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John Deere

MODEL:
220 Series Diesel Engines
Volume 1 of 2

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF


JOHN DEERE OR IT'S SUCCESSORS. JOHN DEERE AND IT'S SUCCESSORS
ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS,
AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.

JD-S-CTM3
JOHN DEERE
SERIES 220
DIESEL ENIGINES

JOHN DEERE LAWN & GROUNDS CARE


DIVISION
CTM3
Introduction

Each section will be identified with a symbol, letter


or a number. Safety
All information, illustrations and specifications in
this manual are based on the latest information
availahle at the time of publication. The right is Specifications and ,
reserved to make changes at any time without
notice.
General Information
~--------------------
iii

I 3TN66, 3TNA72 (3009)

3TN75, 3TN78, 3TNC78 (3011),


3TN82,3TNA82,3TN84 (3014)

i4TN78T, 4TN82,.4TN84(T) (4019) I


i4TN1001

. Accessories
.. Power·.
I
SPECIFICATIONS AND
GENERAL INFORMATION

General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1
Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4
Fuels, Lubricants and Coolant. . . . . . . . . . . . . . . . . . . . . .. 8
Repair Information ............................... 15
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 inj"ornzafioll elsewhere. 3009D ............... Definition explained
following. (See
'I
i
Location "Engine Model
All except 4TNlOO: The engine serial number plate Designation".)
is located on the rocker arm cover.
Sequential Number
4TN] 00: The engine serial number plate is located
on the side of the engine, under exhaust manifold. 000000 .............. 6-digit sequential
serial number
Refer to the engine model designation on your
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:

3TNA 72UJK Engine


3 ........................ Number of cylinders
T ........................... Usage (tractor)
NA .......................... Engine type
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
CH3029DOOOOOO 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


CH3009DOOOOOO E-SP .......... Export - Sperry Company
CH. . . . . . . . . . . . . . . . .. Factory producing engine
3009D ............ Engine model designation
000000 ...... Sequential serial number

8/31/93 G-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
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
Crankshaft, Main Bearings and Flywheel

STUB SHAFT - 3TN66 (330/332 LGT,


F915 FM) AND 3TNA72 (430 LGT, Cap Screw (2)
M10 x 75
N
ut
(2)

F925/35 FM) 49 N·m (36 Ib-ft) 88 Nom (65 Ib-ft)

I. Remove electric clutch. (See procedure


Machine Technical Manual.)
2. Remove cover.
111

~
/ ~-- ~-...
Cap Screw (5) .,
M8 x 70 r
3. Measure stub shaft TlR (total indicated runout)
using a dial indicator. If TIR exceeds (0.20 mm
26 Nom (226 Ib-ft)
Guide
Pin (2) II
I
~
(0.008 in.), replace stub shaft. / Stub

~~
/

(/
'" Plug
capsc<ew?
M8 x 20
59 Nom (44 Ib-ft)

3TNA72
I M82286A
I

5. Measure stub shaft mounting flange t1atness.


Place a straight edge across stub shaft mounting
surface. Measure clearance between straight edge
and mounting surface with a feeler gauge. If
4. Remove stub shaft. clearance exceeds 0.05 mm (OJ)o2 in.), replace
stub shaft.
Installation is done in reverse order of removal.

8/30/93 1-51
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.

I
Shims
If equipped.
NOTE: Washer is 011 670 CUT, 455 LGT and 3009 M37762
OEM ollly.
3. Remove nut, washer, if equipped, and throttle 8. Rotate throttle shaft assembly as shown.
lever. 9. Remove tapered pin from tapered hole lIsing a
4. Remove cap screw and throttle shaft retaining punch.
plate. lO.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.
Set Screw
Apply thread lock and seaier
(low strength) on threads.
Governor Shaft
Retaining Plate

a-Ring./'
Replace.
ing

Fuel Shutoff Lever


M37760

1-106 8/31/93
3TN75, 3TN78, 3TNC78 (3011)
3TN82, 3TNA82, AND
3TN84 (3014)
ENGINES

Specifications ................................... 2-1


Cylinder Head, Valves and Manifolds ............... 2-17
Pistons, Rods and Cylinder Block .................. 2-30
Crankshaft, Main Bearings and Flywheel ............ 2-43
Camshaft and Timing Gear Train ................... 2-54
Lubrication System ............................. 2-63
Cooling System ................................ 2-69
Fuel System ................................... 2-77
Starter ....................................... 2-86
Alternator .................................... 2-102
Diagnosis .................................... 2-116
Checks, Tests and Adjustments ................... 2-119
Operational Tests .............................. 2-136

Section 2
4TN78T, 4TN82 AND
4TN84(T) (4019)
ENGINES

I
Specifications ................................... 3-1
Cylinder Head, Valves and Manifolds ............... 3-17
Pistons, Rods and Cylinder Block .................. 3-30
Crankshaft, Main Bearings and Flywheel ............ 3-41
Camshaft and Timing Gear Train ................... 3-53
Lubrication System ............................. 3-62
Cooling System ................................ 3-69
Fuel System ................................... 3-77
Starter ....................................... 3-86
Alternator .................................... 3-.105
Diagnosis .................................... 3-119
Checks, Tests and Adjustments ................... 3-122
Operational Tests .............................. 3-139

Section 3
4TN100 ENGINE

Specifications ................................... 4-1


Cylinder Head, Valves and Manifolds ................ 4-8
Pistons, Rods and Cylinder Block .................. 4-21
Crankshaft, Main Bearings and Flywheel ............ 4-30
Camshaft and Timing Gear Train ................... 4-40
Lubrication System ............................. 4-49
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
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
Miscellaneous ................................ 10-43
Engine Tune-up ............................... 10-44
I
Operational Tests and Adjustments ................ 10-47
Dealer Fabricated Tools ......................... 10-62

Section 10
ENGINE, AIR INTAKE
AND FUEL SYSTEM

Component Location ............................ 20-1


Theory of Operation ............................. 20-4

Section 20
ELECTRICAL SYSTEM
SERIES 220
POWER UNIT ENGINES

Electrical System ............................... 21-1


Component Location ............................ 21-2
Schematics ................................... 21-4

Section 21
Index

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), Tes t/lns pecti on . . . . . . . . . . . . . . . . . . . .. 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 ................... 1O-7 Disassembly ....................... 1-128
4019T ............................. 10-8 Inspection/Test . . . . . . . . . . . . . . . . . . . .. 1-129
Air Heater, Removal/lnstallation .......... 10-39 Alternator - 3TNA72 (670 CUT, 15 EX)
Air Intake System, Check. . . . . . . . . . . . . . .. 10-45 (Kokosan 20A)
Air Intake System, Leakage Test Assembly . . . . . . . . . . . . . . . . . . . . . . . .. 1-122
Disassembly/lnspection .............. 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/lnspection .............. 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/lnspection ..................... 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 - 4TN82ESPjRJE, 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
(Nippon den so 35A) Inspection/Test . . . . . . . . . . . . . . . . . . . . . 3-117
Assembly ......................... 2-110
Disassembly ....................... 2-108
Inspection/Test . . . . . . . . . . . . . . . . . . . . . 2-110
Alternator - 3TN75, 3TNC78 (3011), 3TN82
Alternator - 4TN82RJK, 4TN84RJK

(Ko~~~:r:n~~:~ ........................ 3- 105


Disassembly/lnspection .............. 3-105
1
(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)
4TNI00 ............................ 4-48
(Hitachi 25A)
Assembly ......................... 2-105
Disassembly ....................... 2-103
Inspection/Test . . . . . . . . . . . . . . . . . . . . . 2-105

8/10/93 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 ................ 0-4 Connecting Rod Check - 3TN66, 3TNA72 (3009)
Bearing Clearance. . . . . . . . . . . . . . . . . .. 1-136
SidePlay .......................... 1-136
1: Connecting Rod Check - 3TN75, 3TN78,
Cam Followers - 3TN66, 3TNA 72 (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 - 4 TN 100
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
Inspection/Replacement ............... 2-56
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-55 Coolant Temperature Switch - 3TN82, 3TNA82,
Removal ........................... 2-55 3TN84 (3014)
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 . . . . . . . . . . . . . . . . . . . . . . . . .. 10-3:
Removal ........................... 3-54
Combustion Chamber Operation
(Direct Injection) ....................... 20-40

Index-2 8/10/93
Index

Cooling System Crankshaft and Main Bearings - 4TN78T, 4TN82,


Check and Service .. . . . . . . . . . . . . . . .. 10-45 4TN84(T) (4019)
Flushing and Servicing ................ 0-13 InspectionlReplacement . . . . . . . . . . . . . . . 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 LOT, 455 LOT,
4TNI00 ............................ 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
InspectionlReplacement . . . . . . . . . . . . . .. 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
InspectionlReplacement . . . . . . . . . . . . . . . 2-49 Cylinder Bore - 3TN75, 3TN78, 3TNC78 (3011)
Installation ............i • • • • • • • • • • • • • 2-47 Deglazing . . . . . . . . . . . . . . . . . . . . . . . . .. 2-421
Removal . . . . . . . . . . . . . • . . . . . . . . . . . . . 2-46 Inspe~tion . . . . . . . . . . . . . . . . . . . . . . . . .. 2-40
Crankshaft and Main Bearings - 3TN82, 3TNA82, Rebonng . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
3TN84 (3014) Cylinder Bore - 3TN82, 3TNA82, 3TN84 (3014)
InspectionlReplacement . . . . . . . . . . . . . . . 2-49 Deglazing .......................... 2-42
Installation ......................... 2-47 Inspection . . . . . . . . . . . . . . . . . . . . . . . . .. 2-40
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46 Reboring ........................... 2-42
Crankshaft and Main Bearings - 4TNI00 Cylinder Bore - 4TNI00
InspectionlReplacement ............... 4-36 Deglazing .......................... 4-28
Installation ....... . . . . . . . . . . . . . . . . . . 4-34 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Removal ........................... 4-32 Reboring ........................... 4-29

8/10/93 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/lnstallation .................. 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/lnstallation .................. 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-l 0
InspectionlReplacement ............... 2-23
Removal/lnstallation. . . . . . . . . . . . . . . . . . 2-21 Engine Oil Pressure, Test
3009,3011,3014,4019 .............. 10-50
Cylinder Head and Valves - 4TN100
3TN66, 3TNA72 (3009) .............. 1-154
Disassembly/Assembly ................ 4-13
3TN75, 3TN78, 3TNC78 (3011) ....... 2-136
Inspection/Replacement ............... 4-14
3TN82, 3TNA82, 3TN84 (3014) ....... 2-136
Removal/Installation .................. 4-12
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-l
InspectionlReplacement ............... 3-23 Serial Number Information .............. G-l
Removal/lnstallation .................. 3-21
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
4TNI00 ............................. 4-1
4TN78T, 4TN82, 4TN84(T) (4019) ..... 3-140
Engine, Clean .......................... G-17

I~aler Fabricated Tools


DFRO 1 Extended Indicator Tip. . . . . . .. 10-62
Exhaust Manifold
3TN66 ............................. 1-27
3TN75, 3TN78, 3TNC78 (3011) ........ 2-26
DFR02 Extended Indicator Tip ........ 10-63 3TN82, 3TNA82, 3TN84 (3014) ........ 2-26
Diagnosis 3TNA72 (3009) ...................... 1-28
3TN66, 3TNA72 (3009) .............. 1-132 4TNIOO ............................ 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
Diesel Engine Oil ........................ 0-8
f
Fan/Alternator Belt
Diesel Fuel ............................. 0-8 Adjustment. . . . . . . . . . . . . . . . . . . . . . .. 10-34
Dynamometer Test - 3009, 3011, Replacement ....................... 10-34
3014,4019 ........................... 10-47

Index-4 8/10/93
III\.IeA

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) (40]9) ...... 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
Removal/Installation .................. 2-83
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
Disassembly/Assembly ................ 4-67
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
Disassembly/Assembly ................ 3-841
Fuel Control and Governor Linkage - Removal/Installation. . . . . . . . . . . . . . . . . . 3-83
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
4TNI00 ........................... 4-100 Static Timing Adjustment. ............ 2-131
4TN78, 4TN82, 4TN84(T) (4019) ...... 3-143

8/10/93 Index-5
I I IU'I;OA

Fuel Injection Pump - 3TN82, 3TNA82, Fuel Supply Pump - 3TN75, 3TNC78 (30 II),
3TN84 (3014) 3TNA82, 3TN84 (3014)
Installation ......................... 2-81 Pressure Test. ...................... 2-137
Removal ........................... 2-80 Replacement ........................ 2-78
Static Timing Adjustment ............. 2-131 Fuel Supply Pump - 3TNA 72 (670 CUT, 3009 OEM)
Fuel Injection Pump - 4TN 100 Pressure Test ..................... " 1- 155
Installation ......................... 4-65 Replacement. . . . . . . . . . . . . . . . . . . . . . .. 1-92
Removal ........................... 4-64 Fuel Supply Pump - 4TN 100
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
Removal ........................... 3-80 Replacement ........................ 3-78
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/lnstallation. . . . . . . . . . . . . . . .. 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/1nstallation. . . . . . . . . . . . . . . . .. 1-66

I
Adjustment. . . . . . ... . . . . . . . . . . . . . . .. 10-56 Idler Gear - 3TN75, 3TN78, 3TNC78 (3011)
A. mperage Test . . . . . . . . . . . . . . . . . . . .. 10-55 Inspection/Replacement ............... 2-61
Fuel Shutoff Solenoid, Adjustment Removal/lnstallation .................. 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/lnstallation .................. 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/lnstallation. . . . . . . . . . . . . . . . . . 4-46
Removal/lnstallation. . . . . . . . . . . . . . . .. 10-37
Idler Gear - 4TN78T, 4TN82, 4TN84(T) (4019)
Fuel Supply Pump - 3011, 3014, 4019 Inspection/Replacement ............... 3-60
Pressure Test. ...................... 10-52 Removal/lnstallation .................. 3-59
Removal/lnstallation ................. 10-38
Idler Gear - Early 3TNA72 (430 LGT)
Inspection/Replacement . . . . . . . . . . . . . .. 1-65
Removal/lnstallation. . . . . . . . . . . . . . . . .. 1-65

Index-6 8/10/93
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 (30] 1) ........ 2-27 4TN84T (4019TF006) ................ 3-67
3TN82, 3TNA82, 3TN84 (3014) ........ 2-27 Early 3TNA72 (430LGT) ............. 1-81
3TNA72 (3009) ...................... 1-29 Later 3TNA72 ....................... 1-82
4TNI00 ............................ 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
Disassembly/Assembly ................ 1-79
Lubrication System Operation ............ 20-14 Inspection . . . . . . . . . . . . . . . . . . . . . . . . .. 1-80
Removal/Installation. . . . . . . . . . . . . . . . .. 1-79
M Oil Pump - 3TN75, 3TN78, 3TNC78 (3011)
Disassembly/Assembly ................ 2-66
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)
Disassembly/Assembly ................ 2-66
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
.Q 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
Oil Pan and Strainer
3TN66 ............................. 1-72
.e
Piston and Connecting Rod - 3TN66, 3TNA72
(3009)
I
3TN75, 3TN78, 3TNC78 (3011) ........ 2-64
3TN82, 3TNA82, 3TN84 (3014) ........ 2-64 Assembly ......................... . 1-35
3TNA72 ........................... 1-73 Disassembly ....................... . 1-34
4TNI00 ............................ 4-50 Inspection!Replacement .............. . 1-36
4TN78T, 4TN82, 4TN84(T) (4019) ...... 3-63 Installation ........................ . 1-33
Removal .......................... . 1-33

8/10/93 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, 4TNlOO ............................ 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
Removal/lnstallation. . . . . . . . . . . . . . . . .. 1-19
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
Installation ......................... 4-22 Inspection .......................... 2-20
Removal ........................... 4-22 Removal/lnstallation .................. 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/lnstallation. . . . . . . . . . . . . . . . . . 2-19
Installation ......................... 3-31 Rocker Arm Assembly - 4TNI00
Removal ........................... 3-31 Disassembly/Assembly ................ 4-10
Piston Cooling Nozzles Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4TNI00 ............................ 4-54 Remova1/1nstallation .................. 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/lnstallation. . . . . . . . . . . . . . . . . . 3-19
3TN82, 3TNA82, 3TN84 (3014) ........ 2-29 Rocker Arm Cover
4TNI00 ............................ 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
(Ind~re~t Injectio.n) ... '.' ................ 20-38
I
4TNIOO ............................. 4-9
4TN78T, 4TN82, 4TN84(T) (4019) ...... 3-18
Prehmmary Engme Testmg . . . . . . . . . . . . .. 10-44

.R
Radiator Slow Idle Speed Adjustment
Installation ........................ 10-33 3009,3011,3014,4019 .............. 10-53
Removal/lnspection . . . . . . . . . . . . . . . .. 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
Disassem bi y/lnspecti on . . . . . . . . . . . . .. 1-1 r
3TN82, 3TNA82, 3TN84 (3014) ....... 2-135
Test ............................. , I-II:'
4TN100 ............................ 4-97
4TN78T, 4TN82, 4TN84(T) (4019) ..... 3-140

Index-8 8/10/93
Index

Starter - 3TNA72 (3009 OEM) (Hitachi 008 kW) Starter Motor - 3TN78, 3TN82 (30 EX)
Assembly 0000 0000000000000000000 00 1-114 (Hitachi 200 kW)
Disassembly/Inspection 000000000 00 000 1-113 Assembly 0000000000000 0000 000000000 2-87
Test 0000000000 000000000000000 00 000 1-115 Disassembly 000 0000000 00000 000000000 2-87
Starter - 4TN78T (Hitachi 008 kW) Inspectionffest!Replacement 0 00 000 00000 2-87
Assembly 0000 000000000000000 000000 0 3-88 Starter Motor - 3TN82 (575 SSL)
Disassembly/lnspection 0000000 00000 000 3-87 (Nippondenso 1.4 kW)
Test 00000 00000000 000000 000000 000000 3-89 Assembly 0000000000000000 00 000 00000 2-97
Starter Gear Train and Overrunning Clutch - Disassembly 0000000000 0000 00 000 00000 2-96
3TN75, 3TNC78 (3011), 3TNA82, 3TN84 Inspectionffest!Replacement 0 00 000000 00 2-97
(870 CUT, 955 CUT) (Nippondenso 1.0 kW) Starter Motor - 3TNA72 (All Except 3009 OEM)
Assembly 000 00 000000000 00000000 0000 2-95 (Nippondenso 100 kW)
Disassembly/lnspection 00000000 0000000 2-93 Assembly 0000000000000000000000000 1-117
Starter Gear Train and Overrunning Clutch - Disassembly 00000000000000000000000 1-116
3TNA72 (All Except 3009 OEM) Inspectionffest!Replacement 00 00000000 1-117
(Nippondenso 1.0 kW) Starter Motor - 3TNA82, 3TN84
Assembly 0000000000000000000000000 1-120 (870 CUT, 3014 OEM) (Nippondenso 102 kW)
Disassembly/lnspection 00 000000 0000 00 1-119 Assembly 0000000000000000 00 0000 00 00 2-91
Starter Gear Train and Overrunning Clutch - Disassembly 0 000 000000000000 00 0000 00 2-91
3TNA82, 3TN84 (870 CUT, 3014 OEM) Inspectionffest!Replacement 00 0 000 000 00 2-92
(Nippondenso 102 kW) Starter Motor - 4TN100
Assembly 000 00000 00000000 000 000 0000 2-95 Assembly 000000000000000 000 00 0000 00 4-70
Disassembly/lnspection 000 00 0000000000 2-93 Disassembly 00000 0000000000 000000000 4-70
Starter Gear Train and Overrunning Clutch - Inspectionffest!Replacement 000 000 000 00 4-70
4TN82RJK, 4TN84RJK (Nippon den so 1.0 kW) Starter Motor - 4TN82ESP, 4TN84(T) (4019)
Assembly 0000 0000000000000 00 0000 000 3-99 (Nippondenso 1.4 kW)
Disassembly/lnspection 00 00000000 00000 3-97 Assembly 000000 00000000000 000 00000 3-101
Starter Gear Train and Solenoid - 3TN82 (575 SSL) Disassembly 000000000000000 00000000 3-100
(Nippondenso 1.4 kW) Inspectionffest!Replacement 00 00000000 3-101
Assembly 00 00000000000000 000 000 000 2-101 Starter Motor - 4TN82RJE (Hitachi 200 kW)
Disassembly/lnspection 00000000 0000000 2-99 Assembly 00000000000000000 000 0000 00 3-91
Starter Gear Train and Solenoid - 4TN100 Disassembly 00000000000 0000 0000 000 00 3-90
(Nippondenso 1.4 kW) Inspectionffest!Replacement 000 000 00000 3-91
Assembly 00000000000000000000000000 4-74 Starter Motor - 4TN82RJK, 4TN84RJK
Disassembly/lnspection 0000000000 00000 4-72 (Nippondenso 100 kW)
Starter Gear Train and Solenoid - 4TN82ESP, Assembly 000 00000000000000 000000000 3-95
4TN84(T) (4019) (Nippondenso 1.4 kW) Disassembly 0 00000000000000 000000000 3-94
Assembly 0000 000000000 000 0000 00 000 3-104 Inspectionffest!Replacement 00 0 00000000 3-951
Disassembly/lnspection 000000 00000000 3-102 Starter Overrunning Clutch - 3TN78,
Starter Identification Chart 3TN82 (30 EX) (Hitachi 200 kW)
3TN75, 3TN78, 3TNC78 (3011) 00 0000 00 2-86 Assembly 00000000000000000 000000000 2-90
3TN82, 3TNA82, 3TN84 (3014) 00000000 2-86 Disassembly 000000000000000 000000000 2-89
4TN78T, 4TN82, 4TN84(T) (4019) 000000 3-86 Starter Overrunning Clutch - 4TN82RJE
Starter Motor - 3TN75, 3TNC78 (3011), (Hitachi 200 kW)
3TNA82, 3TN84 (870 CUT, 955 CUT) Assembly 000000000000000000 00000000 3-93
(Nippondenso 1.0 kW) Disassembly 0000 00000000000 00 00000 00 3-93
Assembly 000000 00000000000000 00 0000 2-91 Starter Solenoid - 3TN75, 3TNC78 (3011),
Disassembly 00000000000000000000 0000 2-91 3TNA82, 3TN84 (870 CUT, 955 CUT)
Inspectionffest!Replacement 000000 00000 2-92 (Nippondenso 1.0 kW)
Assembly 00000000000000000 0 00000000 2-96
Disassembly/lnspection 000000 0000 000 00 2-95

8/10/93 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 - 3TNA 72 (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 flnspection . . . . . . . . . . . . .. 1-121 Thellllostat 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
Disassemblyflnspection ............... 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/lnspection ............... 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
I 3TN75, 3TN78, 3TNC78 (3011) ....... 2-116
3TN82, 3TNA82, 3TN84 (3014) ....... 2-116
II The~~~~~~g-i~~~~'.~~~~~~ ~~~~~~ ...... 1-144
Replacement. . . . . . . . . . . . . . . . . . . . . . .. 1-84
4TN100 ............................ 4-80
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 - 4 TN 100 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 ........ " 10-1S'
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 8/10/93
Index

y JY
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/lnstallation. . . . . . . . . . . . . . . . .. 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 Remov al/lnstallation. . . . . . . . . . . . . . . . . . 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/lnstallation. . . . . . . . . . . . . . . . .. 1-88
4TN78T, 4TN82, 4TN84(T) (4019) ...... 3-28
Water Pump - 4TNlOO
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/lnstallation. . . . . . . . . . . . . . . . .. 3-71
4TN100 ............................ 4-75
4TN78T ........................... 3-106 Water Pump - 4TN82RJK, 4TN84RJK
Assembly .......................... 3-76
Voltage Regulator, Replacement Disassembly ........................ 3-75
(Nippondenso 35A) Removal/lnstallation. . . . . . . . . . . . . . . . . . 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
Voltage Regulator, Replacement
(Nippondenso 40A)
I
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

8/10/93 Index-11