MODEL: 220 Series Diesel Engines Volume 1 of 2

Transcription

1 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

2 JOHN DEERE SERIES 220 DIESEL ENIGINES JOHN DEERE LAWN & GROUNDS CARE DIVISION CTM3

3 Introduction Each section will be identified with a symbol, letter or a number. All information, illustrations and specifications in this manual are based on the latest information availahle at the time of publication. The right is reserved to make changes at any time without notice. Safety Specifications and, General Information ~ I 3TN66, 3TNA72 (3009) iii 3TN75, 3TN78, 3TNC78 (3011), 3TN82,3TNA82,3TN84 (3014) i4tn78t, 4TN82,.4TN84(T) (4019) I i4tn1001. Accessories.. Power.

4 I SPECIFICATIONS AND GENERAL INFORMATION General Information Engine Specifications Fuels, Lubricants and Coolant Repair Information... 15

5 General Information ENGINE SERIAL NUMBER PLATE NOTE: The engine serial number plate can be easily destroyed. Before "hot tank" cleaning the block. remove the plate or record the inj"ornzafioll elsewhere. Location All except 4TNlOO: The engine serial number plate is located on the rocker arm cover. 4TN] 00: The engine serial number plate is located on the side of the engine, under exhaust manifold. Refer to the engine model designation on your engine's serial number plate to identify as to which section to use for repair information. Engine Serial Number Information Each engine has a 13-digit John Deere engine serial number identifying the producing factory, engine model designation, and a 6-digit sequential number. The following are examples: 3TN and 4TN Series Engines CH3029DOOOOOO CH... Factory producing engine (Yanmar) 3029D... Engine model designation "... Sequential serial number Series 220 OEM Engines CH3009DOOOOOO CH Factory producing engine 3009D... Engine model designation Sequential serial number Factory Code CH... Yanmar Engine Model Designation 3009D... Definition explained 'I following. (See i "Engine Model Designation".) Sequential Number digit sequential serial number Engine Model Designation - 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 Engine Type Bore diameter U... Fuel Injection (Type) JK.... Application NA... Diesel G... Gasoline Fuel Injection (Type) Application U... Indirect injection R... Direct injection JK... John Deere E-SP... Export - Sperry Company 8/31/93 G-1

6 3TN66 AND 3TNA72 (3009) ENGINES Specifications Cylinder Head, Valves and Manifolds Pistons, Rods and Cylinder Block Crankshaft, Main Bearings and Flywheel Camshaft and Timing Gear Train Lubrication System Cooling System Fuel System Starter Alternator Diagnosis Checks, Tests and Adjustments Operational Tests Section 1

7 Crankshaft, Main Bearings and Flywheel STUB SHAFT - 3TN66 (330/332 LGT, F915 FM) AND 3TNA72 (430 LGT, F925/35 FM) I. Remove electric clutch. (See procedure 111 Machine Technical Manual.) 2. Remove cover. 3. Measure stub shaft TlR (total indicated runout) using a dial indicator. If TIR exceeds (0.20 mm (0.008 in.), replace stub shaft. 4. Remove stub shaft. Cap Screw (2) N (2) M10 x 75 ut 49 N m (36 Ib-ft) 88 Nom (65 Ib-ft) / ~-- ~ ~-... Cap Screw (5)., M8 x 70 r Guide 26 Nom (226 Ib-ft) Pin (2) II ~ / (/ '" Plug / Stub I ~ capsc<ew? ~ M8 x 20 I I 59 Nom (44 Ib-ft) M82286A 3TNA72 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 clearance exceeds 0.05 mm (OJ)o2 in.), replace stub shaft. Installation is done in reverse order of removal. 8/30/

8 Fuel System Disassembly 1. Remove spring. 2. Remove seal and sealing wire. NOTE: Shims are on all engines except 670 CUT and 3009 OEM applications. 7. Remove governor shaft, governor linkage assembly, shims and O-ring. I NOTE: Washer is CUT, 455 LGT and 3009 OEM ollly. 3. Remove nut, washer, if equipped, and throttle lever. 4. Remove cap screw and throttle shaft retaining plate. 5. Remove cap screw and governor shaft retaining plate. 6. Remove set screw, fuel shutoff lever, spring and O-ring. 8. Rotate throttle shaft assembly as shown. Shims If equipped. M Remove tapered pin from tapered hole lising a punch. lo.remove throttle shaft, shaft lever and O-ring. Tapered Pin Shaft Lever Governor Shaft Retaining Plate Set Screw Apply thread lock and seaier (low strength) on threads. ing a-ring./' Replace. Fuel Shutoff Lever M /31/93

9 3TN75, 3TN78, 3TNC78 (3011) 3TN82, 3TNA82, AND 3TN84 (3014) ENGINES Specifications Cylinder Head, Valves and Manifolds Pistons, Rods and Cylinder Block Crankshaft, Main Bearings and Flywheel Camshaft and Timing Gear Train Lubrication System Cooling System Fuel System Starter Alternator Diagnosis Checks, Tests and Adjustments Operational Tests Section 2

10 4TN78T, 4TN82 AND 4TN84(T) (4019) ENGINES I Specifications Cylinder Head, Valves and Manifolds Pistons, Rods and Cylinder Block Crankshaft, Main Bearings and Flywheel Camshaft and Timing Gear Train Lubrication System Cooling System Fuel System Starter Alternator Diagnosis Checks, Tests and Adjustments Operational Tests Section 3

11 4TN100 ENGINE Specifications Cylinder Head, Valves and Manifolds Pistons, Rods and Cylinder Block Crankshaft, Main Bearings and Flywheel Camshaft and Timing Gear Train Lubrication System Cooling System Fuel System Starter (Nippondenso 1.4 kw) Alternator (Hitachi 25A) Diagnosis Checks, Tests and Adjustments Operational Tests Section 4

12 ACCESSORIES SERIES 220 POWER UNIT ENGINES Specifications Intake and Exhaust Systems Cooling System Fuel System Electrical System Miscellaneous Engine Tune-up Operational Tests and Adjustments Dealer Fabricated Tools I Section 10

13 ENGINE, AIR INTAKE AND FUEL SYSTEM Component Location Theory of Operation Section 20

14 ELECTRICAL SYSTEM SERIES 220 POWER UNIT ENGINES Electrical System Component Location Schematics Section 21

15 Index Air Cleaner Operation 3009 (3TNA72) (3TNC78), 3014 (3TN84), 4019D (4TN84), 4019T (4TN84T) Air Cleaner, Inspection ,3014,4019D... 1O T Air Heater, Removal/lnstallation Air Intake System, Check Air Intake System, Leakage Test 3009,3011,3014, TN66, 3TNA72 (3009) TN75, 3TN78, 3TNC78 (3011) TN82, 3TNA82, 3TN84 (3014) TN TN78T, 4TN82, 4TN84(T) (4019) Alternator - 3TN66 (375 SSL, 330/332 LGT, F915 FM) (Kokosan 20A) Assembly Disassembly/lnspection Alternator - 3TN66 (655 CUT) (Nippondenso 35A) Assembly Disassembly Test/lnspection Alternator - 3TN66 (655 CUT) (Nippondenso 40A) Assembly Disassembly Inspection/Test Alternator - 3TN75 (855/56 CUT), 3TN82 (575 SSL), 3TNA82, 3TN84 (870 CUT, 955 CUT) (Nippon den so 35A) Assembly Disassembly Inspection/Test Alternator - 3TN75, 3TNC78 (3011), 3TN82 (575 SSL), 3TN84 (955 CUT, 3014 OEM) (Nippondenso 40A) Assembly Disassembly Inspection/Test Alternator - 3TN78, 3TN82 (30 EX) (Hitachi 25A) Assembly Disassembly Inspection/Test Alternator - 3TNA72 (430 LGT, 670 CUT, 755/56 CUT, F925/35 FM) (Nippondenso 35A) Assembly Disassembly T es t/lns pecti on Alternator - 3TNA72 (455 LGT, 755/56 CUT, 3009 OEM) (Nippondenso 40A) Assembly Disassembly Inspection/Test Alternator - 3TNA72 (670 CUT, 15 EX) (Kokosan 20A) Assembly Disassembly/lnspection Alternator - 3TNA82, 3TN84 (870 CUT) (Kokosan 20A) Assembly Disassembly/Inspection Alternator - 4TN100 (Hitachi 25A) Assembly Disassembly Inspection/Test Alternator - 4TN78T (Hitachi 25A) Assembly Disassembly Inspection/Test Alternator - 4TN82, 4TN84RJK (Nippondenso 35A) Assembly Disassembly Inspection/Test Alternator - 4TN82ESPjRJE, 4TN84(T) (4019) (Nippondenso 40A) Assembly Disassembly Inspection/Test Alternator - 4TN82RJK, 4TN84RJK (Ko~~~:r:n~~:~ Disassembly/lnspection Altitude Compensation Guidelines Amperage Test , 3011, 3014, 4019 Regulated Unregulated Auxiliary Drive Gear 4TNI /10/93 Index-1

16 I Index B Balancer Assembly - 4TN82RJK, 4TN84RJK Disassembly/Assembly Removal/Installation Basic Engine Specifications : Cam Followers - 3TN66, 3TNA 72 (3009) Inspection Removal/Installation Cam Followers - 3TN75, 3TN78, 3TNC78 (3011) Inspection Removal/Installation Cam Followers - 3TN82, 3TNA82, 3TN84 (3014) Inspection Removal/Installation Cam Followers - 4TN100 Inspection Removal/Installation Cam Followers - 4TN78T, 4TN82, 4TN84(T) (4019) Inspection Removal/Installation Camshaft - 3TN66, 3TNA 72 (3009) End Play Check Inspection/Replacement Installation Removal Camshaft - 3TN75, 3TN78, 3TNC78 (3011) End Play Check Inspection/Replacement Installation Removal Camshaft - 3TN82, 3TNA82, 3TN84 (3014) End Play Check Inspection/Replacement Installation Removal Camshaft - 4TN100 End Play Check Inspection/Replacement Installation Removal Camshaft - 4TN78T, 4TN82, 4TN84(T) (4019) End Play Check Inspection/Replacement Installation Removal Combustion Chamber Operation (Direct Injection) Component Location Engine Components - Direct Injection Engine Components -Indirect Injection Engine Electrical Components Instrument Panel Components Connecting Rod Check - 3TN66, 3TNA 72 (3009) Bearing Clearance SidePlay Connecting Rod Check - 3TN75, 3TN78, 3TNC78 (3011) Bearing Clearance Side Play Connecting Rod Check - 3TN82, 3TNA82, 3TN84 (3014) Bearing Clearance Side Play Connecting Rod Check - 4 TN 1 00 Bearing Clearance Side Play Connecting Rod Check - 4TN78T, 4TN82, 4TN84(T) (4019) Bearing Clearance Side Play Coolant Temperature Sender Replacement Test Coolant Temperature Sender - 4TN100 Replacement Test Coolant Temperature Sensor - 3TN66, 3TNA 72 (3009) Replacement Test Coolant Temperature Switch - 3TN75, 3TN78, 3TNC78 (3011) Replacement Test Coolant Temperature Switch - 3TN82, 3TNA82, 3TN84 (3014) Replacement Test Coolant Temperature Switch - 4TN78T, 4TN82, 4TN84(T) (4019) Replacement Test Cooling Fan Installation Removal : Index-2 8/10/93

17 Index Cooling System Check and Service Flushing and Servicing Theory of Operation Cooling System, Pressure Test 3009,3011,3014, TN66, 3TNA72 (3009) TN75, 3TN78, 3TNC78 (3011) TN82, 3TNA82, 3TN84 (3014) TN TN78T, 4TN82, 4TN84(T) (4019) Crankcase Breather Operation 3TN66, 3TNA72 (3009), 4TN All Except 3TN66, 3TNA72 (3009), 4TN Crankcase Extension Housing 3TN75, 3TNC78 (3011 OEM), 3TN82 (575 SSL), 3TN84 (955 CUT, 3014 OEM) TN78 (25 EX), 3TN82 (30 EX), 3TNA82 (770 CUT), 3TN84 (870 CUT) TNA72 (15 EX and 3009 OEM) TNA72 (670 CUT) TNI TN78T,4TN82RJK, 4TN84RJK TN82RJE,4TN82ESP, 4TN84(T) (4019) Crankcase Ventilation System, Check Crankshaft and Main Bearings - 3TN66, 3TNA72 (3009) InspectionlReplacement Installation Removal Crankshaft and Main Bearings - 3TN75, 3TN78, 3TNC78 (3011) InspectionlReplacement Installation... i 2-47 Removal Crankshaft and Main Bearings - 3TN82, 3TNA82, 3TN84 (3014) InspectionlReplacement Installation Removal Crankshaft and Main Bearings - 4TNI00 InspectionlReplacement Installation Removal Crankshaft and Main Bearings - 4TN78T, 4TN82, 4TN84(T) (4019) InspectionlReplacement Installation Removal Crankshaft Front Oil Seal 3TN66, 3TNA 72 (3009) TN75, 3TN78, 3TNC78 (3011) TN82, 3TNA82, 3TN84 (3014) TN TN78T, 4TN82, 4TN84(T) (4019) Crankshaft Main Bearing, Clearance Check 3TN66, 3TNA72 (3009) TN75, 3TN78, 3TNC78 (3011) TN82, 3TNA82, 3TN84 (3014) TN TN78T, 4TN82, 4TN84(T) (4019) Crankshaft Rear Oil Seal 3TN TN75, 3TN78, 3TNC78 (3011) TN82, 3TNA82, 3TN84 (3014) TNA 72 (15 EX, 670 CUT, 3009 OEM) TNA72 (430 LOT, 455 LOT, 755/56 CUT, F925/35 FM) TN TN78T, 4TN82, 4TN84(T) (4019) Crankshaft, End Play Check 3TN66, 3TNA 72 (3009) TN75, 3TN78, 3TNC78 (3011) TN82, 3TNA82, 3TN84 (3014) TN TN78T, 4TN82, 4TN84(T) (4019) Cylinder Bore - 3TN66, 3TNA 72 (3009) Deglazing Inspection Reboring Cylinder Bore - 3TN75, 3TN78, 3TNC78 (3011) Deglazing Inspe~tion Rebonng Cylinder Bore - 3TN82, 3TNA82, 3TN84 (3014) Deglazing Inspection Reboring Cylinder Bore - 4TNI00 Deglazing Inspection Reboring /10/93 Index-3

18 Index Cylinder Bore - 4TN78T, 4TN82, 4TN84(T) (4019) Deglazing Inspection Reboring Cylinder Head and Valves - 3TN66, 3TNA 72 (3009) Disassembly/Assembly Inspection/Replacement Removal/lnstallation Cylinder Head and Valves - 3TN75, 3TN78, 3TNC78 (3011) Disassembly/Assembly Inspection/Replacement Removal/lnstallation Cylinder Head and Valves - 3TN82, 3TNA82, 3TN84 (3014) Disassembly/Assembly InspectionlReplacement Removal/lnstallation Cylinder Head and Valves - 4TN100 Disassembly/Assembly Inspection/Replacement Removal/Installation Cylinder Head and Valves - 4TN78T, 4TN82, 4TN84(T) (4019) Disassembly/Assembly InspectionlReplacement Removal/lnstallation Cylinder, Compression Pressure Test ,3014, TN66, 3TNA72 (3009) TN75, 3TN78, 3TNC78 (3011) TN82, 3TNA82, 3TN84 (3014) TN TN78T, 4TN82, 4TN84(T) (4019) I~aler Fabricated Tools DFRO 1 Extended Indicator Tip DFR02 Extended Indicator Tip Diagnosis 3TN66, 3TNA72 (3009) TN75, 3TN78, 3TNC78 (3011) TN82, 3TNA82, 3TN84 (3014) TN TN78T, 4TN82, 4TN84(T) (4019) Diesel Engine Oil Diesel Fuel Dynamometer Test , 3011, 3014, E Electrical Component Location Engine Instrument Panel Electrical Schematic 3009 Power Unit , 3014 and 4019 Power Units Optional Equipment Electrical System, Check Engine Application Chart Industrial Equipment.... G-3 Lawn and Grounds Care Equipment.... G-2 OEM Application... G-3 Engine Balancer Operation Engine Coolant Recommendations... G-9 Specifications... G-l 0 Engine Oil Pressure, Test 3009,3011,3014, TN66, 3TNA72 (3009) TN75, 3TN78, 3TNC78 (3011) TN82, 3TNA82, 3TN84 (3014) TN TN78T, 4TN82, 4TN84(T) (4019) Engine Serial Number Plate Location... G-l Serial Number Information... G-l Engine Specifications 3TN TNA72 (3009) TN75, 3TN78, 3TNC78 (3011) TN82, 3TNA82, 3TN84 (3014) TN78T TN82, 4TN84(T) (4019) TNI Engine, Clean... G-17 Exhaust Manifold 3TN TN75, 3TN78, 3TNC78 (3011) TN82, 3TNA82, 3TN84 (3014) TNA72 (3009) TNIOO TN78T, 4TN82, 4TN84(T) (4019) Exhaust System, Check f Fan/Alternator Belt Adjustment Replacement Index-4 8/10/93

19 III\.IeA Fan/Alternator Drive Belt, Adjustment 3TN66, 3TNA72 (3009) TN75, 3TN78, 3TNC78 (3011) TN82, 3TNA82, 3TN84 (3014) TN TN78T, 4TN82, 4TN84(T) (4019) Fan/Alternator Drive Belt, Inspection Fast Idle Speed Adjustment ,3014, Flywheel 3TN66, 3TNA72 (3009) TN75, 3TN78, 3TNC78 (3011) TN82, 3TNA82, 3TN84 (3014) TN TN78T, 4TN82, 4TN84(T) (4019) Flywheel Housing 3TN TN78, 3TNC78 (3011), 3TN82, 3TN84 (3014) TNA72 (15 EX, 3009 OEM) TNA72 (All Except 15 EX and 3009 OEM) TN TN78T, 4TN82RJE, 4TN82ESP, 4TN84(T) (4019) Flywheel Plate 3TN75, 3TNC78 (3011), 3TNA82, 3TN84 (3014) TN82RJK,4TN84RJK, 4TN84(T) (4019) Fuel Control and Governor Linkage - 3TN66 and Later 3TNA 72 Assembly Disassembly Inspection Installation Removal Fuel Control and Governor Linkage - Early 3TNA72 (430 LGT) Inspection Installation Removal Fuel Drain Back Test 3009,3011,3014, TN66, 3TNA72 (3009) TN75, 3TN78, 3TNC78 (3011) TN82, 3TNA82, 3TN84 (3014) TNI TN78, 4TN82, 4TN84(T) (4019) Fuel Filter Assembly ,3014 and TN66, 3TNA72 (3009) TN75, 3TN78, 3TNC78 (3011) TN82, 3TNA82, 3TN84 (3014) TN TN78T, 4TN82, 4TN84(T) (40]9) Fuel Injection Nozzles - 3TN66, 3TNA72 (3009) Cleaning/Inspection Cross Section Disassembly/Assembly Removal/Installation Test Fuel Injection Nozzles - 3TN75, 3TN78, 3TNC78 (3011) Cleaning/Inspection Cross Section Disassembly/Assembly Removal/Installation Test Fuel Injection Nozzles - 3TN82, 3TNA82, 3TN84 (3014) Cleaning/Inspection Cross Section Disassembly/Assembly Removal/Installation Test Fuel Injection Nozzles - 4TN100 Cleaning/Inspection Cross Section Disassembly/Assembly Removal/Installation Test Fuel Injection Nozzles - 4TN78T, 4TN82, 4TN84(T) (4019) Cleaning/Inspection Cross Section Disassembly/Assembly Removal/Installation Test Fuel Injection Pump - 3TN66, 3TNA 72 (3009) Installation Removal Fuel Injection Pump - 3TN75, 3TN78, 3TNC78 (3011) Installation Removal Static Timing Adjustment /10/93 Index-5

20 II IU'I;OA I A. Fuel Injection Pump - 3TN82, 3TNA82, 3TN84 (3014) Installation Removal Static Timing Adjustment Fuel Injection Pump - 4TN 100 Installation Removal Static Timing Adjustment Fuel Injection Pump - 4TN78T, 4TN82, 4TN84(T) (4019) Installation Removal Fuel Injection Pump Camshaft - 3TN66 and Later 3TNA 72 Assembly., Disassembly Inspection Installation Removal Fuel Injection Pump Camshaft - Early 3TNA72 (430 LGT) Assembly Disassembly Inspection Installation Removal Fuel Injection Pump Operation Fuel Injection Pump Static Timing Adjustment 3TN66 and Later 3TNA TN78T TN82, 4TN84(T) (4019) Early 3TNA72 (430 LGT) Fuel Shutoff Solenoid Replacement Fuel Shutoff Solenoid , 3011, 3014, 4019 Adjustment mperage Test Fuel Shutoff Solenoid, Adjustment 3TN66, 3TNA72 (3009) TN75, 3TN78, 3TNC78 (3011) TN82, 3TNA82, 3TN84 (3014) TN78T, 4TN82, 4TN84(T) (4019) Fuel Supply Pump Pressure Test Removal/lnstallation Fuel Supply Pump , 3014, 4019 Pressure Test Removal/lnstallation Fuel Supply Pump - 3TN75, 3TNC78 (30 II), 3TNA82, 3TN84 (3014) Pressure Test Replacement Fuel Supply Pump - 3TNA 72 (670 CUT, 3009 OEM) Pressure Test... " Replacement Fuel Supply Pump - 4TN 1 00 Pressure Test Removal/Installation Fuel Supply Pump - 4TN82, 4TN84(T) (4019) Pressure Test Replacement Fuel System Operation Fuel System, Bleed ,3014, TN66, 3TNA72 (3009) TN75, 3TN78, 3TNC78 (3011) TN82, 3TNA82, 3TN84 (3014) TN78T, 4TN82, 4TN84(T) (4019) G General Tune-Up Recommendations Glow Plugs Removal/lnstallation Test Governor Operation Grease... G-9 I Īdler Gear - 3TN66 and Later 3TNA 72 Inspection/Replacement Removal/1nstallation Idler Gear - 3TN75, 3TN78, 3TNC78 (3011) Inspection/Replacement Removal/lnstallation Idler Gear - 3TN82, 3TNA82, 3TN84 (3014) Inspection/Replacement Removal/lnstallation Idler Gear - 4TN100 Inspection/Replacement Removal/lnstallation Idler Gear - 4TN78T, 4TN82, 4TN84(T) (4019) Inspection/Replacement Removal/lnstallation Idler Gear - Early 3TNA72 (430 LGT) Inspection/Replacement Removal/lnstallation Index-6 8/10/93

21 Index Injection Nozzle Operation Hole Type Pintle Type Instrument Panel , 3011, 3014, Intake Manifold 3TN TN75, 3TN78, 3TNC78 (30] 1) TN82, 3TNA82, 3TN84 (3014) TNA72 (3009) TNI TN78T, 4TN82, 4TN84(T) (4019) Lubrication System Operation M Muffler, Removal/Installation ,3014, 4019D T Q Oil Cooler - 3TN84 (955 CUT) Leakage Test Removal/Installation Oil Cooler - 4TN100 Leakage Test Removal/Installation Oil Cooler - 4TN8T, 4TN84T (4019TF001, 005) Leakage Test Removal/Installation Oil Cooler By-Pass Valve 4TN Oil Cooler Operation Oil Filter Operation Oil Pan and Strainer 3TN TN75, 3TN78, 3TNC78 (3011) TN82, 3TNA82, 3TN84 (3014) TNA TNI TN78T, 4TN82, 4TN84(T) (4019) Oil Pressure Regulating Valve 3TN TN75, 3TN78, 3TNC78 (3011) TN82, 3TNA82, 3TN84 (3014) TN84 (955 CUT) TN TN78T, 4TN84T (4019TF001, 005) TN82, 4TN84 (4019DF), 4TN84T (4019TF006) Early 3TNA72 (430LGT) Later 3TNA Theory of Operation Oil Pressure Switch, Replacement Oil Pump - 3TN66 and Later 3TNA 72 Disassembly/Assembly Inspection Removal/Installation Oil Pump - 3TN75, 3TN78, 3TNC78 (3011) Disassembly/Assembly Inspection Removal/Installation Oil Pump - 3TN82, 3TNA82, 3TN84 (3014) Disassembly/Assembly Inspection Removal/Installation Oil Pump - 4TN100 Disassembly/Assembly Inspection Removal/Installation Oil Pump - 4TN78T, 4TN82, 4TN84(T) (4019) Disassembly/Assembly Inspection Removal/Installation Oil Pump - Early 3TNA 72 (430 LGT) Inspection Installation Removal e Piston and Connecting Rod - 3TN66, 3TNA 72 (3009) Assembly.... Disassembly.... Inspection!Replacement.... Installation.... Removal I 8/10/93 Index-7

22 Index I Piston and Connecting Rod - 3TN75, 3TN78, 3TNC78 (3011) Assembly Disassembly Inspection/Replacement Installation Removal Piston and Connecting Rod - 3TN82, 3TNA82, 3TN84 (3014) Assembly Disassembly Inspection/Replacement Installation Removal Piston and Connecting Rod - 4TN100 Assembly Disassembly Inspection/Replacement Installation Removal Piston and Connecting Rod - 4TN78T, 4TN82, 4TN84(T) (4019) Assembly Disassembly Inspection/Replacement Installation Removal Piston Cooling Nozzles 4TNI TN78T, 4TN84T (4019TF001, 005) Theory of Operation Piston-to-Cylinder Head Clearance 3TN66, 3TNA72 (3009) TN75, 3TN78, 3TNC78 (3011) TN82, 3TNA82, 3TN84 (3014) TNI TN78T, 4TN82, 4TN84(T) (4019) Precombustion Chamber Operation (Ind~re~t Injectio.n)... '.' Prehmmary Engme Testmg R Radiator Installation Removal/lnspection Radiator Cap, Pressure Test 3009,3011,3014, TN66, 3TNA72 (3009)... " TN75, 3TN78, 3TNC78 (3011) TN82, 3TNA82, 3TN84 (3014) TN TN78T, 4TN82, 4TN84(T) (4019) Radiator Mount - If Equipped Radiator, Bubble Test 3009,3011,3014, TN66, 3TNA72 (3009) TN75, 3TN78, 3TNC78 (3011) TN82, 3TNA82, 3TN84 (3014) TN78T, 4TN82, 4TN84(T) (4019) TNlOO Regulated Voltage Test 3009,3011,3014, Rocker Arm Assembly - 3TN66, 3TNA72 (3009) Disassembly/Assembly Inspection Removal/lnstallation Rocker Arm Assembly - 3TN75, 3TN78, 3TNC78 (3011) Disassembly/Assembly Inspection Removal/lnstallation Rocker Arm Assembly - 3TN82, 3TNA82, 3TN84 (3014) Disassembly/Assembly Inspection Removal/lnstallation Rocker Arm Assembly - 4TNI00 Disassembly/Assembly Inspection Remova1/1nstallation Rocker Arm Assembly - 4TN78T, 4TN82, 4TN84(T) (4019) Disassembly/Assembly Inspection Removal/lnstallation Rocker Arm Cover 3TN66, 3TNA72 (3009) TN75, 3TN78, 3TNC78 (3011) TN82, 3TNA82, 3TN84 (3014) TNIOO TN78T, 4TN82, 4TN84(T) (4019) Slow Idle Speed Adjustment 3009,3011,3014, Specifications Engine Accessories Starter - 3TN66 (Hitachi 0.8 kw) Assembly Disassem bi y /lnspecti on r Test..., I-II:' Index-8 8/10/93

23 Index Starter - 3TNA 72 (3009 OEM) (Hitachi 008 kw) Assembly Disassembly /Inspection Test Starter - 4TN78T (Hitachi 008 kw) Assembly Disassembly/lnspection Test Starter Gear Train and Overrunning Clutch - 3TN75, 3TNC78 (3011), 3TNA82, 3TN84 (870 CUT, 955 CUT) (Nippondenso 1.0 kw) Assembly Disassembly/lnspection Starter Gear Train and Overrunning Clutch - 3TNA 72 (All Except 3009 OEM) (Nippondenso 1.0 kw) Assembly Disassembly/lnspection Starter Gear Train and Overrunning Clutch - 3TNA82, 3TN84 (870 CUT, 3014 OEM) (Nippondenso 102 kw) Assembly Disassembly/lnspection Starter Gear Train and Overrunning Clutch - 4TN82RJK, 4TN84RJK (Nippon den so 1.0 kw) Assembly Disassembly/lnspection Starter Gear Train and Solenoid - 3TN82 (575 SSL) (Nippondenso 1.4 kw) Assembly Disassembly/lnspection Starter Gear Train and Solenoid - 4TN100 (Nippondenso 1.4 kw) Assembly Disassembly/lnspection Starter Gear Train and Solenoid - 4TN82ESP, 4TN84(T) (4019) (Nippondenso 1.4 kw) Assembly Disassembly/lnspection Starter Identification Chart 3TN75, 3TN78, 3TNC78 (3011) TN82, 3TNA82, 3TN84 (3014) TN78T, 4TN82, 4TN84(T) (4019) Starter Motor - 3TN75, 3TNC78 (3011), 3TNA82, 3TN84 (870 CUT, 955 CUT) (Nippondenso 1.0 kw) Assembly Disassembly Inspectionffest!Replacement Starter Motor - 3TN78, 3TN82 (30 EX) (Hitachi 200 kw) Assembly Disassembly Inspectionffest!Replacement Starter Motor - 3TN82 (575 SSL) (Nippondenso 1.4 kw) Assembly Disassembly Inspectionffest!Replacement Starter Motor - 3TNA 72 (All Except 3009 OEM) (Nippondenso 100 kw) Assembly Disassembly Inspectionffest!Replacement Starter Motor - 3TNA82, 3TN84 (870 CUT, 3014 OEM) (Nippondenso 102 kw) Assembly Disassembly Inspectionffest!Replacement Starter Motor - 4TN100 Assembly Disassembly Inspectionffest!Replacement Starter Motor - 4TN82ESP, 4TN84(T) (4019) (Nippondenso 1.4 kw) Assembly Disassembly Inspectionffest!Replacement Starter Motor - 4TN82RJE (Hitachi 200 kw) Assembly Disassembly Inspectionffest!Replacement Starter Motor - 4TN82RJK, 4TN84RJK (Nippondenso 100 kw) Assembly Disassembly Inspectionffest!Replacement Starter Overrunning Clutch - 3TN78, 3TN82 (30 EX) (Hitachi 200 kw) Assembly Disassembly Starter Overrunning Clutch - 4TN82RJE (Hitachi 200 kw) Assembly Disassembly Starter Solenoid - 3TN75, 3TNC78 (3011), 3TNA82, 3TN84 (870 CUT, 955 CUT) (Nippondenso 1.0 kw) Assembly Disassembly/lnspection /10/93 Index-9

24 Index II Starter Solenoid - 3TN78, 3TN82 (30 EX) (Hitachi 2.0 kw) Assembly Disassembly Starter Solenoid - 3TNA 72 (All Except 3009 OEM) (Nippondenso 1.0 kw) Assembly Disassembly flnspection Starter Solenoid - 3TNA82, 3TN84 (870 CUT 3014 OEM) (Nippondenso 1.2 kw) Assembly Disassemblyflnspection Starter Solenoid - 4TN82RJE (Hitachi 2.0 kw) Assembly Disassembly Starter Solenoid - 4TN82RJK, 4TN84RJK (Nippondenso 1.0 kw) Assembly Disassembly/lnspection Starter Solenoid, Test 3009,3011,3014, Starter, AMP Draw/RPM Test 3009,3011,3014, Starter, No-Load AMP Draw/RPM Test 3009,3011,3014, Starter, No-Load Amp Draw/RPM Test 3TN66, 3TNA72 (3009) TN75, 3TN78, 3TNC78 (3011) TN82, 3TNA82, 3TN84 (3014) TN TN78T, 4TN82, 4TN84(T) (4019) Stub Shaft 3TN66 (330/332 LGT, F915 FM) TNA72 (430 LGT, F925/35 FM) I The~~~~~~g-i~~~~'.~~~~~~ ~~~~~~ Replacement Thermostat - 3TN75, 3TNC78 (3011), 3TN82 (575 SSL), 3TNA82, 3TN84 (870 CUT) Opening Test Replacement Thermostat - 4 TN 100 Opening Test Replacement Thermostat - 4TN78T, 4TN82, 4TN84(T) (4019) Opening Test Thermostat - 4TN82RJK, 4TN84RJK Replacement Thermostat and Housing - 3TN78, 3TN82 (30 EX), 3TN84 (955 CUT, 3014 OEM) Opening Test Thermostat Replacement Thermostat and Housing - 4TN78T, 4TN82RJE, 4TN82ESP, 4TN84(T) (4019) Opening Test Thellllostat Replacement Timing Gear Backlash, Check 3TN66 and Later 3TNA TN75, 3TN78. 3TNC78 (3011) TN82, 3TNA82, 3TN84 (3014) TN TN78T, 4TN82, 4TN84(T) (4019) Early 3TNA72 (430 LGT) Timing Gear Cover 3TN TN75, 3TN78, 3TNC78 (3011) TN82, 3TNA82, 3TN84 (3014) TN TN78T, 4TN82, 4TN84(T) (4019) Early 3TNA 72 (430 LGT)..., 1-62 Later 3TNA Timing Gear Cover Mounting Plate 3TN75, 3TN78, 3TNC78 (3011) TN82, 3TNA82, 3TN84 (3014) TN78T, 4TN82, 4TN84(T) (4019) Timing Gear Housing 3TN TN Early 3TNA Later 3TNA Torque Values Metric... G-15 Unified Inch... G-16 Troubleshooting Chart 3TN66, 3TNA72 (3009) TN75, 3TN78, 3TNC78 (3011) TN82, 3TNA82, 3TN84 (3014) TN TN78T, 4TN82, 4TN84(T) (4019) Turbocharger Assembly Disassembly Disconnect Oil Inlet Line... G-17 Extending Life Failure Analysis Inspection Installation Removal Rotor Shaft Axial Play Check... " 10-1S' Rotor Shaft Radial Play Check Seven-Step Inspection Theory of Operation Index-10 8/10/93

25 Index y Valve Clearance, Check and Adjustment 3TN66 and Later 3TNA TN75, 3TN78, 3TNC78 (3011) TN82, 3TNA82, 3TN84 (3014) TN TN78T, 4TN82, 4TN84(T) (4019) Early 3TNA72 (430 LGT) Valve Lift Check 3TN66, 3TNA72 (3009) TN75, 3TN78, 3TNC78 (3011) TN82, 3TNA82, 3TN84 (3014) TN TN78T, 4TN82, 4TN84(T) (4019) Valve Seats, Grind 3TN66, 3TNA72 (3009) TN75, 3TN78, 3TNC78 (3011) TN82, 3TNA82, 3TN84 (3014) TN TN78T, 4TN82, 4TN84(T) (4019) Valves, Lap 3TN66, 3TNA 72 (3009) TN75, 3TN78, 3TNC78 (3011) TN82, 3TNA82, 3TN84 (3014) TN TN78T, 4TN82, 4TN84(T) (4019) Voltage Regulator, Replacement (Hitachi 25A) 3TN78, 3TN82 (30 EX) TN TN78T Voltage Regulator, Replacement (Nippondenso 35A) 3TN66 (655 CUT) TN75, (855/56 CUT), 3TN82 (575 SSL), 3TNA82, 3TN84 (870 CUT, 955 CUT) TNA72 (430 LGT, 670 CUT, 755/56 CUT, F925/35 FM) TN82, 4TN84RJK Voltage Regulator, Replacement (Nippondenso 40A) 3TN66 (655 CUT) TN75, 3TNC78 (3011), 3TN82 (575 SSL), 3TN84 (955 CUT, 3014 OEM) TNA72 (455 LGT, 755/56 CUT, 3009 OEM) TN82ESP/RJE, 4TN84(T) (4019) JY Water Pump - 3TN66 Assembly Disassembly... " 1-86 Removal/lnstallation Water Pump - 3TN75, 3TNC78 (3011), 3TN82 (575 SSL), 3TNA82, 3TN84 (870 CUT) Assembly Disassembly Remov al/lnstallation Water Pump - 3TN78, 3TN82 (30 EX), 3TN84 (955 CUT, 3014 OEM) Assembly Disassembly Removal/Installation Water Pump - 3TNA72 Assembly Disassembly Removal/lnstallation Water Pump - 4TNlOO Assembly Disassembly Removal/Installation Water Pump - 4TN78T, 4TN82RJE, 4TN82ESP, 4TN84(T) (4019) Assembly Disassembly Removal/lnstallation Water Pump - 4TN82RJK, 4TN84RJK Assembly Disassembly Removal/lnstallation I 8/10/93 Index-11