TN82, 4TN84(T) (4019) 3

Accessories - Series 220

Engine, Air Intake and

Electrical System - Series 220

RECOGNIZE SAFETY INFORMATION HANDLE FLUIDS SAFELY-AVOID

This is the safety-alert symbol. When you see this

Understand Signal Words

Replace missing or damaged safety signs. See the

USE CARE IN HANDLING AND • If acid is swallowed:

SERVICE COOLING SYSTEM SAFELY

Prevent Battery Explosions

Service Engines Safely Support Engine Properly and Use

If you must work on a lifted engine, securely support

Shut Down Engine Work In A Clean Area

• Before starting a job:

Illuminate Your Work Area Safely

X9811 TS1132 TS1133

Direct exposure to hazardous chemicals can cause LIVE WITH SAFETY

ENGINE SERIAL NUMBER PLATE Factory Code

NOTE: The engine serial number plate can be CH. . . . . . . . . . . . . . . . . . Yanmar

Engine Model Designation -Series 220 Aspiration Code

ENGINE APPLICATION CHART - LAWN AND GROUNDS CARE EQUIPMENT

ENGINE APPLICATION CHART - INDUSTRIAL EQUIPMENT

Machine Model No. Engine Model

ENGINE APPLICATION CHART - OEM APPLICATION

Machine Model No. Engine Model

BASIC ENGINE SPECIFICATIONS

DIESEL FUEL performance; these properties may result in longer

DIESEL ENGINE OIL

OILSCAN® AND COOLSCAN™

• SAE Multipurpose EP Grease • Coolant make-up should be mixed at same

• In tropical areas where antifreeze of John Deere Water Quality Specifications

Ethylene Glycol Concentrate

TS281 DO NOT use ethylene glycol concentrate

DO NOT use concentrate containing less than

John Deere Low Silicate Antifreeze is the ethylene

NALCOOL 3000® is a registered trademark of the NALCO Company.

IMPORTANT: John Deere Liquid Coolant CHECK EFFECTIVENESS OF

- AL66608 (formally DD14346) 200 L (53

described earlier. If COOLSCAN analysis is not

If frequent coolant make-up is required, the

Shut off engine. Remove the radiator filler

FLEETGARD® is a registered trademark of the Cummins Engine Company.

METRIC BOLT AND CAP SCREW TORQUE VALUES

Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9

UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES

Grade 1 Grade 2b Grade 5, 5.1 or 5.2 Grade 8 or 8.2

DISCONNECT TURBOCHARGER OIL

Hydraulic lock occurs when trapped oil in the

ENGINE SPECIFICATIONS - 3TN66

Piston Pin, continued

Timing Gear Housing Cap Screw Torque

Starter - Hitachi 0.8 kW

ENGINE SPECIFICATIONS - 3TNA72 (3009)

Valve Guides, continued

Stub Shaft (430 LGT, F925/35 FM)

Oil Pump - Later 3TNA72, continued

Fuel Injection Nozzles