Yanmar Diesel

3TN and 4TN Series
Yanmar
Diesel Engines
John Deere Horicon Works
CTM3 (03JAN90)
LITHO IN U.S.A.
ENGLISH
3TN and 4TN Series Yanmar Engines CTM3 (03JAN90)
This Component Technical Manual contains
necessary instructions to repair the engine, engine
fuel, and engine electrical systems.
Use this Component Technical Manual in conjunction
with the Machine Technical Manual. An engine
application listing in the introduction identifies
product-model/engine type-model relationship. See the
Machine Technical Manual for information on engine
removal and installation, theory of operation,
diagnostic, and testing procedures.
N
CAUTION: THIS IS THE SAFETY-ALERT
symbol. When you see this symbol on the
machine or in this manual, be alert to the
potential for personal injury.
M21,TM300,1 -19-27AUG87
Introduction
CTM3 (03JAN90) 3TN/4TN Series Yanmar Engines
010897
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Group 05 . . . . . . . . . . . . . . . . . . . . . . . . . .
About This Manual . . . . . . . . . . . . . . . . . . . 05-2
Engine Serial Number Plate . . . . . . . . . . . . . 05-3
Engine Application Chart . . . . . . . . . . . . . . . 05-4
Engine Torque Specifications . . . . . . . . . . . . 05-5
Metric Torque Specifications . . . . . . . . . . . . 05-6
Group 06Repair Specifications
Engine
3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . 06-1
3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . 06-6
3TN75 . . . . . . . . . . . . . . . . . . . . . . . . . 06-13
3TN78/4TN78 . . . . . . . . . . . . . . . . . . . . 06-18
3TN82/3TN84/4TN82/4TN84 . . . . . . . . . . 06-23
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . 06-33
Group 10Valve Train and Camshaft
Service Equipment and Tools . . . . . . . . . . . . 10-1
Other Materials . . . . . . . . . . . . . . . . . . . . . 10-1
Service Part Kits . . . . . . . . . . . . . . . . . . . . 10-2
Rocker Arm
Remove and Disassemble Cover . . . . . . . . 10-2
Measure and Adjust Valve Clearance . . . . . 10-3
Measure and Adjust Valve Clearance
(4TN100) . . . . . . . . . . . . . . . . . . . . . . 10-6
Remove and Disassemble Assembly . . . . . 10-8
Remove and Inspect Pushrods and
Cam Followers . . . . . . . . . . . . . . . . . 10-11
Install Pushrods and Cam Followers . . . . . 10-14
Assemble and Install Assembly . . . . . . . . 10-15
Assemble and Install Cover . . . . . . . . . . 10-18
Camshaft
Remove . . . . . . . . . . . . . . . . . . . . . . . 10-19
Disassemble and Inspect . . . . . . . . . . . . 10-21
Assemble . . . . . . . . . . . . . . . . . . . . . . 10-25
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
Group 15Cylinder Head, Valves, and Manifolds
Essential Tools . . . . . . . . . . . . . . . . . . . . . 15-1
Page
Exhaust Manifold
Remove, Repair, and Install . . . . . . . . . . . 15-2
Intake Manifold
Remove, Repair, and Install . . . . . . . . . . . 15-4
Cylinder Head
Remove . . . . . . . . . . . . . . . . . . . . . . . . 15-5
Disassemble . . . . . . . . . . . . . . . . . . . . . 15-6
Assemble . . . . . . . . . . . . . . . . . . . . . . 15-14
Install . . . . . . . . . . . . . . . . . . . . . . . . . 15-17
Group 20Flywheel
Flywheel Housing and Flywheel
Remove . . . . . . . . . . . . . . . . . . . . . . . . 20-1
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . 20-3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . 20-4
Group 25Connecting Rods and Pistons
Other Materials . . . . . . . . . . . . . . . . . . . . . 25-1
Measure Side Play . . . . . . . . . . . . . . . . . . . 25-2
Measure Bearing Clearance . . . . . . . . . . . . . 25-3
Pistons and Connecting Rods
Remove . . . . . . . . . . . . . . . . . . . . . . . . 25-4
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . 25-6
Deglaze . . . . . . . . . . . . . . . . . . . . . . . . 25-14
Rebore Cylinder Block . . . . . . . . . . . . . . 25-16
Assemble . . . . . . . . . . . . . . . . . . . . . . 25-17
Install . . . . . . . . . . . . . . . . . . . . . . . . . 25-19
Group 30Crankshaft and Main Bearings
Other Materials . . . . . . . . . . . . . . . . . . . . . 30-1
Measure Crankshaft End Play . . . . . . . . . . . 30-2
Continued on next page
COPYRIGHT 1989
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual
All information, illustrations and specifications in this manual are based on
the latest information available at the time of publication. The right is
reserved to make changes at any time without notice.
CTM3-19-03JAN90
Contents
CTM3 (03JAN90) i 3TN/4TN Series Yanmar Engines
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Balancer Assembly4TN82/84
Remove . . . . . . . . . . . . . . . . . . . . . . . . 30-2
Disassemble and Inspect . . . . . . . . . . . . . 30-3
Assemble and Install . . . . . . . . . . . . . . . . 30-4
Remove and Install Crankcase Extension
Housing . . . . . . . . . . . . . . . . . . . . . . . 30-5
Measure Crankshaft Bearing Clearance . . . . . 30-6
Crankshaft Oil Seal
Remove . . . . . . . . . . . . . . . . . . . . . . . . 30-9
Install . . . . . . . . . . . . . . . . . . . . . . . . . 30-10
Crankshaft
Remove . . . . . . . . . . . . . . . . . . . . . . . 30-12
Assemble . . . . . . . . . . . . . . . . . . . . . . 30-17
Install . . . . . . . . . . . . . . . . . . . . . . . . . 30-17
Group 35Gear Housing
Other Material . . . . . . . . . . . . . . . . . . . . . . 35-1
Timing Gear Cover
Remove . . . . . . . . . . . . . . . . . . . . . . . . 35-2
Install . . . . . . . . . . . . . . . . . . . . . . . . . . 35-4
Timing Gears (Early 3TNA72UJ)
Remove and Inspect . . . . . . . . . . . . . . . . 35-6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . 35-7
Timing Gears (3TN66, Later 3TNA72)
Remove and Inspect . . . . . . . . . . . . . . . . 35-9
Install . . . . . . . . . . . . . . . . . . . . . . . . . 35-11
Timing Gears (All Except 3TN66/3TNA72
Remove and Inspect . . . . . . . . . . . . . . . 35-13
Install . . . . . . . . . . . . . . . . . . . . . . . . . 35-14
Gear Housing
Remove . . . . . . . . . . . . . . . . . . . . . . . 35-16
Install . . . . . . . . . . . . . . . . . . . . . . . . . 35-18
Group 40Lubrication System
Other Materials . . . . . . . . . . . . . . . . . . . . . 40-1
Remove and Install Oil Pump . . . . . . . . . . . . 40-2
Oil Pump (Early 3TNA72UJ)
Remove . . . . . . . . . . . . . . . . . . . . . . . . 40-3
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . 40-8
Install . . . . . . . . . . . . . . . . . . . . . . . . . 40-11
Oil Pressure Regulating Valve (Early
3TNA72UJ)
Remove . . . . . . . . . . . . . . . . . . . . . . . 40-18
Install . . . . . . . . . . . . . . . . . . . . . . . . . 40-20
Page
Oil Pump (All Engines Except Early
3TNA72UJ)
Assemble and Install . . . . . . . . . . . . . . . 40-24
Oil Pressure Regulating Valve . . . . . . . . . . 40-25
Remove, Inspect and Install Oil Cooler
(3TN84UJ) . . . . . . . . . . . . . . . . . . . . . . 40-28
Engine Oil Cooler Leak Test . . . . . . . . . . . 40-29
Remove/Inspect/Install Oil Pressure
Control Valve . . . . . . . . . . . . . . . . . . . . 40-29
4TN100RJF Lubrication System
Remove and Inspect Oil Pump . . . . . . . . 40-30
Assemble and Install Oil Pump . . . . . . . . 40-31
Remove and Inspect Oil Cooler . . . . . . . . 40-32
Assemble and Install Oil Cooler . . . . . . . . 40-32
Inspect Oil Cooler By-Pass Valve . . . . . . 40-33
Inspect Oil Pressure Control Valve . . . . . . 40-33
Inspect Piston Cooling Nozzles . . . . . . . . 40-34
Group 45Cooling System
Essential Tools . . . . . . . . . . . . . . . . . . . . . 45-1
Thermostat and Housing
Remove . . . . . . . . . . . . . . . . . . . . . . . . 45-2
Install . . . . . . . . . . . . . . . . . . . . . . . . . . 45-4
Water Pump
Remove . . . . . . . . . . . . . . . . . . . . . . . . 45-7
Disassemble . . . . . . . . . . . . . . . . . . . . . 45-9
Assemble . . . . . . . . . . . . . . . . . . . . . . 45-13
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-21
Group 50Fuel Injection Pump, Camshaft, and
Nozzles
Essential Tools . . . . . . . . . . . . . . . . . . . . . 50-1
Other Materials . . . . . . . . . . . . . . . . . . . . . 50-2
Fuel Injection Pump (3TN66, 3TNA72)
Remove . . . . . . . . . . . . . . . . . . . . . . . . 50-3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . 50-5
Fuel Injection Pump
(3TN75/3TN78/3TN82/3TN84/4TN78/4TN82/4 . . .
Remove . . . . . . . . . . . . . . . . . . . . . . . . 50-8
Install . . . . . . . . . . . . . . . . . . . . . . . . . 50-10
Fuel Injection Pump (4TN100RJF)
Remove . . . . . . . . . . . . . . . . . . . . . . . 50-12
Install . . . . . . . . . . . . . . . . . . . . . . . . . 50-13
Continued on next page
Contents
CTM3 (03JAN90) ii 3TN/4TN Series Yanmar Engines
010897
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Fuel Injection Pump Camshaft
Remove (Early 3TNA72UJ) . . . . . . . . . . . 50-14
Remove (3TN66 and Later 3TNA72) . . . . 50-17
Pintle Type Fuel Injection Nozzle
Operation and Application . . . . . . . . . . . . 50-24
Remove . . . . . . . . . . . . . . . . . . . . . . . 50-25
Test . . . . . . . . . . . . . . . . . . . . . . . . . . 50-27
Disassemble . . . . . . . . . . . . . . . . . . . . 50-29
Cross Section . . . . . . . . . . . . . . . . . . . . 50-30
Clean and Inspect . . . . . . . . . . . . . . . . . 50-31
Assemble . . . . . . . . . . . . . . . . . . . . . . 50-31
Install . . . . . . . . . . . . . . . . . . . . . . . . . 50-33
Hole Type Fuel Injection Nozzle
Operation and Application . . . . . . . . . . . . 50-35
Remove . . . . . . . . . . . . . . . . . . . . . . . 50-36
Test . . . . . . . . . . . . . . . . . . . . . . . . . . 50-38
Disassemble . . . . . . . . . . . . . . . . . . . . 50-40
Clean and Inspect . . . . . . . . . . . . . . . . . 50-41
Cross Section View . . . . . . . . . . . . . . . . 50-42
Group 55Fuel Control and Governor Linkage
Other Materials . . . . . . . . . . . . . . . . . . . . . 55-1
Fuel Control and Governor Linkage (Early
3TNA72UJ)
Remove . . . . . . . . . . . . . . . . . . . . . . . . 55-2
Install . . . . . . . . . . . . . . . . . . . . . . . . . . 55-8
Fuel Control & Governor Linkage (3TN66
& Later 3TNA72)
Remove . . . . . . . . . . . . . . . . . . . . . . . 55-13
Disassemble . . . . . . . . . . . . . . . . . . . . 55-15
Assemble . . . . . . . . . . . . . . . . . . . . . . 55-19
Install . . . . . . . . . . . . . . . . . . . . . . . . . 55-21
Fuel Control and Governor Linkage
Service . . . . . . . . . . . . . . . . . . . . . . . . 55-22
Fuel Supply Pump (4TN100RJF)
Group 60Starter
Starter Specifications . . . . . . . . . . . . . . . . . 60-1
Starter Application Chart . . . . . . . . . . . . . . . 60-1
Bench Test Starter (All Engines) . . . . . . . . . . 60-2
Page
Nippon Denso 1.0 kW Starter
Disassemble and Service . . . . . . . . . . . . . 60-3
Assemble . . . . . . . . . . . . . . . . . . . . . . . 60-9
Hitachi 0.8 kW
Disassemble and Service . . . . . . . . . . . . 60-15
Assemble . . . . . . . . . . . . . . . . . . . . . . 60-19
Nippon Denso 1.4 kW Starter
Disassemble and Service . . . . . . . . . . . . 60-20
Service Gear Train . . . . . . . . . . . . . . . . 60-24
Assemble . . . . . . . . . . . . . . . . . . . . . . 60-26
Group 65Alternator
Specifications . . . . . . . . . . . . . . . . . . . . . . 65-1
Nippon Denso Alternator
Replace Voltage Regulator . . . . . . . . . . . . 65-2
Disassemble . . . . . . . . . . . . . . . . . . . . . 65-3
Test Rotor . . . . . . . . . . . . . . . . . . . . . . . 65-4
Test Stator and Rectifier . . . . . . . . . . . . . 65-6
Assemble . . . . . . . . . . . . . . . . . . . . . . 65-10
Service 20A Kokosan Alternator . . . . . . . . . 65-13
Hitachi 24V/25A Alternator
Replace Voltage Regulator . . . . . . . . . . . 65-16
Disassemble . . . . . . . . . . . . . . . . . . . . 65-18
Test Rotor . . . . . . . . . . . . . . . . . . . . . . 65-19
Test Stator and Rectifier . . . . . . . . . . . . 65-21
Assemble . . . . . . . . . . . . . . . . . . . . . . 65-24

Contents
CTM3 (03JAN90) iii 3TN/4TN Series Yanmar Engines
010897
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Contents
CTM3 (03JAN90) iv 3TN/4TN Series Yanmar Engines
010897
PN=353
INTRODUCTION
This manual is part of a total service support program.
FOS MANUALSREFERENCE
TECHNICAL MANUALSMACHINE SERVICE
COMPONENT MANUALSCOMPONENT SERVICE
Fundamentals of Service (FOS) Manuals cover basic
theory of operation, fundamentals of troubleshooting,
general maintenance, and basic types of failures and
their causes. FOS Manuals are for training new
personnel and for reference by experienced technicians.
Technical Manuals are concise service guides for specific
machines. Technical manuals are on-the-job guides
containing only the vital information needed by an
experienced service technician.
Component Technical Manuals are concise service
guides for specific components. Component Technical
Manuals are written as stand alone manuals covering
multiple machine applications.
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O53,INTRO2 -19-03JUL85
Group 05
Introduction
CTM3 (03JAN90) 05-1 3TN/4TN Series Yanmar Engines
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FEATURES OF THIS TECHNICAL MANUAL
John Deere ILLUSTRUCTION format emphasizing
illustrations and concise instructions in easy-to-use
modules.
Emphasis on diagnosis, analysis, and testing so you can
understand the problem and correct it.
Diagnostic information presented with the most logical
and easiest to isolate problems first to help you identify
the majority of routine failures quickly.
Step-by-step instructions for teardown and assembly.
Summary listing at the beginning of each group of all
applicable specifications, wear tolerances, torque values,
essential tools, and materials needed to do the job.
An emphasis throughout on safetyso you do the job
right without getting hurt.
This technical manual was planned and written for
youan experienced service technician. Keep it in a
permanent binder in the shop where it is handy. Refer to
it when you need to know correct service procedures or
specifications.
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ABOUT THIS MANUAL
This Component Technical Manual (CTM-3) covers
the recommended repair procedures for all Yanmar
Diesel Engines removed from the machine.
Some components may be serviced without removing
the engine from the machine. You may want to
determine the repair procedure before you remove
the engine.
The repair procedure for the Yanmar diesel engines
in this manual are similar. The 3TNA72UJ engine is
shown except where differences are noted by engine
model number. Refer to Engine Application Chart in
this group to identify product-model/engine type-model
relationship.
Read each module completely before performing
service to check for differences in procedure or
specifications. Follow only the steps that apply to the
engine model number you are working on. If only one
step is given, that step applies to all Yanmar diesel
engines in this manual.
O53,INTRO3 -19-07OCT85
M21,TM305,1 -19-21APR86
Introduction/About This Manual
010897
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2
ENGINE SERIAL NUMBER PLATE
The engine serial number plate is located on the rocker
arm cover.
Refer to the engine model designation on your engines
serial number plate to identify repair information covered
in the Component Technical Manual.
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M21,TM305,2 -19-21APR86
Introduction/Engine Serial Number Plate
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ENGINE APPLICATION CHART
Refer to the engine application chart to identify
product-model/engine type-model relationship.
CONSUMER PRODUCTS
Lawn and Garden Tractors
Machine No. Engine Model
330 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TN66UJ
332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TN66UJ
430 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNA72UJ*
Compact Utility Tractors
655 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TN66UJ
670 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNA72UJX
755 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNA72UJ
770 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNA82RJX
855 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TN75RJ
870 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TN84RJX
955 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TN84RJ
970 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4TN82RJX
1070 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4TN84RJX
Front Mowers
F915 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TN66UJ
F935 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNA72UJ
Skid Steer Loaders
375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TN66E-SP
575 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TN82E-SP
675 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4TN82E-SP
INDUSTRIAL
Loaders
84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4TN1004JF
Excavators
15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNA72UJB
25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TN78RJB
30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TN82RJB
50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4TN78TRJB
Golf and Turf
756 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TNA72UJ
856 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3TN75RJ
3325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4TN82RJ
*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.
M21,TM305,4 -19-27AUG87
Introduction/Engine Application Chart
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ENGLISH TORQUE SPECIFICATIONS
NOTE: Wrench torque tolerance is 20%.
Bolt Three Six
Diameter Plain Head* Radial Dashes* Radial Dashes*
lb-ft Nm lb-ft Nm lb-ft Nm
1/4 in. 6 8 9 12 12 16
5/16 in. 10 14 18 24 25 34
3/8 in. 20 27 30 41 45 61
7/16 in. 30 41 50 68 70 95
1/2 in. 45 61 75 101 110 149
9/16 in. 70 95 110 150 155 210
5/8 in. 95 128 155 210 215 290
3/4 in. 165 225 270 365 385 520
7/8 in. 170 230 435 590 620 840
1 in. 255 345 660 895 930 1260
Torque figures indicated above and in the Specification Sections of this manual are valid for non-greased or
non-oiled threads and heads unless otherwise specified. Therefore, do not grease or oil bolts or cap screws
unless otherwise specified in this manual.
* Torque value for bolts and cap screws are identified by their head
markings.
S11,2000,DD -19-11JUL85
Introduction/Engine Torque Specifications
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METRIC TORQUE SPECIFICATIONS
NOTE: Wrench torque tolerance is 20%.
Bolt Property Class 8.8* Property Class 10.9*
Diameter lb-ft Nm lb-ft Nm
M5 5 6 7 9
M6 8 10 11 15
M8 18 25 26 35
M10 37 50 52 70
M12 66 90 92 125
M16 166 225 229 310
M20 321 435 450 610
M24 554 750 775 1050
Torque figure indicated above and in the Specification Sections of this manual are valid for non-greased or
non-oiled threads and heads unless otherwise specified. Therefore, do not grease or oil bolts or cap screws
unless otherwise specified in this manual.
* Torque value for bolts and cap screws are identified by their head
markings.
S11,2000,DE -19-11JUL85
Introduction/Metric Torque Specifications
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ENGINE: 3TN66
GROUP 10Valve Train and Camshaft
Item Standard mm (inches) Wear Limit mm (in.)
Valve Clearance . . . . . . . . . . . . . . . . . 0.2 (0.008)
Rocker Arm
Shaft O.D. . . . . . . . . . . . . . . . . . . . . 9.979.99 (0.39250.3933) . . . . . . . . . . . . . . . . . . 9.95 (0.392)
Shaft Support I.D. . . . . . . . . . . . . . . . 10.010.02 (0.39370.3945) . . . . . . . . . . . . . . . . . 10.1 (0.398)
Arm I.D. . . . . . . . . . . . . . . . . . . . . . 10.010.02 (0.39370.3945) . . . . . . . . . . . . . . . . . 10.1 (0.398)
Shaft Clearance . . . . . . . . . . . . . . . . 0.010.05 (0.00040.0020) . . . . . . . . . . . . . . . . . . 0.13 (0.005)
Rocker Arm Assembly Cap Screw
and Nut Torque . . . . . . . . . . . . . . . . 26 Nm (226 lb-in.)
Rocker Arm Cover Nut Torque . . . . . . 18 Nm (160 lb-in.)
Push Rod
Maximum T.I.R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.075 (0.003)
Length . . . . . . . . . . . . . . . . . . . . . . . 114115 (4.4884.528) . . . . . . . . . . . . . . . . . . . . . . 114 (4.49)
Diameter . . . . . . . . . . . . . . . . . . . . . 5 (0.197)
Cam Follower
O.D. . . . . . . . . . . . . . . . . . . . . . . . . 17.9517.968 (0.70670.7074) . . . . . . . . . . . . . . . 17.93 (0.706)
Bore I.D. . . . . . . . . . . . . . . . . . . . . . 18.0018.018 (0.70870.7094) . . . . . . . . . . . . . . . 18.05 (0.711)
Bore Clearance . . . . . . . . . . . . . . . . . 0.0320.068 (0.00130.0027)
Camshaft
End Play . . . . . . . . . . . . . . . . . . . . . 0.050.15 (0.0020.006) . . . . . . . . . . . . . . . . . . . . . . 0.4 (0.16)
Maximum Gear Backlash Between
Each Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 (0.008)
End Journals O.D. . . . . . . . . . . . . . . . 35.9435.96 (1.4151.416) . . . . . . . . . . . . . . . . . . 35.85 (1.411)
Intermediate Journals O.D. . . . . . . . . . 35.9135.94 (1.4141.415) . . . . . . . . . . . . . . . . . . 35.81 (1.410)
Lobe Height . . . . . . . . . . . . . . . . . . . 29.9730.03 (1.1801.182) . . . . . . . . . . . . . . . . . . 29.7 (1.169)
Bushing I.D.
(Gearcase Side) . . . . . . . . . . . . . . . 36.0036.065 (1.4171.420) . . . . . . . . . . . . . . . . . 36.1 (1.421)
Intermediate and Flywheel
End Bores I.D. . . . . . . . . . . . . . . . . 36.0036.025 (1.4171.418) . . . . . . . . . . . . . . . . . 36.1 (1.421)
End Journal Clearance . . . . . . . . . . . . 0.0400.125 (0.00160.0049) . . . . . . . . . . . . . . . . 0.18 (0.007)
Intermediate Journal Clearance . . . . . . 0.0650.115 (0.00260.0045) . . . . . . . . . . . . . . . . 0.18 (0.007)
Attaching Cap Screw Torque . . . . . . . . 11 Nm (96 lb-in.)
Gear Housing Cover Cap Screw Torque 9 Nm (78 lb-in.)
Crankshaft Pulley Cap Screw Torque . . 115 Nm (85 lb-ft)
GROUP 15Cylinder Head, Valves, and Manifolds
Item Standard mm (in.) Wear Limit mm (in.)
Manifold
Exhaust Manifold Cap Screw Torque . . 11 Nm (96 lb-in.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake Manifold Cap Screw Torque . . . 11 Nm (96 lb-in.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5M4,TM306,1 -19-28AUG87
Group 06
Repair Specifications
010897
PN=10
06
1
ENGINE: 3TN66
Cylinder Head
Valve Recession Intake . . . . . . . . . . . 0.4 (0.016) . . . . . . . . . . . . . . . . 0.50 (0.020)
Exhaust . . . . . . . . . . 0.85 (0.034) . . . . . . . . . . . . . . . . 0.50 (0.020)
Valve Spring Free Length (Approx.) . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 (1.102)
Valve Spring Test Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 (0.59)
@ Test Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 N (28 lb)
Cylinder Head
Valve Stem O.D.
(Intake) . . . . . . . . . . . . . . . . . . . . 5.4605.475 (0.2150.216) . . . . 5.40 (0.213)
(Exhaust) . . . . . . . . . . . . . . . . . . . 5.4455.460 (0.2140.215) . . . . 5.40 (0.213)
Valve Guide I.D. . . . . . . . . . . . . . . . . 5.55.515 (0.21650.217) . . . . . 5.58 (0.220)
Valve Guide-to-Valve Stem Clearance:
(Replace) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 (0.008)
(Knurl) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.150.20 (0.0060.008)
Valve Seat Width
Intake . . . . . . . . . . . . . . . . . . . . . 1.15 (0.045) . . . . . . . . . . . . . . . . 1.65 (0.065)
Exhaust . . . . . . . . . . . . . . . . . . . . 1.41 (0.056) . . . . . . . . . . . . . . . . 1.91 (0.075)
Valve Seat Angle
Intake . . . . . . . . . . . . . . . . . . . . . 120
Exhaust . . . . . . . . . . . . . . . . . . . . 90
Cylinder Head Flatness
(Maximum Distortion) . . . . . . . . . . . . Less than 0.5 (0.002) . . . . . . . . . 0.15 (0.006)
Mill Cylinder Head No More Than . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 (0.008)
Valve Guide Height . . . . . . . . . . . . . . 7 (0.276)
Cylinder Head Cap Screw Torque
In Sequence (Lubricated) . . . . . . . . 34 Nm (25 lb-ft)
GROUP 20Flywheel
Stub Shaft
Maximum T.I.R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 (0.008)
Flatness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 (0.002)
Attaching Cap Screw Torque . . . . . . . 59 Nm (44 lb-ft)
Flywheel
Flatness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 (0.002)
Flywheel Housing
Mounting Plate or Housing
Cap Screw Torque . . . . . . . . . . . . . . 49 Nm (36 lb-ft)
Starter-to-Mounting Plate
Cap Screw Torque . . . . . . . . . . . . . . 49 Nm (36 lb-ft)
Flywheel Housing or Shield
Cap Screw or Nut Torque
M10 . . . . . . . . . . . . . . . . . . . . . . . 49 Nm (36 lb-ft)
M8 . . . . . . . . . . . . . . . . . . . . . . . 26 Nm (226 lb-in.)
M12 Nut . . . . . . . . . . . . . . . . . . . . 88 Nm (65 lb-ft)
5M4,TM306,2 -19-28AUG87
Repair Specifications/Engine
010897
PN=11
06
2
ENGINE: 3TN66
GROUP 25Connecting Rods and Pistons
Connecting Rod
Side Clearance . . . . . . . . . . . . . . . . . 0.20.4 (0.00790.0157) 0.55 (0.0217)
End-Cap Screw Torque . . . . . . . . . . . 23 Nm (200 lb-in.)
Bearing Clearance (Crankpin) . . . . . . . 0.0200.0072 (0.00080.0028) . . 0.15 (0.006)
Bearing Clearance (Piston Pin) . . . . . . 0.0250.047 (0.00100.0019) . . . 0.12 (0.005)
Maximum Twist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08 (0.003)
Journal O.D. . . . . . . . . . . . . . . . . . . 35.9735.98 (1.4161.417) . . . . 35.92 (1.414)
Bearing I.D. (Crankpin) . . . . . . . . . . . 36.0036.042 (1.4171.419) . . . . 36.07 (1.420)
Piston
Ring Groove Clearance
Top Ring . . . . . . . . . . . . . . . . . . . 0.0650.1 (0.00260.0039) . . . . 0.2 (0.08)
Second Ring . . . . . . . . . . . . . . . . . 0.0650.1 (0.00260.0039) . . . . 0.2 (0.08)
Oil Ring . . . . . . . . . . . . . . . . . . . . 0.0650.1 (0.00260.0039) . . . . 0.2 (0.08)
Ring End Gap (1st and Oil) . . . . . . . . 0.150.35 (0.0060.014) . . . . . . 1.5 (0.059)
Ring End Gap (2nd) . . . . . . . . . . . . . 0.250.40 (0.0100.016) . . . . . . 1.5 (0.059)
Piston Pin O.D. . . . . . . . . . . . . . . . . 19.99120.0 (0.7870.7874) . . . . 19.9 (0.786)
Pin Bushing I.D. . . . . . . . . . . . . . . . . 20.02520.038 (0.7880.789) . . . 20.1 (0.791)
Piston Pin Clearance . . . . . . . . . . . . . 00.17 (00.0007) . . . . . . . . . . 0.045 (0.0018)
Pin Bore I.D. . . . . . . . . . . . . . . . . . . 20.00020.008 (0.7870.788) . . . 20.02 (0.788)
Pin Bore Clearance . . . . . . . . . . . . . . 0.0.017 (00.0007) . . . . . . . . . . 0.045 (0.0018)
Piston O.D. . . . . . . . . . . . . . . . . . . . 65.92765.957 (2.5962.597) . . . 65.85 (2.593)
Cylinder Block Cylinder Bore I.D. . . . . . 66.0066.03 (2.5992.600) . . . . 66.20 (2.606)
Maximum Piston Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.33 (0.013)
Cylinder Out-of-Round . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 (0.001)
GROUP 30Crankshaft and Main Bearings
Crankshaft
End Play . . . . . . . . . . . . . . . . . . . . . 0.0950.266 (0.0040.011) . . . . 0.33 (0.013)
Main Bearing Cap Screw Torque . . . . . 54 Nm (40 lb-ft)
Main Bearing Clearance . . . . . . . . . . . 0.0200.072 (0.00080.0028) . . . 0.15 (0.0059)
Oil Seal Case Cap Screw Torque
Seal Case to Block . . . . . . . . . . . . 11 Nm (96 lb-in.)
Oil Pan to Seal Case . . . . . . . . . . . 9 Nm (78 lb-in.)
Main Bearing Journal O.D. . . . . . . . . . 39.9739.98 (1.57361.5740) . . . 39.9 (1.572)
Main Bearing I.D. . . . . . . . . . . . . . . . 40.0040.042 (1.5751.577) . . . . 40.07 (1.578)
5M4,TM306,3 -19-28AUG87
010897
PN=12
06
3
ENGINE: 3TN66
GROUP 35Gear Housing
Gear Housing Cap Screw Torque . . . . . . 9 Nm (78 lb-in.)
Crankshaft Pulley Cap Screw Torque . . . 115 Nm (85 lb-ft)
Timing Gear Backlash
Fuel Injection Pump . . . . . . . . . . . . . 0.040.12 (0.00160.0047) . . . . 0.20 (0.008)
Idler . . . . . . . . . . . . . . . . . . . . . . . . 0.040.12 (0.00160.0047) . . . . 0.20 (0.008)
Camshaft . . . . . . . . . . . . . . . . . . . . . 0.040.12 (0.00160.0047) . . . . 0.20 (0.008)
Crankshaft . . . . . . . . . . . . . . . . . . . . 0.110.19 (0.00430.0075) . . . . 0.20 (0.008)
Oil Pump . . . . . . . . . . . . . . . . . . . . . 0.110.19 (0.00430.0075) . . . . 0.20 (0.008)
Timing Gear
Idler Gear Bushing Diameter . . . . . . . . 20.0020.021 (0.7860.788) . . . . 20.08 (0.791)
Idler Shaft Diameter . . . . . . . . . . . . . 19.95919.980 (0.7860.787) . . . 19.93 (0.785)
Idler Shaft Oil Clearance . . . . . . . . . . 0.020.062 (0.0010.002) . . . . . 0.15 (0.006)
GROUP 49Lubrication System
Oil Pump
Gear Backlash . . . . . . . . . . . . . . . . . 0.110.19 (0.00430.0075) . . . . 0.20 (0.008)
Rotor Recess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 (0.010)
Outer Rotor-to-Pump Body Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 (0.010)
Inner Rotor-to-Outer Rotor Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 (0.010)
Oil Pump Attaching Cap Screw Torque . 25 Nm (18 lb-ft)
Oil Pressure Regulating Valve
Valve Spring Free Length (Approx.) . . . 21.924.5 (0.860.96)
Valve Spring Test Length . . . . . . . . . . 14.7 (0.58)
Oil Pressure Change Per 1 mm
(0.039 in.) of Shim Thickness . . . . . . . 13.8 kPa (2 psi)
Oil Pan
Strainer Tube Attaching
Cap Screw Torque . . . . . . . . . . . . . 11 Nm (96 lb-in.)
Oil Pan-to-Block Cap Screw Torque . . . 11 Nm (96 lb-in.)
Oil Pan-to-Gear Housing
Cover Torque . . . . . . . . . . . . . . . . . 9 Nm (78 lb-in.)
5M4,TM306,4 -19-28AUG87
010897
PN=13
06
4
ENGINE: 3TN66
GROUP 45Cooling System
Item Specification
Thermostat
Begin Opening Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71C (160F)
Fully Open Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85C (184F)
Housing Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Nm (78 lb-in.)
Water Pump
Plate Screws Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Nm (78 lb-in.)
Pulley Cap Screws Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Nm (96 lb-in.)
Attaching Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm (226 lb-in.)
Alternator Belt Deflection . . . . . . . . 13 mm (0.5 in.) at 107 N (24 lb) Force applied midway between pulleys.
GROUP 50Fuel Injection Pump, Camshaft, and
Nozzles
Fuel Injection Pump
Pump Mounting Hardware Torque . . . . 20 Nm (180 lb-in.)
Gear Backlash . . . . . . . . . . . . . . . . . 0.040.12 (0.00160.0047) . . . . 0.2 (0.008)
Gear Attaching Nut Torque . . . . . . . . . 88 Nm (65 lb-ft)
Pump Camshaft Lobe Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.9 (1.217)
Camshaft Bearing Screw Torque . . . . . 20 Nm (180 lb-in.)
Screw Torque . . . . . . . . . . . . . . . . . 20 Nm (180 lb-in.)
Fuel Injection Nozzles
Nozzle Opening Pressure . . . . . . . . . . 11722 480 kPa (1700 70 psi)
Minimum Leakage Time . . . . . . . . . . . 10 Seconds
@ 11032 kPa (1600 psi) Pressure
Retaining Nut-to-Nozzle Body Torque . . 40 Nm (30 lb-ft)
Nozzle-to-Cylinder Head Torque . . . . . 50 Nm (37 lb-ft)
Leak-Off Fitting-to-Nozzle Torque . . . . . 40 Nm (30 lb-ft)
GROUP 55Fuel Control and Governor Linkage
Governor Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.90 (0.311)
Fuel Control Linkage Bore I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15 (0.321)
Sleeve Bore I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.20 (0.323)
Sleeve Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.90 (0.311)
Sleeve Oil Clearance
(Sleeve Bore I.D. Minus Shaft O.D.) . . . . . . . . . . . . . . . . . . . . . . . . . . 0.150 (0.006)
Governor Shaft Clearance
Linkage Bore Minus Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 (0.0071)
GROUP 60Starter
See Starter Specifications in this Group
GROUP 65Alternator
See Alternator Specifications in this Group
5M4,TM306,5 -19-28AUG87
010897
PN=14
06
5
ENGINE: 3TNA72
Valve Clearance . . . . . . . . . . . . . . . . . 0.20 (0.008)
Rocker Arm
Shaft O.D. . . . . . . . . . . . . . . . . . . . . 11.96611.984 (0.4710.472) . . . 11.96 (0.471)
Shaft Support I.D. . . . . . . . . . . . . . . . 12.0012.02 (0.4720.473) . . . . 12.09 (0.476)
Arm I.D. . . . . . . . . . . . . . . . . . . . . . 12.0012.02 (0.4720.473) . . . . 12.09 (0.476)
Shaft Clearance . . . . . . . . . . . . . . . . 0.0160.054 . . . . . . . . . . . . . . . 0.13 (0.005)
Push Rod
Maximum T.I.R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.075 (0.003)
Length . . . . . . . . . . . . . . . . . . . . . . 141142 (5.555.59) . . . . . . . . . 141.0 (5.55)
Diameter . . . . . . . . . . . . . . . . . . . . . 5 (0.197)
Cam Follower
O.D. . . . . . . . . . . . . . . . . . . . . . . . . 20.92720.960 (0.8240.825) . . . 20.93 (0.824)
Bore I.D. . . . . . . . . . . . . . . . . . . . . . 21.021.021 (0.8270.828) . . . . 21.05 (0.829)
Bore Clearance . . . . . . . . . . . . . . . . 0.040.094 (0.00160.0037)
Camshaft
End Play . . . . . . . . . . . . . . . . . . . . . 0.050.15 (0.0020.006) . . . . . . 0.40 (0.016)
Each Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 (0.008)
Journal O.D. (Gearcase Side) . . . . . . . 39.9439.96 (1.5721.573) . . . . 39.85 (1.569)
Journal O.D. (Intermediate) . . . . . . . . . 39.91039.935 (1.5711.572) . . . 39.85 (1.569)
Journal O.D. (Flywheel Side) . . . . . . . 39.9439.96 (1.5721.573) . . . . 40.1 (1.579)
Lobe Height . . . . . . . . . . . . . . . . . . . 33.9534.05 (1.3371.341) . . . . 33.75 (1.329)
Bushing I.D. (Gearcase Side) . . . . . . . 40.040.065 (1.5751.577) . . . . 40.10 (1.579)
Bore I.D. (Intermediate and
Flywheel Side) . . . . . . . . . . . . . . . . 40.040.065 (1.5751.577) . . . . 40.10 (1.579)
End Journal Clearance . . . . . . . . . . . . 0.0400.085 (0.00160.0033) . . . 0.18 (0.007)
Intermediate Journal Clearance . . . . . . 0.0650.115 (0.00260.0045)
Attaching Cap Screw Torque . . . . . . . 11 Nm (96 lb-in.)
Fuel Shut-Off Solenoid Bracket
Cap Screw Torque (Early Units)
Manifold
Exhaust Manifold Cap Scrw Torque . . . 26 Nm (226 lb-in.)
Intake Manifold Cap Screw Torque . . . 11 Nm (96 lb-in.)
5M4,TM306,6 -19-28AUG87
010897
PN=15
06
6
ENGINE: 3TNA72
Cylinder Head
Valve Recession
Intake . . . . . . . . . . . . . . . . . . . . . 0.50 (0.020)
Exhaust . . . . . . . . . . . . . . . . . . . . 0.85 (0.033)
Valve Spring Free Length (Approx.) . . . 37.4 (1.472)
Valve Spring Test Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.5 (0.87)
Valve Stem O.D. . . . . . . . . . . . . . . . . 6.9456.960 (0.2730.274) . . . . 6.90 (0.272)
Valve Guide I.D. . . . . . . . . . . . . . . . . 7.0057.020 (0.27580.2764) . . . 6.90 (0.272)
(Replace) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 (0.008)
(Knurl) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.150.20 (0.0060.008)
Valve Seat Width
Intake . . . . . . . . . . . . . . . . . . . . . 1.44 (0.057) . . . . . . . . . . . . . . . . 1.98 (0.078)
Exhaust . . . . . . . . . . . . . . . . . . . . 1.77 (0.070) . . . . . . . . . . . . . . . . 2.27 (0.089)
Valve Seat Angle
Intake . . . . . . . . . . . . . . . . . . . . . 120
Exhaust . . . . . . . . . . . . . . . . . . . . 90
Cylinder Head Flatness
(Maximum Distortion) . . . . . . . . . . . . Less than 0.5 (0.002) . . . . . . . . . 0.15 (0.006)
Valve Guide Height . . . . . . . . . . . . . . 9.00 (0.354)
In Sequence (Lubricated) . . . . . . . . . 61 Nm (45 lb-ft)
GROUP 20Flywheel
Stub Shaft (If Equipped)
Maximum T.I.R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 (0.008)
Flatness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 (0.002)
Attaching Cap Screw Torque . . . . . . 59 Nm (44 lb-ft)
Flywheel
Flatness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 (0.002)
Attaching Cap Screw Torque . . . . . . 83 Nm (61 lb-ft)
Flywheel Housing
Cap Screw Torque . . . . . . . . . . . . . 49 Nm (36 lb-ft)
M10 . . . . . . . . . . . . . . . . . . . . . . . 49 Nm (36 lb-ft)
M8 . . . . . . . . . . . . . . . . . . . . . . . 26 Nm (226 lb-in.)
M12 Nut . . . . . . . . . . . . . . . . . . . . 88 Nm (65 lb-ft)
5M4,TM306,7 -19-28AUG87
010897
PN=16
06
7
ENGINE: 3TNA72
Connecting Rod
Side Clearance . . . . . . . . . . . . . . . . . 0.20.4 (0.00790.0158) . . . . . . 0.55 (0.022)
End-Cap Screw Torque . . . . . . . . . . . 23 Nm (200 lb-in.)
Bearing Clearance (Crankpin) . . . . . . . 0.0200.072 (0.00080.0028) . . . 0.15 (0.006)
Maximum Twist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08 (0.003)
Minimum Journal O.D. (Crankpin) . . . . 39.9739.98 (1.57361.574) . . . . 39.92 (1.572)
Piston
All Rings . . . . . . . . . . . . . . . . . . . 0.0750.11 (0.00300.0043) . . . . 0.20 (0.008)
Ring End Gap (1st) . . . . . . . . . . . . . . 0.10.25 (0.0040.010) . . . . . . . 1.5 (0.059)
Rind End Gap (2nd) . . . . . . . . . . . . . 0.250.80 (0.0100.016) . . . . . . 1.5 (0.059)
Ring End Gap (oil) . . . . . . . . . . . . . . 0.150.35 (0.0060.014) . . . . . . 1.5 (0.059)
Pin O.D. . . . . . . . . . . . . . . . . . . . . . 20.99121.0 (0.8260.827) . . . . 20.98 (0.826)
Pin Bushing I.D. . . . . . . . . . . . . . . . . 21.02521.038 (.082780.8282) . 21.10 (0.831)
Pin Bushing Clearance . . . . . . . . . . . . 0.0250.047 (0.00100.0019) . . . 0.11 (0.004)
Pin Bore I.D. . . . . . . . . . . . . . . . . . . 21.021.009 (0.82680.8271) . . . 21.02 (0.828)
Pin Bore Clearance . . . . . . . . . . . . . . 00.018 (00.0007) . . . . . . . . . 0.045 (0.0018)
Piston O.D. . . . . . . . . . . . . . . . . . . . 71.92271.952 (2.8322.833) . . . 71.81 (2.827)
Cylinder Block
Cylinder Bore I.D. . . . . . . . . . . . . . . . 72.072.03 (2.8352.836) . . . . . 72.20 (2.843)
Crankshaft
End Play . . . . . . . . . . . . . . . . . . . . . 0.090.271 (0.0040.011) . . . . . 0.33 (0.013)
Main Bearing Clearance . . . . . . . . . . . 0.0200.072 (0.0080.0028) . . . . 0.15 (0.006)
Oil Pan to Seal Case . . . . . . . . . . . 9 Nm (78 lb-in.) . . . . . . . . . . . . . 9 Nm (78 lb-in.)
Main Bearing Journal O.D. . . . . . . . . . 43.9743.98 (1.7311.732) . . . . 43.92 (1.729)
Main Bearing I.D. . . . . . . . . . . . . . . . 44.044.042 (1.7321.734) . . . . 44.07 (1.735)
5M4,TM306,8 -19-28AUG87
010897
PN=17
06
8
ENGINE: 3TNA72
Idler . . . . . . . . . . . . . . . . . . . . . . . . 0.040.12 (0.00160.0047) . . . . 0.20 (0.008)
Camshaft . . . . . . . . . . . . . . . . . . . . . 0.040.12 (0.00160.0047) . . . . 0.20 (0.008)
Crankshaft . . . . . . . . . . . . . . . . . . . . 0.110.19 (0.00430.0075) . . . . 0.20 (0.008)
Oil Pump . . . . . . . . . . . . . . . . . . . . . 0.110.19 (0.00430.0075) . . . . 0.20 (0.008)
Timing Gear Wear Specifications
Idler Shaft Oil Clearance . . . . . . . . . . 0.020.062 (0.0010.002) . . . . . 0.15 (0.006)
Oil Pump (Later 3TNA72)
Gear Backlash
3TNA72 . . . . . . . . . . . . . . . . . . . . 0.110.19 (0.0040.0075) . . . . . 0.25 (0.010)
3TNA72-UJB Only . . . . . . . . . . . . . . . 0.110.19 (0.00430.0075) . . . . 0.20 (0.008)
Rotor Recess, Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 (0.010)
Outer Rotor-to-Pump Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 (0.010)
Inner Rotor-to-Outer Rotor Clearance
3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 (0.010)
3TNA72-UJB Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 (0.006)
Oil Pump (Early 3TNA72)
Gear Backlash . . . . . . . . . . . . . . . . . 0.110.19 (0.0040.0075) . . . . . 0.25 (0.010)
Rotor Recess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 (0.010)
Rotor Shaft Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.65 (0.498)
Shaft Bore Diameter Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.80 (0.504)
Shaft-to-Bore Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 (0.004)
Oil Pump Attaching Cap Screw Torque . 9 Nm (78 lb-in.)
5M4,TM306,9 -19-28AUG87
010897
PN=18
06
9
ENGINE: 3TNA72
Item Specification
Oil Pressure Regulating Valve (Later 3TNA72)
Valve Spring Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.548.5 mm (1.711.91 in.)
Valve Spring Test Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.5 mm (1.08 in.)
@ 20.5 3.1 N (4.6 0.7 lb) Force
(0.039 in.) of Shim Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9 kPa (1.6 psi)
Oil Pressure Regulating Valve (3TNA72-UJB Only)
Valve Spring Free Length (Approx.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 mm (1.81 in.)
@ 27.2 N (6.1 lb) Force
Oil Pressure Regulating Valve (Early 3TNA72)
Valve Spring Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.540.5 mm (1.551.59 in.)
Valve Spring Test Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 mm (1.18 in.)
@ 29.4 3.1 N (6.6 0.7 lb) Force
Oil Pressure Change per 1 mm
(0.039 in.) of Shim Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 kPa (4 psi)
Oil Pan
Strainer Tube Attaching Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Nm (96 lb-in.)
Oil Pan-to-Block Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Nm (96 lb-in.)
Oil Pan-to-Gear Housing Cover Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Nm (78 lb-in.)
Item Specification
Thermostat
Housing Cover Cap Screw Torque 3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm (180 lb-in.)
3TNA72-UJB (Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm (226 lb-in.)
Water Pump
Plate Screws Torque
3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Nm (78 lb-in.)
3TNA72-UJB (Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Nm (96 lb-in.)
Alternator Belt Deflection . . . . . . . . . 13 mm (0.5 in.) @ 107 N (24 lb) Force applied midway between pulleys
5M4,TM306,10 -19-28AUG87
010897
PN=19
06
10
ENGINE: 3TNA72
Nozzles
Fuel Injection Pump
Pump Mounting Hardware Torque
3TNA72 . . . . . . . . . . . . . . . . . . . . 20 Nm (180 lb-in.)
3TNA72-UJB (Only) . . . . . . . . . . . . 27 Nm (20 lb-ft)
Maximum Gear Backlash . . . . . . . . . . 0.040.12 (0.00160.0047) . . . . 0.2 (0.008)
Pump Camshaft Minimum Lobe Height . . . . . . . . . . . . . . . . . . . . . . . . . 30.9 (1.217)
Camshaft Bearing Retaining Screw Torque
3TNA72 . . . . . . . . . . . . . . . . . . . . 20 Nm (180 lb-in.)
3TNA72-UJB (Only) . . . . . . . . . . . . 11 Nm (96 lb-in.)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . @ 11032 kPa (1600 psi) Pressure
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (1600 psi) Pressure
Retaining Nut-to-Nozzle Body Torque
3TNA72 . . . . . . . . . . . . . . . . . . . . 40 Nm (28 lb-ft)
Nozzle-to-Cylinder Head Attaching Torque
3TNA72 . . . . . . . . . . . . . . . . . . . . 50 Nm (37 lb-ft)
Fuel Leak-Off Fitting-to-Nozzle Torque
3TNA72 . . . . . . . . . . . . . . . . . . . . 40 Nm (30 lb-ft)
3TNA72-UJB (Only) . . . . . . . . . . . . 15 Nm (130 lb-in.)
5M4,TM306,11 -19-28AUG87
010897
PN=20
06
11
ENGINE: 3TNA72
(Later 3TNA72)
(Fuel Control Linkage Bore
Minus Shaft O.D.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 (0.007)
Sleeve Bore I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.20 (0.323)
Sleeve Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.90 (0.311)
Sleeve Oil Clearance
(Sleeve Bore I.D. Minus Shaft O.D.) . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 (0.006)
(Early 3TNA72)
Bore I.D. Minus Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 (0.007)
Sleeve Bore I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20 (0.362)
Inner Rotor Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.90 (0.350)
Inner Rotor Shaft Clearance
(Sleeve Bore I.D. Minus Shaft O.D.) . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006)
Governor Shaft Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Nm (36 lb-ft)
Governor Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Nm (78 lb-in.)
GROUP 60Starter
GROUP 65Alternator
TM4,TM306,12 -19-28AUG87
010897
PN=21
06
12
ENGINE: 3TN75
Valve Clearance . . . . . . . . . . . . . . . . . 0.20 (0.008)
Rocker Arm
Shaft O.D. . . . . . . . . . . . . . . . . . . . . 15.96615.984 (0.62860.6293) . 15.955 (0.628)
Shaft Support I.D. . . . . . . . . . . . . . . . 16.016.02 (0.6300.631) . . . . . 16.09 (0.633)
Arm I.D. . . . . . . . . . . . . . . . . . . . . . 16.016.02 (0.6300.631) . . . . . 16.09 (0.633)
Shaft Clearance . . . . . . . . . . . . . . . . 0.0160.054 90.00060.0021) . . 0.13 (0.005)
Push Rod
Maximum T.I.R. . . . . . . . . . . . . . . . . 0.075 (0.003)
Length . . . . . . . . . . . . . . . . . . . . . . 146.65147.35 (5.7745.801) . . . 146.6 (5.77)
Diameter . . . . . . . . . . . . . . . . . . . . . 8 (0.315)
Cam Follower
O.D. . . . . . . . . . . . . . . . . . . . . . . . . 11.97511.990 (0.4710.472) . . . 11.93 (0.470)
Bore I.D. . . . . . . . . . . . . . . . . . . . . . 12.012.018 (0.4720.473) . . . . 12.05 (0.474)
Bore Clearance . . . . . . . . . . . . . . . . 0.0100.043 (0.00030.0016)
Camshaft
End Play . . . . . . . . . . . . . . . . . . . . . 0.050.20 (0.0020.008) . . . . . . 0.40 (0.016)
Each Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 (0.008)
End Journals O.D. . . . . . . . . . . . . . . 44.92544.950 (1.7691.770) . . . 44.80 (1.764)
Intermediate Journal O.D. . . . . . . . . . . 44.91044.935 (1.7681.769) . . . 44.80 (1.764)
Lobe Height . . . . . . . . . . . . . . . . . . . 38.63538.765 (1.5211.526) . . . 38.40 (1.512)
Bushing I.D. . . . . . . . . . . . . . . . . . . . 44.99045.055 (1.7711.774) . . . 45.10 (1.776)
End Bores I.D. . . . . . . . . . . . . . . . . 45.045.025 (1.7721.773) . . . . 45.10 (1.776)
PTO Journal Clearance . . . . . . . . . . . 0.0400.130 (0.00150.0050) . . . 0.2 (0.0078)
Intermediate Journal Clearance . . . . . . 0.0650.115 (0.00250.0045) . . . 0.2 (0.0078)
Flywheel Journal Clearance . . . . . . . . 0.0500.100 (0.00190.0039) . . . 0.2 (0.0078)
Idler Gear Shaft Cap Screw Torque . . . 26 Nm (226 lb-in.)
Manifold
Exhaust Manifold Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm (226 lb-in.)
Intake Manifold Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm (226 lb-in.)
5M4,TM306,13 -19-28AUG87
010897
PN=22
06
13
ENGINE: 3TN75
Cylinder Head
Intake and Exhaust Valve Recession . . 0.300.59 (0.0120.020) . . . . . . 1.0 (0.039)
Valve Spring Free Length (Approx.) . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.5 (1.63)
Valve Stem O.D. . . . . . . . . . . . . . . . . 6.9456.960 (0.2730.274) . . . . 6.90 (0.272)
(Replace) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 (0.008)
(Knurl) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.150.20 (0.0060.008)
Valve Seat Width
Intake . . . . . . . . . . . . . . . . . . . . . 1.361.53 (0.0540.060) . . . . . . 1.98 (0.078)
Exhaust . . . . . . . . . . . . . . . . . . . . 1.661.87 90.0650.074) . . . . . . 2.27 (0.089)
Valve Seat Angle
Intake . . . . . . . . . . . . . . . . . . . . . 120
Exhaust . . . . . . . . . . . . . . . . . . . . 90
Cylinder Head Flatness . . . . . . . . . . . Less than 0.05 (0.002) . . . . . . . . 0.15 (0.006)
Valve Guide Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.00 (0.472)
In Sequence (Lubricated) . . . . . . . . . . 69 Nm (51 lb-ft)
GROUP 20Flywheel
Maximum T.I.R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 (0.008)
Flatness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 (0.002)
Flywheel
Flatness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 (0.002)
Flywheel Housing
M10 . . . . . . . . . . . . . . . . . . . . . . . 49 Nm (36 lb-ft)
M8 . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm (226 lb-in.)
M12 Nut . . . . . . . . . . . . . . . . . . . . 88 Nm (65 lb-ft)
5M4,TM306,14 -19-28AUG87
010897
PN=23
06
14
ENGINE: 3TN75
Connecting Rod
Side Clearance . . . . . . . . . . . . . . . . . 0.20.4 (0.00790.0158) . . . . . . 0.55 (0.22)
End-Cap Screw Torque . . . . . . . . . . . 39 Nm (29 lb-ft)
Maximum Twist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08 (0.003)
Journal O.D. . . . . . . . . . . . . . . . . . . 42.95242.962 (1.6911.6914) . . 42.91 (1.689)
Piston
Top Ring . . . . . . . . . . . . . . . . . . . 0.0700.105 (0.00280.0041) . . . 0.25 (0.010)
Second Ring . . . . . . . . . . . . . . . . . 0.0350.070 (0.00140.0028) . . . 0.25 (0.010)
Oil Ring . . . . . . . . . . . . . . . . . . . . 0.0300.060 (0.00120.0024) . . . 0.20 (0.008)
Ring End Gap . . . . . . . . . . . . . . . . . 0.20.4 (0.0080.016) . . . . . . . . 1.50 (0.059)
Pin O.D. . . . . . . . . . . . . . . . . . . . . . 22.99123.0 (0.9050.906) . . . . 22.90 (0.902)
Pin Bushing I.D. . . . . . . . . . . . . . . . . 23.02523.038 (0.90650.9070) . 23.10 (0.909)
Pin Bore I.D. . . . . . . . . . . . . . . . . . . 23.023.009 (0.90550.9059) . . . 23.02 (0.906)
Piston O.D. . . . . . . . . . . . . . . . . . . . 74.91374.943 (2.9492.951) . . . 74.81 (2.945)
Cylinder Block
Cylinder Bore I.D. . . . . . . . . . . . . . . . 75.075.03 (2.9532.954) . . . . . 75.20 (2.961)
Crankshaft
End Play . . . . . . . . . . . . . . . . . . . . . 0.090.271 (0.0040.011) . . . . . 0.33 (0.013)
Main Bearing Cap Cap Screw Torque . 78 Nm (57 lb-ft)
Seal Case to Block . . . . . . . . . . . . . 26 Nm (226 lb-in.)
Oil Pan to Seal Case . . . . . . . . . . . . 9 Nm (78 lb-in.)
Main Bearing Journal O.D. . . . . . . . . . 46.95246.962 (1.84851.8489) . 46.91 (1.847)
Main Bearing I.D. . . . . . . . . . . . . . . . 47.047.045 (1.8501.852) . . . . 47.10 (1.854)
5M4,TM306,15 -19-28AUG87
010897
PN=24
06
15
ENGINE: 3TN75
Idler . . . . . . . . . . . . . . . . . . . . . . . . 0.040.12 (0.00160.0047) . . . . 0.20 (0.008)
Camshaft . . . . . . . . . . . . . . . . . . . . . 0.040.12 (0.00160.0047) . . . . 0.20 (0.008)
Crankshaft . . . . . . . . . . . . . . . . . . . . 0.110.19 (0.00430.0075) . . . . 0.20 (0.008)
Oil Pump . . . . . . . . . . . . . . . . . . . . . 0.110.19 (0.00430.0075) . . . . 0.20 (0.008)
Idler Shaft Oil Clearance . . . . . . . . . . 0.0250.075 (0.00090.0029) . . . 0.15 (0.006)
Oil Pump
Gear Backlash . . . . . . . . . . . . . . . . . 0.110.19 (0.00430.0075) . . . . 0.20 (0.0079)
Rotor Recess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.13 (0.005)
Valve Spring Free Length (Approx.) . . . 46.0 (1.81)
@ 20.5 N (4.6 lb) Force
(0.039 in.) of Shim Thickness . . . . . . 15.6 kPa (2.3 psi)
Oil Pan
Oil Pan-to-Gear Housing Cover Torque . 26 Nm (226 lb-in.)
5M4,TM306,16 -19-28AUG87
010897
PN=25
06
16
ENGINE: 3TN75
Item Specification
Thermostat
Housing Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm (180 lb-in.)
Water Pump
Bottom of Pulley Flange-to-Housing Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 mm (0.67 in.)
Distance Top of Impeller is Below Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 mm (0.08 in.)
Alternator Belt Deflection . . . . . . . . . 13 mm (0.5 in.) at 107N (24 lb) Force applied midway between pulleys.
Nozzles
Fuel Injection Pump
Pump Mounting Hardware Torque . . . . 27 Nm (20 lb-ft)
Gear Backlash . . . . . . . . . . . . . . . . . 0.040.12 (0.00160.0047) . . . . 0.2 (0.008)
Nozzle-to-Cylinder Head
Attaching Torque . . . . . . . . . . . . . . . 45 Nm (39 lb-in.)
Fuel Leak-Off
Fitting-to-Nozzle Torque . . . . . . . . . . 15 Nm (130 lb-in.)
GROUP 60Starter
GROUP 65Alternator
5M4,TM306,17 -19-28AUG87
010897
PN=26
06
17
ENGINE: 3TN78 & 4TN78
Valve Clearance . . . . . . . . . . . . . . . . . 0.20 (0.008)
Rocker Arm
Shaft O.D. . . . . . . . . . . . . . . . . . . . . 15.96615.984 (0.62860.6293) . 15.955 (0.628)
Shaft Support I.D. . . . . . . . . . . . . . . . 16.016.02 (0.6300.631) . . . . . 16.09 (0.633)
Arm I.D. . . . . . . . . . . . . . . . . . . . . . 16.016.02 (0.6300.631) . . . . . 16.09 (0.633)
Shaft Clearance . . . . . . . . . . . . . . . . 0.0160.054 90.00060.0021) . . 0.13 (0.005)
Push Rod
Maximum T.I.R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.075 (0.003)
Length . . . . . . . . . . . . . . . . . . . . . . 146.65147.35 (5.7745.801) . . . 146.6 (5.77)
Diameter . . . . . . . . . . . . . . . . . . . . . 8 (0.315)
Cam Follower
O.D. . . . . . . . . . . . . . . . . . . . . . . . . 11.97511.990 (0.4710.472) . . . 11.93 (0.470)
Bore I.D. . . . . . . . . . . . . . . . . . . . . . 12.012.018 (0.4720.473) . . . . 12.05 (0.474)
Bore Clearance . . . . . . . . . . . . . . . . 0.0100.043 (0.00030.0016)
Camshaft
End Play . . . . . . . . . . . . . . . . . . . . . 0.050.20 (0.0020.008) . . . . . . 0.40 (0.016)
Maximum Gear Backlash between
each gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 (0.008)
End Journals O.D. . . . . . . . . . . . . . . 44.92544.950 (1.7691.770) . . . 44.80 (1.764)
Lobe Height . . . . . . . . . . . . . . . . . . . 38.63538.765 (1.5211.526) . . . 38.40 (1.512)
Bushing I.D. . . . . . . . . . . . . . . . . . . . 44.99045.055 (1.7711.774) . . . 45.10 (1.776)
End Bores I.D. . . . . . . . . . . . . . . . . 45.045.025 (1.7721.773) . . . . 45.10 (1.776)
ROUP 15Cylinder Head, Valves, and Manifol ds
Manifold
5M4,TM306,18 -19-28AUG87
010897
PN=27
06
18
Cylinder Head
Valve Spring Free Length (Approx.) . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.5 (1.63)
@ 313 N (70 lb) Force
Valve Stem O.D. . . . . . . . . . . . . . . . . 6.9456.960 (0.2730.274) . . . . 6.90 (0.272)
(Replace) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 (0.008)
(Knurl) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.150.20 (0.0060.008)
Valve Seat Width
Intake . . . . . . . . . . . . . . . . . . . . . 1.361.53 (0.0540.060) . . . . . . 1.98 (0.078)
Exhaust . . . . . . . . . . . . . . . . . . . . 1.661.87 90.0650.074) . . . . . . 2.27 (0.089)
Valve Seat Angle
Intake . . . . . . . . . . . . . . . . . . . . . 120
Exhaust . . . . . . . . . . . . . . . . . . . . 90
Valve Guide Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.00 (0.472)
In Sequence (Lubricated) . . . . . . . . . . 69 Nm (51 lb-ft)
GROUP 20Flywheel
Maximum T.I.R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 (0.008)
Flatness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 (0.002)
Flywheel
Flatness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 (0.002)
Flywheel Housing
Starter-to-mounting Plate
M10 . . . . . . . . . . . . . . . . . . . . . . . 49 Nm (36 lb-ft)
M8 . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm (226 lb-in.)
M12 Nut . . . . . . . . . . . . . . . . . . . . 88 Nm (65 lb-ft)
5M4,TM306,19 -19-28AUG87
010897
PN=28
06
19
Connecting Rod
Side Clearance . . . . . . . . . . . . . . . . . 0.20.4 (0.00790.0158) . . . . . . 0.55 (0.22)
Maximum Twist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08 (0.003)
Journal O.D. . . . . . . . . . . . . . . . . . . 42.95242.962 (1.6911.6914) . . 42.91 (1.689)
Piston
Top Ring . . . . . . . . . . . . . . . . . . . 0.0700.105 (0.00280.0041) . . . 0.25 (0.010)
Second Ring . . . . . . . . . . . . . . . . . 0.0350.070 (0.00140.0028) . . . 0.25 (0.010)
Oil Ring . . . . . . . . . . . . . . . . . . . . 0.0300.060 (0.00120.0024) . . . 0.20 (0.008)
Ring End Gap . . . . . . . . . . . . . . . . . 0.20.4 (0.0080.016) . . . . . . . . 1.50 (0.059)
Pin O.D. . . . . . . . . . . . . . . . . . . . . . 22.99123.0 (0.9050.906) . . . . 22.90 (0.902)
Pin Bushing I.D. . . . . . . . . . . . . . . . . 23.02523.038 (0.90650.9070) . 23.10 (0.909)
Pin Bore I.D. . . . . . . . . . . . . . . . . . . 23.023.009 (0.90550.9059) . . . 23.02 (0.906)
Piston O.D. . . . . . . . . . . . . . . . . . . . 77.89577.925 (3.0673.068) . . . 77.81 (3.063)
Cylinder Block
Cylinder Bore I.D. . . . . . . . . . . . . . . . 78.078.03 (3.0713.072) . . . . . 78.20 (3.079)
Crankshaft
End Play . . . . . . . . . . . . . . . . . . . . . 0.090.271 (0.0040.011) . . . . . 0.33 (0.013)
Main Bearing Cap Cap Screw Torque . 78 Nm (57 lb-ft)
Seal Case to Block . . . . . . . . . . . . . 26 Nm (226 lb-in.)
Oil Pan to Seal Case . . . . . . . . . . . . 9 Nm (78 lb-in.)
Main Bearing I.D. . . . . . . . . . . . . . . . 47.047.045 (1.8501.852) . . . . 47.10 (1.854)
5M4,TM306,20 -19-28AUG87
010897
PN=29
06
20
Idler . . . . . . . . . . . . . . . . . . . . . . . . 0.040.12 (0.00160.0047) . . . . 0.20 (0.008)
Camshaft . . . . . . . . . . . . . . . . . . . . . 0.040.12 (0.00160.0047) . . . . 0.20 (0.008)
Crankshaft . . . . . . . . . . . . . . . . . . . . 0.110.19 (0.00430.0075) . . . . 0.20 (0.008)
Oil Pump . . . . . . . . . . . . . . . . . . . . . 0.110.19 (0.00430.0075) . . . . 0.20 (0.008)
Oil Pump
Gear Backlash . . . . . . . . . . . . . . . . . 0.110.19 (0.00430.0075) . . . . 0.20 (0.0079)
Rotor Recess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.13 (0.005)
Valve Spring Free Length (Approx.)
3TN78 . . . . . . . . . . . . . . . . . . . . . 46.0 (1.81)
4TN78 . . . . . . . . . . . . . . . . . . . . . 48.5 (1.91)
Valve Spring Test Length
3TN78 . . . . . . . . . . . . . . . . . . . . . 24.5 (0.96)
@ 27.2 N (6.1 lb) Force
4TN78 . . . . . . . . . . . . . . . . . . . . . 33 (1.30)
@ 80 N (18 lb) Force
Oil Pan
5M4,TM306,21 -19-28AUG87
010897
PN=30
06
21
Item Specification
Thermostat
Housing Plate Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm (226 lb-in.)
Housing Attaching Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm (226 lb-in.)
Water Pump
Attaching Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Nm (96 lb-in.)
Nozzles
Fuel Injection Pump
Gear Backlash . . . . . . . . . . . . . . . . . 0.040.12 (0.00160.0047) . . . . 0.2 (0.008)
Attaching Torque . . . . . . . . . . . . . . . 4.5 Nm (39 lb-in.)
Fuel Leak-Off
GROUP 60Starter
GROUP 65Alternator
5M4,TM306,22 -19-28AUG87
010897
PN=31
06
22
Valve Clearance . . . . . . . . . . . . . . . . . 0.20 (0.008)
Rocker Arm
Shaft O.D. . . . . . . . . . . . . . . . . . . . . 15.96615.984 (0.62860.6293) . 15.955 (0.628)
Shaft Support I.D. . . . . . . . . . . . . . . . 16.016.02 (0.6300.631) . . . . . 16.09 (0.633)
Arm I.D. . . . . . . . . . . . . . . . . . . . . . 16.016.02 (0.6300.631) . . . . . 16.09 (0.633)
Shaft Clearance . . . . . . . . . . . . . . . . 0.0160.054 90.00060.0021) . . 0.13 (0.005)
Push Rod
Maximum T.I.R. . . . . . . . . . . . . . . . . 0.075 (0.003)
Length . . . . . . . . . . . . . . . . . . . . . . 178.25178.75 (7.0187.037) . . . 178.2 (7.02)
Diameter . . . . . . . . . . . . . . . . . . . . . 8 (0.315)
Cam Follower
O.D. . . . . . . . . . . . . . . . . . . . . . . . . 11.97511.990 (0.4710.472) . . . 11.93 (0.470)
Bore I.D. . . . . . . . . . . . . . . . . . . . . . 12.012.018 (0.4720.473) . . . . 12.05 (0.474)
Bore Clearance . . . . . . . . . . . . . . . . 0.0100.043 (0.00030.0016)
Camshaft
End Play . . . . . . . . . . . . . . . . . . . . . 0.050.20 (0.0020.008) . . . . . . 0.40 (0.016)
each gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 (0.008)
End Journals O.D. . . . . . . . . . . . . . . 44.92544.950 (1.7691.770) . . . 44.80 (1.764)
Lobe Height . . . . . . . . . . . . . . . . . . . 38.63538.765 (1.5211.526) . . . 38.40 (1.512)
Bushing I.D. . . . . . . . . . . . . . . . . . . . 44.99045.055 (1.7711.774) . . . 45.10 (1.776)
End Bores I.D. . . . . . . . . . . . . . . . . 45.045.025 (1.7721.773) . . . . 45.10 (1.776)
Manifold
5M4,TM306,23 -19-28AUG87
010897
PN=32
06
23
Cylinder Head (Continued)
Cylinder Head
Valve Spring Free Length (Approx.) . . . 40 (1.575) . . . . . . . . . . . . . . . . . 39.5 (1.55)
@ 319 N (72 lb) Force
Valve Stem O.D. . . . . . . . . . . . . . . . . 7.9607.975 (0.3130.314) . . . . 7.90 (0.311)
Valve Guide I.D. . . . . . . . . . . . . . . . . 8.0108.030 (0.31540.3160) . . . 8.10 (0.319)
(Replace) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 (0.008)
(Knurl) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.150.20 (0.0060.008)
Valve Seat Width
Intake . . . . . . . . . . . . . . . . . . . . . 1.071.24 (0.0420.049) . . . . . . 1.74 (0.069)
Exhaust . . . . . . . . . . . . . . . . . . . . 1.241.45 (0.0490.057) . . . . . . 1.94 (0.076)
Valve Seat Angle
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
GROUP 20Flywheel
Maximum T.I.R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 (0.008)
Flatness . . . . . . . . . . . . . . . . . . . . . 0.05 (0.002)
Flywheel
Flatness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 (0.002)
Attaching Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Nm (61 lb-ft)
Flywheel Housing
M10 . . . . . . . . . . . . . . . . . . . . . . . 49 Nm (36 lb-ft)
M8 . . . . . . . . . . . . . . . . . . . . . . . 26 Nm (226 lb-in.)
M12 Nut . . . . . . . . . . . . . . . . . . . . 88 Nm (65 lb-ft)
5M4,TM306,24 -19-28AUG87
010897
PN=33
06
24
Connecting Rod
Side Clearance . . . . . . . . . . . . . . . . . 0.20.4 (0.00790.0158) . . . . . . 0.55 (0.022)
Maximum Twist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08 (0.003)
Journal O.D. . . . . . . . . . . . . . . . . . . 47.95247.962 (1.88791.8883) . 47.91 (1.886)
Piston
Top Ring . . . . . . . . . . . . . . . . . . . 0.0750.105 (0.00280.0041) . . . 0.25 (0.010)
Second Ring . . . . . . . . . . . . . . . . . 0.0450.080 (0.00180.0031) . . . 0.25 (0.010)
Oil Ring . . . . . . . . . . . . . . . . . . . . 0.0250.060 (0.00100.0024) . . . 0.20 (0.008)
Ring End Gap (1st Ring) . . . . . . . . . . 0.250.40 (0.0100.016) . . . . . . 1.50 (0.059)
Ring End Gap (2nd and Oil Rings) . . . 0.200.35 (0.0080.014) . . . . . . 1.50 (0.059)
Pin O.D. . . . . . . . . . . . . . . . . . . . . . 25.98726.0 (1.0231.024) . . . . 25.90 (1.020)
Pin Bushing I.D. . . . . . . . . . . . . . . . . 26.02526.038 (1.02461.0251) . 26.10 (0.028)
Pin Bore I.D. . . . . . . . . . . . . . . . . . . 26.026.009 (1.0236l1.0240) . . . . 26.02 (1.024)
Piston O.D. . . . . . . . . . . . . . . . . . . . 81.89881.928 (3.2243.226) . . . 81.80 (3.220)
Cylinder Block
Cylinder Bore I.D. . . . . . . . . . . . . . . . 82.082.03 (3.2283.230) . . . . . 82.20 (3.236)
Crankshaft
End Play . . . . . . . . . . . . . . . . . . . . . 0.0900.271 (0.0040.011) . . . . 0.33 (0.013)
Main Bearing I.D. . . . . . . . . . . . . . . . 50.050.045 (1.9691.970) . . . . 50.10 (1.972)
5M4,TM306,25 -19-28AUG87
010897
PN=34
06
25
Idler . . . . . . . . . . . . . . . . . . . . . . . . 0.040.12 (0.00160.0047) . . . . 0.20 (0.008)
Camshaft . . . . . . . . . . . . . . . . . . . . . 0.040.12 (0.00160.0047) . . . . 0.20 (0.008)
Crankshaft . . . . . . . . . . . . . . . . . . . . 0.040.12 (0.00160.0047) . . . . 0.20 (0.008)
Oil Pump . . . . . . . . . . . . . . . . . . . . . 0.040.12 (0.00160.0047) . . . . 0.20 (0.008)
Oil Pump
Gear Backlash . . . . . . . . . . . . . . . . . 0.04 (0.12 (0.00160.0047) . . . . . 0.20 (0.008)
Rotor Recess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.13 (0.005)
Valve Spring Free Length (Approx.)
3TN82-RJB (only) . . . . . . . . . . . . . 46.0 (1.81)
3TN82/4TN82 . . . . . . . . . . . . . . . . 46.0 (1.81)
Valve Spring Test Length
3TN82-RJB (only) . . . . . . . . . . . . . 24.5 (0.96) @ 27.2 N (6.1 lb) Force
3TN82/4TN82 . . . . . . . . . . . . . . . . 27.5 (1.08) @ 20.5 N (4.6 lb) Force
(0.039 in.) of Shim Thickness . . . . . . 15.6 kPa (2.3 psi)
Oil Pan
5M4,TM306,26 -19-28AUG87
010897
PN=35
06
26
Item Specification
Thermostat
Water Pump
Nozzles
Fuel Injection Pump
Fuel Leak-Off
GROUP 60Starter
GROUP 65Alternator
5M4,TM306,27 -19-28AUG87
010897
PN=36
06
27
Valve Clearance . . . . . . . . . . . . . . . . . 0.20 (0.008)
Rocker Arm
Shaft O.D. . . . . . . . . . . . . . . . . . . . . 15.96615.984 (0.62860.6293) . 15.955 (0.628)
Shaft Support I.D. . . . . . . . . . . . . . . . 16.016.02 (0.6300.631) . . . . . 16.09 (0.633)
Arm I.D. . . . . . . . . . . . . . . . . . . . . . 16.016.02 (0.6300.631) . . . . . 16.09 (0.633)
Shaft Clearance . . . . . . . . . . . . . . . . 0.0160.054 90.00060.0021) . . 0.13 (0.005)
Push Rod
Maximum T.I.R. . . . . . . . . . . . . . . . . 0.075 (0.003)
Length . . . . . . . . . . . . . . . . . . . . . . 178.25178.75 (7.0187.037) . . . 178.2 (7.02)
Diameter . . . . . . . . . . . . . . . . . . . . . 8 (0.315)
Cam Follower
O.D. . . . . . . . . . . . . . . . . . . . . . . . . 11.97511.990 (0.4710.472) . . . 11.93 (0.470)
Bore I.D. . . . . . . . . . . . . . . . . . . . . . 12.012.018 (0.4720.473) . . . . 12.05 (0.474)
Bore Clearance . . . . . . . . . . . . . . . . 0.0100.043 (0.00030.0016)
Camshaft
End Play . . . . . . . . . . . . . . . . . . . . . 0.050.20 (0.0020.008) . . . . . . 0.40 (0.016)
each gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 (0.008)
End Journals O.D. . . . . . . . . . . . . . . 44.92544.950 (1.7691.770) . . . 44.80 (1.764)
Lobe Height . . . . . . . . . . . . . . . . . . . 38.63538.765 (1.5211.526) . . . 38.40 (1.512)
Bushing I.D. . . . . . . . . . . . . . . . . . . . 44.99045.055 (1.7711.774) . . . 45.10 (1.776)
End Bores I.D. . . . . . . . . . . . . . . . . 45.045.025 (1.7721.773) . . . . 45.10 (1.776)
Manifold
5M4,TM306,28 -19-28AUG87
010897
PN=37
06
28
Cylinder Head (Continued)
Cylinder Head
Intake and Exhaust Valve Recession . . 0.300.50 mm (0.0120.020 in.)
Valve Spring Free Length (Approx.) . . . 41.5 mm (1.63 in.)
Valve Spring Test Length . . . . . . . . . . 24.0 mm (0.95 in.)
Valve Stem O.D. . . . . . . . . . . . . . . . . 7.9607.975 (0.3130.314) . . . . 7.90 (0.311)
Valve Guide I.D. . . . . . . . . . . . . . . . . 8.0108.030 (0.31540.3160) . . . 8.10 (0.319)
(Replace) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 (0.008)
(Knurl) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.150.20 (0.0060.008)
Valve Seat Width
Intake . . . . . . . . . . . . . . . . . . . . . 1.071.24 (0.0420.049) . . . . . . 1.74 (0.069)
Exhaust . . . . . . . . . . . . . . . . . . . . 1.241.35 (0.0490.053) . . . . . . 1.94 (0.076)
Valve Seat Angle
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
GROUP 20Flywheel
Maximum T.I.R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 (0.008)
Flatness . . . . . . . . . . . . . . . . . . . . . 0.05 (0.002)
Flywheel
Flatness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 (0.002)
Attaching Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Nm (61 lb-ft)
Flywheel Housing
M10 . . . . . . . . . . . . . . . . . . . . . . . 49 Nm (36 lb-ft)
M8 . . . . . . . . . . . . . . . . . . . . . . . 26 Nm (226 lb-in.)
M12 Nut . . . . . . . . . . . . . . . . . . . . 88 Nm (65 lb-ft)
5M4,TM306,29 -19-28AUG87
010897
PN=38
06
29
Connecting Rod
Side Clearance . . . . . . . . . . . . . . . . . 0.20.4 (0.00790.0158) . . . . . . 0.55 (0.022)
Maximum Twist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08 (0.003)
Journal O.D. . . . . . . . . . . . . . . . . . . 47.95247.962 (1.88791.8883) . 47.91 (1.886)
Piston
Top Ring . . . . . . . . . . . . . . . . . . . 0.0750.105 (0.00280.0041) . . . 0.25 (0.010)
Second Ring . . . . . . . . . . . . . . . . . 0.0450.080 (0.00180.0031) . . . 0.25 (0.010)
Oil Ring . . . . . . . . . . . . . . . . . . . . 0.0250.060 (0.00100.0024) . . . 0.20 (0.008)
Ring End Gap (1st and 2nd Rings) . . . 0.200.40 (0.0080.016) . . . . . . 1.50 (0.059)
Ring End Gap (Oil Ring) . . . . . . . . . . 0.250.45 (0.0100.018) . . . . . . 1.5 (0.059)
Pin O.D. . . . . . . . . . . . . . . . . . . . . . 25.98726.0 (1.0231.024) . . . . 25.90 (1.020)
Pin Bushing I.D. . . . . . . . . . . . . . . . . 26.02526.038 (1.02461.0251) . 26.10 (0.028)
Pin Bore I.D. . . . . . . . . . . . . . . . . . . 26.026.009 (1.0236l1.0240) . . . . 26.02 (1.024)
Piston O.D. . . . . . . . . . . . . . . . . . . . 83.89883.928 (3.3033.304) . . . 83.80 (3.299)
Cylinder Block
Cylinder Bore I.D. . . . . . . . . . . . . . . . 84.084.03 (3.3073.308) . . . . . 84.20 (3.315)
Crankshaft
End Play . . . . . . . . . . . . . . . . . . . . . 0.0900.271 (0.0040.011) . . . . 0.33 (0.013)
Main Bearing I.D. . . . . . . . . . . . . . . . 50.050.045 (1.9691.970) . . . . 50.10 (1.972)
5M4,TM306,30 -19-28AUG87
010897
PN=39
06
30
Idler . . . . . . . . . . . . . . . . . . . . . . . . 0.040.12 (0.00160.0047) . . . . 0.20 (0.008)
Camshaft . . . . . . . . . . . . . . . . . . . . . 0.040.12 (0.00160.0047) . . . . 0.20 (0.008)
Crankshaft . . . . . . . . . . . . . . . . . . . . 0.040.12 (0.00160.0047) . . . . 0.20 (0.008)
Oil Pump . . . . . . . . . . . . . . . . . . . . . 0.040.12 (0.00160.0047) . . . . 0.20 (0.008)
Oil Pump
Gear Backlash . . . . . . . . . . . . . . . . . 0.04 (0.12 (0.00160.0047) . . . . . 0.20 (0.008)
Rotor Recess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.13 (0.005)
Valve Spring Free Length . . . . . . . . . . 46.0 (1.81)
Valve Spring Test Length . . . . . . . . . . 27.5 (1.08) @ 20.5 N (4.6 lb) Force
(0.039 in.) of Shim Thickness . . . . . . . 15.6 kPa (2.3 psi)
Oil Pan
5M4,TM306,31 -19-28AUG87
010897
PN=40
06
31
Item Specification
Thermostat
Water Pump
Nozzles
Fuel Injection Pump
Fuel Leak-Off
GROUP 60Starter
GROUP 65Alternator
5M4,TM306,32 -19-28AUG87
010897
PN=41
06
32
ENGINE: 4TN100
Item Specification
Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.)
Rocker Arm
Minimum Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.35 mm (0.722 in.)
Maximum Shaft Support I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.60 mm (0.732 in.)
Maximum Arm I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.60 mm (0.732 in.)
Maximum Shaft Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 mm (0.002 in.)
Rocker Arm Assembly Cap Screw and Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm (226 lb-in.)
Rocker Arm Cover Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Nm (160 lb-in.)
Push Rod
Maximum T.I.R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm(0.012 in.)
Minimum Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182.0 mm (7.17 in.)
Cam Follower
Minimum O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.17 mm (0.558 in.)
Maximum Bore I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.30 mm (0.563 in.)
Maximum Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)
Camshaft
Maximum End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.29 mm (0.011 in.)
Maximum Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
Minimum Journal O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.80 mm (2.236 in.)
Minimum Lobe Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.10 mm (1.815 in.)
Maximum Bushing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.10 mm (2.248 in.)
Maximum Intermediate and Flywheel
End Bores I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.10 mm (2.248 in.)
Maximum Journal Clearance
Gear Case End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.14 mm (0.006 in.)
Intermediate and Flywheel End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.12 mm (0.005 in.)
Attaching Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm (226 lb-in.)
Gear Housing Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm (226 lb-in.)
Crankshaft Pulley Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Nm (85 lb-ft)
Item Specification
Manifold
Exhaust Manifold Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm (226 lb-in.)
Intake Manifold Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm (226 lb-in.)
5M4,TM306,33 -19-28AUG87
010897
PN=42
06
33
ENGINE: 4TN100
Item Specification
Cylinder Head
Intake and Exhaust Valve Recession . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.80 mm (0.071 in.)
Valve Spring Free Length (Approx.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.5 mm (1.67 in.)
@ 12.6 N (2.8 lb) Force
Minimum Valve Stem O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.90 mm (0.350 in.)
Exhaust Valve Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Intake Valve Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Maximum Valve Guide I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10 mm (0.358 in.)
(Replace) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
(Knurl) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.150.20 mm (0.0060.008 in.)
Maximum Valve Seat Width
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12 mm (0.084 in.)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.73 mm (0.108 in.)
Valve Seat Angle
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Cylinder Head Flatness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)
Mill Cylinder Head No More Than . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
Valve Guide Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.50 mm (0.453 in.)
In Sequence (Lubricated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Nm (116 lb-ft)
GROUP 20Flywheel
Item Specification
Flywheel
Flatness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)
Attaching Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 Nm (145 lb-ft)
Flywheel Housing
Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Nm (36 lb-ft)
Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Nm (65 lb-ft)
M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Nm (36 lb-ft)
M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm (226 lb-in.)
M12 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Nm (65 lb-ft)
5M4,TM306,34 -19-28AUG87
010897
PN=43
06
34
ENGINE: 4TN100
Item Specification
Connecting Rod
Maximum Side Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.45 mm (0.018 in.)
End-Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Nm (69 lb-ft)
Maximum Bearing Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09 mm (0.004 in.)
Minimum Journal O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59.90 mm (2.358 in.)
Maximum Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.10 mm (2.366 in.)
Piston
Maximum Ring Groove Clearance
Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
Second Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
Maximum Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.059 in.)
Minimum Pin O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.99 mm (1.338 in.)
Maximum Pin Bushing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.10 mm (1.343 in.)
Maximum Pin Bushing Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 mm (0.0024 in.)
Maximum Pin Bore I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.01 mm (1.339 in.)
Maximum Pin Bore Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.001 in.)
Minimum Piston O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.79 mm (3.929 in.)
Maximum Cylinder Bore I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100.20 mm (3.945 in.)
Maximum Piston Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 mm (0.014 in.)
Item Specification
Crankshaft
Maximum End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.29 mm (0.011 in.)
Main Bearing Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 Nm (145 lb-ft)
Maximum Main Bearing Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09 mm (0.004 in.)
Seal Case to Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm (226 lb-in.)
Oil Pan to Seal Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Nm (180 lb-in.)
Minimum Main Bearing Journal O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69.90 mm (2.752 in.)
Maximum Main Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70.10 mm (2.760 in.)
5M4,TM306,35 -19-28AUG87
010897
PN=44
06
35
ENGINE: 4TN100
Item Specification
Gear Housing Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm (226 lb-in.)
Crankshaft Pulley Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Nm (85 lb-ft)
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
Idler Gear Bushing Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.08 mm (1.814 in.)
Idler Shaft Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.93 mm (1.808 in.)
Idler Shaft Oil Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
Item Specification
Oil Pump
Gear Backlash, Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
Rotor Recess, Maximum
Outer Rotor-to-Pump Body Maximum Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
Inner Rotor-to-Outer Rotor Maximum Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
Shaft-to-Bore Clearance, Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 mm (0.008 in.)
Oil Pump Body Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Nm (53 lb-in.)
Oil Pump Attaching Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm (221 lb-ft)
Valve Spring Free Length (Approx.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.0 mm (2.01 in.)
@ 5.4 Nm (1.2 lb) Force
Oil Pan
Strainer Tube Attaching Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm (226 lb-in.)
Oil Pan-to-Block Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm (226 lb-in.)
Oil Pan-to-Gear Housing Cover Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Nm (180 lb-in.)
Oil Pan Spacer-to-Block Cap Screw Torque
M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm (226 lb-in.)
M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Nm (65 lb-ft)
Oil Pan Spacer-to-Crankshaft Seal Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Nm (180 lb-in.)
5M4,TM306,36 -19-28AUG87
010897
PN=45
06
36
ENGINE: 4TN100
GROUP 40Lubrication System (Continued)
Item Specification
Oil Cooler-to-Oil Cooler Housing Nuts Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Nm (36 lb-ft)
Oil Cooler Housing Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Nm (212 lb-in.)
By-Pass Valve Spring Free Length (Approx.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.0 mm (2.48 in.)
By-Pass Valve Spring Test Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.0 mm (1.45 in.)
@ 3.75 N (0.84 lb) Force
Item Specification
Thermostat
Water Pump
Bottom of Pulley Flange-to-Housing Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 mm (0.50 in.)
Clearance Between Impeller and Pump Body . . . . . . . . . . . . . . . . . . . . . . 0.31.1 mm (0.0120.043 in.)
Nozzles
Item Specification
Fuel Injection Pump
Pump Mounting Hardware Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Nm (20 lb-ft)
Maximum Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 mm (0.008 in.)
Gear Attaching Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Nm (65 lb-ft)
Nozzle Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20100 490 kPa (2915 71 psi)
Minimum Leakage Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Seconds
Retaining Nut-to-Nozzle Body Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Nm (31 lb-ft)
Nozzle-to-Cylinder Head Attaching Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 Nm (39 lb-in.)
Fuel Supply Pump
Pump Mounting Nuts Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Nm (96 lb-in.)
GROUP 60Starter
GROUP 65Alternator
5M4,TM306,37 -19-28AUG87
010897
PN=46
06
37
010897
PN=47
06
38
SERVICE EQUIPMENT AND TOOLS
NOTE: Order tools from the U.S. SERVICEGARD Catalog or from the European Microfiche Tool Catalog
(MTC). Some tools may be available from a local supplier.
Name Use
Feeler Gauge Measure valve clearance
Outside Micrometer Measure engine components
Telescoping Gauge Measure engine components
Valve Inspect Center Measure pushrod TIR
Vernier Calipers Measure pushrod length
Strap Wrench Hold crankshaft pulley
13-Ton Puller Set Remove crankshaft pulley
Magnetic Base with Adjustable Arm To hold dial indicator
Dial Indicator Measure gear and shaft end play
Magnetic Follower Holder Kit To hold cam followers in place when removing
camshaft
Bushing, Bearing, and Seal Driver Set To service bushings, bearings, and oil seals
Press To service camshaft gear
OTHER MATERIAL
Number Name Use
PT502 John Deere GASKET MAKER
To seal camshaft plug

T43512 John Deere LOCTITE
Thread Lock Apply to threads of crankshaft

and Sealer (Medium Strength) pulley cap screw.
PT94 John Deere Form-In-Place Gasket To seal gear case cover.
(RTV rubber silicone sealant)
GASKET MAKER is a trademark of the Permatex Corp.
LOCTITE is a trademark of the Loctite Corp.
M21,TM310,1 -19-05FEB86
M21,TM310,2 -19-23JUL87
Group 10
Valve Train and Camshaft
010897
PN=48
10
1
SERVICE PARTS KITS
The following kits are available through your parts
catalog:
Cylinder Block Gasket Kit.
Cylinder Head Gasket Kit.
REMOVE AND DISASSEMBLE ROCKER ARM
COVER
1. Remove rocker arm cover.
2. Remove O-ring (A) from special nuts.
3. Remove oil fill cap (B) and O-ring (C).
M
3
5
3
2
7

-
U
N
-
2
9
A
U
G
8
8
4. Remove O-ring or gasket (B) and crankcase breather
tube (C).
5. Remove screws and lock washers to remove baffle
(A).
Remove crankcase breather cover (D).
ABaffle
BO-Ring
CCrankcase Breather Tube
DCrankcase Breather Cover
3TN75 Shown
M
3
5
3
2
8

-
U
N
-
2
9
A
U
G
8
8
M
3
7
4
9
8

-
U
N
-
2
9
A
U
G
8
8
M21,TM310,3 -19-17MAR86
M21,TM310,7 -19-04AUG87
M21,TM310,8 -19-23JUL87
Valve Train and Camshaft/Rocker Arm
010897
PN=49
10
2
6. Remove gasket from baffle.
Remove screen, packing (A) and O-ring (B). Wash
packing in a safe solvent and blow dry with air pressure.
If packing comes apart or is deteriorated, replace it.
3TN75 Shown
M
3
5
3
2
9

-
U
N
-
2
9
A
U
G
8
8
M
3
7
4
9
9

-
U
N
-
2
9
A
U
G
8
8
MEASURE AND ADJUST VALVE
CLEARANCE (ALL EXCEPT 4TN100)
1. Turn crankshaft clockwise until No.1 cylinder intake
valve (A) opens.
NOTE: Number one cylinder is closest to the flywheel
end.
M
3
5
2
5
5

-
U
N
-
2
9
A
U
G
8
8
M21,TM310,9 -19-23JUL87
M21,TM310,10 -19-24JUL87
010897
PN=50
10
3
NOTE: TDCTop Dead Center (the piston at its highest
point).
2. Continue turning crankshaft until No. 1 timing mark
lines up with index mark. (TDC on compression stroke).
ANo. 1 Timing Mark
BIndex Arrow
CNo. 1 Timing Mark
DIndex Mark on Flywheel Housing
ENo. 1 Timing Mark
FIndex Mark
3TNA72UJ Engine (Early Units)
Engines with Flywheel Housing
Engines Without Flywheel Housing
M
3
5
2
5
6

-
U
N
-
2
9
A
U
G
8
8
M
3
7
5
0
0

-
U
N
-
2
9
A
U
G
8
8
M
3
7
5
0
1

-
U
N
-
2
9
A
U
G
8
8
M21,TM310,11 -19-14SEP87
010897
PN=51
10
4
3. Measure valve clearance.
VALVE CLEARANCE SPECIFICATIONS
Intake valves (A) . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
Exhaust valves (B) . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
4. To adjust valves (A and B), loosen nut (C) and turn
adjusting screw (D) to proper clearance. Hold screw
while tightening nut.
AIntake Valve
BExhaust Valve
CNut
DAdjusting Screw
View From Flywheel End
M
3
5
2
5
7

-
U
N
-
2
9
A
U
G
8
8
M21,TM310,12 -19-17FEB86
010897
PN=52
10
5
5. To adjust remaining valves (A and B):
a. Turn crankshaft until No. 2 cylinder intake valve (C)
opens.
For 4 cylinder engine, turn crankshaft until No. 4 cylinder
intake valve opens.
b. For 3TNA72UJ engine (early unit), continue turning
crankshaft to align the No. 2 timing mark on crankshaft
pulley with arrow on gear housing cover.
Continue turning crankshaft to align the No. 2 timing
mark on flywheel with mark on flywheel housing or
mounting plate.
For 4 cylinder engine, continue turning crankshaft to
align the No. 4 timing mark on flywheel with mark on
mounting plate.
c. See Step 4 to adjust intake and exhaust valve.
View From Flywheel End M
3
5
2
5
8

-
U
N
-
2
9
A
U
G
8
8
MEASURE AND ADJUST VALVE
CLEARANCE (4TN100)
1. Remove plug from timing hole on flywheel housing.
NOTE: Top Dead Center (TDC) is the piston at its
highest point.
2. Turn crankshaft pulley cap screw clockwise until No. 1
cylinder TDC mark (A) aligns with the timing mark (3) on
the flywheel housing.
M
5
1
5
6
1

-
U
N
-
3
1
A
U
G
8
8
M21,TM310,13 -19-27JUL87
M21,TM310,A1 -19-27JUL87
010897
PN=53
10
6
3. Remove rocker arm cover.
NOTE: No. 1 cylinder is the closest to the flywheel.
4. Try to move both No. 1 cylinder rocker arms or push
rods.
If rocker arm pushrods are not loose, rotate flywheel one
revolution (360). If both rocker arm push rods are loose
the piston is at TDC on compression stroke.
5. Measure intake (A) and exhaust (B) valve clearance.
AIntake Valve
Intake valves (A) . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.)
BExhaust Valve
Exhaust valves (B) . . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.)
CNut
DAdjusting Screw
6. To adjust valves, loosen nut (C) and turn adjusting
screw (D) until proper clearance is obtained. Hold screw
while tightening lock nut.
M
5
1
5
9
2

-
U
N
-
3
1
A
U
G
8
8
7. Turn crankshaft pulley cap screw clockwise to turn
flywheel one revolution (360). This puts No. 4 cylinder
at TDC on compression stroke.
8. Measure intake (A) and Exhaust (B) valve clearances.
See Step 5 to adjust valves.
9. Install rocker arm cover and gasket.
10. Install plug in timing hole on flywheel housing.
M
5
1
5
9
3

-
U
N
-
3
1
A
U
G
8
8
M21,TM310,A2 -19-28AUG87
M21,TM310,A3 -19-27JUL87
010897
PN=54
10
7
REMOVE AND DISASSEMBLE ROCKER ARM
ASSEMBLY
1. Remove rocker arm assembly.
3TN75 Shown
M
3
5
2
5
9

-
U
N
-
2
9
A
U
G
8
8
M
3
7
5
0
3

-
U
N
-
2
9
A
U
G
8
8
NOTE: For all engines except 3TN66/3TNA72, go to
Step 4.
2. Remove snap ring and parts (AF).
AExhaust Rocker Arm
BSupport
CIntake Rocker Arm
DSpring
ENut
FAdjusting Screw
M
3
5
2
6
0

-
U
N
-
2
9
A
U
G
8
8
3. Remove set screw and parts (AH).
ASupport
BIntake Rocker Arm
CSpring
DExhaust Rocker Arm
ENut
FAdjusting Screw
GRocker Arm Shaft
HSnap Ring
M
3
5
2
6
1

-
U
N
-
2
9
A
U
G
8
8
M21,TM310,14 -19-27JUL87
M21,TM310,15 -19-27JUL87
M21,TM310,16 -19-17FEB86
010897
PN=55
10
8
4. Remove three studs using two M8 nuts. Remove parts
(AF).
Remove snap ring and cap screw (G). Remove parts
(AF).
ASupport
BRocker Arm
CSpring
DNut
EAdjusting Screw
FRocker Arm Shaft
GCap Screw
All except 3TN66/3TNA72/4TN100
M
3
7
5
0
4

-
U
N
-
2
9
A
U
G
8
8
M
5
1
5
6
2

-
U
N
-
3
1
A
U
G
8
8
5. Measure shaft at each rocker arm location.
ROCKER ARM SHAFT O.D. SPECIFICATIONS (MIN)
3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.96 mm (0.392 in.)
3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.96 mm (0.471 in.)
3TN75/3TN78/3TN82/3TN84/
4TN78/4TN82/4TN84 . . . . . . . . . . . . . . . . . 15.96 mm (0.628 in.)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.35 mm (0.722 in.)
If rocker arm shaft diameter is less than wear tolerance,
replace shaft.
M
3
5
2
6
2

-
U
N
-
2
9
A
U
G
8
8
M21,TM310,17 -19-14SEP87
M21,TM310,18 -19-14SEP87
010897
PN=56
10
9
6. Measure each support.
ROCKER ARM SHAFT SUPPORT I.D. SPECIFICATIONS (MAX)
3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.09 mm (0.397 in.)
3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.09 mm (0.476 in.)
3TN75/3TN78/3TN82/3TN84/
4TN78/4TN82/4TN84 . . . . . . . . . . . . . . . . . 16.09 mm (0.633 in.)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.60 mm (0.732 in.)
If rocker arm shaft support diameter exceeds wear
tolerance, replace support.
M
3
5
2
6
3

-
U
N
-
2
9
A
U
G
8
8
7. Measure each rocker arm inside diameter and
determine rocker arm shaft clearance (rocker arm I.D.
minus rocker arm shaft O.D.).
Inspect rocker arm to valve surface and adjusting screw
for metal flakes or wear.
ROCKER ARM SPECIFICATIONS
Arm I.D. (Max)
3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.09 mm (0.397 in.)
3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . . 12.09 mm (0.476 in.)
3TN75/3TN78/3TN82/3TN84/
4TN78/4TN82/4TN84 . . . . . . . . . . . . . . . . 16.09 mm (0.633 in.)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . 18.60 mm (0.732 in.)
Shaft Clearance (Max)
All except 4TN100 . . . . . . . . . . . . . . . . . . . . 0.13 mm (0.005 in.)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 mm (0.002 in.)
If rocker arm bore diameter exceeds wear tolerance,
replace rocker arm.
If shaft clearance exceeds wear tolerance, replace rocker
arm shaft, rocker arm, or both.
M
3
5
2
6
4

-
U
N
-
2
9
A
U
G
8
8
M21,TM310,19 -19-28AUG87
M21,TM310,20 -19-04AUG87
010897
PN=57
10
10
REMOVE AND INSPECT PUSHRODS AND
CAM FOLLOWERS
1. Remove pushrods.
M
3
5
2
6
5

-
U
N
-
2
9
A
U
G
8
8
2. Measure pushrod TIR (Total Indicator Runout) using
Valve Inspection Center.
SPECIFICATION
Pushrod TIR (Max) . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm
(0.012 in.)
If pushrod TIR exceeds 0.30 mm (0.012 in.), replace it.
M
3
5
4
0
0

-
U
N
-
0
6
S
E
P
8
8
3. Measure pushrod length.
PUSHROD LENGTH SPECIFICATIONS (MIN)
3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114.0 mm (4.49 in.)
3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141.0 mm (5.55 in.)
3TN75/3TN78/4TN78 . . . . . . . . . . . . . . . . . . . . 146.6 mm (5.77 in.)
3TN82/3TN84/
4TN82/4TN84 . . . . . . . . . . . . . . . . . . . . . . . 178.2 mm (7.02 in.)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182.0 mm (7.17 in.)
If pushrod length is less than wear tolerance, replace it.
M
3
5
2
6
6

-
U
N
-
2
9
A
U
G
8
8
M21,TM310,21 -19-17FEB86
M21,TM310,22 -19-22APR86
M21,TM310,23 -19-04AUG86
010897
PN=58
10
11
4. For 3TN66 or 3TNA72 engine only, remove cylinder
head. (See Group 15 in this manual).
5. For all other engines, remove camshaft and oil pan.
(See Group 10 and 40 in this manual.)
IMPORTANT: Cam followers must be installed in the
same bores from which they were
removed.
6. Put a mark on each cam follower and cylinder block
bore to aid in assembly.
3TN75 Shown
7. Remove cam followers.
M
3
5
2
6
7

-
U
N
-
2
9
A
U
G
8
8
8. Measure cam followers outside diameter.
CAM FOLLOWER O.D. SPECIFICATIONS (MIN)
3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.93 mm (0.706 in.)
3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.93 mm (0.824 in.)
3TN75/3TN78/3TN82/3TN84/
4TN78/4TN82/4TN84 . . . . . . . . . . . . . . . . . 11.93 mm (0.470 in.)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.17 mm (0.558 in.)
If cam follower diameter is less than wear tolerance,
replace it.
9. Inspect cam follower-to-camshaft surface for uneven
wear or damage; replace as necessary.
3TN75 Shown
M
3
5
2
6
8

-
U
N
-
2
9
A
U
G
8
8
M
3
7
5
1
0

-
U
N
-
0
6
S
E
P
8
8
M21,TM310,24 -19-04AUG87
M21,TM310,25 -19-28AUG87
010897
PN=59
10
12
10. Measure cam follower bore inside diameter and
determine cam follower clearance (cam follower bore I.D.
minus cam follower O.D.).
CAM FOLLOWER BORE SPECIFICATIONS
Bore I.D. (Max)
3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.05 mm (0.711 in.)
3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . . 21.05 mm (0.829 in.)
3TN75/3TN78/3TN82/3TN84/
4TN78/4TN82/4TN84 . . . . . . . . . . . . . . . . 12.05 mm (0.474 in.)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . 14.30 mm (0.563 in.)
Clearance (Max)
All except 3TNA72/4TN100 . . . . . . . . . . . . . . 0.10 mm (0.004 in.)
3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)
If cam follower bore diameter exceeds wear tolerance,
replace cylinder block.
If cam follower clearance exceeds wear tolerance;
replace cam follower, cylinder block or both.
M
3
5
2
6
9

-
U
N
-
2
9
A
U
G
8
8
M21,TM310,26 -19-04AUG87
010897
PN=60
10
13
INSTALL PUSH RODS AND CAM
FOLLOWERS
1. Put clean engine oil on cam followers.
IMPORTANT: Cam followers must be installed in the
same bores from which they were
removed.
2. Install cam followers.
3. For 3TN66/3TNA72 engines only, install cylinder head.
(See Group 15 in this manual.)
4. For all other engines, install camshaft and oil pan.
(See Groups 10 and 40 in this manual.)
3TN75 Shown
M
3
5
2
6
7

-
U
N
-
2
9
A
U
G
8
8
M
3
7
5
0
9

-
U
N
-
2
9
A
U
G
8
8
5. Install the pushrods.
M
3
5
2
6
5

-
U
N
-
2
9
A
U
G
8
8
M21,TM310,27 -19-28AUG87
M21,TM310,28 -19-17FEB86
010897
PN=61
10
14
ASSEMBLE AND INSTALL ROCKER ARM
ASSEMBLY
NOTE: For all engines except 3TN66/3TNA72, go to step
5.
1. Install parts (AH) on rocker arm shaft.
2. Align set screw hole in support with center hole in
rocker arm shaft. Install and tighten set screw.
ASupport
BIntake Rocker Arm
CSpring
DExhaust Rocker Arm
ENut
FAdjusting Screw
GRocker Arm Shaft
HSnap Ring
M
3
5
2
6
1

-
U
N
-
2
9
A
U
G
8
8
3. Install parts (AF) on rocker arm shaft.
4. Install snap ring.
AExhaust Rocker Arm
BSupport
CIntake Rocker Arm
DSpring
ENut
FAdjusting Screw
M
3
5
2
6
0

-
U
N
-
2
9
A
U
G
8
8
M21,TM310,29 -19-08AUG87
M21,TM310,30 -19-17FEB86
010897
PN=62
10
15
5. Install parts (AF) on rocker arm shaft. Install and
tighten three studs using two M8 nuts.
Align hole in last support with hole in rocker arm shaft.
Install and tighten cap screw (G). Install snap ring.
ASupport
BRocker Arm
CSpring
DNut
EAdjusting Screw
FRocker Arm Shaft
GCap Screw
All except 3TN66/3TNA72/4TN100
4TN100
M
3
7
5
0
4

-
U
N
-
2
9
A
U
G
8
8
M
5
1
5
6
2

-
U
N
-
3
1
A
U
G
8
8
M21,TM310,31 -19-28AUG87
010897
PN=63
10
16
7. Install rocker arm assembly. Be sure adjusting screws
(A) are in push rod sockets.
8. Install and tighten two nuts and cap screw to 26 Nm
(226 lb-in.).
Install and tighten eight cap screws to 26 Nm (226
lb-in.).
All except 3TN66/3TNA72
M
3
5
2
9
7

-
U
N
-
2
9
A
U
G
8
8
M
3
7
5
0
5

-
U
N
-
2
9
A
U
G
8
8
9. Measure valve clearance. (See Measure and Adjust
Valve Clearance in this section.)
All Except 4TN100
Intake Valves (A) . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
Exhaust Valves (B) . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
4TN100
Intake Valves (A) . . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.)
Exhaust Valves (B) . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.)
AIntake Valve
BExhaust Valve
CNut
DAdjusting Screw
M
3
5
2
5
7

-
U
N
-
2
9
A
U
G
8
8
M21,TM310,32 -19-28AUG87
M21,TM310,33 -19-17FEB86
010897
PN=64
10
17
ASSEMBLE AND INSTALL ROCKER ARM
COVER
1. Install a new gasket on baffle.
Install a new O-ring (B) in crankcase breather cover.
Install packing (A) and screen.
3TN75 Shown
M
3
5
3
2
9

-
U
N
-
2
9
A
U
G
8
8
M
3
7
4
9
9

-
U
N
-
2
9
A
U
G
8
8
2. Install crankcase breather tube (C) and O-ring or
gasket (B).
3. Install baffle (A) and fasten with four lock washers and
screws.
Install crankcase breather cover (D) and fasten with two
cap screws.
ABaffle
BO-Ring
CCrankcase Breather Tube
DCrankcase Breather Cover
3TN75 Shown
M
3
5
3
2
8

-
U
N
-
2
9
A
U
G
8
8
M
3
7
4
9
8

-
U
N
-
2
9
A
U
G
8
8
M21,TM310,34 -19-04AUG87
M21,TM310,35 -19-04AUG87
010897
PN=65
10
18
4. Install rocker arm cover.
5. Install O-ring (C) on oil fill cap (B). Install oil fill cap.
6. Install an O-ring (A) on each special nut.
7. For all engines except 4TN100, install special nuts
and tighten to specification.
For 4TN100 engine, install cap screws and tighten to
specification.
TORQUE SPECIFICATIONS
All except 4TN100 . . . . . . . . . . . . . . . . . . . . . . . 18 Nm (160 lb-in.)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm (226 lb-in.)
M
3
5
2
9
8

-
U
N
-
2
9
A
U
G
8
8
REMOVE CAMSHAFT
1. Remove engine. (See Machine Technical Manual.)
2. Remove fan, if equipped, alternator belt, and
alternator.
3. Remove rocker arm cover, rocker arm assembly, and
pushrods. (See Group 10 in this manual.)
4. Remove timing gear cover. (See Group 35 in this
manual.) M
3
5
2
7
0

-
U
N
-
2
9
A
U
G
8
8
5. Measure camshaft end play. If end play exceeds
specifications, replace camshaft thrust plate.
CAMSHAFT END PLAY SPECIFICATIONS (MAX)
All except 4TN100 . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.29 mm (0.011 in.)
M
3
7
5
1
2

-
U
N
-
0
6
S
E
P
8
8
M21,TM310,36 -19-28AUG87
M21,TM310,37A -19-04AUG87
M21,TM310,43A -19-05AUG87
Valve Train and Camshaft/Camshaft
010897
PN=66
10
19
6. If end play is correct, measure camshaft gear
backlash.
Check backlash of other timing gears; replace these
gears as necessary. (See Group 35 in this manual for
backlash specifications.)
M
3
7
5
1
3

-
U
N
-
0
6
S
E
P
8
8
NOTE: If a magnetic follower holder kit is not available,
turn engine until oil pan is upward, to hold cam
followers away from camshaft.
7. Hold cam followers away from camshaft using a
magnetic follower holder kit such as JT01783.
M
3
7
5
1
4

-
U
N
-
0
6
S
E
P
8
8
8. Turn engine on engine stand with flywheel side down.
IMPORTANT: DO NOT allow camshaft lobes to hit
bearing surfaces while removing
camshaft. Machined surfaces can be
damaged.
9. Remove two cap screws and carefully remove
camshaft.
M
3
5
2
7
9

-
U
N
-
2
9
A
U
G
8
8
M21,TM310,44A -19-05AUG87
M21,TM310,45A -19-05AUG87
M21,TM310,46A -19-05AUG87
010897
PN=67
10
20
DISASSEMBLE AND INSPECT CAMSHAFT
1. Inspect gear for chipped or broken teeth, replace if
necessary.
IMPORTANT: Be sure to hold camshaft while
removing camshaft gear.
2. Remove gear using 11/16-in. driver disk (A) and a
press.
3. Remove thrust plate (B). M
3
5
2
8
0

-
U
N
-
2
9
A
U
G
8
8
4. Measure camshaft end journal diameter (A), and
intermediate journal diameter (B).
NOTE: For some engines, the camshaft has only one
intermediate journal.
CAMSHAFT END AND INTERMEDIATE JOURNAL O.D.
SPECIFICATIONS (MIN)
3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.85 mm (1.411 in.)
3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.85 mm (1.569 in.)
3TNA72 (Flywheel End) . . . . . . . . . . . . . . . . . . . . . 40.1 (1.579 in.)
3TN75/3TN78/3TN82/3TN84/
4TN78/4TN82/4TN84 . . . . . . . . . . . . . . . . . 44.80 mm (1.764 in.)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.80 mm (2.236 in.)
If end journal diameter or intermediate journal diameter
is less than wear tolerance replace camshaft.
M
3
5
2
8
2

-
U
N
-
2
9
A
U
G
8
8
M21,TM310,47 -19-18FEB86
M21,TM310,48 -19-28AUG87
010897
PN=68
10
21
5. Measure camshaft lobe height.
CAMSHAFT LOBE HEIGHT SPECIFICATIONS (MIN)
3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.75 mm (1.171 in.)
3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.75 mm (1.329 in.)
3TN75/3TN78/3TN82/3TN84/
4TN78/4TN82/4TN84 . . . . . . . . . . . . . . . . . 38.40 mm (1.512 in.)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.10 mm (1.815 in.)
If height is less than wear tolerance, replace camshaft.
T
8
1
2
6
2

-
U
N
-
0
1
N
O
V
8
8
6. Measure gear housing side camshaft bushing
diameter.
CAMSHAFT BUSHING I.D. SPECIFICATIONS (MAX)
3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.10 mm (1.421 in.)
3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.10 mm (1.579 in.)
3TN75/3TN78/3TN82/3TN84/
4TN78/4TN82/4TN84 . . . . . . . . . . . . . . . . . 45.10 mm (1.776 in.)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.10 mm (2.248 in.)
If diameter exceeds wear tolerance, replace bushing.
Use a chisel to remove bushing. Be careful not to push
bushing inside of engine.
M
3
5
2
8
4

-
U
N
-
2
9
A
U
G
8
8
M
3
5
2
8
5

-
U
N
-
2
9
A
U
G
8
8
M21,TM310,49 -19-28AUG87
M21,TM310,50 -19-28AUG87
010897
PN=69
10
22
7. Measure camshaft intermediate bore diameter.
CAMSHAFT BORE I.D. SPECIFICATIONS (MAX)
3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.10 mm (1.421 in.)
3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.10 mm (1.579 in.)
3TN75/3TN78/3TN82/3TN84/
4TN78/4TN82/4TN84 . . . . . . . . . . . . . . . . . 45.10 mm (1.776 in.)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.10 mm (2.248 in.)
If diameter exceeds wear tolerance, replace cylinder
block.
8. Measure the other intermediate and flywheel side
camshaft bore diameters using the following procedure:
a. Remove flywheel assembly. (See Group 15 in this
(manual.)
M
3
5
2
8
6

-
U
N
-
2
9
A
U
G
8
8
b. Remove plug using a wooden dowel. Remove plug
from gear housing side.
M
3
5
2
8
7

-
U
N
-
2
9
A
U
G
8
8
M21,TM310,64 -19-28AUG87
M21,TM310,51 -19-18FEB86
010897
PN=70
10
23
NOTE: Some engines do not have an intermediate
journal on the flywheel side.
c. Measure intermediate and flywheel side camshaft bore
diameters.
CAMSHAFT BORE I.D. SPECIFICATIONS (MAX)
3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.10 mm (1.421 in.)
3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.10 mm (1.579 in.)
3TN75/3TN78/3TN82/3TN84/
4TN78/4TN82/4TN84 . . . . . . . . . . . . . . . . . 45.10 mm (1.776 in.)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.10 mm (2.248 in.)
d. Determine camshaft journal clearance (bushing, or
bore diameter minus journal diameter).
CAMSHAFT JOURNAL CLEARANCE SPECIFICATIONS (MAX)
4TN100
Gearcase End . . . . . . . . . . . . . . . . . . . . . . . 0.14 mm (0.006 in.)
End Clearance . . . . . . . . . . . . . . . . . . . . . 0.12 mm (0.005 in.)
If diameter exceeds wear tolerance, replace cylinder
block.
If clearance exceeds wear tolerance replace camshaft,
cylinder block, or both.
M
3
5
2
8
8

-
U
N
-
2
9
A
U
G
8
8
M21,TM310,52 -19-28AUG87
010897
PN=71
10
24
ASSEMBLE CAMSHAFT
N
CAUTION: DO NOT heat oil over 182C (360F).
Oil fumes or oil can ignite above 193C (380F).
Use a thermometer. Do not allow a flame or
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 burns.
1. Heat camshaft gear to approximately 150C (300F).
2. Install thrust plate (B) on camshaft.
3. Put gear with timing mark side downward on press
table.
4. Align slot in gear with key in shaft.
IMPORTANT: Be sure thrust plate is not between
camshaft gear and camshaft shoulder
while installing gear.
5. Push camshaft gear tight against camshaft shoulder
using 1 11/16 in. driver disk (A) and a press.
6. Thrust plate must spin freely on camshaft; if it does
not, remove gear and repeat steps 15.
T
8
1
1
9
1

-
U
N
-
2
3
F
E
B
8
9
M
3
5
2
8
1

-
U
N
-
2
9
A
U
G
8
8
INSTALL CAMSHAFT
1. Thoroughly clean and dry all parts. Use a cylinder
block and cylinder head gasket kit when assembling the
engine.
2. Apply gasket maker or an equivalent on outer edge of
plug.
3. Install plug flush with surface of cylinder block.
M
3
5
2
8
7

-
U
N
-
2
9
A
U
G
8
8
M21,TM310,53 -19-28AUG87
M21,TM310,54 -19-19FEB86
Valve Train and Camshaft/Install
010897
PN=72
10
25
4. Install flywheel assembly. (See Group 15 in this
manual.)
5. Align oil holes (A) in bushing and cylinder block.
Install bushing flush with surface of cylinder block using
the correct driver disks (B and C).
DISK DIAMETERS
Engine Size (in.)
(B) (C)
3TN66 1 7/16 1 1/2
3TNA72 1 9/16 1 11/16
3TN75/3TN78/3TN82/
3TN84/4TN78/
4TN82/4TN84 1 3/4 1 7/8
4TN100 2 1/4 2 3/8
M
3
5
2
8
9

-
U
N
-
2
9
A
U
G
8
8
M
3
5
2
9
1

-
U
N
-
2
9
A
U
G
8
8
M21,TM310,55 -19-28AUG87
010897
PN=73
10
26
6. Turn engine on engine stand with flywheel side down.
7. Put clean engine oil on camshaft bearing journals.
IMPORTANT: DO NOT allow camshaft lobes to hit
bearing surfaces while installing
camshaft. Machined surfaces can be
damaged.
8. Remove idler gear (B).
Carefully install camshaft (E). Align timing marks (A) and
3TNA72 (Early Units)
install idler gear.
Remove snap ring (C) and washer (D) to remove idler
gear (B).
install idler gear.
Install washer and snap ring.
Remove snap ring (C) and washer (D) to remove idler
gear (B).
3TNA72
install idler gear.
Install washer and snap ring.
Remove two cap screws (F) to remove idler gear shaft
(G) and idler gear (B).
install idler gear.
Install idler gear shaft. Install and tighten two cap screws
to 26 Nm (226 lb-in.)
ATiming Marks 3TN66
BIdler Gear
CSnap Ring
DWasher
ECamshaft
FCap Screws
GIdler Gear Shaft
M
3
7
5
1
5

-
U
N
-
0
6
S
E
P
8
8
M
3
7
5
1
6

-
U
N
-
0
6
S
E
P
8
8
M
3
7
5
1
7

-
U
N
-
0
6
S
E
P
8
8
M
3
7
5
1
8

-
U
N
-
0
6
S
E
P
8
8
M21,TM310,56 -19-28AUG87
010897
PN=74
10
27
9. Install and tighten two cap screws to specifications.
CAMSHAFT CAP SCREW TORQUE SPECIFICATIONS
3TN66/3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . 11 Nm (96 lb-in.)
All except 3TN66/3TNA72 . . . . . . . . . . . . . . . . . 26 Nm (226 lb-in.)
10. Install timing gear cover. (See Group 35 in this
manual.)
11. Install push rods, rocker arm assembly, and rocker
arm cover. (See Group 10 in this manual.)
M
3
5
2
9
2

-
U
N
-
2
9
A
U
G
8
8
M21,TM310,57A -19-28AUG87
010897
PN=75
10
28
ESSENTIAL TOOLS
Number Name Use
D-20018WI Valve Guide Knurler To knurl valve guides on 3TNA72/3TN75
engines
D-20019WI Valve Guide Knurler To knurl valve guides on
3TN82/3TN84/4TN82/4TN84 engines
D-20020WI Valve Guide Reamer To ream valve guides on 3TNA72/3TN75
engines
D-20021WI Valve Guide Reamer To ream valve guides on
3TN82/3TN84/4TN82/4TN84 engines
JDE-118 Valve Guide Driver Remove and install valve guide on
3TNA72/3TN75/3TN82/3TN84/4TN82/4TN84
engines
JDG-504 Valve Guide Driver Remove and install valve guides on 3TN66
engines
9 mm Knurler To knurl valve guides on 4TN100 engine
9 mm Reamer To ream valve guides on 4TN100 engine
M21,TM315,1 -19-05AUG87
Group 15
Cylinder Head, Valves, and Manifolds
010897
PN=76
15
1
Name Use
Depth Gauge Measure valve recession
Valve Spring Compressor Remove and install valves
Valve Inspection Center Measure valve out-of-round
Outside Micrometer Measure valves
Valve Guide Brush Clean valve guide internal bores
Ball Gauge Measure valve guide internal bores
Vernier Calipers Measure Valve seat width
Valve Seat Grinder Recondition valve seat
Feeler Gauge Measure cylinder head flatness
Spring Compression Tester Check valve springs
SERVICE PART KITS
catalog:
Cylinder Head Gasket Kit
REMOVE, REPAIR, AND INSTALL EXHAUST
MANIFOLD
1. Remove four nuts to remove exhaust pipe or muffler
and gasket (A).
M
3
5
4
8
2

-
U
N
-
0
6
S
E
P
8
8
M21,TM315,2 -19-22APR86
M21,TM315,3 -19-19FEB86
M21,TM315,6 -19-19FEB86
Cylinder Head, Valves, and Manifolds/Exhaust Manifold
010897
PN=77
15
2
NOTE: Exhaust manifold can be removed with engine in
the tractor.
2. Remove cap screws, nuts, and exhaust manifold.
3. Remove gasket material.
4. Inspect manifold and gasket for cracks and holes.
Replace or repair as necessary.
M
3
5
4
4
3

-
U
N
-
0
6
S
E
P
8
8
5. Install gasket, manifold, nuts, and cap screws. Tighten
nuts and cap screws to specifications.
EXHAUST MANIFOLD CAP SCREW AND
NUT TORQUE SPECIFICATIONS
3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Nm (96 lb-in.)
All except 3TN66 . . . . . . . . . . . . . . . . . . . . . . . 26 Nm (226 lb-in.)
M
3
5
4
4
4

-
U
N
-
0
6
S
E
P
8
8
6. Install a new gasket (A).
7. Fasten exhaust pipe or muffler with four nuts. Tighten
nuts.
8. Start engine and check exhaust system for leaks.
After engine is at normal operating temperature, retighten
exhaust manifold cap screws and nuts to specifications.
M
3
5
4
8
3

-
U
N
-
0
6
S
E
P
8
8
M
3
5
4
8
2

-
U
N
-
0
6
S
E
P
8
8
M21,TM315,7 -19-19FEB86
M21,TM315,8 -19-05AUG87
M21,TM315,9 -19-22APR86
Cylinder Head, Valves, and Manifolds/Exhaust Manifold
010897
PN=78
15
3
REMOVE, REPAIR, AND INSTALL INTAKE
MANIFOLD
NOTE: Intake manifold can be removed with engine in
the tractor.
1. Remove cap screws and intake manifold.
2. Remove gasket material.
3. Inspect manifold for cracks and holes. Replace or
repair as necessary. M
3
5
4
4
6

-
U
N
-
0
6
S
E
P
8
8
4. Install new gasket, manifold, and cap screws. Tighten
cap screws to specifications.
INTAKE MANIFOLD CAP SCREW TORQUE SPECIFICATIONS
3TN66/3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . 11 Nm (96 lb-in.)
M
3
5
4
4
7

-
U
N
-
0
6
S
E
P
8
8
M
3
5
4
4
8

-
U
N
-
0
6
S
E
P
8
8
M21,TM315,10 -19-19FEB86
M21,TM315,11 -19-05AUG87
Cylinder Head, Valves, and Manifolds/Intake Manifold
010897
PN=79
15
4
REMOVE CYLINDER HEAD
NOTE: Cylinder head can be removed with engine in the
tractor. If cylinder head is removed for valve
service only, do not remove parts (A, D, E, and
F).
1. Remove manifold (A). (See Group 15 in this manual.)
2. Remove pump (C). (See Group 45 in this manual.)
3. Remove lines (G) and nozzles (F). (See Group 50 in
this manual.)
4. Remove glow plugs (D), if equipped.
5. Remove manifold (E). (See Group 15 in this manual.)
6. Remove cover (B), rocker arm assembly, and
pushrods. (See Group 10 in this manual.)
AExhaust Manifold EIntake Manifold
BRocker Arm Cover FFuel Injection
CWater Pump Nozzles
DGlow Plugs GFuel Injection Lines
M
3
5
2
9
9

-
U
N
-
2
9
A
U
G
8
8
7. Remove valve caps, if equipped.
M
3
5
4
0
1

-
U
N
-
0
6
S
E
P
8
8
8. Remove cap screws to remove cylinder head and
gasket.
M
3
5
3
0
0

-
U
N
-
2
9
A
U
G
8
8
M21,TM315,12 -19-05AUG87
M21,TM315,13 -19-19FEB86
M21,TM315,14 -19-19FEB86
Cylinder Head, Valves, and Manifolds/Cylinder Head
010897
PN=80
15
5
DISASSEMBLE CYLINDER HEAD
1. Remove two lifting brackets.
M
3
5
3
0
1

-
U
N
-
2
9
A
U
G
8
8
2. If equipped, remove studs using exhaust manifold
nuts.
M
3
5
3
0
2

-
U
N
-
2
9
A
U
G
8
8
M21,TM315,15 -19-05AUG87
M21,TM315,16 -19-05AUG87
010897
PN=81
15
6
3. Measure valve recession.
VALVE RECESSION SPECIFICATIONS
Intake Standard Wear Tolerance (MAX)
3TN66 0.40 mm (0.016 in.)
3TNA72 0.50 mm (0.020 in.)
3TN75/3TN78/
3TN82/3TN84/
4TN78/4TN82/
4TN84 0.300.50 mm 1.00 mm (0.039 in.)
(0.0120.020 in.)
4TN100 1.80 mm (0.071 in.)
Exhaust Standard Wear Tolerance (MAX)
3TN66 0.85 mm (0.033 in.)
3TNA72 0.85 mm (0.033 in.)
3TN75/3TN78/
3TN82/3TN84/
4TN78/4TN82/
4TN84 0.300.50 mm 1.00 mm (0.039 in.)
(0.0120.020 in.)
4TN100 1.80 mm (0.071 in.)
M
3
5
3
0
3

-
U
N
-
2
9
A
U
G
8
8
4. Compress valve springs using a valve spring
compressor. Remove retainers. Release spring pressure
and remove compressor.
Inspect retainers for groove, wear, or damage on outside
surface and wear or damage to inside tang. Replace
retainers as necessary.
M
3
5
3
0
4

-
U
N
-
2
9
A
U
G
8
8
M21,TM315,17 -19-28AUG87
M21,TM315,18 -19-19FEB86
010897
PN=82
15
7
5. Remove spring retainers (A) and springs.
6. Inspect springs for damaged or weak coils. Check
spring using a spring compression tester. If spring
strength is not correct, install new spring.
SPRING SPECIFICATIONS
Engine Measurement Wear Tolerance (MAX)
3TN66 Free length 27.5 mm
(approx) (1.083 in.)
Test length at 17 mm
125 N (0.591 in.)
(28 lb) Force
3TNA72 Free length 36.9 mm
(approx) (1.453 in.)
Test length 22.5 mm
at 299 N (0.886 in.)
(67 lb) Force
3TN75/ Free length 41.5 mm
3TN78/ (approx) (1.634 in.)
4TN78 Test length at 25.2 mm
313 N (0.992 in.)
(70 lb) Force
3TN82/3TN84/ Free length 41.5 mm
4TN82/4TN84 (approx) (1.634 in.)
Test length at 24 mm
319 N (0.945 in.)
(72 lb) Force
4TN100 Free length 42.5 mm
(approx.) (1.673 in.)
Test length at 41.5 mm
12.6 N (1.634 in.)
(5.7 lb) Force
M
3
5
3
0
5

-
U
N
-
2
9
A
U
G
8
8
M21,TM315,19 -19-28AUG87
010897
PN=83
15
8
7. Remove intake and exhaust valves.
M
3
5
3
0
6

-
U
N
-
2
9
A
U
G
8
8
8. Clean carbon from valve face, head, and stem using a
soft wire wheel on a bench grinder.
9. Remove scratches from valve stems using steel wool
or crocus cloth.
10. Inspect valve for damage, corrosion, pitting, or
burned face.
11. Check valve for out-of-round, bent, or warped
condition using a valve inspection center.
M
3
5
3
0
7

-
U
N
-
2
9
A
U
G
8
8
12. Measure valve stem diameter.
VALVE STEM O.D. SPECIFICATIONS (MIN)
3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.40 mm (0.213 in.)
3TNA72/3TN75/3TN78/4TN78 . . . . . . . . . . . . . . 6.90 mm (0.272 in.)
3TN82/4TN82/4TN84 . . . . . . . . . . . . . . . . . . . . 7.90 mm (0.311 in.)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.90 mm (0.350 in.)
M
3
5
3
0
8

-
U
N
-
2
9
A
U
G
8
8
M21,TM315,20 -19-19FEB86
M21,TM315,21 -19-19FEB86
M21,TM315,22 -19-28AUG87
010897
PN=84
15
9
13. If valve faces are worn, burned or pitted, grind
valves to proper face angle (A) following manufacturers
instructions. If valve face margin (B) is less than 0.51
mm (0.020 in.) after grinding, replace valve.
VALVE ANGLE
Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
M
3
6
2
6
7

-
U
N
-
2
9
A
U
G
8
8
IMPORTANT: Do not reuse valve stem seals if seals
are removed.
14. If necessary, remove valve stem seal and discard.
M
3
5
3
0
9

-
U
N
-
2
9
A
U
G
8
8
15. Clean valve guides using a valve guide brush.
M
3
5
3
1
0

-
U
N
-
2
9
A
U
G
8
8
M21,TM315,23 -19-22APR86
M21,TM315,24 -19-22APR86
M21,TM315,25 -19-19FEB86
010897
PN=85
15
10
16. Measure valve guide diameter.
17. If diameter is correct, determine guide-to-stem
clearance (guide diameter minus stem diameter).
VALVE GUIDE SPECIFICATIONS
Guide I.D. (MAX)
3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.58 mm (0.220 in.)
3TNA72/3TN75/3TN78/4TN78 . . . . . . . . . . . . 7.08 mm (0.279 in.)
3TN82/3TN84/
4TN82/4TN84 . . . . . . . . . . . . . . . . . . . . . . 8.10 mm (0.319 in.)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10 mm (0.358 in.)
Clearance (MAX)
All Engines . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
If valve guide diameter exceeds wear tolerance, knurl or
replace valve guide.
If clearance exceeds 0.15 mm (0.006 in.) but is less than
0.20 mm (0.008 in.), knurl valve guide.
If clearance exceeds 0.20 mm (0.008 in.), replace valve
guide.
M
3
5
3
1
1

-
U
N
-
2
9
A
U
G
8
8
18. Knurl valve guide using a valve guide knurler. Follow
tool manufactures instructions.
VALVE GUIDE KNURLERS
Engine Number Item
3TN72/ D-20018WI Knurler
3TN75/3TN78/
4TN78 D-20020WI Reamer
3TN82/3TN84/ D-20019WI Knurler
4TN82/4TN84 D-20021WI Reamer
4TN100 9 mm Knurler
9 mm Reamer
M
3
5
3
1
2

-
U
N
-
2
9
A
U
G
8
8
M21,TM315,26 -19-05AUG87
M21,TM315,27 -19-28AUG87
010897
PN=86
15
11
19. If necessary, remove valve guides using JDE-118 or
JDG-504 (3TN66UJ Engine only) Valve Guide Driver.
M
3
5
3
1
3

-
U
N
-
2
9
A
U
G
8
8
20. Clean carbon from valve seats using a wire brush
and an electric drill.
21. Inspect valve seats for cracks, pits, or excessive
wear.
22. Measure valve seat width.
VALVE SEAT WIDTH SPECIFICATIONS
Engine Valve Nominal Wear Limit (MAX)
3TN66 Intake 1.15 mm 1.65 mm
(0.045 in.) (0.065 in.)
Exhaust 1.41 mm 1.91 mm
(0.056 in.) (0.075 in.)
3TNA72/ Intake 1.44 mm 1.98 mm
3TN75/3TN78/ (0.057 in.) (0.078 in.)
4TN78 Exhaust 1.77 mm 2.27 mm
(0.070 in.) (0.089 in.)
3TN82/ Intake 1.16 mm 1.74 mm
(0.046 in.) (0.069 in.)
3TN84/ Exhaust 1.35 mm 1.94 mm
4TN82/4TN84 (0.053 in.) (0.076 in.)
4TN100 Intake 1.47 mm 2.12 mm
(0.058 in.) (0.084 in.)
Exhaust 2.01 mm 2.73 mm
(0.079 in.) (0.108 in.)
If necessary, grind valve seats to recondition or to meet
specifications.
M
3
5
3
1
4

-
U
N
-
2
9
A
U
G
8
8
M21,TM315,28 -19-20FEB86
M21,TM315,29 -19-28AUG87
010897
PN=87
15
12
IMPORTANT: Valve seats should never be cut.
Cutting a valve seat can damage its
sealing surface, which may result in
leaks or valve/seat failure. Valve seats
should be ground and lapped.
NOTE: LIGHTLY grind valve seats for a few seconds
only to avoid excessive valve seat width.
23. Grind intake valve seat using a 30 seat grinder and
exhaust valve seat using a 45 seat grinder. Follow tool
manufactures instructions.
R
2
6
1
4
3
N

-
U
N
-
0
9
D
E
C
8
8
24. Measure valve seat width after grinding.
25. If seat is too wide after grinding, grind lower seat
surface using a 70 seat grinder (B) until seat width (A)
is close to specifications.
Grind upper seat surface using a 15 Seat grinder (B)
until seat width (A) is narrowed to specifications.
26. If valve seats are ground, measure valve recession
and check contact pattern between the seat and valve
with bluing dye.
If valve recession exceeds maximum specifications or
seats cannot be reconditioned, replace valves, valve
seats and/or cylinder head.
NOTE: Valve seat inserts are available for 3TNA72 and
3TN75 engines only.
R
W
5
3
8

-
U
N
-
3
0
N
O
V
8
8
R
W
5
3
9

-
U
N
-
3
0
N
O
V
8
8
M21,TM315,30 -19-22APR86
M21,TM315,31 -19-22APR86
010897
PN=88
15
13
27. Carefully clean carbon deposits from combustion
chamber and gasket surface with a soft wire brush.
Thoroughly clean cylinder head in solvent.
28. Inspect cylinder head for cracks or discoloration.
29. Measure cylinder head flatness in several directions.
CYLINDER HEAD FLATNESS SPECIFICATIONS (MAX)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)
If cylinder head distortion exceeds specification,
resurface or replace cylinder head. Remove only enough
metal to make cylinder head flat; but do not remove
more than 0.20 mm (0.008 in.).
If cylinder head is milled down to head flatness
specification, measure valve recession.
M
3
5
3
1
6

-
U
N
-
2
9
A
U
G
8
8
ASSEMBLE CYLINDER HEAD
1. Thoroughly clean and dry all parts. Use a cylinder
head gasket kit when assembling the engine.
2. Install valve guides, with grooves upward, using
JDE-118 or JDG-504 (3TN66 Engine only) Valve Guide
Driver. Push valve guide down until top of valve guide is
specified distance above machined surface of cylinder
head.
VALVE GUIDE HEIGHT SPECIFICATIONS
3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.00 mm (0.276 in.)
3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.00 mm (0.354 in.)
3TN75/3TN78/4TN78 . . . . . . . . . . . . . . . . . . . 12.00 mm (0.472 in.)
3TN82/3TN84/
4TN82/4TN84 . . . . . . . . . . . . . . . . . . . . . . . . 15.00 mm (0.591 in.)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.50 mm (0.453 in.)
M
3
5
3
1
3

-
U
N
-
2
9
A
U
G
8
8
M
3
7
5
2
0

-
U
N
-
0
6
S
E
P
8
8
M21,TM315,32 -19-28AUG87
M21,TM315,33 -19-29AUG87
010897
PN=89
15
14
3. Measure new valve guide diameter.
4. If necessary, ream inside diameter of valve guides to
specifications using a valve guide reamer.
M
3
5
3
1
8

-
U
N
-
2
9
A
U
G
8
8
IMPORTANT: Do not reuse valve stem seals if seals
were removed.
5. Install new valve stem seals.
M
3
5
3
1
9

-
U
N
-
2
9
A
U
G
8
8
6. Put clean engine oil on valve stems.
7. Install intake and exhaust valves
If new valves are installed, measure valve recession.
Grind valve seats as required.
M
3
5
3
0
6

-
U
N
-
2
9
A
U
G
8
8
8. Install springs, with smaller pitch end (paint mark)
toward cylinder head, and spring retainers (A).
M
3
5
3
0
5

-
U
N
-
2
9
A
U
G
8
8
M21,TM315,34 -19-20FEB86
M21,TM315,35 -19-20FEB86
M21,TM315,36 -19-20FEB86
M21,TM315,37 -19-20FEB86
010897
PN=90
15
15
9. Compress valve springs using a valve spring
compressor. Install retainers. Release spring pressure
and remove compressor.
M
3
5
3
0
4

-
U
N
-
2
9
A
U
G
8
8
10. Hit valve stems lightly to seat the retainers.
M
3
5
3
2
0

-
U
N
-
2
9
A
U
G
8
8
11. If used, install studs, with short threaded end in
cylinder head. Use exhaust manifold nuts to turn studs
until studs bottom out.
M
3
5
3
0
2

-
U
N
-
2
9
A
U
G
8
8
12. Install two lifting brackets.
M
3
5
3
0
1

-
U
N
-
2
9
A
U
G
8
8
M21,TM315,38 -19-20FEB86
M21,TM315,39 -19-20FEB86
M21,TM315,40 -19-06AUG87
M21,TM315,41 -19-06AUG87
010897
PN=91
15
16
INSTALL CYLINDER HEAD
IMPORTANT: Oil passage (A) in gasket must be
located over oil passage in block.
1. Install new gasket on cylinder block. Be sure to keep
gasket dry.
M
3
5
3
2
1

-
U
N
-
2
9
A
U
G
8
8
2. Install cylinder head on cylinder block.
3. Dip entire cylinder head cap screws in clean engine
oil. Install cap screws. Tighten cap screws, in the
sequence shown, in three stages of gradually-increasing
torque:
First stagetighten all cap screws to 31% of specified
torque.
Second stagetighten all cap screws to 62% of
specified torque.
3-Cylinder Engines
Third stagetighten all cap screws to final specified
torque.
IMPORTANT: Cylinder head cap screws must be
checked for proper torque after 50
hours of engine operation.
CYLINDER HEAD CAP SCREW TORQUE SPECIFICATIONS
3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Nm (25 lb-ft)
3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Nm (45 lb-ft)
3TN75/3TN78/4TN78 . . . . . . . . . . . . . . . . . . . . . . 69 Nm (51 lb-ft) 4-Cylinder Engines
3TN82/3TN84/
4TN82/4TN84 . . . . . . . . . . . . . . . . . . . . . . . . . 78 Nm (58 lb-ft)
AFlywheel End
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Nm (116 lb-ft)
M
3
5
3
2
2

-
U
N
-
2
9
A
U
G
8
8
M
3
7
5
2
1

-
U
N
-
0
6
S
E
P
8
8
M21,TM315,42 -19-22APR86
M21,TM315,43 -19-06AUG87
010897
PN=92
15
17
4. If equipped, install valve caps.
M
3
5
4
0
1

-
U
N
-
0
6
S
E
P
8
8
5. Install pushrods, rocker arm assembly, and cover (B).
(See Group 10 in this manual.)
6. Install manifold (E). (See Group 15 in this manual.)
7. Install glow plugs (D).
8. Install nozzles (F) and lines (G). (See Group 50 in this
manual.)
9. Install pump (C). (See Group 45 in this manual.)
10. Install manifold (A). (See Group 15 in this manual.)
AExhaust Manifold
BRocker Arm Cover
CWater Pump
DGlow Plugs
EIntake Manifold
FFuel Injection Nozzles
GFuel Injection Lines
M
3
5
2
9
9

-
U
N
-
2
9
A
U
G
8
8
M21,TM315,44 -19-06AUG87
M21,TM315,45 -19-20FEB86
010897
PN=93
15
18
Name Use
Dial Indicator Measure stub shaft TIR
Feeler Gauge Measure flywheel flatness
REMOVE FLYWHEEL HOUSING AND
FLYWHEEL
1. Remove engine (See Machine Technical Manual.)
2. If equipped, remove electric clutch assembly. (See
Machine Technical Manual.)
3. If equipped, remove nuts and cap screws to remove
flywheel housing or flywheel shield.
M
3
5
3
3
0

-
U
N
-
2
9
A
U
G
8
8
4. While turning crankshaft, measure stub shaft TIR (total
indicator runout) using a dial indicator. Maximum TIR is
0.20 mm (0.008 in.).
NOTE: Turn engine crankshaft using crankshaft pulley
cap screw.
If stub shaft TIR exceeds 0.20 mm (0.008 in.), replace
stub shaft.
M
3
5
3
3
1

-
U
N
-
2
9
A
U
G
8
8
5. If equipped, remove four cap screws to remove stub
shaft.
M
3
5
3
3
2

-
U
N
-
2
9
A
U
G
8
8
M21,TM320,1 -19-22APR86
M21,TM320,3 -19-06AUG87
M21,TM320,4 -19-06AUG87
M21,TM320,5 -19-06AUG87
Group 20
Flywheel
010897
PN=94
20
1
6. Remove cap screws to remove flywheel.
M
3
5
3
3
3

-
U
N
-
2
9
A
U
G
8
8
7. Remove nuts or cap screws to remove starter.
8. If equipped remove two pins or studs (A).
M
3
5
3
3
4

-
U
N
-
2
9
A
U
G
8
8
9. Remove large-headed cap screws to remove mounting
plate and seal (A).
Remove large-headed cap screws to remove mounting
plate or housing.
3TN75 Shown
M
3
5
3
3
5

-
U
N
-
2
9
A
U
G
8
8
M
3
7
6
8
1

-
U
N
-
0
6
S
E
P
8
8
M21,TM320,6 -19-03MAR86
M21,TM320,7 -19-06AUG87
M21,TM320,8 -19-06AUG87
Flywheel/Flywheel Housing and Flywheel
010897
PN=95
20
2
INSPECT FLYWHEEL AND STUB SHAFT
1. Check flywheel and stub shaft flatness using a straight
edge and feeler gauge.
2. New part flatness specification is 0.05 mm (0.002 in.)
for stub shaft and 0.02 mm (0.0008 in.) for flywheel.
3. Inspect flywheel ring gear for chipped or broken teeth.
Replace flywheel as necessary.
4. For 4TN100 engine, inspect pilot bearing (A) for wear
and smooth rotation. Replace bearing as necessary.
M
3
5
3
3
6

-
U
N
-
2
9
A
U
G
8
8
M
3
5
3
3
7

-
U
N
-
2
9
A
U
G
8
8
M
3
5
3
3
8

-
U
N
-
2
9
A
U
G
8
8
M
5
1
5
6
3

-
U
N
-
3
1
A
U
G
8
8
M21,TM320,9 -19-28AUG87
010897
PN=96
20
3
INSTALL FLYWHEEL AND FLYWHEEL
HOUSING
1. Install foam seal (3TN66/3TNA72 engines only).
3TN66/3TNA72 M
3
5
3
4
1

-
U
N
-
2
9
A
U
G
8
8
2. Install mounting plate. Tighten cap screws to 49 Nm
(36 lb-ft).
Install mounting plate or housing. Tighten cap screws to
49 Nm (36 lb-ft).
3TN75 Shown
M
3
5
3
4
2

-
U
N
-
2
9
A
U
G
8
8
M
3
7
6
8
2

-
U
N
-
0
6
S
E
P
8
8
M21,TM320,10 -19-06AUG87
M21,TM320,11 -19-06AUG87
010897
PN=97
20
4
3. If equipped, install two pins or studs (A).
4. Install starter and two nuts or cap screws. Tighten
nuts or cap screws to specifications.
STARTER CAP SCREW OR NUT TORQUE SPECIFICATIONS
3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Nm (36 lb-ft)
All except 3TN66 . . . . . . . . . . . . . . . . . . . . . . . . 88 Nm (65 lb-ft)
M
3
5
3
4
3

-
U
N
-
2
9
A
U
G
8
8
5. Align hole (A) in flywheel with pin (B) in crankshaft.
IMPORTANT: Install new cap screws each time
flywheel is removed.
6. Apply clean engine oil to cap screw threads and
under head. Install flywheel and cap screws. Tighten cap
screws to specifications.
FLYWHEEL CAP SCREW TORQUE SPECIFICATIONS
All except 4TN100 . . . . . . . . . . . . . . . . . . . . . . . . 83 Nm (61 lb-ft)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 Nm (145 lb-ft)
M
3
5
3
4
4

-
U
N
-
2
9
A
U
G
8
8
M
3
5
3
4
5

-
U
N
-
2
9
A
U
G
8
8
M21,TM320,12 -19-28AUG87
M21,TM320,13 -19-06AUG87
010897
PN=98
20
5
7. If equipped, install stub shaft and four cap screws.
Tighten cap screws to specification.
STUB SHAFT CAP SCREW TORQUE SPECIFICATION
All Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Nm (44 lb-ft)
M
3
5
3
4
6

-
U
N
-
2
9
A
U
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8
8
8. If equipped, install flywheel housing or flywheel
shields, nuts, and cap screws.
FLYWHEEL HOUSING OR SHIELD TORQUE
Engine Item Specification
3TN66 Cap Screw (A) 49 Nm
(2 used) (36 lb-ft)
Cap Screw (B) 26 Nm
(6 used) (226 lb-in.)
3TNA72 Cap Screw (A) 49 Nm
(2 used) (36 lb-ft)
Cap Screw (B) 26 Nm
(5 used) (226 lb-in.)
Nut (C) (2 used) 88 Nm (65 lb-ft)
3TN75 Cap Screw (A) 49 Nm
(5 used) (36 lb-ft)
Cap Screw (B) 26 Nm
(3 used) (226 lb-in.)
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M21,TM320,14 -19-06AUG87
M21,TM320,15 -19-06AUG87
010897
PN=99
20
6
Name Use
Feeler Gauge Measure clearances
Outside Micrometer Measure engine components
Cylinder Bore Ridge Reamer To remove ridge from top of cylinder bore
Telescoping Gauge Measure engine components
Piston Ring Expander Remove and install piston rings
Bushing, Bearing, and Seal Driver Set Remove and install connecting rod bushing
Vernier Calipers Measure piston O.D.
Inside Micrometer Measure piston bore I.D.
Flex Hone To deglaze cylinder bores
Piston Ring Compressor Install pistons in cylinder block
OTHER MATERIALS
Name Use
PLASTIGAGE
Measure connecting rod bearing clearance

PLASTIGAGE is a trademark of the TRW Corporation
SERVICE PART KITS
catalog:
Cylinder Block Gasket Kit.
Cylinder Head Gasket Kit.
M21,TM325,1 -19-06AUG87
M21,TM325,2 -19-22APR86
M21,TM325,3 -19-03MAR86
Group 25
Connecting Rods and Pistons
010897
PN=100
25
1
MEASURE CONNECTING ROD SIDE PLAY
2. If equipped, remove electric clutch assembly (A). (See
3. Remove flywheel assembly (B). (See Group 20 in this
manual.)
4. Remove oil pan (C). (See Group 40 in this manual.)
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8
8
5. Measure connecting rod side play.
CONNECTING ROD SIDE PLAY SPECIFICATIONS (MAX)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.45 mm (0.018 in.)
If side play exceeds wear tolerance, replace connecting
rod and connecting rod cap.
M
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9

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M21,TM325,9 -19-06AUG87
M21,TM325,10 -19-28AUG87
Connecting Rods and Pistons/Measure Side Play
010897
PN=101
25
2
MEASURE CONNECTING ROD BEARING
CLEARANCE
Measure each connecting rod bearing clearance, using
the following PLASTIGAGE method or by measuring
after the pistons have been removed:
PLASTIGAGE Method
IMPORTANT: Connecting rod end caps must be
installed on the same connecting rod
and in the same direction to prevent
crankshaft and connecting rod damage.
1. Remove connecting rod cap.
2. Wipe oil from bearing insert and crankshaft journal.
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3. Put PLASTIGAGE (A) or an equivalent on the full
length of the bearing insert about 6 mm (0.25 in.) off
center.
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4. Turn crankshaft about 30 from BDC (bottom dead
center). Install connecting rod cap and cap screws.
Tighten cap screws to specifications
CONNECTING ROD CAP SCREW TORQUE SPECIFICATIONS
3TN66/3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm (200 lb-in.)
3TN75/3TN78/4TN78 . . . . . . . . . . . . . . . . . . . . . . 39 Nm (29 lb-ft)
3TN82/3TN84/
4TN82/4TN84 . . . . . . . . . . . . . . . . . . . . . . . . . 47 Nm (35 lb-ft)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Nm (69 lb-ft)
M
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M21,TM325,11 -19-22APR86
M21,TM325,12 -19-03MAR86
M21,TM325,13 -19-06AUG87
Connecting Rods and Pistons/Measure Bearing Clearance
010897
PN=102
25
3
5. Remove cap screws and connecting rod cap.
6. The flattened PLASTIGAGE will be found on either
the bearing or crankshaft journal.
7. Use the graduation marks on the envelope to
compare the width of the flattened PLASTIGAGE at its
WIDEST point.
8. Determine bearing clearance. The number within the
graduation marks indicates the bearing clearance in
inches or in millimeters depending on which side of the
envelope is used. Remove PLASTIGAGE.
CONNECTING ROD BEARING CLEARANCE SPECIFICATIONS
3TN66/3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
3TN75/3TN78/3TN82/3TN84/
4TN78/4TN82/4TN84 . . . . . . . . . . 0.16 mm (0.006 in.)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09 mm (0.004 in.)
If clearance exceeds wear tolerance, replace bearings.
If clearance is correct, install connecting rod caps. Install
and tighten cap screws to specifications.
M
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3

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8
REMOVE PISTONS AND CONNECTING
RODS
manual.)
Remove cylinder head. (See Group 15 in this manual.)
M21,TM325,14 -19-28AUG87
M21,TM325,15 -19-04MAR86
Connecting Rods and Pistons/Pistons and Connecting Rods
010897
PN=103
25
4
5. Remove two cap screws, oil suction strainer (A), and
dipstick (B).
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6. Before piston removal, check cylinder bore for ridges.
These ridges can cause damage to piston if ridge is not
removed.
7. If necessary, remove ridge from top of cylinder bore
using a ridge reamer.
IMPORTANT: Connecting rod caps must be installed
on the same connecting rod they were
removed from.
8. Remove two cap screws to remove connecting rod
cap.
M
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9. Push piston and connecting rod out of cylinder bore
using a wooden dowel.
M
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M21,TM325,16 -19-04MAR86
M21,TM325,17 -19-04MAR86
M21,TM325,18 -19-04FEB86
M21,TM325,19 -19-22APR86
010897
PN=104
25
5
INSPECT PISTONS AND CONNECTING
RODS
1. Measure crankshaft connecting rod journal diameter.
Measure several places around each journal and each
side of every journal.
NOTE: If engine has had a previous major overhaul,
connecting rod journals may have been ground
and undersize bearing inserts installed.
CONNECTING ROD JOURNAL O.D. SPECIFICATIONS (MIN)
3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.92 mm (1.414 in.)
3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.92 mm (1.572 in.)
3TN75/3TN78/4TN78 . . . . . . . . . . . . . . . . . . . 42.91 mm (1.689 in.)
3TN82/3TN84/
4TN82/4TN84 . . . . . . . . . . . . . . . . . . . . . . 47.91 mm (1.886 in.)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59.90 mm (2.358 in.)
2. If journal diameter is less than wear tolerance, replace
crankshaft or have journals ground undersize by a
qualified machine shop.
If journals are ground, undersize bearing inserts must be
installed. Bearing inserts are available in 0.25 mm (0.010
in.) undersize.
M
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8

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8
M21,TM325,20 -19-06AUG87
010897
PN=105
25
6
3. Install connecting rod cap and bearing insert on
connecting rod. Tighten connecting rod cap screws to
specifications.
4. Measure connecting rod bearing diameter and
connecting rod bearing clearance (bearing I.D. minus
journal O.D.).
3TN66/3TNA72 . . . . . . . . . . . . . . . . . . . . . . . 23 Nm (200 lb-in.)
3TN75/3TN78/4TN78 . . . . . . . . . . . . . . . . . . . . 39 Nm (29 lb-ft)
3TN82/3TN84/
4TN82/4TN84 . . . . . . . . . . . . . . . . . . . . . . . . 47 Nm (35 lb-ft)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Nm (69 lb-ft)
CONNECTING ROD BEARING SPECIFICATIONS
Bearing I.D. (MAX)
3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.07 mm (1.420 in.)
3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . . 40.07 mm (1.578 in.)
3TN75/3TN78/4TN78 . . . . . . . . . . . . . . . . . 43.07 mm (1.696 in.)
3TN82/3TN84/
4TN82/4TN84 . . . . . . . . . . . . . . . . . . . . . 48.07 mm (1.893 in.)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . 60.10 mm (2.366 in.)
Clearance (MAX)
3TN66/3TNA72 . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
3TN75/3TN78/3TN82/3TN84/
4TN78/4TN82/4TN84 . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09 mm (0.004 in.)
If bearing diameter exceeds wear tolerance, replace
bearing inserts.
If bearing clearance exceeds wear tolerance, grind
crankshaft connecting rod journals and install undersize
bearing inserts, or replace bearing inserts and
crankshaft.
If bearing diameter and clearance are within
specifications and bearings are not damaged, bearings
can be reused.
M
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3
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9

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8
M21,TM325,21 -19-28AUG87
010897
PN=106
25
7
5. Measure piston ring groove clearance. Measure
several places around each piston.
PISTON RING GROOVE CLEARANCE SPECIFICATIONS
Engine Measurement Wear Tolerance (MAX)
3TN66/ (All Rings) 0.20 mm
3TNA72 (0.008 in.)
3TN75/3TN78/3TN82/ (Top Ring and 0.25 mm
3TN84/4TN78/ Second Ring) (0.010 in.)
4TN82/4TN84 (Oil Ring) 0.20 mm (0.008 in.)
4TN100 (Top Ring) 0.20 mm (0.008 in.)
(Second and 0.15 mm (0.006 in.)
Oil Rings)
If clearance exceeds wear tolerance, replace rings or
piston.
M
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6. Remove piston rings using a piston ring expander.
7. If necessary, clean piston ring groove with a piston
ring groove cleaner, or the end of a piston ring filed to a
sharp point.
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3
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8
M21,TM325,22 -19-28AUG87
M21,TM325,23 -19-04FEB86
010897
PN=107
25
8
8. Measure piston ring end gap. Push ring into cylinder
bore until ring is approximately 30 mm (1.181 in.) from
bottom of cylinder bore.
PISTON RING END GAP SPECIFICATIONS (MAX)
All Engines . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.059 in.)
If end gap exceeds wear tolerance, replace rings.
M
3
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3
6
2

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8
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IMPORTANT: Pistons must be installed in the same
direction and on the same connecting
rod they were removed from.
9. Put a mark on each piston and connecting rod for
proper identification to aid in assembly.
10. Remove two snap rings.
11. Remove piston pin using a wooden dowel.
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8
M21,TM325,24 -19-28AUG87
M21,TM325,25 -19-04MAR86
010897
PN=108
25
9
12. Measure diameter of piston pin at six places; two
measurements 90 apart at each end and two
measurements 90 at center.
PISTON PIN O.D. SPECIFICATIONS (MIN)
3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.98 mm (0.786 in.)
3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.98 mm (0.826 in.)
3TN75/3TN78/4TN78 . . . . . . . . . . . . . . . . . . . 22.90 mm (0.902 in.)
3TN82/3TN84/
4TN82/4TN84 . . . . . . . . . . . . . . . . . . . . . . 25.90 mm (1.020 in.)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.99 mm (1.338 in.)
If pin diameter is less than wear tolerance, replace pin.
M
3
5
3
6
5

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8
8
13. Measure piston pin bushing and piston pin bushing
clearance (bushing I.D. minus pin O.D.).
PISTON PIN BUSHING SPECIFICATIONS
Bushing I.D. (MAX)
3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.10 mm (0.791 in.)
3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . . 21.10 mm (0.831 in.)
3TN75/3TN78/4TN78 . . . . . . . . . . . . . . . . . 23.10 mm (0.909 in.)
3TN82/3TN84/
4TN82/4TN84 . . . . . . . . . . . . . . . . . . . . . 26.10 mm (1.028 in.)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . 34.10 mm (1.343 in.)
Clearance (MAX)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . 0.060 mm (0.0024 in.)
If bushing diameter exceeds wear tolerance, replace
bushing.
If bushing clearance exceeds wear tolerance, replace
bushing, piston pin, or both.
M
3
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3
6
6

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8
M21,TM325,26 -19-28AUG87
M21,TM325,27 -19-28AUG87
010897
PN=109
25
10
14. Measure piston pin bore in piston and piston pin
clearance (bore I.D. minus pin O.D.).
PISTON PIN BORE SPECIFICATIONS
Bore I.D. (MAX)
3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.02 mm (0.788 in.)
3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . . 21.02 mm (0.828 in.)
3TN75/3TN78/4TN78 . . . . . . . . . . . . . . . . . 23.02 mm (0.906 in.)
3TN82/3TN84/
4TN82/4TN84 . . . . . . . . . . . . . . . . . . . . . 26.02 mm (1.024 in.)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . 34.01 mm (1.339 in.)
Clearance (MAX)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm (0.001 in.)
If piston pin bore diameter exceeds wear tolerance,
replace piston.
If piston pin clearance exceeds wear tolerance, replace
piston, piston pin, or both.
M
3
7
6
8
3

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6
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8
8
15. Remove bushing using driver disks (A and B).
DISKS FOR BUSHING REMOVAL
Engine Size (in.)
(A) (B)
3TN66 13/16 3/4
3TNA72 15/16 13/16
3TN75/3TN78/4TN78 15/16 7/8
3TN82/3TN84/
4TN82/4TN84 1 1/16 1
4TN100 1 3/8 1 5/16
M
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M21,TM325,28 -19-06AUG87
M21,TM325,29 -19-28AUG87
010897
PN=110
25
11
16. Measure piston O.D. perpendicular to piston bore at
approximate specified distance from bottom of piston.
oversize pistons and rings may have been
installed. Pistons and rings are available in 0.25
mm (0.010 in.) oversize.
PISTON (STANDARD) SPECIFICATIONS
Engine Measurement Wear Tolerance (MIN)
3TN66 O.D. at 5.00 mm 65.85 mm
(0.197 in.) (2.593 in.)
3TNA72 O.D. at 8.00 mm 71.81 mm
(0.315 in.) (2.827 in.)
3TN75 O.D. at 12.50 mm 74.81 mm
(0.492 in.) (2.945 in.)
3TN78/4TN78 O.D. at 22.00 mm 77.81 mm
(0.866 in.) (3.063 in.)
3TN82/4TN82 O.D. at 22.00 mm 81.80 mm
(0.866 in.) (3.220 in.)
3TN84/4TN84 O.D. at 29.00 mm 83.80 mm
(1.142 in.) (3.299 in.)
4TN100 O.D. at 25.50 mm 99.79 mm
(1.004 in.) (3.929 in.)
If piston diameter is less than wear tolerance, install a
new piston.
Inspect piston for cracks at ring lands, skirts, and pin
bores. Inspect piston for scuffling or scoring; replace as
necessary.
M
3
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3
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9

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8
M21,TM325,30 -19-06AUG87
010897
PN=111
25
12
17. Measure piston bore I.D. at six places; two
measurements 90 apart at top, middle, and bottom of
ring travel.
oversize pistons and rings may have been
installed.
CYLINDER BORE I.D. (STANDARD) SPECIFICATIONS
Engine Nominal Wear Tolerance (MAX)
3TN66 66.0066.03 mm 66.20 mm
(2.5982.600 in.) (2.606 in.)
3TNA72 72.0072.03 mm 72.20 mm
(2.8352.836 in.) (2.843 in.)
3TN75 75.0075.03 mm 75.20 mm
(2.9532.954 in.) (2.961 in.)
3TN78/4TN78 78.0078.03 mm 78.20 mm
(3.0713.072 in.) (3.079 in.)
3TN82/4TN82 82.0082.03 mm 82.20 mm
(3.2283.230 in.) (3.236 in.)
3TN84/4TN84 84.0084.03 mm 84.20 mm
(3.3073.308 in.) (3.315 in.)
4TN100 100.00100.03 mm 100.20 mm
(3.9373.938 in.) (3.945 in.)
CYLINDER BORE I.D. (OVERSIZE) SPECIFICATIONS
Engine Nominal Wear Tolerance (MAX)
3TN66 66.25 mm (2.608 in.) 66.45 mm (2.616 in.)
3TNA72 72.25 mm (2.844 in.) 72.45 mm (2.852 in.)
3TN75 75.25 mm (2.963 in.) 75.45 mm (2.970 in.)
3TN78/
4TN78 78.25 mm (3.081 in.) 78.45 mm (3.089 in.)
3TN82/
4TN82 82.25 mm (3.238 in.) 82.45 mm (3.246 in.)
3TN84/
4TN84 84.25 mm (3.317 in.) 84.45 mm (3.325 in.)
4TN100 100.25 mm (3.947 in.) 100.45 mm (3.955 in.)
M
3
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M21,TM325,31 -19-28AUG87
010897
PN=112
25
13
18. Measure piston clearance (piston bore I.D. minus
piston O.D.).
PISTON/CYLINDER BORE CLEARANCE SPECIFICATIONS (MAX)
3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.28 mm (0.011 in.)
3TN75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.22 mm (0.009 in.)
3TN78/3TN82/3TN84/4TN78/
4TN82/4TN84 . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 mm (0.014 in.)
If cylinder bore exceeds wear tolerance, replace cylinder
block or have cylinder rebored by a qualified machine
shop. If cylinder is rebored, oversize piston and rings
must be installed. Pistons and rings are available in 0.25
mm (0.010 in.) oversize.
If piston clearance exceeds wear tolerance, replace
cylinder block, piston or both; or rebore cylinder and
install oversize piston and rings.
DEGLAZE CYLINDER BORES
IMPORTANT: If cylinder bores are to be deglazed
with crankshaft installed in engine, put
clean shop towels over crankshaft to
protect journal and bearing surfaces
from any abrasives.
1. Deglaze cylinder bores using a flex-hone with 180 grit
stones.
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MX,TM325,A1 -19-25MAY89
M21,TM325,32 -19-04MAR86
010897
PN=113
25
14
2. Use flex-hone as instructed by manufacturer to obtain
3040 crosshatch pattern as shown.
IMPORTANT: Do not use gasoline, kerosene, or
commercial solvents to clean cylinder
bores. Solvents will not remove all
abrasives from cylinder walls.
3. Remove excess abrasive residue from cylinder walls
using a clean dry rag. Clean cylinder walls using clean
white rags and warm soapy water. Continue to clean
cylinder until white rags show no discoloration. M
5
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9
5
8

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A
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8
9
M21,TM325,33 -19-04MAR86
010897
PN=114
25
15
REBORE CYLINDER BLOCK
NOTE: The cylinder block can be rebored to use 0.25
mm (0.010 in.) oversize pistons and rings. (See
this group for cylinder bore I.D. specifications.)
1. Align center of bore to drill press center.
IMPORTANT: Check stone for wear or damage. Use a
rigid hone with 300 grit stones.
2. Adjust hone so lower end is even with lower end of
cylinder bore.
3. Adjust rigid hone stones until they contact narrowest
point of cylinder.
4. Coat cylinder with honing oil. Hone should turn by
hand. Adjust if too tight.
5. Run drill press at about 250 RPM. Move hone up and
down in order to obtain a 3040 crosshatch pattern.
NOTE: Measure bore when cylinder is cool.
6. Stop press and check cylinder diameter several times
during rebore procedure.
NOTE: Finish should not be smooth. It should have a
3040 crosshatch pattern.
7. Remove rigid hone when cylinder is within 0.03 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 this
group.)
IMPORTANT: Do not use solvents to clean cylinder
bore. Solvents will not remove all metal
particles and abrasives produced
during honing.
10. Clean cylinder thoroughly using warm soapy water
until clean white rags show no discoloration.
11. Dry cylinder and apply engine oil.
M
5
2
9
5
9

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N
-
0
5
A
P
R
8
9
MX,TM325,A2 -19-25MAY89
010897
PN=115
25
16
ASSEMBLE PISTONS AND CONNECTING
RODS
1. Turn bushing so oil holes in bushing and connecting
rod are aligned.
2. Install bushing using driver disks (A and B).
DISKS FOR BUSHING INSTALLATION
Engine Size (in.)
(A) (B)
3TN66 1 3/4
3TNA72 1 13/16
3TN75/3TN78/4TN78 1 1/4 7/8
3TN82/3TN84/
4TN82/4TN84 1 5/16 1
4TN100 1 1/2 1 5/16
M
3
5
3
6
8

-
U
N
-
2
9
A
U
G
8
8
IMPORTANT: Pistons must be installed on
connecting rods from which they were
removed.
3. Identification marks on piston must be the same side
as marks on connecting rod. If a new piston or
connecting rod is used, assemble piston to connecting
rod with piston recess (A) opposite bearing insert groove
(B).
4. Put clean engine oil on piston pin. Install pin through
piston and connecting rod.
5. Install snap rings. Be sure snap rings are fastened in
groove all around.
M
3
7
6
8
5

-
U
N
-
0
6
S
E
P
8
8
M
3
5
3
6
4

-
U
N
-
2
9
A
U
G
8
8
M21,TM325,34 -19-06AUG87
M21,TM325,35 -19-04MAR86
010897
PN=116
25
17
6. Install oil ring expander in bottom piston ring groove.
Turn expander so ends are above either end of piston
pin
7. Install oil ring over expander with a piston ring
expander. Turn oil ring so ends are on opposite side of
piston from the expander ends.
M
3
5
3
6
1

-
U
N
-
2
9
A
U
G
8
8
IMPORTANT: Piston rings must be installed with
chamfer (A), if present, toward top of
piston. Install rings with identification
mark (B) toward top of piston.
Identification mark (B) may be a T,
R, or RN.
8. Install second ring in middle groove. Turn ring until
gap is 120 away from second ring gap.
Install chrome ring in top groove. Turn ring until gap is
120 away from second ring gap. M
3
5
3
7
2

-
U
N
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0
8
S
E
P
8
8
M
3
7
6
8
6

-
U
N
-
0
6
S
E
P
8
8
M21,TM325,36 -19-04MAR86
M21,TM325,37 -19-28AUG87
010897
PN=117
25
18
INSTALL PISTONS AND CONNECTING
RODS
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. Put clean engine oil on pistons, rings, and cylinder
bore.
2. Install pistons with piston recess (A) toward fuel
injection pump using a piston ring compressor. Push
pistons down until top ring is in cylinder.
For 4TN100 engine, insert piston with size mark (A)
toward camshaft.
APiston Size Mark
BFuel Injection Pump Side
CGear Case Side
M
3
7
6
8
7

-
U
N
-
0
6
S
E
P
8
8
M
5
1
5
6
5

-
U
N
-
3
1
A
U
G
8
8
IMPORTANT: Do not touch the bearing insert
surface. Oil and acid from your finger
will corrode the bearing surface.
3. Install bearing insert in connecting rod with tang (B) in
groove (A).
4. Put clean engine oil on insert and crankshaft journal.
5. Pull connecting rod to crankshaft.
M
3
5
3
7
4

-
U
N
-
0
8
S
E
P
8
8
6. Install bearing insert in connecting rod cap with tang
(A) in groove (B).
7. Put clean engine oil on insert.
M
3
5
3
7
5

-
U
N
-
0
6
S
E
P
8
8
M21,TM325,38 -19-06AUG87
M21,TM325,39 -19-04MAR86
M21,TM325,40 -19-04MAR86
010897
PN=118
25
19
removed from and in the same
direction.
8. Install cap on connecting rod with tangs (A) to same
side.
M
3
5
3
7
6

-
U
N
-
0
6
S
E
P
8
8
IMPORTANT: Never reuse connecting rod cap
screws.
9. Dip entire connecting rod cap screw in clean engine
oil. Install cap screws in connecting rods.
10. Tighten cap screws to specifications.
3TN66/3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm (200 lb-in.)
3TN75/3TN78/4TN78 . . . . . . . . . . . . . . . . . . . . . . 39 Nm (29 lb-ft)
3TN82/3TN84/
4TN82/4TN84 . . . . . . . . . . . . . . . . . . . . . . . . . 47 Nm (35 lb-ft)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Nm (69 lb-ft)
M
3
5
3
7
7

-
U
N
-
0
6
S
E
P
8
8
11. If a new piston and connecting rod have been
installed, stamp a number corresponding to the cylinder
number on the connecting rod cap and connecting rod.
M
3
5
3
7
8

-
U
N
-
0
6
S
E
P
8
8
M21,TM325,41 -19-04MAR86
M21,TM325,42 -19-28AUG87
M21,TM325,43 -19-04MAR86
010897
PN=119
25
20
12. Install dipstick (B), oil suction strainer (A), and two
cap screws.
13. Install oil pan. (See Group 40 in this manual.)
manual.)
15. Install cylinder head. (See Group 15 in this manual.)
16. If equipped, install electric clutch assembly. (See
17. Install engine. (See Machine Technical Manual.)
M
3
5
3
7
9

-
U
N
-
0
6
S
E
P
8
8
M21,TM325,44 -19-23APR86
010897
PN=120
25
21
MEASURE PISTON-TO-CYLINDER HEAD
CLEARANCE
1. Place three 10 mm (0.4 in.)-long pieces of 1.5 mm
(0.06 in.) diameter soft wire (A) in three positions on flat
part of piston crown.
2. Install cylinder head and gasket to engine block.
Tighten cylinder head cap screws in proper sequence to
specified torque. (See Group 15.)
3. Slowly turn crankshaft one complete revolution.
4. Remove cylinder head. (See Group 15.)
5. Measure thickness of flattened section of each piece
of wire. Compute average thickness of wires and
compare to specifications.
If clearance is below specification replace parts as
necessary to correct.
PISTON TO CYLINDER HEAD CLEARANCE
SPECIFICATIONS (NOMINAL)
3TN66 . . . . . . . . . . . . . . . . . . . . 0.590.74 mm (0.0230.029 in.)
3TNA72 . . . . . . . . . . . . . . . . . . . 0.610.79 mm (0.0240.031 in.)
3TN75 . . . . . . . . . . . . . . . . . . . . 0.590.77 mm (0.0230.030 in.)
3TN78/4TN78/ . . . . . . . . . . . . . . 0.630.77 mm (0.0250.030 in.)
3TN82/4TN82 . . . . . . . . . . . . . . . 0.640.82 mm (0.0250.032 in.)
3TN84/4TN84
4TN100 . . . . . . . . . . . . . . . . . . . 0.710.89 mm (0.0280.035 in.)
M
5
2
9
6
0

-
U
N
-
0
5
A
P
R
8
9
MX,TM325,A3 -19-25MAY89
010897
PN=121
25
22
Name Use
Dial Indicator Measure crankshaft end play
Bushing, Bearing, and Seal Driver Set Remove and install seals
13-Ton Puller Set Remove crankshaft gear
Press To service crankshaft gear
Outside Micrometer Measure crankshaft journals
Telescoping Gauge Measure crankshaft bearing bore
SERVICE PART KITS
catalog:
Cylinder Block Gasket Kit
Cylinder head Gasket Kit
OTHER MATERIAL
Number Name Use
PLASTIGAGE
Measure crankshaft bearing

clearance
PT94 John Deere Form-In-Place Gasket To seal oil seal case
PLASTIGAGE is a trademark of the TRW Corporation
LOCTITE is a trademark of the LOCTITE Corp.
M21,TM330,1 -19-05MAR86
M21,TM330,2 -19-23APR86
M21,TM330,3 -19-06AUG87
Group 30
Crankshaft and Main Bearings
010897
PN=122
30
1
MEASURE CRANKSHAFT END PLAY
1. Fasten dial indicator to engine.
IMPORTANT: Do not use excessive force when
moving crankshaft to avoid damaging
bearings.
2. Push crankshaft toward front then toward rear.
3. Measure crankshaft end play.
CRANKSHAFT END PLAY SPECIFICATIONS (MAX)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.29 mm (0.011 in.)
If crankshaft end play exceeds wear tolerance, remove
crankshaft and inspect thrust bearings for wear.
M
3
5
3
8
0

-
U
N
-
0
6
S
E
P
8
8
REMOVE ENGINE BALANCER
ASSEMBLY4TN82/84
1. Drain engine oil.
2. Remove oil pan.
3. Locate and align balancer-to-crankshaft timing marks
(A). (Extension housing removed for photographic
purposes).
IMPORTANT: Rotate crankshaft to find marks or
mark a tooth on balancer gear and
crankshaft gear before removing
balancer.
M
4
8
2
6
8

-
U
N
-
0
1
N
O
V
8
9
M21,TM330,6 -19-28AUG87
MX,TM330Z,1 -19-06OCT89
Crankshaft and Main Bearings/Balancer Assembly4TN82/84
010897
PN=123
30
2
4. Remove oil pickup cap screws (A).
5. Remove cap screws (B). Carefully remove balancer.
M
4
8
3
0
9

-
U
N
-
0
1
N
O
V
8
9
DISASSEMBLE AND INSPECT
BALANCER4TN82/84
1. Disassemble balancer by removing nut (A), cap
screws (B) and shafts (C).
2. Inspect bushing (D) for signs of wear or scoring.
Clean and check oil passages for debris or blockage.
3. Check gear teeth for chipping of excessive wear.
Balancer gears (E) are pressed on shafts. If gear (F) is
damaged, check crankshaft gear and replace as
necessary. See crankshaft removal.
M
4
8
3
1
1

-
U
N
-
0
1
N
O
V
8
9
MX,TM330Z,2 -19-06OCT89
MX,TM330Z,3 -19-06OCT89
010897
PN=124
30
3
ASSEMBLE AND INSTALL BALANCER
1. Press gears (B) on shaft, flush with beveled edge.
2. When installing new bushings, align hole in bushings
with oil passage ports (C).
3. Coat bushings with oil and install balancer shafts,
aligning timing marks (A). Tighten retaining bolts to 27
Nm (20 lb-ft).
M
4
8
3
5
3

-
U
N
-
0
1
N
O
V
8
9
M
4
8
3
1
2

-
U
N
-
0
1
N
O
V
8
9
4. Install drive gear and nut (A). Tighten nut to 106 Nm
(78 lb-ft).
5. Install new o-ring (B). Install balancer assembly and
tighten cap screws to 27 Nm (20 lb-ft).
M
4
8
3
5
4

-
U
N
-
0
1
N
O
V
8
9
MX,TM330Z,4 -19-01OCT89
MX,TM330Z,5 -19-06OCT89
010897
PN=125
30
4
REMOVE AND INSTALL CRANKCASE
EXTENSION HOUSING
1. Remove two rear plate-to-extension housing cap
screws (A).
2. Remove three rear bearing-to-extension housing cap
screws (B).
3. Remove all external cap screws (C). (Front extension
housing-to-timing gear cover cap screws not shown).
4. Remove all internal cap screws (D) and remove
housing.
5. Clean gasket surfaces. Apply a bead of Form-in-Place
Gasket or equivalent on sealing surface and reinstall
housing.
TORQUE SPECIFICATIONS
Extension housing-to-block . . . . . . . . . . . . . . . . . . 27 Nm (20 lb-ft)
Extension housing-to-timing
cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm (16 lb-ft)
Rear bearing housing-to-
extension housing . . . . . . . . . . . . . . . . . . . . . . 27 Nm (20 lb-ft)
Rear plate-to-extension housing . . . . . . . . . . . . . . . 49 Nm (36 lb-ft)
Oil pan cap screws . . . . . . . . . . . . . . . . . . . . . . . 27 Nm (20 lb-ft)
M
4
8
3
1
0

-
U
N
-
0
1
N
O
V
8
9
MX,TM330Z,6 -19-06OCT89
010897
PN=126
30
5
MEASURE CRANKSHAFT BEARING
CLEARANCE
Machine Technical Manual).
manual.)
M
3
5
4
5
3

-
U
N
-
0
6
S
E
P
8
8
5. Remove oil suction strainer (A), and dipstick (B).
M
3
5
3
5
4

-
U
N
-
2
9
A
U
G
8
8
M21,TM330,7 -19-05MAR86
M21,TM330,8 -19-06AUG87
Crankshaft and Main Bearings/Measure Crankshaft Bearing Clearance
010897
PN=127
30
6
6. Measure reach crankshaft bearing clearance using the
following PLASTIGAGE method or by measuring after
the crankshaft has been removed.
PLASTIGAGE method:
IMPORTANT: Main bearing caps must be installed on
the same main bearing from which they
were removed. Arrows on bearing caps
point toward flywheel end of block.
a. Remove main bearing cap.
b. Wipe oil from bearing insert and crankshaft journal.
M
3
5
3
8
1

-
U
N
-
0
6
S
E
P
8
8
c. Put a piece of PLASTIGAGE (A) or an equivalent on
the full length of the bearing insert about 6 mm (1/4 in.)
off center.
M
3
5
3
8
2

-
U
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-
0
6
S
E
P
8
8
d. Install main bearing cap and cap screws. Tighten cap
screws to specifications.
MAIN BEARING CAP SCREW TORQUE SPECIFICATIONS
3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Nm (40 lb-ft)
3TN75/3TNA72/3TN78/4TN78 . . . . . . . . . . . . . . . . 79 Nm (58 lb-ft)
3TN82/3TN84/
4TN82/4TN84 . . . . . . . . . . . . . . . . . . . . . . . . . 98 Nm (72 lb-ft)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 Nm (145 lb-ft) M
3
5
3
8
3

-
U
N
-
0
6
S
E
P
8
8
M21,TM330,9 -19-05MAR86
M21,TM330,10 -19-05MAR86
M21,TM330,11 -19-28AUG87
010897
PN=128
30
7
e. Remove cap screws and main bearing cap.
f. The flattened PLASTIGAGE will be found on either the
bearing or crankshaft journal.
g. Use the graduation marks on the envelope to
compare the width of the flattened PLASTIGAGE at its
WIDEST point.
h. Determine main bearing clearance. The number within
the graduation marks on the envelope indicates the
bearing clearance in thousandths of an inch or in
millimeters depending on which side of the envelope is
used. Remove PLASTIGAGE.
MAIN BEARING CLEARANCE SPECIFICATIONS
3TN66/3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
3TN75/3TN78/4TN78/
3TN82/4TN82/
3TN84/4TN84 . . . . . . . . . . . . . . . . . . . . . . . 0.16 mm (0.006 in.)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09 mm (0.004 in.)
If clearance exceeds wear tolerance, remove crankshaft.
If clearance is correct, install main bearing caps and
tighten cap screws to specifications.
M
3
5
3
8
4

-
U
N
-
0
6
S
E
P
8
8
M21,TM330,12 -19-28AUG87
010897
PN=129
30
8
REMOVE CRANKSHAFT OIL SEAL
2. If equipped, remove electric clutch (A). (See Machine
Technical Manual).
manual.)
M
3
5
4
5
2

-
U
N
-
0
6
S
E
P
8
8
4. Remove attaching cap screws.
5. Remove oil seal case.
M
3
5
4
0
4

-
U
N
-
0
6
S
E
P
8
8
M
3
5
4
0
5

-
U
N
-
0
6
S
E
P
8
8
M21,TM330,13 -19-05MAR86
M21,TM330,14 -19-05MAR86
Crankshaft and Main Bearings/Crankshaft Oil Seal
010897
PN=130
30
9
6. Remove oil seal using driver disks (A and B).
7. Remove old gasket material from plate.
DISKS FOR SEAL REMOVAL
Engine Size (in.)
(A) (B)
3TN66/3TNA72 3-13/16 2-5/16
3TN75/3TN78/3TN82/3TN84/
4TN78/4TN82/4TN84 3-1/2 2-7/8
4TN100 4-1/2 3-3/4
M
3
5
3
8
7

-
U
N
-
0
6
S
E
P
8
8
INSTALL CRANKSHAFT OIL SEAL
1. Install seal, with lip of seal, toward cylinder block. Use
driver disks (A and B) to push seal even with surface of
oil seal case.
If crankshaft is grooved at oil seal contact point, seal can
be installed 3.0 mm (0.12 in.) farther into oil seal case.
DISKS FOR SEAL INSTALLATION
Engine Size (in.)
(A) (B)
3TN66/3TNA72 3-13/16 2-5/16
3TN75/3TN78/3TN82/3TN84/
4TN78/4TN82/4TN84 3-1/2 2-7/8
4TN100 4-1/2 3-3/4
M
3
5
3
8
7

-
U
N
-
0
6
S
E
P
8
8
M21,TM330,15 -19-06AUG87
M21,TM330,16 -19-06AUG87
010897
PN=131
30
10
2. Apply RTV rubber silicone sealant or an equivalent on
the oil seal case.
3. Align oil seal case with dowel pins on the cylinder
block.
4. Install and tighten cap screws to specifications.
OIL SEAL CASE CAP SCREW TORQUE SPECIFICATIONS
3TN66/3TNA72 Seal case to block 11 Nm (96 lb-in.)
Oil pan to seal case 9 Nm (78 lb-in.)
3TN75/3TN78/
3TN82/3TN84/
4TN78/4TN82/
4TN84 Seal case to block 26 Nm (226 lb-in.)
4TN100 Oil pan to seal case 21 Nm (180 lb-in.)
manual.)
6. If equipped, install electric clutch. (See Machine
Technical Manual).
M
3
5
4
0
6

-
U
N
-
0
6
S
E
P
8
8
M
3
5
4
0
7

-
U
N
-
0
6
S
E
P
8
8
M21,TM330,17 -19-06AUG87
010897
PN=132
30
11
REMOVE CRANKSHAFT
2. Measure crankshaft end play. (See Group 30 in this
manual.)
3. Remove cylinder head (A) and cam followers. (See
Group 15 in this manual.)
4. Remove camshaft (B). (See Group 15 in this manual.)
5. Remove gear housing (C). (See Group 35 in this
manual.)
6. Remove flywheel assembly (E). (See Group 20 in this
manual.)
7. Remove oil pan (D). (See Group 40 in this manual.)
M
3
5
3
2
3

-
U
N
-
2
9
A
U
G
8
8
8. Remove attaching cap screws.
9. Remove oil seal case.
M
3
5
3
8
5

-
U
N
-
0
6
S
E
P
8
8
M
3
5
3
8
6

-
U
N
-
0
6
S
E
P
8
8
M21,TM330,18 -19-23APR86
M21,TM330,19 -19-05MAR86
Crankshaft and Main Bearings/Crankshaft
010897
PN=133
30
12
10. Remove oil seal using driver disks (A and B).
11. Remove old gasket material from plate.
Engine Size (in.)
(A) (B)
3TN66/3TNA72 3-13/16 2-5/16
3TN75/3TN78/3TN82/3TN84/
4TN78/4TN82/4TN84 3-1/2 2-7/8
4TN100 4-1/2 3-3/4
M
3
5
3
8
7

-
U
N
-
0
6
S
E
P
8
8
12. Remove oil suction strainer (A), and dipstick (B).
M
3
5
3
5
4

-
U
N
-
2
9
A
U
G
8
8
IMPORTANT: Connecting rod end caps must be
installed on the same connecting rod
from which they were removed.
13. Remove cap screws and connecting rod caps.
14. Push pistons and connecting rod away from
crankshaft but not out of the block.
M
3
5
3
5
6

-
U
N
-
2
9
A
U
G
8
8
M21,TM330,20 -19-07AUG87
M21,TM330,21 -19-07AUG87
M21,TM330,22 -19-05MAR86
010897
PN=134
30
13
the same main bearings from which
they were removed.
15. Remove cap screws and main bearing caps (A).
16. Remove two cap screws, main bearing cap (B), and
thrust bearing set.
M
3
5
3
8
8

-
U
N
-
0
6
S
E
P
8
8
17. Remove crankshaft.
M
3
5
3
8
9

-
U
N
-
0
6
S
E
P
8
8
18. Remove thrust bearings.
M
3
5
3
9
0

-
U
N
-
0
6
S
E
P
8
8
DISASSEMBLE AND INSPECT CRANKSHAFT
1. Inspect gear for chipped or broken teeth; replace if
necessary.
IMPORTANT: Be sure to hold crankshaft while
removing crankshaft gear.
2. Remove gear using a 1-in. driver disk (A), bearing
puller attachment, and a press.
M
3
5
3
9
1

-
U
N
-
0
6
S
E
P
8
8
M21,TM330,23 -19-07AUG87
M21,TM330,24 -19-05MAR86
M21,TM330,25 -19-05MAR86
M21,TM330,26 -19-05MAR86
010897
PN=135
30
14
3. Measure crankshaft main bearing journal diameter.
crankshaft journals may have been ground and
undersize bearing inserts installed.
4. Measure several places around each journal and each
side of every journal. For connecting rod journal
specifications, see Pistons and Connecting Rods in
Group 25.
MAIN BEARING JOURNAL O.D. SPECIFICATIONS (MIN)
3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.92 mm (1.572 in.)
3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.92 mm (1.729 in.)
3TN75/3TN78/4TN78 . . . . . . . . . . . . . . . . . . . 46.91 mm (1.847 in.)
3TN82/3TN84/
4TN82/4TN84 . . . . . . . . . . . . . . . . . . . . . . 49.90 mm (1.965 in.)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69.90 mm (2.752 in.)
If journal diameter is less than wear tolerance, replace
crankshaft or have journals ground undersize by a
qualified machine shop.
in.) undersize.
M
3
5
3
9
2

-
U
N
-
0
6
S
E
P
8
8
M21,TM330,27 -19-07AUG87
010897
PN=136
30
15
5. Install main bearing cap and bearing insert on main
bearing. Tighten main bearing cap screws to
specifications.
6. Measure main bearing diameter and main bearing
clearance (bearing I.D. minus journal O.D.).
3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Nm (40 lb-ft)
3TNA72/3TN75/3TN78/4TN78 . . . . . . . . . . . . . . . . 79 Nm (58 lb-ft)
3TN82/3TN84/
4TN82/4TN84 . . . . . . . . . . . . . . . . . . . . . . . . . 98 Nm (72 lb-ft)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 Nm (145 lb-ft)
MAIN BEARING SPECIFICATIONS
Bearing I.D. (MAX)
3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.07 mm (1.578 in.)
3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . . 44.07 mm (1.735 in.)
3TN75/3TN78/4TN78 . . . . . . . . . . . . . . . . . 47.10 mm (1.854 in.)
3TN82/3TN84/
4TN82/4TN84 . . . . . . . . . . . . . . . . . . . . . 50.10 mm (1.972 in.)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09 mm (0.004 in.)
Clearance (MAX)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09 mm (0.004 in.)
If bearing diameter exceeds wear tolerance, replace
bearing inserts.
If bearing clearance exceeds wear tolerance; replace
bearing inserts and crankshaft, or have crankshaft main
bearing journals ground undersize by a qualified machine
shop.
in.) undersize.
If bearing diameter and clearance are within
specifications and bearings are not damaged, bearings
can be reused.
M
3
5
4
0
8

-
U
N
-
0
6
S
E
P
8
8
M21,TM330,28 -19-28AUG87
010897
PN=137
30
16
7. Clean and inspect oil passages in main bearing
journals, connecting rod journals, and main bearing bores
in cylinder block. Use a piece of wire to clean oil
passages if necessary.
8. Inspect crankshaft for cracks or other damage; replace
crankshaft as necessary.
M
3
5
3
9
4

-
U
N
-
0
6
S
E
P
8
8
ASSEMBLE CRANKSHAFT
N
CAUTION: DO NOT heat oil over (182C) 360F.
Oil fumes or oil can ignite above (193C) 380F.
Use a thermometer. Do not allow a flame or
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 burns.
1. Heat crankshaft gear to approximately 150C (300F).
2. Install gear (B) with timing mark A or dot on press
table.
3. Align slot in gear with key in shaft.
4. Push crankshaft into gear until gear is tight against
crankshaft shoulder. Use a 1-11/16 in. driver disk (A)
and a press.
T
8
1
1
9
1

-
U
N
-
2
3
F
E
B
8
9
INSTALL CRANKSHAFT
1. Install bearing inserts in crankshaft bearing bores with
tang (A) in groove (B).
2. Put clean engine oil on inserts.
M
3
5
3
9
6

-
U
N
-
0
6
S
E
P
8
8
M21,TM330,29 -19-05MAR86
M21,TM330,30 -19-28AUG87
M21,TM330,31 -19-05MAR86
010897
PN=138
30
17
3. Install thrust bearings, with oil grooves to the outside,
in the number 1 main bearing bore.
M
3
5
3
9
0

-
U
N
-
0
6
S
E
P
8
8
4. Install bearing inserts in main bearing caps with tang
(A) in groove (B).
5. Put clean engine oil on insert.
M
3
5
3
9
7

-
U
N
-
0
6
S
E
P
8
8
6. Put clean engine oil on crankshaft main bearing
journals.
7. Install crankshaft in cylinder block.
M
3
5
3
8
9

-
U
N
-
0
6
S
E
P
8
8
M21,TM330,32 -19-05MAR86
M21,TM330,33 -19-05MAR86
M21,TM330,34 -19-05MAR86
010897
PN=139
30
18
the same main bearing from which they
were removed. Main bearing caps and
cylinder block are numbered.
8. Install main thrust bearing, with oil grooves to the
outside, in the number 1 main bearing bore.
9. Install main bearing caps in cylinder block. Caps and
cylinder block are numbered, so caps can be installed in
their original locations. Arrows (A) must point toward
flywheel side of engine.
10. Dip entire main bearing cap screws in clean engine
oil.
11. Install cap screws in main bearing cap. Tighten cap
screws tight.
M
3
5
3
9
8

-
U
N
-
0
6
S
E
P
8
8
12. Lightly hit the front end of the crankshaft with a
soft-faced hammer; then the rear end of the crankshaft
to align the main thrust bearing halves.
M
3
5
4
0
9

-
U
N
-
0
6
S
E
P
8
8
M21,TM330,35 -19-05MAR86
M21,TM330,36 -19-05MAR86
010897
PN=140
30
19
IMPORTANT: DO NOT use high speed power tools or
air wrenches to tighten main bearing
cap screws.
13. Tighten main bearing cap screws to specifications.
Turn crankshaft by hand. If it does not turn easily,
disassemble parts and find the cause.
3TN66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Nm (40 lb-ft)
3TNA72/3TN75/3TN78/4TN78 . . . . . . . . . . . . . . . . 79 Nm (58 lb-ft)
3TN82/3TN84/
4TN82/4TN84 . . . . . . . . . . . . . . . . . . . . . . . . . 98 Nm (72 lb-ft)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 Nm (145 lb-ft)
M
3
5
4
1
0

-
U
N
-
0
6
S
E
P
8
8
removed from and in the same
direction.
14. Install cap on connecting rod with tang (A) to same
side.
M
3
5
3
7
6

-
U
N
-
0
6
S
E
P
8
8
M21,TM330,37 -19-07AUG87
M21,TM330,38 -19-05MAR86
010897
PN=141
30
20
IMPORTANT: Never reuse connecting rod cap
screws.
15. Dip entire connecting rod cap screw in clean engine
oil. Install cap screws in connecting rods.
16. Tighten cap screws to specifications.
3TN66/3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm (200 lb-in.)
3TN75/3TN78/4TN78 . . . . . . . . . . . . . . . . . . . . . . 39 Nm (29 lb-ft)
3TN82/3TN84/
4TN82/4TN84 . . . . . . . . . . . . . . . . . . . . . . . . . 47 Nm (35 lb-ft)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Nm (69 lb-ft)
M
3
5
3
7
7

-
U
N
-
0
6
S
E
P
8
8
17. Install dipstick (B), and oil suction strainer (A).
M
3
5
3
7
9

-
U
N
-
0
6
S
E
P
8
8
M21,TM330,39 -19-28AUG87
M21,TM330,40 -19-07AUG87
010897
PN=142
30
21
18. Install seal with lip of seal toward cylinder block. Use
driver disks (A and B) to push seal even with surface of
oil seal case.
If crankshaft is grooved at oil seal contact point, seal can
be installed 3.0 mm (0.12 in.) farther into oil seal case.
Engine Size (in.)
(A) (B)
3TN66/3TNA72 3-13/16 2-5/16
3TN75/3TN78/3TN82/3TN84/
4TN78/4TN82/4TN84 3-1/2 2-7/8
4TN100 4-1/2 3-3/4
M
3
5
3
8
7

-
U
N
-
0
6
S
E
P
8
8
M21,TM330,41 -19-07AUG87
010897
PN=143
30
22
19. Apply RTV rubber silicone sealant or an equivalent
on the oil seal case.
20. Align oil seal case with dowel pins on the cylinder
block.
21. Install and tighten cap screws to specifications.
OIL SEAL CASE CAP SCREW TORQUE
Oil pan to seal case 9 Nm (78 lb-in.)
All except
22. Install oil pan. (See Group 40 in this manual.)
manual.)
24. If equipped, install electric clutch assembly. (See
25. Install gear housing. (See Group 35 in this manual.)
26. Install camshaft. (See Group 15 in this manual.)
27. Install cam followers and cylinder head. (See Group
15 in this manual.)
M
3
5
4
1
1

-
U
N
-
0
6
S
E
P
8
8
M21,TM330,42 -19-28AUG87
010897
PN=144
30
23
010897
PN=145
30
24
Name Use
Strap Wrench Remove crankshaft pulley
13-Ton Puller Set Remove crankshaft pulley and gears
Dial Indicator Measure timing gear backlash
Telescoping Gauge Measure idler gear bushing diameter
Outside Micrometer Measure idler shaft diameter
Belt Tension Gauge Check belt tension
O-Ring Seal Tool Set Remove and install O-rings
OTHER MATERIAL
Number Name Use
PT94 John Deere Form-In-Place Gasket To seal gear housing cover and
(RTV rubber silicone sealant) gear housing.
AT52853 John Deere LOCTITE Thread Lock Apply to threads of gear housing
and Sealer (Low Strength) studs.
T43512 John Deere LOCTITE Thread Lock Apply to threads of crankshaft
LOCTITE is a trademark of the LOCTITE Corp.
M21,TM335,1 -19-23MAY86
M21,TM335,2 -19-07AUG87
Group 35
Gear Housing
010897
PN=146
35
1
REMOVE TIMING GEAR COVER
2. Remove fan, if equipped.
3. Remove alternator belt and alternator.
4. Hold crankshaft pulley using a strap wrench. Remove
cap screw and washer.
M
3
5
2
7
0

-
U
N
-
2
9
A
U
G
8
8
5. Remove crankshaft pulley using puller, shaft protector,
and two 8 mm cap screws.
M
3
7
5
0
8

-
U
N
-
2
9
A
U
G
8
8
NOTE: For all engines except 3TNA72UJ (Early Units)
go to step 8.
6. Remove cotter pin and washer (A) to disconnect fuel
shut-off solenoid linkage.
M
3
5
2
7
2

-
U
N
-
2
9
A
U
G
8
8
7. Remove two nuts and one cap screw to remove
bracket and fuel shut-off solenoid.
M
3
5
2
7
3

-
U
N
-
2
9
A
U
G
8
8
M21,TM335,5 -19-07AUG87
M21,TM310,38 -19-18FEB86
M21,TM310,39 -19-18FEB86
M21,TM310,40 -19-18FEB86
Gear Housing/Timing Gear Cover
010897
PN=147
35
2
8. Remove cap screws to remove gear housing cover.
Remove gasket material from cover and gear housing.
M
3
7
5
1
1

-
U
N
-
0
6
S
E
P
8
8
9. Remove seal using the correct driver disks (A and B)
or screwdriver.
Engine Size (in.)
(A) (B)
3TN66 1 11/16 2 3/8
3TNA72 1 3/4 2 7/16
3TN75/3TN78/3TN82/3TN84/
4TN78/4TN82/4TN84 2 1/8 2 3/4
4TN100 1 5/8 2 3/8
M
3
5
2
7
5

-
U
N
-
2
9
A
U
G
8
8
M21,TM310,41 -19-18FEB86
M21,TM310,42 -19-07AUG87
010897
PN=148
35
3
INSTALL TIMING GEAR COVERS
1. Thoroughly clean and dry all parts. Use new gaskets,
O-rings, and oil seals when assembling the engine.
2. Install seal with lip of seal toward inside of gear
housing cover. Use the correct driver disks (A and B) to
install seal flush with surface of gear housing cover.
Engine Size (in.)
(A) (B)
3TN66 1 11/16 2 1/2
3TNA72 1 3/4 2 9/16
3TN75/3TN78/3TN82/3TN84/
4TN78/4TN82/4TN84 2 1/8 2 7/8
4TN100 1 5/8 2 1/2
M
3
5
2
7
5

-
U
N
-
2
9
A
U
G
8
8
3. Apply a bead of plastic gasket or equivalent on
sealing surface of gear housing cover.
4. Install gear housing cover and fasten with cap screws.
Tighten cap screws to specifications.
GEAR HOUSING COVER CAP SCREW TORQUE
3TN66/3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Nm (78 lb-in.)
M
3
7
5
1
9

-
U
N
-
0
6
S
E
P
8
8
M21,TM335,6 -19-07AUG87
M21,TM335,7 -19-07AUG87
010897
PN=149
35
4
NOTE: For all engines except 3TNA72UJ (Early Units),
go to step 7.
5. Install bracket and fuel shut-off solenoid. Install and
tighten two nuts and cap screws to 9 Nm (78 lb-in.).
M
3
5
2
9
4

-
U
N
-
2
9
A
U
G
8
8
6. Fasten fuel shut-off solenoid linkage with washer and
cotter pin.
M
3
5
2
7
2

-
U
N
-
2
9
A
U
G
8
8
7. Align pin (A) (if equipped) in crankshaft pulley with
hole (B). Install pulley.
M
3
5
2
9
5

-
U
N
-
2
9
A
U
G
8
8
8. Apply thread lock and sealer (medium strength) on
threads of cap screw. Install washer and cap screw.
Tighten cap screw to 115 Nm (85 lb-ft).
9. Install alternator, alternator belt, and fan, if equipped.
M
3
5
2
9
6

-
U
N
-
2
9
A
U
G
8
8
M21,TM335,8 -19-07AUG87
M21,TM335,9 -19-01SEP87
M21,TM335,10 -19-01SEP87
M21,TM335,11 -19-07AUG87
010897
PN=150
35
5
REMOVE AND INSPECT TIMING GEARS
(EARLY 3TNA72UJ)
1. Measure backlash between gears.
TIMING GEAR BACKLASH SPECIFICATIONS (MAX)
Fuel Injection Pump (A) . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
Idler (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
Camshaft (C) . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
Crankshaft (D) . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
Oil Pump (E) . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
If backlash exceeds the wear tolerance specifications,
replace gears as necessary.
NOTE: Due to the odd number of teeth on the idler gear,
timing marks will only align periodically. Number
one cylinder is closest to the flywheel.
M
3
5
4
8
9

-
U
N
-
0
6
S
E
P
8
8
2. Remove idler gear. Inspect gear for chipped or broken
teeth; replace if necessary.
M
3
5
4
9
1

-
U
N
-
2
6
A
U
G
8
8
3. Measure bushing inside diameter.
If diameter exceeds 20.08 mm (0.791 in.), replacing
bushing.
M
3
5
4
9
2

-
U
N
-
2
6
A
U
G
8
8
M21,TM335,12 -19-23APR86
M21,TM335,13 -19-07FEB86
M21,TM335,14 -19-07FEB86
Gear Housing/Timing Gears (Early 3TNA72UJ)
010897
PN=151
35
6
4. If necessary, remove bushing using a 7/8 in. driver
disk (A) and 3/4 in. driver disk (B).
M
3
5
4
9
3

-
U
N
-
2
6
A
U
G
8
8
5. Measure idler shaft diameter.
If diameter is less than 19.3 mm (0.785 in.), replace idler
shaft.
6. Determine idler shaft clearance (bushing diameter
minus shaft diameter).
If clearance exceeds 0.15 mm (0.006 in.), replace idler
shaft, idler bushing, or both.
M
3
5
4
9
4

-
U
N
-
2
6
A
U
G
8
8
7. Remove set screw.
M
3
5
4
9
5

-
U
N
-
2
6
A
U
G
8
8
8. Remove idler shaft using a slide hammer and puller.
AGear Housing Cover Cap Screw
BWasher
CBearing Puller
DH-Bar
ESlide Hammer
M
3
5
4
9
6

-
U
N
-
2
6
A
U
G
8
8
M21,TM335,15 -19-07FEB86
M21,TM335,16 -19-07FEB86
M21,TM335,17 -19-07FEB86
M21,TM335,18 -19-07FEB86
010897
PN=152
35
7
INSTALL TIMING GEARS (EARLY 3TNA72UJ)
1. Thoroughly clean and dry all parts.
2. Install idler shaft with flange toward cylinder block.
Idler shaft flange must be tight against bottom of cylinder
block bore.
M
3
5
4
9
7

-
U
N
-
2
6
A
U
G
8
8
3. Install and tighten set screw.
M
3
5
4
9
5

-
U
N
-
2
6
A
U
G
8
8
4. Align holes in bushing and idler gear.
5. Install bushing even with surface of idler gear using a
1-in. driver disk (A) and 3/4 in. driver disk (B).
M
3
5
4
9
3

-
U
N
-
2
6
A
U
G
8
8
M21,TM335,19 -19-07FEB86
M21,TM335,20 -19-07FEB86
M21,TM335,21 -19-07FEB86
010897
PN=153
35
8
6. Install gears, if removed.
7. Align timing marks between crankshaft, idler, fuel
injection pump, and camshaft gears.
NOTE: Number one cylinder is closest to flywheel.
8. Carefully install idler gear.
TIMING MARKS
Timing Mark Gear
AA Crankshaft-to-idler
BB Engine Camshaft-to-idler
CC Fuel Injection Pump
Camshaft-to-Idler
M
5
2
9
5
6

-
U
N
-
0
5
A
P
R
8
9
(3TN66/LATER 3TNA72)
1. Measure backlash between gear.
Fuel Injection Pump (A) . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
Idler (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
Camshaft (C) . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
Crankshaft (D) . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
Oil Pump (E) . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
replace gears as required.
M
3
7
8
3
2

-
U
N
-
2
9
A
U
G
8
8
M21,TM335,22 -19-23APR86
M21,TM335,23 -19-08AUG87
Gear Housing/Timing Gears (3TN66, Later 3TNA72)
010897
PN=154
35
9
2. Remove snap ring and washer (A) to remove idler
gear. Inspect gear for chipped or broken teeth; replace if
necessary.
M
3
7
8
3
3

-
U
N
-
2
9
A
U
G
8
8
If diameter exceeds 20.08 mm (0.791 in.), replacing
bushing.
M
3
5
4
9
2

-
U
N
-
2
6
A
U
G
8
8
4. If necessary, remove bushing using a 7/8 in. driver
disk (A) and 3/4 in. driver disk (B).
M
3
5
4
9
3

-
U
N
-
2
6
A
U
G
8
8
If diameter is less than 19.93 mm (0.785 in.), replace
idler shaft.
6. Determine idler shaft oil clearance (bushing diameter
If clearance exceeds 0.15 mm (0.006 in.), replace idler
M
3
7
8
3
4

-
U
N
-
2
9
A
U
G
8
8
M21,TM335,24 -19-07FEB86
M21,TM335,14 -19-07FEB86
M21,TM335,15 -19-07FEB86
M21,TM335,25 -19-23APR86
010897
PN=155
35
10
7. Remove three cap screws to remove idler shaft.
M
3
7
8
3
5

-
U
N
-
2
9
A
U
G
8
8
INSTALL TIMING GEARS (3TN66/LATER
3TNA72)
2. Install idler shaft and three cap screws. Tighten cap
screws.
M
3
7
8
3
5

-
U
N
-
2
9
A
U
G
8
8
3. Align oil holes in bushing and idler gear.
1 in. driver disk (A) and 3/4 in. driver disk (B).
M
3
5
4
9
3

-
U
N
-
2
6
A
U
G
8
8
M21,TM335,26 -19-07FEB86
M21,TM335,27 -19-08AUG87
M21,TM335,28 -19-07FEB86
010897
PN=156
35
11
6. Align timing marks (A, B, and C) between crankshaft,
idler, fuel injection pump and camshaft gears.
NOTE: Number one cylinder is closest to the flywheel.
7. Install idler gear, washer, and snap ring.
(Later 3TNA72UJ)
(3TN66UJ)
M
3
7
8
0
5

-
U
N
-
2
9
A
U
G
8
8
M
3
7
8
0
6

-
U
N
-
2
9
A
U
G
8
8
M21,TM335,29 -19-23APR86
010897
PN=157
35
12
(ALL EXCEPT 3TN66/3TNA72)
1. Measure backlash between gears.
3TN75/3TN78/3TN82/3TN84/4TN78/4TN82/4TN84
Fuel Injection Pump (A) . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
Idler (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
Camshaft (C) . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
Crankshaft (D) . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
Oil Pump (E) . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
4TN100
Fuel Injection Pump (A) . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
Idler (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
Camshaft (C) . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
Crankshaft (D) . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
Oil Pump (E) . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.)
replace gears as required.
M
3
7
8
3
6

-
U
N
-
2
9
A
U
G
8
8
2. Remove two cap screws to remove idler shaft and
idler gear. Inspect gear for chipped or broken teeth;
replace if necessary.
M
3
7
8
3
7

-
U
N
-
2
9
A
U
G
8
8
M21,TM335,30 -19-08AUG87
M21,TM335,31 -19-07FEB86
Gear Housing/Timing Gears (All Except 3TN66/3TNA72
010897
PN=158
35
13
If diameter exceeds 46.08 mm (1.814 in.), replace
bushing.
M
3
7
8
3
8

-
U
N
-
2
9
A
U
G
8
8
4. If necessary, remove bushing using a 1 15/16 in.
driver disk (A) and 1 13/16 in. driver disk (B).
M
3
7
8
3
9

-
U
N
-
2
9
A
U
G
8
8
If diameter is less than 45.93 mm (1.808 in.), replace
idler shaft.
6. Determine idler shaft oil clearance (bushing diameter
If oil clearance exceeds 0.15 mm (0.006 in.) replace idler
M
3
7
8
4
0

-
U
N
-
2
9
A
U
G
8
8
INSTALL TIMING GEARS (ALL EXCEPT
3TN66/3TNA72)
2. Align oil holes in bushing and idler gear.
2 1/4 in. driver disk (A) and 1 13/16 in. driver disk (B).
M
3
7
8
3
9

-
U
N
-
2
9
A
U
G
8
8
M21,TM335,32 -19-23APR86
M21,TM335,33 -19-07FEB86
M21,TM335,34 -19-07FEB86
M21,TM335,35 -19-10AUG87
010897
PN=159
35
14
5. Align timing marks (A, B, and C) between crankshaft,
idler, fuel injection pump, and camshaft gear.
7. Install idler shaft and two cap screws. Tighten cap
screws
TIMING MARKS
Timing Mark Gear
AA Engine Camshaft-to-idler
BB Fuel Injection Pump-to-idler
CC Crankshaft-to-idler
3TN75,78,82,84/4TN78,82,84
AA Crankshaft-to-idler
BB Fuel Injection
Pump-to-idler
CC Engine camshaft-to-idler
4TN100
M
3
7
8
4
1

-
U
N
-
2
9
A
U
G
8
8
M
5
1
5
6
4

-
U
N
-
3
1
A
U
G
8
8
M21,TM335,36 -19-10AUG87
010897
PN=160
35
15
REMOVE GEAR HOUSING
1. Remove timing gear cover. (See Group 35 in this
manual).
2. Remove fuel injection pump and camshaft (A). (See
Group 50 in this manual).
3. Remove idler gear (B). (See Group 35 in this manual).
4. Remove engine camshaft and gear (C). (See Group
10 in this manual).
5. Remove oil pump assembly (D). (See Group 40 in this
manual.)
AInjection Pump Camshaft/Gear
BIdler Gear
CEngine Camshaft/Gear
DOil Pump/Gear
Later 3TNA72UJ Shown
M
3
7
8
4
2

-
U
N
-
2
9
A
U
G
8
8
NOTE: For all engines except early 3TNA72U go to step
12.
6. Remove throttle linkage (A). (See Group 55 in this
manual).
7. Remove governor linkage (B). See Group 55 in this
manual.)
8. Remove oil pump cover (C) and oil pump (D). (See
AThrottle Linkage
BGovernor Linkage
COil Pump Cover
DOil pump
M
3
5
5
0
2

-
U
N
-
2
6
A
U
G
8
8
M21,TM335,37 -19-10AUG87
M21,TM335,38 -19-07FEB86
Gear Housing/Gear Housing
010897
PN=161
35
16
9. Remove cover and gasket (A).
M
3
5
5
0
3

-
U
N
-
2
6
A
U
G
8
8
10. Remove seven studs and two spring pins (A).
M
3
5
5
0
4

-
U
N
-
2
6
A
U
G
8
8
11. Remove two cap screws to remove bracket.
M
3
5
5
0
5

-
U
N
-
2
6
A
U
G
8
8
NOTE: Early 3TNA72UJ: be careful not to lose special
screws (A) while removing gear housing.
12. Remove cap screws to remove gear housing.
13. Remove old gasket material from gear housing and
cylinder block.
3TNA72UJ Shown M
3
5
5
0
6

-
U
N
-
2
6
A
U
G
8
8
M21,TM335,39 -19-07FEB86
M21,TM335,40 -19-11MAR86
M21,TM335,41 -19-07FEB86
M21,TM335,42 -19-07FEB86
010897
PN=162
35
17
INSTALL GEAR HOUSING
1. Thoroughly clean and dry all parts. Use new gaskets,
O-rings, and oil seals when assembling the engine.
2. Apply plastic gasket or an equivalent on the gear
housing.
NOTE: Early 3TNA72: Install special screw (A) before
installing gear housing.
3. Align gear housing holes with dowel pins on the
cylinder block. Install gear housing.
4. Install and tighten cap screws.
CAP SCREW TORQUE SPECIFICATIONS
3TN66/3TNA72
Cast Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Nm (96 lb-in.)
Aluminum . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Nm (78 lb-in.)
Cast Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm (220 lb-in.)
Aluminum . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm (177 lb-in.)
M
3
5
5
0
6

-
U
N
-
2
6
A
U
G
8
8
NOTE: For all engines except early 3TNA72UJ go to
step 13.
5. Install bracket and fasten with two cap screws.
M
3
5
5
0
5

-
U
N
-
2
6
A
U
G
8
8
M21,TM335,43 -19-10AUG87
M21,TM335,44 -19-07FEB86
010897
PN=163
35
18
6. Install two spring pins (A).
7. Apply thread lock and sealer (low strength) on the
threads of studs.
8. Install seven studs with short-threaded end in gear
housing.
M
3
5
5
0
4

-
U
N
-
2
6
A
U
G
8
8
9. Install new gasket (A) and cover.
M
3
5
5
0
3

-
U
N
-
2
6
A
U
G
8
8
10. Install oil pump (D) and oil pump cover (C). (See
11. Install governor linkage (B). (See Group 55 in this
manual.)
12. Install throttle linkage (A). (See Group 55 in manual.)
AThrottle Linkage
BGovernor Linkage
COil Pump Cover
DOil Pump
M
3
5
5
0
2

-
U
N
-
2
6
A
U
G
8
8
M21,TM335,45 -19-07FEB86
M21,TM335,46 -19-07FEB86
M21,TM335,47 -19-23APR86
010897
PN=164
35
19
13. Install oil pump (D). (See Group 40 in this manual.)
IMPORTANT: Make sure to align timing marks
between crankshaft, idler, injection
pump, and camshaft gears.
14. Install injection pump camshaft (C). (See Group 50 in
this manual.)
15. Install camshaft (B). (See Group 10 in this manual.)
16. Install idler gear (A). (See Group 35 in this manual.)
17. Install timing gear cover (See Group 35 in this
manual.) AIdler Gear
BEngine Camshaft/Gear
CInjection Pump Camshaft/Gear
DOil Pump/Gear
M
3
5
5
0
1

-
U
N
-
2
6
A
U
G
8
8
M21,TM335,48 -19-07FEB86
010897
PN=165
35
20
Name Use
Strap Wrench Remove crankshaft pulley
13-Ton Puller Set Remove crankshaft pulley and gears
Dial Indicator Measure oil pump gear backlash
Depth Micrometer Measure oil pump body depth
Outside Micrometer Measure oil pump components
Telescoping Gauge Measure oil pump components
Vernier Calipers Measure rotor ring diameter
Belt Tension Gauge Check belt tension
Spring Compression Tester Check oil pressure regulating valve spring
O-Ring Seal Tool Set Remove and install O-rings
OTHER MATERIAL
Number Name Use
T43512 John Deere LOCTITE
Thread Lock Apply to threads of crankshaft

PT94 John Deere Form-In-Place Gasket To seal gear housing cover, oil pan
(RTV rubber silicone sealant) spacer, crankshaft seal case, and
oil pan.
M21,TM340,1 -19-28AUG87
M21,TM340,2 -19-28AUG87
Group 40
Lubrication System
010897
PN=166
40
1
REMOVE AND INSTALL OIL PAN
1. Drain engine oil. (See Machine Technical Manual for
engine oil capacity specifications.)
2. Remove engine oil dipstick.
3. Remove cap screws (A and B) to remove oil pan.
4. Remove cap screws to remove oil strainer tube and
seal.
3TNA72 Shown
NOTE: For all engines except 4TN100, go to step 9.
5. Remove cap screws to remove oil pan spacer.
6. Remove old gasket material from spacer and engine
block. Clean and dry gasket application surfaces.
7. Apply plastic gasket, or an equivalent, to spacer.
8. Install spacer. Tighten cap screws to specifications.
IMPORTANT: DO NOT reuse oil strainer tube seal. To
avoid oil leakage install new seal.
3TNA72 Shown
9. Install seal and oil strainer tube. Tighten cap screws
to specifications.
10. Remove old gasket material from oil pan and engine
block (or spacer). Clean and dry gasket application
surfaces.
M
3
5
5
8
1

-
U
N
-
2
6
A
U
G
8
8
M
3
5
6
3
2

-
U
N
-
2
6
A
U
G
8
8
MX,TM340,A14 -19-25MAY89
Lubrication System/Remove and Install Oil Pump
010897
PN=167
40
2
11. Apply plastic gasket, or an equivalent, to oil pan.
12. Install oil pan. Tighten cap screws to specifications.
13. Install dipstick. Fill engine with oil to specifications.
(See Machine Technical Manual for type and capacity of
engine oil.)
CAP SCREW TORQUE SPECIFICATIONS
Strainer Tube
3TN66/3TNA72 . . . . . . . . . . . . . . . . . . . . . . . 11 Nm (96 lb-in.)
All except 3TN66/3TNA72 . . . . . . . . . . . . . . . . 26 Nm (226 lb-in.)
Oil Pan-to-Block
3TN66/3TNA72 . . . . . . . . . . . . . . . . . . . . . . . 11 Nm (96 lb-in.)
All except 3TN66/3TNA72 . . . . . . . . . . . . . . . . 26 Nm (226 lb-in.)
Oil Pan-to-Gear Housing Cover
3TN66/3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . 9 Nm (78 lb-in.)
3TN75/3TN78/3TN82/3TN84/
4TN78/4TN82/4TN84 . . . . . . . . . . . . . . . . . . . 26 Nm (226 lb-in.)
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Nm (180 lb-in.)
Oil Pan Spacer-to-Block
4TN100
M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm (226 lb-in.)
M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Nm (65 lb-ft)
Oil Pan Spacer-to-Crankshaft Seal Case
4TN100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Nm (180 lb-in.)
REMOVE OIL PUMP (EARLY 3TNA72UJ
ENGINES)
1. Remove engine. (See Section 20 in Machine
Technical Manual.)
2. Remove fuel injection lines (A) and fuel injection pump
(B) as instructed in Group 50.
3. Remove alternator belt.
M
3
5
6
3
0

-
U
N
-
2
6
A
U
G
8
8
MX,TM340,A14A -19-12JUL89
M21,TM340,5 -19-23APR86
Lubrication System/Oil Pump (Early 3TNA72UJ)
010897
PN=168
40
3
4. Remove crankshaft pulley cap screw and washer.
5. Remove crankshaft pulley. Use a puller, shaft
protector, two cap screws from water pump, and a strap
wrench.
M
3
5
2
7
1

-
U
N
-
2
9
A
U
G
8
8
6. Disconnect shut-off linkage. Remove two nuts and cap
screw to remove fuel shut-off solenoid bracket.
M
3
5
2
7
3

-
U
N
-
2
9
A
U
G
8
8
7. Remove 17 cap screws to remove gear housing
cover. Remove old gasket material from cover and gear
housing.
M
3
5
5
3
2

-
U
N
-
2
6
A
U
G
8
8
8. Measure oil pump gear backlash using a dial
indicator. New backlash specification is 0.110.19 mm
(0.0040.008 in.)
9. If backlash exceeds 0.20 mm (0.008 in.), replace
gear.
10. Check backlash of other gears in gear housing. (See
M
3
5
5
3
3

-
U
N
-
2
6
A
U
G
8
8
M21,TM340,6 -19-05MAR86
M21,TM340,7 -19-05MAR86
M21,TM340,8 -19-05MAR86
M21,TM340,9 -19-05MAR86
010897
PN=169
40
4
11. Put a shop towel between gear teeth. Loosen lock
nut.
M
3
5
5
3
4

-
U
N
-
2
6
A
U
G
8
8
12. Remove idler gear.
M
3
5
5
3
5

-
U
N
-
2
6
A
U
G
8
8
13. Remove bearing retaining screw.
M
3
5
5
3
6

-
U
N
-
2
6
A
U
G
8
8
IMPORTANT: DO NOT allow fuel injection pump
camshaft lobes to hit bearing surfaces
while removing camshaft. Machined
surfaces may be damaged.
14. Carefully remove injection pump camshaft assembly.
Use a slide hammer puller and two cap screws from the
housing cover.
M
3
5
5
3
7

-
U
N
-
2
6
A
U
G
8
8
M21,TM340,10 -19-05MAR86
M21,TM340,11 -19-05MAR86
M21,TM340,12 -19-05MAR86
M21,TM340,13 -19-23APR86
010897
PN=170
40
5
15. Remove oil filter and oil dipstick tube.
16. Remove two cap screws to remove bracket and four
washers (A).
17. Remove two cap screws (B) to remove cover (C)
and gasket (D).
AWasher (4 used)
BCap Screw (4 used)
CCover
DGasket
M
3
5
5
3
9

-
U
N
-
2
6
A
U
G
8
8
18. Remove sealing wire (A).
19. Loosen nut (B). Turn slow idle adjusting screw (C)
counterclockwise several turns.
M
3
5
5
4
0

-
U
N
-
2
6
A
U
G
8
8
20. Remove two cap screws and nut to remove cover
and gasket (A).
M
3
5
5
4
1

-
U
N
-
2
6
A
U
G
8
8
21. Disconnect spring from governor linkage.
M
3
5
5
4
2

-
U
N
-
2
6
A
U
G
8
8
M21,TM340,14 -19-23APR86
M21,TM340,15 -19-05MAR86
M21,TM340,16 -19-05MAR86
M21,TM340,17 -19-05MAR86
010897
PN=171
40
6
22. Remove governor shaft and washer (A).
M
3
5
5
4
3

-
U
N
-
2
6
A
U
G
8
8
23. Remove governor shaft lever.
M
3
5
5
4
4

-
U
N
-
2
6
A
U
G
8
8
24. Remove nut.
M
3
5
5
4
5

-
U
N
-
2
6
A
U
G
8
8
25. Remove oil pump gear using a three-jaw puller.
26. Inspect gear for chipped or broken teeth. Replace as
necessary.
M
3
5
5
4
6

-
U
N
-
2
6
A
U
G
8
8
M21,TM340,18 -19-05MAR86
M21,TM340,19 -19-05MAR86
M21,TM340,20 -19-05MAR86
M21,TM340,21 -19-05MAR86
010897
PN=172
40
7
27. Remove four cap screws and nut to remove oil pump
cover and gasket (A).
NOTE: For repair of oil pressure regulating valve (B),
see Remove Oil Pressure Regulating Valve in
this group.
M
3
5
5
4
7

-
U
N
-
2
6
A
U
G
8
8
28. Remove oil pump assembly.
M
3
5
5
4
8

-
U
N
-
2
6
A
U
G
8
8
INSPECT OIL PUMP ASSEMBLY (EARLY
3TNA72UJ)
1. Measure rotor-to-pump body clearance (pump body
depth minus rotor depth).
ROTOR-TO-PUMP BODY SPECIFICATIONS
Difference of two measurements
(new parts) . . . . . . . . . . . . . . . . . . . . . . . 0.080.15 mm
(0.0030.006 in.)
Maximum difference allowed . . . . . . . . . . . 0.25 mm
(0.010 in.)
NOTE: The measurement between 0.150.25 mm
(0.0060.010 in.) indicates a tolerable wear
difference that could affect pump efficiency.
If rotor clearance exceeds the maximum specification,
replace gear housing.
M
3
5
5
4
9

-
U
N
-
2
6
A
U
G
8
8
M
3
5
5
5
0

-
U
N
-
2
6
A
U
G
8
8
M21,TM340,22 -19-05MAR86
M21,TM340,23 -19-05MAR86
M21,TM340,24 -19-10AUG87
010897
PN=173
40
8
2. Measure rotor ring-to-pump body clearance (pump
body diameter minus rotor ring diameter).
ROTOR RING-TO-PUMP BODY SPECIFICATIONS
(new parts) . . . . . . . . . . . . . . . . . . . . . . . 0.100.15 mm
(0.0040.006 in.)
(0.010 in.)
If rotor ring clearance exceeds the maximum
specification, replace gear housing.
M
3
5
5
5
1

-
U
N
-
2
6
A
U
G
8
8
M
3
5
5
5
2

-
U
N
-
2
6
A
U
G
8
8
3. Measure inner rotor-to-rotor ring clearance (rotor ring
diameter minus inner rotor diameter).
INNER ROTOR-TO-ROTOR RING SPECIFICATIONS
(new parts) . . . . . . . . . . . . . . . . . . . . . . . 0.100.15 mm
(0.0040.006 in.)
(0.010 in.)
If inner rotor clearance exceeds the maximum
specification, replace oil pump assembly.
M
3
5
5
5
3

-
U
N
-
2
6
A
U
G
8
8
M
3
5
5
5
4

-
U
N
-
2
6
A
U
G
8
8
M21,TM340,25 -19-05MAR86
M21,TM340,26 -19-06MAR86
010897
PN=174
40
9
4. Measure inner rotor shaft diameter.
INNER ROTOR SHAFT SPECIFICATIONS
Shaft Diameter (new parts) . . . . . . . . . . . . 12.6712.685 mm
(0.49880.499 in.)
Shaft Diameter (minimum) . . . . . . . . . . . . . 12.65 mm
(0.4980 in.)
If shaft diameter is less than the minimum specification,
replace oil pump assembly.
M
3
5
5
5
5

-
U
N
-
2
6
A
U
G
8
8
5. Measure oil pump bore diameter.
OIL PUMP BORE SPECIFICATIONS
Bore diameter (new parts) . . . . . . . . . . . . . 12.712.718 mm
(0.50.5007 in.)
Bore diameter (maximum) . . . . . . . . . . . . . 12.8 mm
(0.504 in.)
If bore diameter exceeds the maximum specification,
replace gear housing.
6. Measure inner rotor shaft clearance (oil pump bore
diameter minus inner rotor shaft diameter).
INNER ROTOR SHAFT CLEARANCE SPECIFICATIONS
(new parts) . . . . . . . . . . . . . . . . . . . . . . . 0.0150.048 mm
(0.00060.0019 in.)
(0.0039 in.)
If inner rotor shaft clearance exceeds specifications,
replace gear housing and oil pump assembly.
M
3
5
5
5
6

-
U
N
-
2
6
A
U
G
8
8
M21,TM340,27 -19-06MAR86
M21,TM340,28 -19-06MAR86
010897
PN=175
40
10
INSTALL OIL PUMP (EARLY 3TNA72UJ)
1. Thoroughly clean and dry all parts. Use new gaskets
and seals when assembling the engine.
2. Put clean engine oil on all sides and surfaces of oil
pump rotors.
IMPORTANT: Marks (A) on inner rotor and rotor ring
must be installed toward gear housing.
3. Install rotor ring (B) and inner rotor shaft (C) in gear
housing.
M
3
5
5
5
7

-
U
N
-
2
6
A
U
G
8
8
4. Align splines on inner rotor shaft (A) with splines in
thrust washer (B) and governor weights (C). Install thrust
washer, governor weights, and sleeve (D) on rotor shaft.
AInner Rotor Shaft
BThrust Washer
CGovernor Weights
DSleeve
M
3
5
5
5
8

-
U
N
-
2
6
A
U
G
8
8
M21,TM340,29 -19-10AUG87
M21,TM340,30 -19-06MAR86
010897
PN=176
40
11
5. Install gasket.
6. Align spring pins (A) in cover with holes (B) in gear
housing. Install oil pump cover.
M
3
5
5
5
9

-
U
N
-
2
6
A
U
G
8
8
7. Install and tighten four cap screws and nut to 9 Nm
(78 lb-in.).
M
3
5
5
6
0

-
U
N
-
2
6
A
U
G
8
8
8. Install oil pump gear.
M
3
5
5
6
1

-
U
N
-
2
6
A
U
G
8
8
9. Install nut.
M
3
5
5
4
5

-
U
N
-
2
6
A
U
G
8
8
M21,TM340,31 -19-06MAR86
M21,TM340,32 -19-28AUG86
M21,TM340,33 -19-06MAR86
M21,TM340,34 -19-06MAR86
010897
PN=177
40
12
10. Install washer (A) on governor shaft (B).
11. Install governor shaft lever (C).
12. Install governor shaft through governor shaft lever.
M
3
5
5
4
4

-
U
N
-
2
6
A
U
G
8
8
M
3
5
5
6
2

-
U
N
-
2
6
A
U
G
8
8
13. Tighten governor shaft to 49 Nm (430 lb-in.).
M
3
5
5
6
3

-
U
N
-
2
6
A
U
G
8
8
14. Connect spring to internal lever and then to governor
assembly.
M
3
5
5
4
2

-
U
N
-
2
6
A
U
G
8
8
M21,TM340,35 -19-06MAR86
M21,TM340,36 -19-28AUG86
M21,TM340,37 -19-06MAR86
010897
PN=178
40
13
15. Install gasket.
16. Install cover and fasten with two cap screws and nut.
Tighten cap screws and nut to 9 Nm (78 lb-in.).
M
3
5
5
6
4

-
U
N
-
2
6
A
U
G
8
8
17. Install gasket, cover, and two cap screws (A).
18. Install four washers (B), bracket (C), and two cap
screws (D). Put washers between cover and bracket; two
each over hole location. Tighten four cap screws to 9
Nm (78 lb-in.).
ACap Screw (2 used)
BWasher (4 used)
CBracket
DCap Screw (2 used)
M
3
5
5
6
6

-
U
N
-
2
6
A
U
G
8
8
19. Install dipstick tube (B) and fasten with cap screw.
20. Install oil filter (A).
M
3
5
5
3
8

-
U
N
-
2
6
A
U
G
8
8
21. Apply clean engine oil on fuel injection pump
camshaft bearings.
while installing camshaft. Machined
22. Carefully install fuel injection pump camshaft
assembly. Push bearings to bottom of gear housing
bore.
M
3
5
5
6
8

-
U
N
-
2
6
A
U
G
8
8
M21,TM340,38 -19-10AUG87
M21,TM340,39 -19-10AUG87
M21,TM340,40 -19-06MAR86
M21,TM340,41 -19-06MAR86
010897
PN=179
40
14
23. Install and tighten bearing retaining screw to 20 Nm
(180 lb-in.).
M
3
5
5
6
9

-
U
N
-
2
6
A
U
G
8
8
24. Align timing marks between crankshaft, idler, fuel
injection pump, and camshaft gears.
Timing Marks
Timing Mark Gear
AA Crankshaft-to-Idler
BB Camshaft-to-Idler
CC Fuel Injection Pump
Camshaft-to-Idler M
5
2
9
5
7

-
U
N
-
0
5
A
P
R
8
9
26. Put a shop towel between gear teeth. Tighten lock
nut to 88 Nm (65 lb-ft).
M
3
5
5
7
0

-
U
N
-
2
6
A
U
G
8
8
M21,TM340,42 -19-10AUG87
M21,TM340,43 -19-06MAR86
M21,TM340,44 -19-10AUG87
010897
PN=180
40
15
27. If necessary, replace front crankshaft oil seal using a
1-3/4 in. driver disk (A) and 2-3/8 in. driver disk (B).
Install new seal with lip toward inside of gear housing.
Install flush with face of housing cover.
M
3
5
2
7
5

-
U
N
-
2
9
A
U
G
8
8
28. Apply plastic gasket or an equivalent on gear
housing cover.
29. Install gear housing cover and fasten with 17 cap
screws. Tighten cap screws to 9 Nm (78 lb-in.).
M
3
5
5
7
1

-
U
N
-
2
6
A
U
G
8
8
30. Install fuel shut-off solenoid bracket. Install and
tighten two nuts and cap screw to 9 Nm (78 lb-in.).
M
3
5
2
9
4

-
U
N
-
2
9
A
U
G
8
8
31. Connect fuel shut-off solenoid linkage. Fasten linkage
with washer (A) and cotter pin.
M
3
5
2
7
2

-
U
N
-
2
9
A
U
G
8
8
M21,TM340,45 -19-06MAR86
M21,TM340,46 -19-28AUG87
M21,TM340,47 -19-28AUG87
M21,TM340,48 -19-06MAR86
010897
PN=181
40
16
32. Align pin (A) in crankshaft pulley with hole (B) in
crankshaft. Install pulley.
M
3
5
2
9
5

-
U
N
-
2
9
A
U
G
8
8
33. Hold crankshaft pulley using a strap wrench. Apply
thread lock and sealer (medium strength) on threads of
cap screw. Install washer and cap screw. Tighten cap
screw to 88 Nm (65 lb-ft).
M
3
5
2
9
6

-
U
N
-
2
9
A
U
G
8
8
34. Install alternator belt.
IMPORTANT: When adjusting belt tension, apply
force ONLY to rear alternator housing
(near the belt) to prevent alternator
damage.
35. Apply force against alternator housing and tighten
cap screw.
36. Check belt tension using a belt tension gauge.
Alternator belt must deflect 13 mm (0.5 in.) at 107 N (24
lb) Force applied halfway between pulleys. If necessary,
loosen cap screw and adjust belt tension.
M
3
5
6
6
7

-
U
N
-
2
6
A
U
G
8
8
M21,TM340,49 -19-06MAR86
M21,TM340,50 -19-10AUG87
M21,TM340,51 -19-06MAR86
010897
PN=182
40
17
37. Install fuel injection pump (B) and fuel injection lines
(A). (See Group 50 in this manual.)
39. Bleed fuel injection system. (See Machine Technical
Manual.)
40. Check and adjust slow idle setting. (See Section 230
in Machine Technical Manual.)
M
3
5
6
3
0

-
U
N
-
2
6
A
U
G
8
8
REMOVE OIL PRESSURE REGULATING
VALVE (EARLY 3TNA72UJ)
Technical Manual.)
2. Remove fan belt.
3. Hold crankshaft pulley with strap wrench. Remove cap
screw and washer.
M
3
5
2
7
0

-
U
N
-
2
9
A
U
G
8
8
4. Remove crankshaft pulley. Use a puller, shaft
protector, two cap screws from water pump, and a strap
wrench.
M
3
5
2
7
1

-
U
N
-
2
9
A
U
G
8
8
5. Disconnect fuel shut-off linkage. Remove two nuts and
cap screw to remove fuel shut-off solenoid bracket.
6. Remove 17 gear housing cap screws and remove
gear housing cover.
M
3
5
2
7
3

-
U
N
-
2
9
A
U
G
8
8
M21,TM340,52 -19-06MAR86
M21,TM340,53 -19-10AUG87
M21,TM340,54 -19-06MAR86
M21,TM340,55 -19-06MAR86
Lubrication System/Oil Pressure Regulating Valve (Early 3TNA72UJ)
010897
PN=183
40
18
7. Remove spring retainer.
M
3
5
5
7
2

-
U
N
-
2
6
A
U
G
8
8
IMPORTANT: If oil pressure regulating valve is being
disassembled to be cleaned, the same
number and thicknesses of shims must
be installed when assembled.
8. Remove shims (A), if equipped, spring (B), and valve
(C).
9. Check spring (B) using spring compression tester.
NEW SPRING SPECIFICATIONS
Free Length . . . . . . . . . . . . . . . . . . . . . . . . 39.540.5 mm
(1.551.59 in.)
Test Length at Force of
29.4 3.1 N (6.6 0.7 lb) . . . . . . . . . . . . 30.0 mm (1.18 in.)
10. Inspect valve and housing bore for wear or damage.
Valve must slide freely in bore. Replace parts as
necessary.
M
3
5
5
7
3

-
U
N
-
2
6
A
U
G
8
8
M21,TM340,56 -19-06MAR86
M21,TM340,57 -19-06MAR86
010897
PN=184
40
19
INSTALL OIL PRESSURE REGULATING
VALVE (EARLY 3TNA72UJ)
2. Apply clean engine oil on valve.
3. Install valve (C) and spring (B) in housing bore.
IMPORTANT: If oil pressure regulating valve was
be installed.
4. Install the required amount of shims (A) from shim
pack, until the oil pressure is 365 69 kPa (53 10
psi). After assembling the oil pressure regulating valve,
check the oil pressure. (See Section 220 in Machine
Technical Manual.)
SHIM PACK
Shim Size Approximate Pressure Change
0.20 mm (0.008 in.) 6 kPa (0.85 psi)
0.30 mm (0.012 in.) 9 kPa (1.3 psi)
NOTE: For every 0.20 mm (0.008 in.) of shim thickness,
there is approximately a 6 kPa (0.85 psi) change
in oil pressure.
M
3
5
5
7
3

-
U
N
-
2
6
A
U
G
8
8
5. Install and tighten spring retainer.
M
3
5
5
7
2

-
U
N
-
2
6
A
U
G
8
8
M21,TM340,58 -19-28AUG87
M21,TM340,59 -19-06MAR86
010897
PN=185
40
20
6. If necessary, replace front crankshaft oil seal using a
1 3/4 in. driver disk (A) and a 2 3/8 in. disk (B).
Install new seal with lip facing inside of gear housing.
Press seal flush with face of housing cover.
M
3
5
2
7
5

-
U
N
-
2
9
A
U
G
8
8
7. Apply plastic gasket or an equivalent on gear housing
cover.
8. Install gear housing cover and fasten with 17 cap
screws. Tighten cap screws to 9 Nm (78 lb-in.).
M
3
5
4
9
8

-
U
N
-
2
6
A
U
G
8
8
9. Install fuel shut-off solenoid with bracket and connect
shut-off linkage.
M
3
5
2
9
4

-
U
N
-
2
9
A
U
G
8
8
10. Align pin (A) in crankshaft pulley with hole (B) in
crankshaft. Install pulley.
M
3
5
2
9
5

-
U
N
-
2
9
A
U
G
8
8
M21,TM340,60 -19-06MAR86
M21,TM340,61 -19-10AUG87
M21,TM340,62 -19-06MAR86
M21,TM340,63 -19-06MAR86
010897
PN=186
40
21
11. Hold crankshaft pulley using a strap wrench. Apply
thread lock and sealer (medium strength) on threads of
cap screw.
12. Install washer and cap screw. Tighten cap screw to
88 Nm (65 lb-ft).
M
3
5
2
9
6

-
U
N
-
2
9
A
U
G
8
8
13. Install alternator belt.
damage.
14. Apply force against alternator housing and tighten
cap screw.
16. Install engine. (See Section 20 of Machine Technical
Manual.)
17. Check and adjust engine oil pressure. (See Section
220 of Machine Technical Manual.)
M
3
5
6
6
7

-
U
N
-
2
6
A
U
G
8
8
REMOVE AND INSPECT OIL PUMP (ALL
EXCEPT EARLY 3TNA72UJ/4TN100)
1. Remove gear housing cover as instructed in Remove
Timing Gears, Group 35.
2. Check oil pump gear backlash. Replace gear if
backlash is more than 0.25 mm (0.010 in.).
M
3
7
7
7
2

-
U
N
-
2
9
A
U
G
8
8
M21,TM340,64 -19-06MAR86
M21,TM340,65 -19-23APR86
M21,TM340,66 -19-28AUG87
Lubrication System/Oil Pump (All Engines Except Early 3TNA72UJ)
010897
PN=187
40
22
3. Remove oil pump attaching hardware and remove oil
pump.
M
3
7
7
7
3

-
U
N
-
2
9
A
U
G
8
8
4. Carefully remove backing plate from pump.
M
3
7
7
7
4

-
U
N
-
2
9
A
U
G
8
8
5. Check rotor recess. If rotors are recessed below face
of pump housing more than listed below, replace rotor
assembly.
Engine Maximum Recess
3TN66UJ/3TNA72UJ/3TNA72-UJB/
3TN78-RJB/3TN82-RJB/4TN78T-RJB 0.25 mm (0.10 in.)
3TN75RJ/3TN82ESP/3TN84/
4TN82ESP/4TN84 0.13 mm (0.005 in.)
M
3
7
7
7
5

-
U
N
-
2
9
A
U
G
8
8
M21,TM340,67 -19-06MAR86
M21,TM340,68 -19-06MAR86
M21,TM340,69 -19-28AUG87
010897
PN=188
40
23
6. Check outer rotor-to-pump body clearance. If
clearance is more than 0.25 mm (0.010 in.), replace oil
pump.
M
3
7
7
7
6

-
U
N
-
2
9
A
U
G
8
8
7. Check inner-to-outer rotor clearance. If clearance is
more than listed below, replace rotor assembly.
Engine Maximum Recess
3TNA72-UJ/3TN78-RJB/
3TN82-RJB/4TN78T-RJB 0.15 mm (0.006 in.)
All other engines 0.25 mm (0.010 in.)
M
3
7
7
7
7

-
U
N
-
2
9
A
U
G
8
8
8. Remove outer rotor from pump body.
IMPORTANT: Hold oil pump shaft while pressing
from gear.
9. Support oil pump gear on a knife edge puller. Use a
cap screw (A) to press shaft from gear.
M
3
7
7
7
8

-
U
N
-
2
9
A
U
G
8
8
ASSEMBLE AND INSTALL OIL PUMP (ALL
EXCEPT EARLY 3TNA72UJ/4TN100)
1. Place gear on flat surface. Press shaft with rotor and
pump body into gear until it bottoms.
M
3
7
7
7
9

-
U
N
-
2
9
A
U
G
8
8
M21,TM340,70 -19-06MAR86
M21,TM340,71 -19-28AUG87
M21,TM340,72 -19-23APR86
M21,TM340,73 -19-10AUG87
010897
PN=189
40
24
2. Coat all parts with clean engine oil. Install outer rotor
with identification mark (A) facing inside of housing.
3. Install backing plate onto pump body.
M
3
7
7
8
0

-
U
N
-
2
9
A
U
G
8
8
4. Install oil pump on engine using new gasket. Tighten
hardware to 25 Nm (18 lb-ft).
M
3
7
7
7
3

-
U
N
-
2
9
A
U
G
8
8
SERVICE OIL PRESSURE REGULATING
VALVE (3TN66UJ/LATER 3TNA72UJ/
3TNA72-UJB/3TN75RJ/3TN78-RJB/3TN82E-SP/
3TN84/4TN78T-RJB/4TN82E-SP4TN84
1. Remove oil filter.
2. Remove three attaching cap screws (A). Remove
housing with valve from engine.
M
3
7
7
8
1

-
U
N
-
2
9
A
U
G
8
8
M21,TM340,74 -19-06MAR86
M21,TM340,75 -19-01SEP87
M21,TM340,76 -19-01SEP87
Lubrication System/Oil Pressure Regulating Valve
010897
PN=190
40
25
3. If adjusting pressure only, remove cap (A) and add
shims to inside of cap. Each 1 mm (0.039 in.) of shim
thickness increases oil pressure as listed:
Engine Pressure Increase
3TN66UJ 13.8 kPa (2.0 psi)
3TNA72UJ 10.9 kPa (1.6 psi)
3TN75RJ/3TN82ESP/3TN84/
4TN82ESP/4TN84 15.6 kPa (2.3 psi)
M
3
7
7
8
2

-
U
N
-
2
9
A
U
G
8
8
4. Remove valve attaching nut (A). Remove valve from
housing.
NOTE: If removing valve to adjust engine oil pressure,
attaching nut need not be removed.
M
3
7
7
8
3

-
U
N
-
2
9
A
U
G
8
8
M21,TM340,77 -19-23APR86
M21,TM340,78 -19-06MAR86
010897
PN=191
40
26
5. Remove valve plug (A), shims (B), spring (C), and
valve (D) from valve body.
6. Inspect parts for wear or damage.
7. Check spring free and compressed length.
FREE LENGTH SPECIFICATIONS
Engine Specification
3TN66 21.924.5 mm
(0.860.96 in.)
Later 3TNA72 43.548.5 mm
(1.711.91 in.) AValve Cap
BShims
CSpring
3TNA72-UJB/3TN78-RJB/3TN75/
DValve
3TN82/3TN82-RJB/3TN84/
4TN82/4TN84 46.0 mm (1.81 in.)
4TN78T-RJB 48.5 mm (1.91 in.)
COMPRESSED LENGTH SPECIFICATIONS
Engine Specification
3TN66 14.7 mm (0.58 in.) at
12.0 N (2.7 lb) Force
Later 3TNA72/3TN75/3TN82ESP/
3TN84/4TN82/4TN84 27.5 mm (1.08 in.) at
20.5 N (4.6 lb) Force
3TNA72-UJB/3TN78-RJB/
3TN82-RJB 24.5 mm (0.96 in.) at
27.2 N (6.1 lb) Force
4TN78T-RJB 33.0 mm (1.30 in.) at
80 N (18 lb) Force
NOTE: Valve components are not serviced individually.
Replace complete regulating valve if any
components are defective.
M
3
7
7
8
4

-
U
N
-
2
9
A
U
G
8
8
M21,TM340,79 -19-01SEP87
010897
PN=192
40
27
8. Install valve, spring, and shims into valve body. Install
valve cap and stake to valve body.
9. If removed, screw valve body into housing. Install
retaining nut (A) and tighten to 30 Nm (22 lb-ft).
10. Install housing with valve onto engine. Install oil filter.
M
3
7
7
8
3

-
U
N
-
2
9
A
U
G
8
8
REMOVE, INSPECT AND INSTALL OIL
COOLER (ETN84UJ)
1. Drain cooling system (A).
2. Remove engine oil filter.
3. Remove clamps (B) from coolant hoses.
4. Remove nut (C) and oil cooler (D).
5. Inspect rear of oil cooler for pitting in sealing area.
Pressure test cooler for leaks. (See this group).
6. Replace o-rings (E).
7. Install cooler. Tighten nut to 30 Nm (22 lb-ft).
8. Reinstall hoses and clamps. Refill cooling system and
check for leaks.
ACoolant Drain
BHose Clamps
CCooler Nut
DOil Cooler
EO-Rings
M
4
8
3
9
4

-
U
N
-
0
1
N
O
V
8
9
M
4
8
3
9
5

-
U
N
-
0
1
N
O
V
8
9
M21,TM340,80 -19-06MAR86
MX,TM340Z,1 -19-24OCT89
Lubrication System/Remove, Inspect and Install Oil Cooler (3TN84UJ)
010897
PN=193
40
28
ENGINE OIL COOLER LEAK TEST
1. Plug one of the coolant inlet or outlet passages.
2. Apply regulated air pressure 206483 kPa (3070
psi) to the other coolant passage.
3. Dip oil cooler into water. Check for regular intervals of
air bubbles, indicating a leak. Leave in water several
minutes to disperse air that may have been trapped.
Optional test: If leak did not appear, use hot water bath
to possibly open crack.
REMOVE, INSPECT, AND INSTALL OIL
PRESSURE CONTROL VALVE
1. Remove oil cooler. (See this group.)
2. Remove and replace o-rings (A).
3. Remove three cap screws (B) and pressure control
valve housing (C).
4. Remove control valve (D) from housing. If malfunction
exists, replace control valve. Individual parts are not
available. Control valve is serviced as an assembly.
5. Replace o-ring (E). Coat with oil before installing.
6. Install new gasket between control valve housing and
block.
7. Install control valve housing. Tighten cap screws to 27
Nm (20 lb-ft).
8. Install new o-rings and oil cooler. Tighten cooler nut to
2734 Nm (2025 lb-ft).
AO-Ring
BCap Screws
CControl Valve Housing
DControl Valve
EO-Ring
M
4
8
3
9
6

-
U
N
-
0
1
N
O
V
8
9
M
4
8
3
9
7

-
U
N
-
0
1
N
O
V
8
9
MX,TM340Z,2 -19-24OCT89
MX,TM340Z,3 -19-24OCT89
Lubrication System/Remove/Inspect/Install Oil Pressure Control Valve
010897
PN=194
40
29
REMOVE AND INSPECT OIL PUMP
(4TN100-RJF)
1. Remove gear housing cover and idler gear as
instructed in Remove Timing Gears, Group 35.
2. Check oil pump gear backlash. Replace gear if
backlash is more than 0.25 mm (0.010 in.).
3. Remove cap screws (A) to remove oil pump and
gasket from engine.
M
5
1
5
6
8

-
U
N
-
3
1
A
U
G
8
8
NOTE: Do not remove gear to remove cap screws.
4. Remove four cap screws (A) to separate pump from
housing.
M
5
1
5
6
9

-
U
N
-
3
1
A
U
G
8
8
NOTE: Do not disassemble rotor shaft assembly (A); if
worn or damaged, replace as an assembly.
5. Check rotor shaft outer diameter and the rotor cover
hole diameter. If clearance is more than 0.20 mm (0.008
in.), replace entire assembly.
M
5
1
5
7
0

-
U
N
-
3
1
A
U
G
8
8
6. Check rotor recess. If rotor is below face of pump
housing more than 0.25 mm (0.010 in.), replace rotor.
M
5
1
5
7
1

-
U
N
-
3
1
A
U
G
8
8
M21,TM340,A1 -19-01SEP87
M21,TM340,A2 -19-01SEP87
M21,TM340,A3 -19-10AUG87
M21,TM340,A4 -19-10AUG87
Lubrication System/4TN100RJF Lubrication System
010897
PN=195
40
30
7. Check outer rotor-to-pump body clearance. If
clearance is more than 0.25 mm (0.010 in.), replace oil
pump.
M
5
1
5
7
2

-
U
N
-
3
1
A
U
G
8
8
8. Check inner-to-outer rotor clearance. If clearance is
more than 0.25 mm (0.010 in.), replace rotor assembly.
M
5
1
5
7
3

-
U
N
-
3
1
A
U
G
8
8
ASSEMBLE AND INSTALL OIL PUMP
(4TN100-RJF)
1. Coat all parts with clean engine oil. Install outer rotor
with identification mark (A) facing toward rotor shaft
assembly.
2. Install rotor shaft assembly onto pump housing and
tighten cap screws to 6 Nm (53 lb-in.).
M
5
1
5
7
4

-
U
N
-
3
1
A
U
G
8
8
3. Install new gasket and oil pump. Tighten cap screws
(A) to 25 Nm (18 lb-ft).
4. Install idler gear and gear housing cover as instructed
in Install Timing Gears, Group 35.
M
5
1
5
6
8

-
U
N
-
3
1
A
U
G
8
8
M21,TM340,A5 -19-10AUG87
M21,TM340,A6 -19-10AUG87
M21,TM340,A7 -19-10AUG87
M21,TM340,A8 -19-10AUG87
010897
PN=196
40
31
REMOVE AND INSPECT OIL COOLER
(4TN100-RJF)
1. Remove fuel injection pump as instructed in Remove
Fuel Injection Pump, Group 50.
2. Remove 21 caps screws to remove oil cooler
assembly from engine.
3. Remove four nuts to separate oil cooler (A) from
housing (B).
4. Inspect oil cooler for leaks or cracks; replace if
necessary.
M
5
1
5
7
5

-
U
N
-
3
1
A
U
G
8
8
M
5
1
5
7
6

-
U
N
-
3
1
A
U
G
8
8
ASSEMBLE AND INSTALL OIL COOLER
(4TN100-RJF)
1. Install oil cooler (A) and gaskets in housing (B).
Tighten nuts to 49 Nm (36 lb-ft).
2. Replace O-ring (C) if damaged. Push oil cooler on
water pump.
3. Install oil cooler and gasket on engine. Tighten cap
screws to 24 Nm (18 lb-ft).
4. Install fuel injection pump as instructed in Install Fuel
Injection Pump, Group 50.
M
5
1
5
7
6

-
U
N
-
3
1
A
U
G
8
8
M
5
1
5
7
7

-
U
N
-
3
1
A
U
G
8
8
M21,TM340,A9 -19-01SEP87
M21,TM340,A10 -19-10AUG87
010897
PN=197
40
32
INSPECT OIL COOLER BY-PASS VALVE
(4TN100-RJF)
1. Remove plug (A), washer (B), spring (C), and valve
(D).
2. Inspect parts for wear or damage. Check valve seat
surfaces for nicks or scratches. Replace parts as
needed.
3. Check spring free and compressed lengths.
SPRING LENGTH SPECIFICATION Oil Cooler Removed for Clarity
Length Specification
AValve Plug
Free 63.0 mm (2.48 in.)
BWasher
CSpring
Compressed 37.0 mm (1.45 in.) DValve
@ 3.75 N (0.84 lb) Force
4. Install valve, spring, washer, and valve plug in oil
cooler.
M
5
1
5
7
8

-
U
N
-
3
1
A
U
G
8
8
INSPECT OIL PRESSURE CONTROL VALVE
(4TN100-RJF)
1. Remove plug (A), washer (B), spring (C), and valve
(D). Check for shims between spring and plug.
2. Inspect parts for wear or damage. Check valve seat
surfaces for nicks or scratches. Replace parts as
needed.
3. Check spring free and compressed lengths.
SPRING LENGTH SPECIFICATION Oil Cooler Removed for Clarity
Length Specification
AValve Plug
Free 51.0 mm (2.01 in.)
BWasher
CSpring
Compressed 50.0 mm (1.97 in.) DValve
@ 5.4 N (1.2 lb) Force
4. Install valve, spring, washer, and plug in oil cooler. If
shims are used, install between spring and plug.
M
5
1
5
7
9

-
U
N
-
3
1
A
U
G
8
8
M21,TM340,A11 -19-10AUG87
M21,TM340,A12 -19-01SEP87
010897
PN=198
40
33
INSPECT PISTON COOLING NOZZLES
(4TN100-RJF)
1. Remove oil pan and spacer. (See Group 40 in this
manual.)
2. Remove piston cooling nozzle (A).
3. Inspect nozzle hole for dirt or other foreign material.
Clean if necessary.
Check the nozzle piping for looseness, for damage or
cracks. Replace if necessary.
4. Install nozzle with pin (B) in locating hole of cylinder
block. Tighten cap screw.
5. Install oil pan spacer and oil pan. (See Group 40 in
this manual.)
M
5
1
5
8
0

-
U
N
-
3
1
A
U
G
8
8
M
5
1
5
8
1

-
U
N
-
3
1
A
U
G
8
8
M21,TM340,A13 -19-10AUG87
010897
PN=199
40
34
ESSENTIAL TOOLS
Number Name Use
JDE-152 Bearing Driver Remove and install water pump bearing shaft
on 3TN75RJ/early 3TNA72UJ engines.
JDG-506 Bearing Driver Remove and install water pump bearing shaft
on 3TN66UJ/3TNA72UJ/3TN82E-SP/3TN84/
4TN82E-SP/4TN84 engines.
Name Use
Thermostat Tester Check thermostat opening temperature
Strap Wrench Hold water pump pulley
13-Ton Puller Set Remove water pump pulley flange
Press Remove and install water pump components
O-ring Seal Tool Set Remove and install water pump seals and
O-rings
Bushing, Bearing, and Seal Driver Set Install water pump components
Belt Tension Gauge Check Belt Tension
M21,TM345,1 -19-23APR86
M21,TM345,2 -19-23APR86
Group 45
Cooling System
010897
PN=200
45
1
REMOVE THERMOSTAT AND THERMOSTAT
HOUSING
N
CAUTION: DO NOT remove thermostat until
engine is cool to the touch.
1. Open radiator and engine drain valves to drain
coolant.
2. Disconnect water pump outlet hose.
3. Remove thermostat cover and gasket (A).
4TN82E-SP
M
3
5
6
3
3

-
U
N
-
2
6
A
U
G
8
8
M
3
7
8
4
3

-
U
N
-
2
9
A
U
G
8
8
NOTE: Gasket is only used on some engines.
4. Remove thermostat and gasket (A), if equipped.
4TN82E-SP
M
3
5
6
3
4

-
U
N
-
2
6
A
U
G
8
8
M
3
7
8
4
4

-
U
N
-
2
9
A
U
G
8
8
M21,TM345,5 -19-11AUG87
M21,TM345,6 -19-11OCT87
Cooling System/Thermostat and Housing
010897
PN=201
45
2
5. Check thermostat using a thermostat tester. Heat
thermostat in water to check opening temperature.
THERMOSTAT SPECIFICATIONS
Begin Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 C (160 F)
Fully Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 C (184 F)
If thermostat is not fully open at 85C (184F), replace
thermostat.
M
3
5
6
3
5

-
U
N
-
2
6
A
U
G
8
8
NOTE: Steps 610 apply to 4TN82E-SP engines only.
6. Loosen cap screw (A) to loosen alternator belt.
7. Loosen clamp (B) and remove hose (C).
8. Disconnect temperature sender wiring lead.
9. Remove three cap screws to remove thermostat
housing and gasket (D).
ACap Screw
BClamp 4TN82E-SP
CHose
DGasket
M
3
7
8
4
5

-
U
N
-
2
9
A
U
G
8
8
10. Remove two cap screws to remove plate and gasket
(A).
11. If necessary, remove parts (BF).
AGasket
BFitting
CPlug
DWasher (2 used)
EPlug
FTemperature Sender
4TN82E-SP
M
3
7
8
4
6

-
U
N
-
2
9
A
U
G
8
8
M21,TM345,7 -19-06MAR86
M21,TM345,8 -19-23APR86
M21,TM345,9 -19-06MAR86
010897
PN=202
45
3
INSTALL THERMOSTAT AND THERMOSTAT
HOUSING
NOTE: For all engines except 4TN82E-SP, go to step
11.
2. Apply pipe sealant on threads of fitting (A).
3. Install parts (AE).
4TN82E-SP
4. Install a new gasket on thermostat housing.
5. Install plate and two cap screws. Tighten cap screws
AFitting to 9 Nm (78 lb-in.).
BPlug
CWasher (2 used)
DPlug
ETemperature Sender
M
3
7
8
4
7

-
U
N
-
2
9
A
U
G
8
8
6. Install a new gasket.
7. Install thermostat housing and three cap screws.
Tighten cap screws to 26 Nm (226 lb-in.).
8. Connect temperature sender wiring lead. Connect
hose (A) and fasten with clamp (B).
9. Pull alternator to tighten belt and tighten cap screw
(C).
lb) Force applied halfway between pulleys.
4TN82E-SP
M
3
7
8
4
9

-
U
N
-
2
9
A
U
G
8
8
M
3
7
8
5
0

-
U
N
-
2
9
A
U
G
8
8
M21,TM345,10 -19-11OCT87
M21,TM345,11 -19-11OCT87
010897
PN=203
45
4
11. Install new gasket (A), if equipped and thermostat.
4TN82R-SE
M
3
5
6
3
4

-
U
N
-
2
6
A
U
G
8
8
M
3
7
8
4
4

-
U
N
-
2
9
A
U
G
8
8
12. Install new gasket.
4TN82E-SP
M
3
5
6
3
6

-
U
N
-
2
6
A
U
G
8
8
M
3
7
8
5
1

-
U
N
-
2
9
A
U
G
8
8
M21,TM345,12 -19-11OCT87
M21,TM345,13 -19-06MAR86
010897
PN=204
45
5
13. Install thermostat housing. Tighten cap screws to
specifications.
THERMOSTAT HOUSING CAP SCREW TORQUE SPECIFICATIONS
3TN66UJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Nm (78 lb-in.)
3TN82-RJB/4TN78T-RJB . . . . . . . . . . . . . . . . . 26 Nm (226 lb-in.)
3TNA72UJ/3TN75RJ/3TN82E-SP/
3TN84/4TN82E-SP/4TN84/
4TN100-RJF . . . . . . . . . . . . . . . . . . . . . . . 20.3 Nm (180 lb-in.)
14. Connect water pump outlet hose. Tighten hose
clamp.
15. Fill cooling system with proper coolant to proper
level.
4TN82E-SP
M
3
5
6
3
7

-
U
N
-
2
6
A
U
G
8
8
M
3
7
8
5
2

-
U
N
-
2
9
A
U
G
8
8
M21,TM345,14 -19-01SEP87
010897
PN=205
45
6
REMOVE WATER PUMP
N
CAUTION: DO NOT remove water pump until
engine is cool to the touch.
1. Open the radiator and engine drain valve to drain
coolant.
2. Disconnect inlet and outlet coolant lines from water
pump.
3. Disconnect coolant temperature sender wire.
3TNA72UJ Shown
4. Loosen cap screw and remove alternator belt (A).
Move alternator away from water pump area.
5. Remove four cap screws (B) to remove fan (C) if
equipped.
3TN75RJ Shown
M
3
7
8
5
4

-
U
N
-
2
9
A
U
G
8
8
M
3
7
8
5
5

-
U
N
-
2
9
A
U
G
8
8
M21,TM345,15 -19-01SEP87
Cooling System/Water Pump
010897
PN=206
45
7
6. Remove four (three for 3TN66, five for 4TN100) cap
screws to remove water pump and gasket (A).
Loosen hose clamp (B) and remove hose (C).
4TN82E-SP
4TN100
M
3
7
8
5
7

-
U
N
-
2
9
A
U
G
8
8
M
3
7
8
5
8

-
U
N
-
2
9
A
U
G
8
8
M
5
1
5
6
6

-
U
N
-
3
1
A
U
G
8
8
M21,TM345,16 -19-11AUG87
010897
PN=207
45
8
DISASSEMBLE WATER PUMP
1. Remove thermostat housing and gasket (A).
NOTE: Water pump housings differ slightly, but the
disassembly procedure is the same.
NOTE: For 4TN82E-SP engines, go to step 5
3TNA72UJ Shown
3TN75RJ Shown
M
3
5
6
4
1

-
U
N
-
2
6
A
U
G
8
8
M
3
7
8
5
9

-
U
N
-
2
9
A
U
G
8
8
2. Remove thermostat and gasket (A), if equipped.
M
3
5
6
4
2

-
U
N
-
2
6
A
U
G
8
8
M21,TM345,17 -19-11AUG87
M21,TM345,18 -19-11AUG87
010897
PN=208
45
9
3. Remove temperature sender and washer (A).
3TNA72UJ Shown M
3
7
8
9
9

-
U
N
-
2
9
A
U
G
8
8
4. Hold pulley using a strap wrench. Remove four cap
screws to remove pulley. Remove cap screws (A).
M
3
5
8
5
2

-
U
N
-
2
6
A
U
G
8
8
M21,TM345,19 -19-11AUG87
M21,TM345,20 -19-10MAR86
010897
PN=209
45
10
3TN75RJ/3TN82-ESP/3&4TN84/4TN100RJF
Early 3TNA72UJ
3TN66UJ/3TNA72UJ
5. Remove three screws to remove plate and gasket (A).
Remove five screws to remove plate and gasket (A).
Remove four (eight for 3TN82E-SP 3TN84/4TN84
Engines, 10 for 4TN100RJF Engine) cap screws and
remove parts (AE).
Remove three screws to remove plate and gasket (A).
4TN82E-SP
M
3
5
6
4
4

-
U
N
-
2
6
A
U
G
8
8
M
3
7
9
0
1

-
U
N
-
2
9
A
U
G
8
8
M
3
7
9
0
2

-
U
N
-
2
9
A
U
G
8
8
M
3
7
9
0
3

-
U
N
-
2
9
A
U
G
8
8
M21,TM345,21 -19-01SEP87
010897
PN=210
45
11
6. Remove pulley flange (A) using a puller (B) and small
nuts (C).
M
3
5
6
4
5

-
U
N
-
2
6
A
U
G
8
8
NOTE: Be sure press blocks do not hit impeller.
7. Remove bearing shaft (A) using the correct size
bearing driver (B). (Use JDE-152 or JDG-506 Bearing
Driver.)
M
3
5
6
4
6

-
U
N
-
2
6
A
U
G
8
8
IMPORTANT: Impeller bore is tapered. Allow enough
clearance between cap screw and
impeller bore to prevent cap screw
from binding.
8. Remove impeller (A) using a bearing puller (B), 3/8 in.
cap screw (C), and a press.
M
3
5
6
4
7

-
U
N
-
2
6
A
U
G
8
8
M21,TM345,22 -19-10MAR86
M21,TM345,23 -19-11AUG87
M21,TM345,24 -19-10MAR86
010897
PN=211
45
12
9. Remove shaft seal.
M
3
5
6
4
8

-
U
N
-
2
6
A
U
G
8
8
10. Remove ceramic seal.
M
3
5
6
4
9

-
U
N
-
2
6
A
U
G
8
8
11. Remove O-ring, if equipped.
12. Thoroughly clean and inspect all parts. Replace parts
as necessary.
M
3
5
6
5
0

-
U
N
-
2
6
A
U
G
8
8
ASSEMBLE WATER PUMP
1. Install new O-ring, if equipped.
M
3
5
6
5
0

-
U
N
-
2
6
A
U
G
8
8
M21,TM345,25 -19-10MAR86
M21,TM345,26 -19-10MAR86
M21,TM345,27 -19-10MAR86
M21,TM345,28 -19-10MAR86
010897
PN=212
45
13
2. Install bearing shaft, long end down, using correct size
bearing driver (A) and a press. (Use JDE-152 or
JDG-506 Bearing Driver.)
3. Press shaft into pump body until bearing surface (B)
is flush with housing surface (C).
M
3
5
6
5
1

-
U
N
-
2
6
A
U
G
8
8
4. Install new shaft seal over impeller side of shaft.
M
3
5
6
5
2

-
U
N
-
2
6
A
U
G
8
8
5. Push shaft seal (A) to the bottom of its bore. Use a
25 mm or 1 in. socket (B) and a press.
M
3
5
6
5
3

-
U
N
-
2
6
A
U
G
8
8
M21,TM345,29 -19-11AUG87
M21,TM345,30 -19-10MAR86
M21,TM345,31 -19-10MAR86
010897
PN=213
45
14
IMPORTANT: Support pump on bearing shaft only.
DO NOT support on housing or you
could damage the housing.
6. Support pump on bearing shaft using a driver disk (A).
7. Push pulley flange (B) on bearing shaft until flange is
flush with end of shaft. Use a 1-in. driver disk (C) and a
press.
Push pulley flange (B) on bearing shaft until bottom of
flange is 17 mm (0.67 in.) from top of housing. Use a
3TN66/3TNA72
ram adapter (C) and a press.
For 4TN100RJF, push pulley flange (B) on bearing shaft
until bottom of flange is 13 mm (0.50 in.) from top of
housing.
Push pulley flange (B) on bearing shaft until top of
flange is 27 mm (1.06 in.) from top of housing. Use a
ram adapter (C) and a press.
3TN75RJ/3TN82E-SP/3TN84/4TN84
4TN82E-SP
M
3
5
6
5
4

-
U
N
-
2
6
A
U
G
8
8
M
3
7
9
0
4

-
U
N
-
2
9
A
U
G
8
8
M
3
7
9
0
5

-
U
N
-
2
9
A
U
G
8
8
IMPORTANT: DO NOT touch lapped sealing surface
of ceramic insert with bare hands: it
must be clean and dry.
8. Install new ceramic seal (shaft seal assembly) in
impeller.
M
3
5
6
5
5

-
U
N
-
2
6
A
U
G
8
8
M21,TM345,32 -19-11AUG87
M21,TM345,33 -19-10MAR86
010897
PN=214
45
15
9. Install impeller (A) with ceramic seal toward the shaft
seal.
10. Push impeller on bearing shaft until top of impeller is
even with end of shaft. Use a 1 in. driver disk (B) and a
press.
Push impeller on bearing shaft until top of impeller is 2
mm (0.08 in.) below housing. Use a ram adapter (B) and
press.
Push impeller on bearing shaft until top of impeller is 1
3TN66UJ/3TNA72UJ
mm (0.04 in.) below housing. Use a ram adapter (B) and
a press.
Use a ram adapter and a press to push impeller on
bearing shaft until clearance between impeller and pump
body is 0.31.1 mm (0.0120.043 in.)
3TN75RJ/3TN82E-SP/3TN84/4TN84
4TN82E-SP
4TN100RJF
M
3
5
6
5
6

-
U
N
-
2
6
A
U
G
8
8
M
3
7
9
0
6

-
U
N
-
2
9
A
U
G
8
8
M
3
7
9
0
7

-
U
N
-
2
9
A
U
G
8
8
M
5
1
5
6
7

-
U
N
-
3
1
A
U
G
8
8
M21,TM345,34 -19-11AUG87
010897
PN=215
45
16
11. Install new gasket on water pump housing.
4TN82E-SP
M
3
5
6
5
7

-
U
N
-
2
6
A
U
G
8
8
M
3
7
9
0
8

-
U
N
-
2
9
A
U
G
8
8
M21,TM345,35 -19-10MAR86
010897
PN=216
45
17
12. Install plate and three screws. Tighten screws to 9
Nm (78 lb-in.).
Install plate and five screws. Tighten screws to 9 Nm
(78 lb-in.)
Install parts (AD). Install and tighten four (eight for
3TN82E-SP/3TN84/4TN84 Engines, 10 for 4TN100 RJF
Engine) cap screws to 9 Nm (78 lb-in.).
Install plate and three screws. Tighten screws to 9 Nm
(78 lb-in.).
Early 3TNA72UJ
NOTE: For 4TN82E-SP engines, steps 1317 are not
used.
APlate
BAdapter
CO-Ring
DGasket
3TN66UJ/3TNA72UJ
3TN75RJ/3TN82ESP/3&4TN84/4TN100RJF
4TN82E-SP Engine
M
3
5
6
5
8

-
U
N
-
2
6
A
U
G
8
8
M
3
7
9
0
9

-
U
N
-
2
9
A
U
G
8
8
M
3
7
9
1
0

-
U
N
-
2
9
A
U
G
8
8
M
3
7
9
1
1

-
U
N
-
2
9
A
U
G
8
8
M21,TM345,36 -19-01SEP87
010897
PN=217
45
18
13. Install cap screws (A). Install pulley and four cap
screws. Hold pulley using strap wrench. Tighten cap
screws to 11 Nm (96 lb-in.).
M
3
5
8
5
3

-
U
N
-
2
6
A
U
G
8
8
14. Install washer (A) and temperature sender.
3TNA72UJ Shown M
3
7
8
9
9

-
U
N
-
2
9
A
U
G
8
8
15. Install new gasket (A), if equipped and thermostat.
M
3
5
6
5
9

-
U
N
-
2
6
A
U
G
8
8
M21,TM345,37 -19-11AUG87
M21,TM345,38 -19-11AUG87
M21,TM345,39 -19-11AUG87
010897
PN=218
45
19
17. Install thermostat housing. Tighten cap screws to
specifications.
THERMOSTAT HOUSING CAP SCREW SPECIFICATIONS
Engine Measurement Specifications
3TN66UJ Torque 9 Nm (78 lb-in.)
3TNA72UJ/3TN75RJ/
3TN82E-SP/ 3TN84/
4TN82E-SP/4TN84/
4TN100RJF Torque 20 Nm (180 lb-in.)
3TN82-RJB/
4TN78T-RJB Torque 26 Nm (226 lb-in.)
3TNA72UJ Shown
3TN75RJ Shown
M
3
5
6
6
0

-
U
N
-
2
6
A
U
G
8
8
M
3
5
6
6
1

-
U
N
-
2
6
A
U
G
8
8
M
3
7
9
1
2

-
U
N
-
2
9
A
U
G
8
8
M21,TM345,40 -19-01SEP87
010897
PN=219
45
20
INSTALL WATER PUMP
3. Install water pump. Tighten cap screws to 26 Nm
(226 lb-in.).
Install new gasket.
Install water pump and three cap screws. Tighten cap
screws to 26 Nm (226 lb-in.).
Install hose (A) and fasten with hose clamp (B).
4TN82E-SP
4TN82E-SP
M
3
7
9
1
3

-
U
N
-
2
9
A
U
G
8
8
M
3
7
9
1
4

-
U
N
-
2
9
A
U
G
8
8
M
3
7
9
1
5

-
U
N
-
2
9
A
U
G
8
8
M
3
7
9
1
6

-
U
N
-
2
9
A
U
G
8
8
M21,TM345,41 -19-01SEP87
Cooling System/Install
010897
PN=220
45
21
4. Install fan (C) if equipped and four cap screws (B).
Tighten cap screws to 11 Nm (96 lb-in.).
5. Install alternator belt (A). Pull alternator to tighten belt
and tighten cap screw.
3TNA72UJ Shown
3TN75RJ Shown
M
3
7
8
5
4

-
U
N
-
2
9
A
U
G
8
8
M
3
7
8
5
5

-
U
N
-
2
9
A
U
G
8
8
M21,TM345,42 -19-01SEP87
010897
PN=221
45
22
damage.
7. Connect coolant temperature sender wire.
8. Connect inlet and outlet coolant lines and fasten with
hose clamps.
9. Close the radiator and engine drain valves.
10. Fill cooling system with proper coolant to proper
level.
M
3
5
6
6
7

-
U
N
-
2
6
A
U
G
8
8
M21,TM345,43 -19-10MAR86
010897
PN=222
45
23
010897
PN=223
45
24
ESSENTIAL TOOLS
Number Name Use
D01109AA Diesel Fuel Injection Nozzle Tester To test nozzles
D01110AA Adapter Set To connect nozzle to nozzle tester
23622 Straight Adapter To connect nozzle to nozzle tester
Name Use
Strap Wrench To hold crankshaft pulley
13-Ton Puller Set To remove crankshaft pulley and to service
fuel injection pump camshaft
Bushing, Bearing, and Seal Driver Set To service bushing, bearings, and oil seals
Press To service fuel injection pump camshaft
Dial Indicator Measure fuel injection pump camshaft gear
backlash
Outside Micrometer Measure fuel injection pump camshaft lobe
height
M21,TM350,1 -19-23APR86
M21,TM350,2 -19-23APR86
Group 50
Fuel Injection Pump, Camshaft, and Nozzles
010897
PN=224
50
1
OTHER MATERIAL
Number Name Use
PT94 John Deere Form-In-Place Gasket To seal gear housing cover
T43512 John Deere LOCTITE Thread Lock Apply on threads of Crankshaft
and Sealer (medium strength) pulley cap screw
SERVICE PART KITS
catalog.
Fuel Injection Pump Shim Pack
Fuel Injection Nozzle Shim Pack
M21,TM350,3 -19-01SEP87
M21,TM350,4 -19-07FEB86
Fuel Injection Pump, Camshaft, and Nozzles/Service Part Kits
010897
PN=225
50
2
REMOVE FUEL INJECTION PUMP
(3TN66/3TNA72)
NOTE: If the fuel injection pump is being removed to
check timing. See Fuel Injection Pump Timing
Adjustment in Machine Technical Manual, Section
220.
N
CAUTION: Escaping fluid under pressure can
penetrate the skin causing serious injury.
Relieve pressure before disconnecting
hydraulic or other lines. Tighten all
connections before applying pressure. Keep
hands and body away from pinholes and
nozzles which eject fluids under high pressure.
Use a piece of cardboard or paper to search
for leaks. Do not use your hand.
If ANY fluid is injected into the skin, it must be
surgically removed within a few hours by a
doctor familiar with this type injury or
gangrene may result.
X
9
8
1
1

-
U
N
-
2
3
A
U
G
8
8
IMPORTANT: Never steam clean or pour cold water
on injection pump while the pump is
running or warm. Doing so can damage
the pump.
1. Clean the injection pump lines, and area around the
pump using a parts cleaning solvent or steam cleaner.
2. Remove two screws and clamp from injection lines.
IMPORTANT: When removing injection lines, DO NOT
turn pump delivery valve fittings.
Turning fittings may damage pump
internally.
3. Loose fuel injection line connectors slightly to release
pressure in the fuel system. When loosening connectors,
use another wrench to keep injectors from loosening.
4. Remove fuel injection lines. Close all openings with
caps and plugs to keep dirt out of the fuel system.
M
3
7
7
8
5

-
U
N
-
2
9
A
U
G
8
8
M21,TM350,6 -19-01SEP87
M21,TM350,7 -19-23APR86
Fuel Injection Pump, Camshaft, and Nozzles/Fuel Injection Pump (3TN66, 3TNA72)
010897
PN=226
50
3
5. Remove two cap screws and nut. Remove cover and
gasket (A).
6. Remove cotter pin (B) to disconnect solenoid linkage.
7. Remove four nuts to remove cover (A) with solenoid.
Early 3TNA72UJ
3TN66UJ/Later 3TNA72UJ
M
3
5
8
8
6

-
U
N
-
2
6
A
U
G
8
8
M
3
7
7
8
6

-
U
N
-
2
9
A
U
G
8
8
8. Remove pin (A) to disconnect linkage (B).
M
3
7
7
8
7

-
U
N
-
2
9
A
U
G
8
8
M21,TM350,8 -19-23APR86
M21,TM350,9 -19-08FEB86
010897
PN=227
50
4
IMPORTANT: If injection pump is being removed to
be serviced or replaced, the same
number and thickness of new shims
must be installed when pump is
assembled.
9. Remove four nuts to remove fuel injection pump and
shims (A).
IMPORTANT: DO NOT disassemble fuel injection
pump except for fuel delivery valves. If
repair is necessary, have the pump
serviced only by a qualified fuel
injection repair shop, or replace pump.
M
3
7
7
8
8

-
U
N
-
2
9
A
U
G
8
8
INSTALL FUEL INJECTION PUMP
(3TN66/3TNA72)
IMPORTANT: If a serviced or replacement fuel
injection pump is installed, measure old
shim thickness and install new shims
of the same thickness.
1. Install fuel injection pump and shims into housing.
Align controller rack (A) and governor linkage fork (B).
Install governor linkage (B) over arm on injection pump
Early 3TNA72UJ
rack and fasten with pin (A).
M
3
5
8
8
8

-
U
N
-
2
6
A
U
G
8
8
M
3
7
7
8
7

-
U
N
-
2
9
A
U
G
8
8
M21,TM350,10 -19-08FEB86
M21,TM350,11 -19-23APR86
010897
PN=228
50
5
2. Install and tighten four nuts to 20 Nm (180 lb-in.)
M
3
7
7
8
9

-
U
N
-
2
9
A
U
G
8
8
4. Install cover and fasten with two cap screws and nut.
Install cover (A) with fuel shut-off solenoid and fasten
with four stud nuts.
Connect fuel shut-off linkage and fasten with cotter pin
(B).
Early 3TNA72UJ
M
3
5
8
9
0

-
U
N
-
2
6
A
U
G
8
8
M
3
7
7
8
6

-
U
N
-
2
9
A
U
G
8
8
M21,TM350,12 -19-08FEB86
M21,TM350,13 -19-23APR86
010897
PN=229
50
6
IMPORTANT: When installing injection lines, DO NOT
internally.
5. Install injection lines using two wrenches.
6. Connect fuel inlet hose.
7. Bleed fuel system and check injection pump timing.
See Section 220 of the appropriate Machine Technical
Manual. M
3
7
7
8
5

-
U
N
-
2
9
A
U
G
8
8
M21,TM350,14 -19-01SEP87
010897
PN=230
50
7
(3TN75/3TN78/3TN82/3TN84/
4TN78/4TN82/4TN84)
the pump.
N
2. Loosen fuel injection line connectors slightly to release
X
9
8
1
1

-
U
N
-
2
3
A
U
G
8
8
M21,TM350,15 -19-01SEP87
Fuel Injection Pump, Camshaft, and Nozzles/Fuel Injection Pump (3TN75/3TN78/3TN82/3TN84/4TN78/4TN82/4TN84
010897
PN=231
50
8
3. Remove injection lines (A) and access cover (B).
M
3
7
7
9
0

-
U
N
-
2
9
A
U
G
8
8
4. Disconnect external lube line (A).
5. Note position of timing mark (B) for installation.
6. Remove the 3 attaching stud nuts (C).
M
3
7
7
9
1

-
U
N
-
2
9
A
U
G
8
8
7. Use chalk or paint to mark injection pump gear to
idler gear (A).
8. Remove special nut (B).
M
3
7
7
9
2

-
U
N
-
2
9
A
U
G
8
8
M21,TM350,16 -19-08FEB86
M21,TM350,17 -19-08FEB86
M21,TM350,18 -19-23APR86
010897
PN=232
50
9
9. Assemble a suitable two jaw puller similar to the one
shown.
M
3
7
7
9
3

-
U
N
-
2
9
A
U
G
8
8
10. Install puller onto injection pump gear through access
hole. Pull gear from shaft.
11. Remove injection pump.
M
3
7
7
9
4

-
U
N
-
2
9
A
U
G
8
8
INSTALL INJECTION PUMP
(3TN75/3TN78/3TN82/3TN84/
4TN78/4TN82/4TN84)
1. Put injection pump onto back of gear housing. Align
key on shaft with keyway in gear. Be sure to align gear
timing marks (A) made during removal.
2. Install special nut (B). Tighten to 90 Nm (66 lb-ft).
M
3
7
7
9
2

-
U
N
-
2
9
A
U
G
8
8
M21,TM350,19 -19-23APR86
M21,TM350,20 -19-08FEB86
M21,TM350,21 -19-13AUG87
010897
PN=233
50
10
3. Install external lube line (A).
4. Align timing marks to same place as when removed.
If new injection pump is being installed, check and adjust
timing as instructed in Section 220 of the Machine
Technical Manual.
5. Install the three mounting stud nuts (C). Tighten to 26
Nm (19 lb-ft).
6. Install injection lines and gear access cover. Bleed
fuel system as instructed in Machine Technical Manual.
M
3
7
7
9
1

-
U
N
-
2
9
A
U
G
8
8
M21,TM350,22 -19-01SEP87
010897
PN=234
50
11
(4TN100RJF)
the pump
N
2. Loosen fuel injection line connectors slightly to release
3. Remove injection lines (A), fuel filter hoses (B) and
external lube line (C).
4. Score a line (D) to mark injection pump position on
gear case housing.
AInjection Lines
BHoses
CLube-Line
DLine
X
9
8
1
1

-
U
N
-
2
3
A
U
G
8
8
M
5
1
5
8
2

-
U
N
-
3
1
A
U
G
8
8
M21,TM350,A1 -19-01SEP87
Fuel Injection Pump, Camshaft, and Nozzles/Fuel Injection Pump (4TN100RJF)
010897
PN=235
50
12
5. Remove oil filler neck assembly.
6. Use chalk or paint to mark injection pump gear to
notch (A) on gear case housing.
M
5
1
5
8
3

-
U
N
-
3
1
A
U
G
8
8
7. Remove six cap screw (A) to remove injection pump.
M
5
1
5
8
4

-
U
N
-
3
1
A
U
G
8
8
INSTALL FUEL INJECTION PUMP
(4TN100RJF)
1. Install O-ring (B) on injection pump. Put injection
pump onto gear housing. Align gear timing marks (C)
made during removal.
2. Install six cap screws (A).
3. Install oil filler neck and gasket.
M
5
1
5
8
5

-
U
N
-
3
1
A
U
G
8
8
M21,TM350,A2 -19-13AUG87
M21,TM350,A3 -19-13AUG87
M21,TM350,A4 -19-13AUG87
Fuel Injection Pump, Camshaft, and Nozzles/Fuel Injection Pump (4TN100RJF)
010897
PN=236
50
13
4. Install external lube line (C).
5. Align marks (D) to same place as when removed.
Tighten mounting cap screws to 27 Nm (20 lb-ft).
If new injection pump is being installed, check and adjust
timing as instructed in Section 230 or 9010 of the
Machine Technical Manual.
6. Install injection lines. Bleed fuel system as instructed
in Machine Technical Manual.
AInjection
BHoses
CLube Line
DLine
M
5
1
5
8
2

-
U
N
-
3
1
A
U
G
8
8
CAMSHAFT (EARLY 3TNA72UJ)
Technical Manual.)
2. Remove fuel injection pump (A), as instructed earlier
in this group.
3. Loosen alternator and remove alternator belt (B).
M
3
5
9
7
3

-
U
N
-
2
9
A
U
G
8
8
M21,TM350,A5 -19-01SEP87
M21,TM350,23 -19-13AUG87
Fuel Injection Pump, Camshaft, and Nozzles/Fuel Injection Pump Camshaft
010897
PN=237
50
14
4. Hold crankshaft pulley using a strap wrench. Remove
cap screw and washer.
M
3
5
2
7
0

-
U
N
-
2
9
A
U
G
8
8
5. Remove crankshaft pulley using puller, shaft protector,
two cap screws from water pump, and strap wrench.
M
3
5
2
7
1

-
U
N
-
2
9
A
U
G
8
8
6. Remove cotter pin and washer (A) to disconnect fuel
shut-off solenoid linkage.
M
3
5
2
7
2

-
U
N
-
2
9
A
U
G
8
8
7. Remove two nuts and one cap screw to remove
bracket and fuel shut-off solenoid.
M
3
5
2
7
3

-
U
N
-
2
9
A
U
G
8
8
M21,TM350,24 -19-24MAR86
M21,TM350,25 -19-24MAR86
M21,TM350,26 -19-24MAR86
M21,TM350,27 -19-24MAR86
010897
PN=238
50
15
8. Remove 17 cap screws to remove gear housing
cover. Remove old gasket material from cover and gear
housing.
M
3
5
5
3
2

-
U
N
-
2
6
A
U
G
8
8
9. Remove seal using 1 3/4 in. driver disk (A) and 2 3/8
in. driver disk (B).
M
3
5
2
7
5

-
U
N
-
2
9
A
U
G
8
8
10. Measure fuel injection pump gear backlash using a
dial indicator. New backlash specification is 0.040.12
mm (0.0020.005 in.).
If backlash exceeds 0.20 mm (0.008 in.), replace gear.
M
3
5
9
0
0

-
U
N
-
2
6
A
U
G
8
8
11. Put a shop towel between gear teeth. Loosen lock
nut.
M
3
5
9
0
1

-
U
N
-
2
6
A
U
G
8
8
M21,TM350,28 -19-24MAR86
M21,TM350,29 -19-24MAR86
M21,TM350,30 -19-24MAR86
M21,TM350,31 -19-24MAR86
010897
PN=239
50
16
12. Remove idler gear.
M
3
5
5
3
5

-
U
N
-
2
6
A
U
G
8
8
13. Remove special screw.
M
3
5
5
3
6

-
U
N
-
2
6
A
U
G
8
8
while removing camshaft. Machined
14. Carefully remove fuel injection pump camshaft
assembly. Use a slide hammer puller and two cap
screws from the gear housing cover.
M
3
5
5
3
7

-
U
N
-
2
6
A
U
G
8
8
CAMSHAFT (3TN66/LATER 3TNA72)
1. Remove fuel injection pump as instructed earlier in
this group.
2. Remove gear housing cover.
3. Remove governor housing and flyweight assembly as
instructed in Group 60.
M21,TM350,32 -19-24MAR86
M21,TM350,33 -19-24MAR86
M21,TM350,34 -19-24MAR86
M21,TM350,35 -19-01SEP87
010897
PN=240
50
17
4. Remove camshaft bearing retaining screw (A) and
idler gear (B).
M
3
7
7
9
5

-
U
N
-
2
9
A
U
G
8
8
5. Tap the rear of camshaft (A) with plastic hammer to
remove from housing.
M
3
7
7
9
6

-
U
N
-
2
9
A
U
G
8
8
DISASSEMBLE AND INSPECT FUEL
INJECTION PUMP CAMSHAFT
1. Inspect camshaft gear for chipped, broken or worn
teeth.
IMPORTANT: Hold camshaft while removing gear.
2. Support gear on knife edge puller and press shaft
from gear.
NOTE: Early 3TNA72 injection pump camshafts are
tapered on the gear end. Camshafts on 3TN66
and later 3TNA72 engines are not tapered
Service procedures are the same.
M
3
7
7
9
7

-
U
N
-
2
9
A
U
G
8
8
M21,TM350,36 -19-08FEB86
M21,TM350,37 -19-23APR86
M21,TM350,38 -19-01SEP87
010897
PN=241
50
18
IMPORTANT: Hold camshaft while removing
bearings.
3. Support bearings on knife edge puller and press shaft
from bearings.
Front Bearing
Rear Bearing
M
3
7
7
9
8

-
U
N
-
2
9
A
U
G
8
8
M
3
7
7
9
9

-
U
N
-
2
9
A
U
G
8
8
4. Measure height of each camshaft lobe. Replace
camshaft if lobe height is less than 30.9 mm (1.217 in.)
M
3
5
9
0
5

-
U
N
-
2
6
A
U
G
8
8
M21,TM350,39 -19-08FEB86
M21,TM350,40 -19-08FEB86
010897
PN=242
50
19
ASSEMBLE AND INSTALL FUEL INJECTION
PUMP CAMSHAFT
1. Support camshaft in knife edge puller.
2. Press smaller bearing onto rear end of camshaft using
a 3/4 in. deep well socket. Press until bearing race
bottoms on camshaft shoulder.
M
3
7
8
0
0

-
U
N
-
2
9
A
U
G
8
8
3. Support large bearing on a 3/4 in. deep well socket
and press camshaft into bearing until it bottoms on
bearing race.
M
3
7
8
0
1

-
U
N
-
2
9
A
U
G
8
8
M21,TM350,41 -19-08FEB86
M21,TM350,41A -19-19MAR86
010897
PN=243
50
20
4. Put camshaft gear on a flat surface. Press camshaft
with bearings into gear.
Press until gear face is flush with end of shaft.
M
3
7
8
0
2

-
U
N
-
2
9
A
U
G
8
8
5. Inspect camshaft front bearing support. Check for
cracks, damage or indications that bearing has spun in
support.
6. On 3TN66/later 3TNA72 engines. If necessary,
remove three cap screws (A) and replace support.
On early 3TNA72UJ engines, replace gear housing if
bearing bores are damaged.
M
3
7
8
0
3

-
U
N
-
2
9
A
U
G
8
8
7. Slide camshaft assembly into housing. Tap camshaft
gear with plastic hammer to seat bearings in bores.
8. Install bearing retaining screw (A). Tighten to 20 Nm
(180 lb-in.).
9. Install governor assembly and flyweights as instructed
in Group 60.
10. Install injection pump as instructed earlier in this
group.
M
3
7
8
0
4

-
U
N
-
2
9
A
U
G
8
8
M21,TM350,42 -19-23APR86
M21,TM350,43 -19-13AUG87
M21,TM350,44 -19-08FEB86
010897
PN=244
50
21
11. Install idler gear and align timing marks (A, B, and
C).
NOTE: Number one cylinder is closest to flywheel.
3TNA72
3TN66
M
3
7
8
0
5

-
U
N
-
2
9
A
U
G
8
8
M
3
7
8
0
6

-
U
N
-
2
9
A
U
G
8
8
12. On early 3TNA72UJ engines, put a shop towel
between gear teeth. Install lock washer and nut. Tighten
to 88 Nm (65 lb-ft).
M
3
5
9
0
9

-
U
N
-
2
6
A
U
G
8
8
M21,TM350,45 -19-13AUG87
M21,TM350,46 -19-08FEB86
010897
PN=245
50
22
13. If necessary, replace front crankshaft oil seal.
Use 1-3/4 in. disk (A) and 2-3/8 in. disk (B).
Install new seal with lip facing inward. Install flush with
front face of gear housing cover.
M
3
5
2
7
5

-
U
N
-
2
9
A
U
G
8
8
14. Install gear housing cover. Tighten cap screws to 9
Nm (80 lb-in.)
15. Install and connect fuel shut-off solenoid.
M
3
5
5
7
1

-
U
N
-
2
6
A
U
G
8
8
16. If equipped, align index pin (A) with hole in
crankshaft gear (B).
M
3
5
2
9
5

-
U
N
-
2
9
A
U
G
8
8
M21,TM350,47 -19-08FEB86
M21,TM350,48 -19-08FEB86
M21,TM350,49 -19-08FEB86
010897
PN=246
50
23
17. Apply medium strength thread lock and sealer to
pulley cap screw.
18. Hold pulley with strap wrench and tighten cap screw
19. Install fan and fan belt.
20. Install engine. See section 20 of Machine Technical
Manual.
21. Bleed fuel system. See section 230 of Machine
Technical Manual.
M
3
5
2
9
6

-
U
N
-
2
9
A
U
G
8
8
PINTLE TYPE FUEL INJECTION NOZZLE
OPERATION (3TN66/3TNA72)
The pintle type nozzle is used on indirect injection
engines 3TN66 and 3TNA72. It is different from the hole
type nozzle in that it is threaded into the cylinder head.
High pressure fuel from the injection pump flows through
a fuel inlet passage. Pressure builds beneath the nozzle
valve. When the fuel pressure reaches specified pressure
it overcomes the nozzle spring tension. The nozzle valve
retracts into the nozle body and fuel is injected into the
engine. The nozzle valve is shim adjustable to regulate
the opening pressure.
The nozzle valve is automatically pushed down by the
nozzle spring and closed after fuel is injected.
Leakage (return fuel) flows from beyond the nozzle valve
and nozzle body to the hole on top of the nozzle spring
through the return pipe fitting and back into the fuel tank.
T
6
3
3
3
A
J

-
1
9
-
0
5
J
A
N
8
9
M21,TM350,50 -19-08FEB86
M21,TM350,51A -19-13AUG87
Fuel Injection Pump, Camshaft, and Nozzles/Pintle Type Fuel Injection Nozzle
010897
PN=247
50
24
REMOVE PINTLE TYPE FUEL INJECTION
NOZZLES (3TN66/3TNA72)
N
the pump.
1. Clean the injection pump, injection nozzles, lines, and
area around the nozzles using a parts cleaning solvent
or a steam cleaner.
X
9
8
1
1

-
U
N
-
2
3
A
U
G
8
8
internally.
2. Use two wrenches to loosen fuel line fittings enough
to release any pressure in the fuel system.
3. Disconnect fuel lines from injection nozzles and
remove lines.
4. Cap all openings to keep dirt out of the fuel system. M
3
5
8
8
3

-
U
N
-
2
6
A
U
G
8
8
M21,TM350,52A -19-01SEP87
M21,TM350,53 -19-08FEB86
010897
PN=248
50
25
5. Loosen clamp and disconnect fuel return hose (A).
6. Remove three nuts to remove leak-off line (B).
IMPORTANT: To prevent possible leakage DO NOT
reuse bronze gasket material.
7. Remove and discard bronze gaskets.
M
3
5
9
1
0

-
U
N
-
2
6
A
U
G
8
8
8. Remove clamps to remove hoses (A) and fittings (B).
M
3
5
9
1
1

-
U
N
-
2
6
A
U
G
8
8
9. Remove fuel injection nozzles.
10. Remove and discard bronze gaskets.
11. Test injection nozzles.
M
3
5
9
1
2

-
U
N
-
2
6
A
U
G
8
8
M21,TM350,54 -19-08FEB86
M21,TM350,55 -19-08FEB86
M21,TM350,56 -19-08FEB86
010897
PN=249
50
26
TEST PINTLE TYPE FUEL INJECTION
This test checks the opening pressure, leakage, chatter,
and spray pattern of the fuel injection nozzle. Test the
nozzle before disassembly to determine condition and
necessary repair.
1. Connect fuel injection nozzle (D) to D-01109AA Diesel
Fuel Injection Nozzle Tester (F). Use fittings (A, B, and
G) from D-01110AA Adapter Set and fitting (C).
IMPORTANT: Use clean filtered diesel fuel when
testing fuel injection nozzles to get
best test results.
N
2. Test fuel injection nozzle opening pressure following
the tool manufacturers instructions.
a. Record pressure reading when nozzle valve opens.
b. If pressure reading does not meet specifications,
disassemble injection nozzle and inspect nozzle
assembly for contamination or stuck valve. If necessary,
add or remove shims to change opening pressure. (See
Disassemble Fuel Injection Nozzles in this section.)
A23617 90 Adapter
NOZZLE VALVE OPENING PRESSURE SPECIFICATIONS
B23621 Straight Adapter
C23622 Straight Adapter
3TN66/3TNA72 . . . . . . . . . . . . . . . . . . . . . . . . 11 722 480 kPa DFuel Injection Nozzle
(1700 70 psi) EContainer
FD-01109AA Diesel Fuel Injection Nozzle
G36352 Fuel Line Assembly
X
9
8
1
1

-
U
N
-
2
3
A
U
G
8
8
M
3
5
9
1
3

-
U
N
-
2
6
A
U
G
8
8
M21,TM350,57 -19-01SEP87
010897
PN=250
50
27
3. Test fuel injection nozzle leakage following the tool
manufacturers instructions.
a. Dry nozzle completely using a lint-free cloth.
b. Pressurize nozzle to test specifications.
c. Watch for leakage from nozzle spray orifice
NOZZLE LEAKAGE 3TN66/3TNA72 TEST SPECIFICATIONS
Nozzle Pressure . . . . . . . . . . . . . . . . . . 11 032 kPa (1600 psi)
Minimum Nozzle Leakage Time . . . . . . . . 10 seconds
d. If nozzle leakage time is low, check nozzle for
contamination. Inspect valve seating surface; replace
nozzle assembly as required.
4. Test fuel injection nozzle chatter and spray pattern
following the tool manufacturers instructions.
a. Pressurize nozzle to test specifications.
b. Listen for chatter sound and watch spray pattern.
NOZZLE PRESSURE TEST SPECIFICATIONS
3TN66/3TNA72 . . . . . . . . . . . . . . . . . . . 11 722 480 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
If nozzle does not chatter or spray pattern is toward one
side only and not finely atomized, check nozzle for
M21,TM350,58 -19-08FEB86
M21,TM350,59 -19-08FEB86
010897
PN=251
50
28
DISASSEMBLE PINTLE TYPE FUEL
INJECTION NOZZLES (3TN66/3TNA72)
NOTE: Disassemble fuel injection nozzles in a clean,
lint-free, work area.
1. Remove O-ring (A).
2. Separate injector assembly.
M
3
5
9
1
4

-
U
N
-
2
6
A
U
G
8
8
IMPORTANT: If injector nozzles are being
be installed when nozzles are
assembled.
3. Remove retainer (C), spring (B), and shims (A).
M
3
5
9
1
5

-
U
N
-
2
6
A
U
G
8
8
4. Remove valve (A), valve (B), and nozzle body (C).
M
3
5
9
1
6

-
U
N
-
2
6
A
U
G
8
8
5. Inspect 45 valve seating surfaces; replace nozzle
assembly as required.
6. All internal service parts must have a shiny surface. If
surface is dull, replace part.
M
3
5
9
1
7

-
U
N
-
2
6
A
U
G
8
8
M21,TM350,60 -19-01SEP87
M21,TM350,61 -19-08FEB86
M21,TM350,62 -19-08FEB86
M21,TM350,63 -19-08FEB86
010897
PN=252
50
29
CROSS SECTION OF PINTLE TYPE FUEL
INJECTION NOZZLE (3TN66/3TNA72)
AInjector Body
BO-Ring
CBronze Gasket
DShim (as required)
ENozzle Fitting
FNozzle Body
GValve
HNozzle Assembly
ISeat
JRetainer
KSpring
M
3
5
9
1
8

-
U
N
-
2
6
A
U
G
8
8
M21,TM350,64 -19-14SEP87
010897
PN=253
50
30
CLEAN AND INSPECT PINTLE TYPE FUEL
INJECTION NOZZLES (3TN66/3TNA72)
IMPORTANT: Never use a steel brush or abrasives to
clean nozzles. Doing so will damage
the spray hole.
1. Remove carbon from used nozzles, and clean by
washing in clean diesel fuel. If parts are coated with
hardened carbon or lacquer, it may be necessary to use
a brass wire brush from the JDF-13 Nozzle Cleaning Kit.
NOTE: A worn, damaged, or contaminated nozzle
assembly will cause nozzle leakage. This
condition usually will be noticed when testing the
fuel injection nozzle.
2. Inspect nozzle assembly components for wear or
damage. All internal service parts must have a shiny
surface. If surface is dull, replace part.
3. Inspect the nozzle assembly by performing a slide
test. Use the following procedure:
a. Dip the valve (A) in clean diesel fuel. Insert valve in
nozzle body (B).
b. Hold nozzle assembly vertical and pull valve out about
1/3 of its engaged length.
c. Release valve. Valve should slide down to its seat by
its own weight.
Always replace a nozzle assembly if the valve does not
slide freely to its seat.
M
3
5
9
1
9

-
U
N
-
2
6
A
U
G
8
8
ASSEMBLE PINTLE TYPE FUEL INJECTION
NOTE: Assemble fuel injection nozzles in a
clean,lint-free, work area.
1. Put clean diesel fuel on all internal parts.
2. Install valve (A) in nozzle body (B). Valve must slide
freely in nozzle body.
M
3
5
9
1
9

-
U
N
-
2
6
A
U
G
8
8
M21,TM350,65 -19-01SEP87
M21,TM350,66 -19-14AUG87
010897
PN=254
50
31
3. Install nozzle assembly (B and C) and seat (A).
M
3
5
9
1
6

-
U
N
-
2
6
A
U
G
8
8
IMPORTANT: If injection nozzles were disassembled
to be cleaned, the same number and
thicknesses of shims must be installed.
4. Install the required amount of shims (A) from shim
pack, until the nozzle valve opening pressure is 11 722
480 kPa (1700 70 psi). After assembling fuel
injection nozzles, test opening pressure. (See Fuel
Injection Nozzle Test in this section.)
SHIM PACK
Shim Size Approximate Pressure Change
0.15 mm (0.006 in.) 2170 kPa (315 psi)
0.40 mm (0.016 in.) 5790 kPa (840 psi)
0.50 mm (0.020 in.) 7240 kPa (1050 psi)
0.60 mm (0.024 in.) 8690 kPa (1260 psi)
0.70 mm (0.028 in.) 10 140 kPa (1470 psi)
0.80 mm (0.031 in.) 11 580 kPa (1680 psi)
NOTE: For every 0.10 mm (0.004 in.) of shim thickness,
there is approximately a 1450 kPa (210 psi)
change in nozzle valve opening pressure.
5. Install spring (B) and retainer (C).
M
3
5
9
1
5

-
U
N
-
2
6
A
U
G
8
8
M21,TM350,67 -19-24MAR86
M21,TM350,68 -19-23APR86
010897
PN=255
50
32
6. Assemble nozzle assembly. Tighten to 40 Nm (30
lb-ft).
7. Install new O-ring (A).
M
3
5
9
2
0

-
U
N
-
2
6
A
U
G
8
8
INSTALL PINTLE TYPE FUEL INJECTION
1. Install new bronze gaskets.
M
3
5
9
2
1

-
U
N
-
2
6
A
U
G
8
8
2. Install and tighten injection nozzle into cylinder head
M
3
5
9
2
2

-
U
N
-
2
6
A
U
G
8
8
3. Install hoses (A) and fittings (B). Fasten with clamps.
M
3
5
9
1
1

-
U
N
-
2
6
A
U
G
8
8
M21,TM350,69 -19-14AUG87
M21,TM350,70 -19-14AUG87
M21,TM350,71 -19-14AUG87
M21,TM350,72 -19-08FEB86
010897
PN=256
50
33
4. Install new bronze gaskets (A).
5. Install fuel leak-off line and nuts. Tighten nuts to no
more than 40 Nm (30 lb-ft).
6. Connect fuel return line (B) and fasten with clamp.
M
3
5
9
2
3

-
U
N
-
2
6
A
U
G
8
8
M
3
5
9
2
4

-
U
N
-
2
6
A
U
G
8
8
IMPORTANT: When installing injection lines, DO NOT
turn pump outlet fittings. Turning
fittings may damage pump internally.
7. Install injection lines using two wrenches.
8. Install line clamp and two screws.
9. Bleed the fuel system. (See Section 30 of the
appropriate Technical Manual.)
M
3
5
8
8
5

-
U
N
-
2
6
A
U
G
8
8
M21,TM350,73 -19-14AUG87
M21,TM350,74 -19-08FEB86
010897
PN=257
50
34
HOLE TYPE FUEL INJECTION NOZZLE
OPERATION (ALL EXCEPT 3TN66/3TNA72)
The hole type nozzle is used on direct injection engines
3TN75 and larger. It is different from the pintle type
nozzle in that it is held in the cylinder head by a
retaining bracket instead of being threaded.
High pressure fuel from the injection pump flows through
a fuel inlet passage. Pressure builds beneath the nozzle
valve. When the fuel pressure reaches specified pressure
it overcomes the nozzle spring tension. The nozzle valve
retracts into the nozzle body and fuel is injected into the
engine. The nozzle valve is shim adjustable to regulate
the opening pressure.
The nozzle valve is automatically pushed down by the
nozzle spring and closed after fuel is injected.
Leakage (return fuel) flows from between the nozzle
valve and nozzle body to the hole on top of the nozzle
spring through the return pipe fitting and back into the
fuel tank.
T
6
3
3
3
A
I

-
1
9
-
0
5
J
A
N
8
9
M21,TM350,75A -19-01SEP87
Fuel Injection Pump, Camshaft, and Nozzles/Hole Type Fuel Injection Nozzle
010897
PN=258
50
35
REMOVE HOLE TYPE FUEL INJECTION
NOZZLES (ALL EXCEPT 3TN66/3TNA72)
N
the pump.
1. Clean the injection pump, injection nozzles, lines, and
area around the nozzles using a parts cleaning solvent
or a steam cleaner.
X
9
8
1
1

-
U
N
-
2
3
A
U
G
8
8
internally.
2. Use two wrenches to loosen fuel line fittings enough
to release any pressure in the fuel system.
3. Disconnect fuel lines from injection nozzles and
remove lines.
4. Cap all openings to keep dirt out of the fuel system. M
3
5
8
8
3

-
U
N
-
2
6
A
U
G
8
8
M21,TM350,52B -19-14AUG87
M21,TM350,53 -19-08FEB86
010897
PN=259
50
36
5. Remove nuts from studs and remove retaining plates
(A) from nozzles.
6. Remove leak-off lines (B).
M
3
7
8
0
7

-
U
N
-
2
9
A
U
G
8
8
7. If nozzles are stuck in cylinder head:
Grind the head of a cap screw (A) so it fits inside a nut
from (B), from an old injection line.
Use double nuts to attach a large flat washer (C) to the
cap screw.
Install the assembly onto nozzle and use a suitable
puller and slide hammer to pull nozzles from head.
M
3
7
8
0
8

-
U
N
-
2
9
A
U
G
8
8
8. When removing nozzles, check to see if teflon seal
and ring (A) is removed with nozzle. If heat protector
stays in cylinder head, thread a cap screw into it and
pull from cylinder head.
3. Test injection nozzles.
M
3
7
8
0
9

-
U
N
-
2
9
A
U
G
8
8
M21,TM350,76 -19-08FEB86
M21,TM350,77 -19-08FEB86
M21,TM350,78 -19-08FEB86
010897
PN=260
50
37
TEST HOLE TYPE FUEL INJECTION
This test checks the opening pressure, leakage, chatter,
and spray pattern of the fuel injection nozzle. Test the
nozzle before disassembly to determine condition and
necessary repair.
1. Connect fuel injection nozzle (D) to D-01109AA Diesel
Fuel Injection Nozzle Tester (F). Use fittings (A, B, and
G) from D01110AA Adapter Set and fitting (C).
IMPORTANT: Use clean filtered diesel fuel when
testing fuel injection nozzles to get
best test results.
N
2. Test fuel injection nozzle opening pressure following
the tool manufacturers instructions.
a. Record pressure reading when nozzle valve opens.
b. If pressure reading does not meet specifications,
disassemble injection nozzle and inspect nozzle
assembly for contamination or stuck valve. If necessary,
add or remove shims to change opening pressure. (See
Disassemble Fuel Injection Nozzles in this section.)
A23617 90 Adapter
NOZZLE VALVE OPENING PRESSURE SPECIFICATIONS
B23621 Straight Adapter
C23622 Straight Adapter
3TN75/3TN78/3TN82/3TN84/4TN78 DFuel Injection Nozzle
4TN82/4TN84 . . . . . . . . . . . . . 19 600 480 kPa (2843 70 psi) EContainer
FD-011-09AA Diesel Fuel Injection Nozzle Tester
G36352 Fuel Line Assembly 4TN100 . . . . . . . . . . . . . . . . . . . . . 20 100 490 kPa (2915 PSI)
X
9
8
1
1

-
U
N
-
2
3
A
U
G
8
8
M
3
5
9
1
3

-
U
N
-
2
6
A
U
G
8
8
M21,TM350,79 -19-01SEP87
010897
PN=261
50
38
3. Test fuel injection nozzle leakage following the tool
manufacturers instructions.
a. Dry nozzle completely using a lint-free cloth.
b. Pressurize nozzle to test specifications.
c. Watch for leakage from nozzle spray orifice.
NOZZLE LEAKAGE TEST SPECIFICATIONS
3TN75/3TN78/3TN82/3TN84/4TN78/4TN82/4TN84
Nozzle Pressure . . . . . . . . . . . . . . . . . . . 17 640 kPa (2550 psi)
Minimum Nozzle Leakage Time . . . . . . . . . . . . . . . . . . 5 seconds
4TN100
Nozzle Pressure . . . . . . . . . . . . . . . . . . . 18 100 kPa (2625 psi)
Minimum Nozzle leakage Time . . . . . . . . . . . . . . . . . . . 5 seconds
d. If nozzle leakage time is low, check nozzle for
4. Test fuel injection nozzle chatter and spray pattern
following the tool manufacturers instructions.
a. Pressurize nozzle to test specifications.
b. Listen for chatter sound and watch spray pattern.
NOZZLE PRESSURE TEST SPECIFICATIONS
3TN75/3TN78/3TN82/3TN84/
4TN78/4TN82/4TN84 . . . . . . . . 19 600 480 kPa (2843 70 psi)
4TN100 . . . . . . . . . . . . . . . . . . . 20 100 490 kPa (2915 71 psi)
Slow Hand Lever Movement . . . . . . . . . . . . . . . . . . . chatter sound
Slow Hand Lever Movement . . . . . . . . . . . fine stream spray pattern
Fast Hand Lever Movement . . . . . . . . . . fine atomized spray pattern
If nozzle does not not chatter or spray pattern is toward
one side only and not finely atomized, check nozzle for
M21,TM350,80 -19-01SEP87
M21,TM350,81 -19-01SEP87
010897
PN=262
50
39
DISASSEMBLE HOLE TYPE FUEL
INJECTION NOZZLES (ALL EXCEPT
3TN66/3TNA72)
1. Remove nozzle retaining nut (A).
2. Remove nozzle assembly (B).
3. Remove separator plate and index pins (C).
M
3
7
8
1
0

-
U
N
-
2
9
A
U
G
8
8
4. Remove spring seat (A), spring (B), and shims (C).
M
3
7
8
1
1

-
U
N
-
2
9
A
U
G
8
8
M21,TM350,82 -19-14AUG87
M21,TM350,83 -19-08FEB86
010897
PN=263
50
40
CLEAN AND INSPECT HOLE TYPE
INJECTION NOZZLE COMPONENTS (ALL
EXCEPT 3TN66/3TNA72)
1. Remove anti-corrosive grease from new or
reconditioned nozzles by washing them thoroughly in
diesel fuel.
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 to use a brass
wire brush (supplied in JDF-13 Nozzle Cleaning Kit).
IMPORTANT: Never use a steel brush to clean
nozzles as this will distort the spray
hole.
3. After removing carbon or lacquer from the exterior of
nozzle, inspect the lapped machine surface (D) for nicks
or scratches.
4. Inspect the piston (large) part of nozzle valve (A) to
see that it is not scratched or scored and that lower (tip)
end of valve is not broken. If any of these conditions are
present, replace the nozzle assembly.
5. Inspect condition of seat for nozzle valve and nozzle.
Contact area of seat (both parts) must not be scored or
pitted. Use an inspection magnifier (No. 16487 or
equivalent) to aid making the inspection.
NOTE: A bad nozzle valve seat will cause fuel to drip
from the nozzle. This condition usually will be
noted when performing Leakage Test described
in this group.
6. Further inspect the nozzle assembly by performing a
slide test. Use the following procedure:
a. Dip the nozzle valve (A) in clean diesel fuel. Insert
valve in nozzle (B).
b. Hold nozzle vertical, and pull valve out about 1/3 of its
engaged length (C).
c. Release valve. Valve should slide down to its seat by
its own weight.
7. Always replace a nozzle assembly if the valve does
not slide freely to its seat.
R
G
2
2
3
3

-
U
N
-
2
0
A
P
R
8
9
M21,TM350,84 -19-14AUG87
010897
PN=264
50
41
CROSS SECTION OF HOLE TYPE FUEL
INJECTION NOZZLE (ALL EXCEPT
3TN66/3TNA72)
AFuel Return Pipe
BDowel Pin (3 used)
CSeat
DNozzle Nut
EValve
FNozzle Body
GNozzle Assembly
HRetainer
ISpring
JShim (as required)
KInjector Body
M
3
7
6
8
4

-
U
N
-
0
6
S
E
P
8
8
M21,TM350,85 -19-14SEP87
010897
PN=265
50
42
ASSEMBLE AND INSTALL HOLE TYPE FUEL
1. Install shims as needed into nozzle body.
2. Install spring and spring seat into nozzle body.
3. Install separator plate and index pins (A).
4. Install nozzle assembly (B) and retaining nut (C).
5. Tighten retaining nut to 43 Nm (31 lb-ft). M
3
7
8
1
2

-
U
N
-
2
9
A
U
G
8
8
6. Install new teflon seal (A) into old retaining ring.
7. If any parts were replaced, test nozzles and adjust
opening pressure.
8. Install nozzles into cylinder head.
M
3
7
8
0
9

-
U
N
-
2
9
A
U
G
8
8
9. Install retaining plates and nuts. Tighten nuts to 4.5
Nm (39 lb-in.).
10. Install leak-off lines and injection lines.
11. Bleed fuel system. Refer to section 30 of the
appropriate Technical Manual.
M
3
7
8
1
3

-
U
N
-
2
9
A
U
G
8
8
M21,TM350,86 -19-01SEP87
M21,TM350,87 -19-08FEB86
M21,TM350,88 -19-08FEB86
010897
PN=266
50
43
010897
PN=267
50
44
Name Use
Blind-Hole Puller Set To remove throttle lever bushing
Outside Micrometer To measure speed control linkage components
Telescoping Gage To measure speed control linkage components
Bushing, Bearing, and Seal Driver Set To install throttle lever bushing
OTHER MATERIAL
Number Name Use
AT52853 John Deere LOCTITE
Thread Lock Apply on threads of fuel shut-off

and Sealer (Low Strength) lever set screw
SERVICE PART KITS
catalog:
Fuel Injection Pump Shim Pack
M21,TM355,1 -19-23APR86
M21,TM355,2 -19-23APR86
M21,TM355,3 -19-08FEB86
Group 55
010897
PN=268
55
1
REMOVE FUEL CONTROL AND GOVERNOR
LINKAGE (EARLY 3TNA72UJ)
1. Remove grille and left side panel.
2. Disconnect battery negative () cable.
3. Remove fuel injection pump (A). (See Group 50 in this
manual.)
4. Disconnect throttle cable (B).
5. Disconnect fuel shut-off linkage (C).
6. Remove oil filter (D) and dipstick tube (E).
AFuel Injection Pump
BThrottle Cable
CFuel Shut-Off Linkage
DOil Filter
EDipstick Tube
M
3
5
9
2
7

-
U
N
-
2
6
A
U
G
8
8
7. Remove two cap screws and four washers (A) to
remove bracket.
8. Remove two cap screws (B) to remove cover (C) and
gasket (D).
AWasher (4 used)
BCap Screw (2 used)
CCover
DGasket
M
3
5
9
2
8

-
U
N
-
2
6
A
U
G
8
8
9. Remove sealing wire (A).
10. Remove cap screw (B) to remove slow idle screw
bracket (C).
11. Remove cap nuts (D).
ASealing Wire
BCap Screw
CSlow Idle Screw Bracket
DCap Nuts
M
3
5
9
2
9

-
U
N
-
2
6
A
U
G
8
8
M21,TM355,5 -19-01SEP87
M21,TM355,7 -19-14FEB86
M21,TM355,8 -19-14FEB86
Fuel Control and Governor Linkage/Fuel Control and Governor Linkage (Early 3TNA72UJ)
010897
PN=269
55
2
12. Loosen lock nut to remove fast idle adjusting screw
(A) and seals (B).
M
3
5
9
3
0

-
U
N
-
2
6
A
U
G
8
8
13. Loosen lock nut to remove fuel controller (A) and
seals (B).
M
3
5
9
3
2

-
U
N
-
2
6
A
U
G
8
8
14. Disconnect spring from throttle lever.
M
3
5
9
3
3

-
U
N
-
2
6
A
U
G
8
8
15. Remove nut to remove lever, throttle lever (A), and
O-ring.
M
3
5
9
3
4

-
U
N
-
2
6
A
U
G
8
8
M21,TM355,9 -19-14FEB86
M21,TM355,10 -19-24MAR86
M21,TM355,11 -19-14FEB86
M21,TM355,12 -19-14FEB86
010897
PN=270
55
3
16. Inspect bushing for wear or damage. Do not remove
bushing unless replacement is necessary.
17. If necessary, remove bushing using a 7/16-in.
blind-hole puller.
M
3
5
9
3
5

-
U
N
-
2
6
A
U
G
8
8
18. Remove set screw to remove fuel shut-off lever.
M
3
5
9
3
6

-
U
N
-
2
6
A
U
G
8
8
19. Remove O-ring, snap ring (A), and spring (B).
M
3
5
9
3
7

-
U
N
-
2
6
A
U
G
8
8
IMPORTANT: DO NOT reuse bronze gasket.
20. Remove governor shaft, bronze gasket, and spacer.
M
3
5
9
3
8

-
U
N
-
2
6
A
U
G
8
8
M21,TM355,13 -19-14FEB86
M21,TM355,14 -19-24MAR86
M21,TM355,15 -19-14FEB86
M21,TM355,16 -19-14FEB86
010897
PN=271
55
4
21. Turn governor weights until one weight is toward the
engine. Remove fuel control linkage assembly.
M
3
5
9
4
0

-
U
N
-
2
6
A
U
G
8
8
M
3
5
9
3
9

-
U
N
-
2
6
A
U
G
8
8
22. Measure governor shaft outside diameter.
GOVERNOR SHAFT O.D. SPECIFICATION (MIN)
Shaft Diameter . . . . . . . . . . . . . . . . . . . . . . . . 7.90 mm (0.311 in.)
If diameter is less than minimum specification, replace
governor shaft.
M
3
5
9
4
1

-
U
N
-
2
6
A
U
G
8
8
M21,TM355,17 -19-14FEB86
M21,TM355,18 -19-14FEB86
010897
PN=272
55
5
23. Measure fuel control linkage bore inside diameter.
FUEL CONTROL LINKAGE BORE I.D. SPECIFICATION (MAX)
Bore Diameter . . . . . . . . . . . . . . . . . . . . . . . . 8.15 mm (0.321 in.)
If bore diameter is greater than maximum specification,
replace fuel control linkage assembly.
24. Determine governor shaft clearance (fuel control
linkage bore diameter minus governor shaft diameter).
GOVERNOR SHAFT CLEARANCE SPECIFICATION (MAX)
Governor Shaft Clearance . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.)
If clearance is greater than maximum specification,
replace governor shaft, fuel control linkage assembly, or
both.
M
3
5
9
4
2

-
U
N
-
2
6
A
U
G
8
8
25. Remove spring pin.
M
3
5
9
4
3

-
U
N
-
2
6
A
U
G
8
8
26. Remove snap ring, pin (A), and spring (B).
M
3
5
9
4
4

-
U
N
-
2
6
A
U
G
8
8
M21,TM355,19 -19-14AUG87
M21,TM355,20 -19-14FEB86
M21,TM355,21 -19-14FEB86
010897
PN=273
55
6
27. Remove sleeve (A), governor weights (B), and thrust
washer (C).
M
3
5
9
4
5

-
U
N
-
2
6
A
U
G
8
8
28. Measure sleeve bore inside diameter.
SLEEVE BORE I.D. SPECIFICATION (MAX)
replace sleeve.
M
3
5
9
4
6

-
U
N
-
2
6
A
U
G
8
8
29. Measure inner rotor shaft outside diameter.
INNER ROTOR SHAFT O.D. SPECIFICATION (MIN)
If shaft diameter is less than minimum specification,
replace shaft. Inspect splines on shaft for chipped or
broken teeth. If necessary, replace shaft. (See Group 40
in manual.)
30. Determine inner rotor shaft clearance (sleeve bore
diameter minus inner rotor shaft diameter).
INNER ROTOR SHAFT CLEARANCE SPECIFICATION (MAX)
Shaft Clearance . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
replace sleeve, inner rotor shaft, or both.
M
3
5
9
4
7

-
U
N
-
2
6
A
U
G
8
8
M21,TM355,22 -19-14FEB86
M21,TM355,23 -19-14FEB86
M21,TM355,24 -19-14AUG87
010897
PN=274
55
7
INSTALL FUEL CONTROL AND GOVERNOR
LINKAGE (EARLY 3TNA72UJ)
when assembling the engine.
2. Put clean engine oil on all internal parts.
3. Align splines on inner rotor shaft (A) with splines in
thrust washer (C) and governor weights (B).
4. Install thrust washer, governor weights, and sleeve on
inner rotor shaft.
M
3
5
9
4
5

-
U
N
-
2
6
A
U
G
8
8
5. Install spring (B).
6. Install pin (A) and fasten with snap ring.
M
3
5
9
4
4

-
U
N
-
2
6
A
U
G
8
8
7. Install spring pin.
M
3
5
9
4
8

-
U
N
-
2
6
A
U
G
8
8
M21,TM355,25 -19-23APR86
M21,TM355,26 -19-14FEB86
M21,TM355,27 -19-14FEB86
010897
PN=275
55
8
8. Turn governor weights until one weight is toward the
engine.
9. Install fuel control linkage assembly.
M
3
5
9
4
0

-
U
N
-
2
6
A
U
G
8
8
M
3
5
9
3
9

-
U
N
-
2
6
A
U
G
8
8
10. Install spacer (A) and new bronze gasket (B) on
governor shaft.
11. Install governor shaft through fuel control linkage
assembly.
M
3
5
9
4
9

-
U
N
-
2
6
A
U
G
8
8
12. Tighten governor shaft to 49 Nm (36 lb-ft).
M
4
3
3
7
9

-
U
N
-
2
0
N
O
V
8
9
M21,TM355,28 -19-14FEB86
M21,TM355,29 -19-14FEB86
M21,TM355,30 -19-24APR86
010897
PN=276
55
9
13. Install spring (B), snap ring (A), and new O-ring on
fuel shut-off lever.
M
3
5
9
3
7

-
U
N
-
2
6
A
U
G
8
8
14. Align groove (A) in fuel shut-off lever with hole (B) in
gear housing.
15. Install fuel shut-off lever. Be sure groove is visible
through hole (B).
M
3
5
9
5
1

-
U
N
-
0
8
S
E
P
8
8
16. Apply thread lock and sealer (low strength) on
threads on set screw.
M
3
5
9
3
6

-
U
N
-
2
6
A
U
G
8
8
18. If removed, install bushing, chamfered end first into
gear housing using a 7/8-in. driver disk. Push bushing
even with surface of gear housing.
M
3
5
9
5
2

-
U
N
-
0
8
S
E
P
8
8
M21,TM355,31 -19-14FEB86
M21,TM355,32 -19-14FEB86
M21,TM355,33 -19-14FEB86
M21,TM355,34 -19-14FEB86
010897
PN=277
55
10
19. Install new O-ring on throttle lever.
M
3
5
9
5
3

-
U
N
-
2
9
A
U
G
8
8
20. Install throttle lever (A) and lever. Install and tighten
nut.
M
3
5
9
3
4

-
U
N
-
2
6
A
U
G
8
8
21. Connect spring to throttle lever and then to fuel
control linkage assembly.
M
3
5
9
3
3

-
U
N
-
2
6
A
U
G
8
8
22. Install seals (B) and lock nuts on fuel controller (A).
23. Install fuel controller assembly.
NOTE: DO NOT install cap nut at this time.
M
3
5
9
3
2

-
U
N
-
2
6
A
U
G
8
8
M21,TM355,35 -19-24MAR86
M21,TM355,36 -19-14FEB86
M21,TM355,37 -19-14FEB86
M21,TM355,38 -19-14FEB86
010897
PN=278
55
11
24. Install seals (B) and lock nut on fast idle adjusting
screw (A).
25. Install fast idle adjusting screw assembly.
NOTE: DO NOT install cap nut or sealing wire at this
time.
M
3
5
9
3
0

-
U
N
-
2
6
A
U
G
8
8
26. Install slow idle screw bracket (A) so the stop (B) on
the lever contacts the slow idle screw (C). Install and
tighten cap screw.
27. Install fuel shut-off lever spring on slow idle screw
bracket.
M
3
5
9
5
4

-
U
N
-
2
9
A
U
G
8
8
28. Install new gasket, cover, and two cap screws (A).
29. Install two washers (B) between bracket (C) and
cover in alignment with holes. Install bracket and two
cap screws. Tighten four cap screws to 9 Nm (78 lb-in.).
M
3
5
5
6
6

-
U
N
-
2
6
A
U
G
8
8
M
3
5
9
5
5

-
U
N
-
2
9
A
U
G
8
8
M21,TM355,39 -19-14FEB86
M21,TM355,40 -19-14FEB86
M21,TM355,41 -19-14AUG87
010897
PN=279
55
12
30. Install dipstick tube (D) and fasten with cap screw.
31. Install oil filter (C).
32. Connect fuel shut-off linkage (B).
33. Connect throttle cable (A).
34. Install fuel injection pump (E). (See Group 50 in this
manual.)
35. Connect battery negative () cable.
36. Bleed fuel injection system. (See Machine Technical
Manual.)
37. Check and adjust fuel shut-off lever. (See Technical
Manual.)
38. Check and adjust slow and fast idle setting. (See
Technical Manual.)
M
3
5
9
5
6

-
U
N
-
2
9
A
U
G
8
8
REMOVE FUEL CONTROL AND GOVERNOR
LINKAGE (3TN66/LATER 3TNA72)
1. Remove cotter pin (B) to disconnect solenoid.
2. Remove four nuts to remove cover assembly (A).
M
3
7
7
8
6

-
U
N
-
2
9
A
U
G
8
8
3. Remove pin (A) to disconnect linkage (B).
M
3
7
7
8
7

-
U
N
-
2
9
A
U
G
8
8
M21,TM355,42 -19-23APR86
M21,TM355,43 -19-14AUG87
M21,TM355,44 -19-23APR86
Fuel Control and Governor Linkage/Fuel Control & Governor Linkage (3TN66 & Later 3TNA72)
010897
PN=280
55
13
4. Remove cap screw to remove dipstick (B).
5. Remove three cap screws to remove bracket (A).
6. Remove four remaining cap screws to remove the
linkage housing (C).
M
3
7
7
5
4

-
U
N
-
2
9
A
U
G
8
8
7. Remove sleeve.
M
3
7
7
5
5

-
U
N
-
2
9
A
U
G
8
8
8. Measure sleeve bore inside diameter.
SLEEVE BORE I.D. SPECIFICATION (MAX)
replace sleeve.
M
3
7
7
5
6

-
U
N
-
2
9
A
U
G
8
8
M21,TM355,45 -19-14FEB86
M21,TM355,46 -19-14FEB86
M21,TM355,47 -19-14FEB86
010897
PN=281
55
14
9. Measure shaft outside diameter.
SHAFT O.D. SPECIFICATION (MIN)
If shaft diameter is less than minimum specification,
replace shaft.
10. Determine oil clearance (sleeve bore diameter minus
shaft diameter.
OIL CLEARANCE SPECIFICATION (MAX)
Oil clearance . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
replace sleeve, shaft or both.
M
3
7
7
5
7

-
U
N
-
2
9
A
U
G
8
8
11. Remove nut (A) to remove weights (B).
Inspect governor weights for damage or any binding.
Inspect keyway in shaft and alignment tooth in the
governor weights for wear or damage. Replace if
necessary.
M
3
7
7
5
8

-
U
N
-
2
9
A
U
G
8
8
DISASSEMBLE FUEL CONTROL AND
GOVERNOR LINKAGE (3TN66/LATER
3TNA72)
1. Remove spring (A).
2. Remove seal and sealing wire (B).
M
3
7
7
5
9

-
U
N
-
2
9
A
U
G
8
8
M21,TM355,48 -19-14AUG87
M21,TM355,49 -19-14FEB86
M21,TM355,50 -19-14AUG87
010897
PN=282
55
15
3. Remove nut to remove lever (E). Remove retaining
cap screw (D).
4. Remove retaining cap screw (A).
5. Remove set screw (B) to remove fuel shut-off lever
(C).
ARetaining Cap Screw
BSet Screw
CFuel Shut-Off Lever
DRetaining Cap Screw
ELever
M
3
7
7
6
0

-
U
N
-
2
9
A
U
G
8
8
6. Remove O-ring (A) and spring (B).
M
3
7
7
6
1

-
U
N
-
2
9
A
U
G
8
8
7. Remove shaft (A), fuel control linkage assembly (B)
and shims (C).
M
3
7
7
6
2

-
U
N
-
2
9
A
U
G
8
8
M21,TM355,51 -19-14FEB86
M21,TM355,52 -19-14FEB86
M21,TM355,53 -19-14FEB86
010897
PN=283
55
16
8. Measure fuel control linkage bore inside diameter.
FUEL CONTROL LINKAGE BORE I.D. SPECIFICATION (MAX)
replace fuel control linkage assembly.
9. Measure governor shaft outside diameter.
GOVERNOR SHAFT O.D. SPECIFICATION (MIN)
If diameter is less than minimum specification, replace
governor shaft.
10. Determine governor shaft clearance (fuel control
linkage bore diameter minus governor shaft diameter).
GOVERNOR SHAFT CLEARANCE SPECIFICATION (MAX)
Shaft Clearance . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.)
replace governor shaft, fuel control linkage assembly, or
both.
M
3
7
7
6
3

-
U
N
-
2
9
A
U
G
8
8
11. Remove spring pin (A).
M
3
7
7
6
4

-
U
N
-
2
9
A
U
G
8
8
M21,TM355,54 -19-01SEP87
M21,TM355,55 -19-14FEB86
010897
PN=284
55
17
12. Remove snap ring, pin (A), and spring (B).
M
3
7
7
6
5

-
U
N
-
2
9
A
U
G
8
8
13. Rotate shaft and lever assembly as shown.
14. Remove tapered pin (B) from tapered hole using a
punch.
15. Remove shaft (A) and lever (C).
M
3
7
7
6
6

-
U
N
-
2
9
A
U
G
8
8
16. Remove cover assembly (A) and fuel control stops
(B, C, and D).
ACover Assembly
BSlow Idle Stop
CFuel Controller
DFast Idle Stop
M
3
7
7
6
7

-
U
N
-
2
9
A
U
G
8
8
M21,TM355,56 -19-14FEB86
M21,TM355,57 -19-14FEB86
M21,TM355,58 -19-23APR86
010897
PN=285
55
18
ASSEMBLE FUEL CONTROL AND
GOVERNOR LINKAGE (3TN66/LATER
3TNA72)
when assembling linkage housing.
2. Put clean engine oil on all internal parts.
3. Install fuel control stops (B, C, and D) and cover
assembly (A).
ACover Assembly
BSlow Idle Stop
CFuel Controller
DFast Idle Stop
M
3
7
7
6
7

-
U
N
-
2
9
A
U
G
8
8
4. Install shaft (A) and lever (C). Rotate shaft (A) until
rounded side (D) of shaft is toward the retaining cap
screw.
5. Position lever (C) as shown and install tapered pin (B)
in tapered hole.
AShaft
BTapered Pin
CLever
DRounded Side
M
3
7
7
6
8

-
U
N
-
2
9
A
U
G
8
8
M
3
7
7
6
9

-
U
N
-
2
9
A
U
G
8
8
M21,TM355,59 -19-01SEP87
M21,TM355,60 -19-01SEP87
010897
PN=286
55
19
6. Install pin (A), snap ring and spring (B).
M
3
7
7
6
5

-
U
N
-
2
9
A
U
G
8
8
7. Install spring pin (A).
M
3
7
7
6
4

-
U
N
-
2
9
A
U
G
8
8
8. Install fuel control linkage assembly (B), shims (C),
and shaft (A).
M
3
7
7
6
2

-
U
N
-
2
9
A
U
G
8
8
9. Install O-ring (A) and spring (B) on fuel shut-off lever.
M
3
7
7
6
1

-
U
N
-
2
9
A
U
G
8
8
M21,TM355,61 -19-14FEB86
M21,TM355,62 -19-14FEB86
M21,TM355,63 -19-14FEB86
M21,TM355,64 -19-14FEB86
010897
PN=287
55
20
10. Align groove in fuel shut-off lever with set screw hole
in housing. Install fuel shut-off lever. Be sure groove is
visible through hole.
11. Apply threadlock and sealer (low strength) on
threads of set screw.
13. Install retaining cap screw (A).
14. Install lever (E) and nut. Fasten with retaining cap
screw (D).
ARetaining Cap Screw
BSet Screw
CFuel Shut-Off Lever
DRetaining Cap Screw
ELever
M
3
7
7
6
0

-
U
N
-
2
9
A
U
G
8
8
15. Install spring (A).
M
3
7
7
7
0

-
U
N
-
2
9
A
U
G
8
8
INSTALL FUEL CONTROL LINKAGE
(3TN66/LATER 3TNA72)
when assembling the engine.
2. Put clean engine oil all internal parts.
3. Align tooth in governor weight with slot in shaft. Install
governor weight (A), nut (B), and sleeve (C).
M
3
7
7
7
1

-
U
N
-
2
9
A
U
G
8
8
M21,TM355,65 -19-23APR86
M21,TM355,66 -19-14FEB86
M21,TM355,67 -19-14AUG87
010897
PN=288
55
21
4. Install linkage housing (C), bracket (A), and dipstick
(B). Tighten cap screws.
5. Bleed fuel injection system (See Section 30 in
Machine TM).
6. Check and adjust fuel shut-off lever. (See Machine
TM).
7. Check and adjust fuel controller. (See Machine TM).
8. Check and adjust slow and fast idle settings. (See
Machine TM).
9. After all adjustments are made install new lead seal
wire and crimp using JDF-10 Sealing Wire Pliers.
M
3
7
7
5
4

-
U
N
-
2
9
A
U
G
8
8
SERVICE FUEL CONTROL AND GOVERNOR
LINKAGE (ALL EXCEPT 3TN66/3TNA72)
Do not attempt to service the fuel control and governor
linkage.
If unit is in need of repair, it must be serviced by a
qualified fuel injection repair shop, or the fuel injection
pump assembly must be replaced.
REMOVE AND INSPECT FUEL SUPPLY
PUMP (4TN100RJF)
1. Thoroughly clean the supply pump body and
surrounding area before loosening and fittings, to prevent
dirt from entering the fuel system.
2. Remove fuel line (A), fitting (B) and hand primer
assembly (C).
M
5
1
5
8
6

-
U
N
-
3
1
A
U
G
8
8
M21,TM355,68 -19-23APR86
M21,TM335,69 -19-14AUG87
M21,TM355,A1 -19-18AUG87
Fuel Control and Governor Linkage/Fuel Supply Pump (4TN100RJF)
010897
PN=289
55
22
3. Inspect valves and springs for excessive wear or
damage.
4. Inspect valve seat surfaces for scratches, nicks,
foreign material or pitting.
M
5
1
5
8
7

-
U
N
-
3
1
A
U
G
8
8
5. Remove plug (A) and inspect parts (AE) for wear or
damage. Replace if necessary.
6. Remove three mounting nuts to remove pump body
from engine.
APlug
BWasher
CSpring
DPlunger
ERod
M
5
1
5
8
8

-
U
N
-
3
1
A
U
G
8
8
M
5
1
5
8
9

-
U
N
-
3
1
A
U
G
8
8
M21,TM355,A2 -19-14AUG87
M21,TM355,A3 -19-14AUG87
010897
PN=290
55
23
7. Lift wire retainer (A) to remove pump cam roller
assembly.
8. Inspect cam roller assembly (BF) for wear or
damage. Replace if necessary.
AWire Retainer
BShaft
CRoller
DSlide Pivot (2 used)
EWasher (2 used)
FHolder
M
5
1
5
9
0

-
U
N
-
3
1
A
U
G
8
8
M
5
1
5
9
1

-
U
N
-
3
1
A
U
G
8
8
ASSEMBLE AND INSTALL FUEL SUPPLY
PUMP (4TN100RJF)
1. Assemble cam roller assembly (BF). Install cam
roller assembly into pump body with small hole in holder
towards bottom of pump body.
2. Install wire retainer (A).
AWire Retainer
BShaft
CRoller
DSlide Pivot (2 used)
EWasher (2 used)
FHolder
M
5
1
5
9
1

-
U
N
-
3
1
A
U
G
8
8
M
5
1
5
9
0

-
U
N
-
3
1
A
U
G
8
8
M21,TM355,A4 -19-14AUG87
M21,TM355,A5 -19-14AUG87
010897
PN=291
55
24
3. Install plunger parts (AE) in pump body.
4. Install pump on engine and tighten nuts to 11 Nm (96
lb-in.). Tighten plug (A).
M
5
1
5
8
9

-
U
N
-
3
1
A
U
G
8
8
M
5
1
5
8
8

-
U
N
-
3
1
A
U
G
8
8
5. Install hand primer assembly (C), fitting (B) and fuel
line (A).
M
5
1
5
8
6

-
U
N
-
3
1
A
U
G
8
8
M21,TM355,A6 -19-14AUG87
M21,TM355,A7 -19-14AUG87
010897
PN=292
55
25
010897
PN=293
55
26
Name Use
Volt-Ohm-Amp Meter Check continuity
Armature Growler Check starter armature
13-Ton Puller Set Remove armature shaft bearings
ASSEMBLE HITACHI 0.8 KILOWATT
STARTER
1. Install clutch assembly on armature.
2. Install pinion stopper over shaft. Install retaining wire
and use two pliers to press pinion stopper (A) over
retaining wire.
M
3
7
8
3
1

-
U
N
-
2
9
A
U
G
8
8
STARTER APPLICATION CHART
The various starters covered in this group are identified
by manufacturer and output rating.
Manufacture Rated Output Motor Yoke Outside Diameter
Hitachi 0.8 kW
Nippon Denso 1.0 kW 68.0 mm (2.68 in.)
Nippon Denso 1.4 kW 76.0 mm (3.00 in.)
To help identify the Nippon Denso starters, measure the
outside diameter of the motor yoke.
M21,4010R,1 -19-14JUN85
M21,TM360,33 -19-01SEP87
M21,TM360,0 -19-01SEP87
Group 60
Starter
010897
PN=294
60
1
BENCH TEST STARTER
1. Remove starter from engine.
2. Turn pinion gear by hand. It should turn freely
clockwise only. If gear turns freely both directions, clutch
assembly is defective.
3. If pinion turns freely, perform starter no load running
test.
NOTE: Do not conduct the no-load test unless the
armature turns freely.
4. Connect a 12-volt battery (A) to starter battery
terminal (B) and starter frame (C). Use heavy duty
cables.
5. Connect a remote start switch (D) between switch
terminal (E) and battery terminal (B).
NOTE: A short piece of wire with a small clip on the end
will allow a more positive connection at the
switch terminal.
6. When switch is activated, starter should engage and
run.
7. If solenoid only chatters, hold-in winding is
open-circuited. If nothing happens, either the pull-in
winding is open-circuited or mechanical parts are
sticking. To check for sticking, remove solenoid end
cover and push plunger by hand.
8. If solenoid engages properly, but motor does not run,
check main contact points, bearings, brushes, reduction
gears, armature, and field windings.
A12-Volt Battery
BBattery Terminal
NOTE: The solenoid cannot be repaired although CStarter Frame
DRemote Start Switch
mechanical parts may be replaced. Disassemble
ESwitch Terminal
solenoid to determine cause of problem.
R
W
2
1
5
9

-
U
N
-
0
1
D
E
C
8
8
M21,TM360,1 -19-14AUG87
M21,4010R,5 -19-14JUN85
Starter/Bench Test Starter (All Engines)
010897
PN=295
60
2
DISASSEMBLE AND SERVICE NIPPON
DENSO 1.0 KILOWATT STARTER
1. Disconnect field lead (A).
2. Remove two bolts (B) and separate motor from
solenoid. Remove armature assembly.
M
3
6
7
5
2

-
U
N
-
2
9
A
U
G
8
8
3. Remove two screws to remove end frame (A). Brush
assembly will remain attached to field coil.
M
3
6
7
5
3

-
U
N
-
2
9
A
U
G
8
8
4. Use a screwdriver to pry springs away. Remove field
coil brushes (A) from brush holder.
5. Pry springs away and pull negative side brushes (B)
back about 6 mm (0.25 in.). Release springs to hold
negative brushes in place.
6. Remove brush holder assembly from field coil
assembly.
M
3
6
7
5
4

-
U
N
-
2
9
A
U
G
8
8
7. Measure brush length. Replace if worn below
minimum length of 8.5 mm (0.30 in.).
If negative side brushes mounted on brush holder are
worn, replace the entire brush holder.
If field coil brushes are worn, the entire field coil
assembly must be replaced.
M
3
6
7
5
5

-
U
N
-
2
9
A
U
G
8
8
M21,4010R,6 -19-14AUG87
M21,4010R,7 -19-14JUN85
M21,4010R,8 -19-14JUN85
M21,4010R,9 -19-14JUN85
Starter/Nippon Denso 1.0 kW Starter
010897
PN=296
60
3
8. Test the brush holder using an ohmmeter or test light.
Touch one probe of tester to negative brush holder and
other probe to field brush holder. If there is continuity,
replace the brush holder.
Inspect springs; replace if weak or distorted.
M
3
6
7
5
6

-
U
N
-
2
9
A
U
G
8
8
9. Test for grounded field winding using an ohmmeter or
test light. Touch one probe of tester to field coil brush
and other probe to field frame. Be sure the brush lead is
not touching the frame. If there is continuity, the coil is
grounded and the field frame assembly must be
replaced.
M
3
6
7
5
7

-
U
N
-
2
9
A
U
G
8
8
10. Test for open field coil by touching a probe to each
field coil brush. If there is no continuity, the field coil is
open and the field frame assembly must be replaced.
M
3
6
7
5
8

-
U
N
-
2
9
A
U
G
8
8
M21,4010R,10 -19-14JUN85
M21,4010R,11 -19-14JUN85
M21,4010R,12 -19-14JUN85
010897
PN=297
60
4
IMPORTANT: Do not clean armature with solvent.
Solvent can damage insulation on
windings. Use only mineral spirits and
a brush.
11. Inspect armature. Look for signs of dragging against
pole shoes.
12. Inspect commutator. Look for roughness, burned
bars, or any material which might cause short circuits
between bars. If necessary, clean and touch up with 400
sandpaper. NEVER use emery cloth. Clean all dust from
armature when finished.
M
3
6
7
5
9

-
U
N
-
2
9
A
U
G
8
8
13. Test for grounded windings using an ohmmeter or
test light.
Touch probes on commutator bar and armature shaft.
Armature windings are connected in series, so only one
commutator bar needs to be checked.
If test shows continuity, a winding is grounded and the
armature must be replaced.
M
3
6
7
6
0

-
U
N
-
2
9
A
U
G
8
8
14. Test for open circuited windings using an ohmmeter
or test light.
Touch probes on two different commutator bars. If test
shows no continuity, there is an open circuit and the
M
3
6
7
6
1

-
U
N
-
2
9
A
U
G
8
8
M21,4010R,13 -19-17JUL85
M21,4010R,14 -19-14JUN85
M21,4010R,15 -19-14JUN85
010897
PN=298
60
5
15. Test for short circuited windings using a growler. Put
armature in growler and hold a hacksaw blade above
each slot while slowly rotating armature.
If coil is shorted, the blade will vibrate on the slot.
NOTE: A short circuit most often occurs because of
copper dust or filings between two commutator
segments.
16. If test indicates short circuited windings, clean the
commutator of dust and filings. Check the armature
again. If the test still indicates a short circuit, replace the
armature.
R
W
2
1
6
8

-
U
N
-
0
1
D
E
C
8
8
17. Inspect front and rear armature bearings for smooth
quiet operation. Replace if defective.
18. Remove bearings by using a knife edge bearing
puller.
M
3
6
7
6
2

-
U
N
-
2
9
A
U
G
8
8
INSPECT AND REPAIR GEAR TRAIN AND
OVERRUNNING CLUTCH (NIPPON DENSO
1.0 KILOWATT)
1. Remove two screws.
M
3
6
7
6
3

-
U
N
-
2
9
A
U
G
8
8
M21,4010R,16 -19-14JUN85
M21,4010R,17 -19-14JUN85
M21,4010R,18 -19-14AUG87
010897
PN=299
60
6
2. Hold clutch housing as shown and lift solenoid
housing from clutch.
3. Remove plunger spring (A).
M
3
6
7
6
4

-
U
N
-
2
9
A
U
G
8
8
4. Remove clutch assembly from housing.
5. Remove pinion (A), retainer (B), and five rollers.
Inspect pinion, rollers, and retainer. Replace if worn or
pitted.
M
3
6
7
6
5

-
U
N
-
2
9
A
U
G
8
8
6. Remove steel ball from end of clutch shaft.
7. Put clutch assembly in a soft jaw vise. Be sure rear
vise jaw is against shaft and front jaw is against pinion.
8. Tighten vise slowly until pinion compresses.
9. Push retainer (A) back until snap ring is exposed.
Remove snap ring and retainer.
M
3
6
7
6
6

-
U
N
-
2
9
A
U
G
8
8
M21,4010R,19 -19-14JUN85
M21,4010R,20 -19-14JUN85
M21,4010R,21 -19-14JUN85
010897
PN=300
60
7
N
CAUTION: Shaft could be propelled from clutch
unit with considerable force if spring is not
allowed to extend fully while in vise.
10. While holding clutch assembly, slowly open vise until
all spring compression is relieved.
11. Remove pinion (A), spring (B), and washer (C).
Inspect pinion for excessive wear or damage. Replace if
defective. Replace spring if broken or distorted.
M
3
6
7
6
7

-
U
N
-
2
9
A
U
G
8
8
12. Push shaft against spring in clutch assembly. Turn
toothed washer (A) to remove it from shaft. Remove
shaft and spring from clutch.
Inspect clutch bearings for flat spots in rotation. Replace
entire assembly if bearings are defective.
Inspect shaft spring and replace if broken or distorted.
Inspect shaft for excessive wear or damage. Replace if
defective.
M
3
6
7
6
8

-
U
N
-
2
9
A
U
G
8
8
INSPECT AND REPAIR SOLENOID (NIPPON
DENSO 1.0 KILOWATT)
1. Remove three screws to remove cover and gasket.
M
3
6
7
6
9

-
U
N
-
2
9
A
U
G
8
8
M21,4010R,22 -19-14JUN85
M21,4010R,23 -19-14JUN85
M21,4010R,24 -19-01SEP87
010897
PN=301
60
8
2. Remove plunger.
Inspect plunger spring. Replace plunger if broken.
Inspect copper washer (A) on plunger and contact plates
(B) on solenoid. Clean burnt areas to improve electrical
contact. Replace contacts or plunger if either shows
excessive burning or pitting.
The solenoid is not serviceable. If it is defective, replace
the solenoid housing assembly.
M
3
6
7
7
0

-
U
N
-
2
9
A
U
G
8
8
3. If it is necessary to replace contact plates, remove
terminals. Remove parts in order as shown from each
terminal:
ANut
BWasher
CO-Ring
DInsulator
EBushing
FContact Plate
GTerminal Bolt
M
3
6
7
7
1

-
U
N
-
2
9
A
U
G
8
8
ASSEMBLE NIPPON DENSO 1.0 KILOWATT
STARTER
Assemble Solenoid
NOTE: The assembly sequence of the left and right
terminals is similar. Be sure solenoid terminal
lead (H) is installed between bolt (G) and contact
plate (F). Be sure smaller contact plate is on left
side.
1. Install parts (AH).
ANut FContact Plate
BWasher GTerminal Bolt
CO-Ring HSolenoid Lead
DInsulator Terminal
EBushing
M
3
6
7
7
1

-
U
N
-
2
9
A
U
G
8
8
M21,4010R,25 -19-14JUN85
M21,4010R,26 -19-14JUN85
M21,4010R,27 -19-01SEP87
010897
PN=302
60
9
2. Install solenoid plunger.
M
3
6
7
8
3

-
U
N
-
2
9
A
U
G
8
8
3. Install gasket and cover. Fasten with three screws. Be
sure wire retaining clip (A) is installed as shown.
M
3
6
7
7
3

-
U
N
-
2
9
A
U
G
8
8
ASSEMBLE GEAR TRAIN AND
OVERRUNNING CLUTCH (NIPPON DENSO
1.0 KILOWATT)
1. Apply bearing grease to the steel ball, shaft, springs,
and bearings.
Assemble parts (AJ) in sequence order.
ASteel Ball
BShaft
CClutch Spring
DClutch
EToothed Washer
FWasher
GPinion Spring
HPinion
IRetainer
JSnap Ring
M
3
6
7
7
4

-
U
N
-
2
9
A
U
G
8
8
M21,4010R,28 -19-14JUN85
M21,4010R,29 -19-14JUN85
M21,4010R,30 -19-14AUG87
010897
PN=303
60
10
2. Install steel ball in end of shaft. Use grease to hold it
in place.
3. Install clutch spring and clutch assembly on shaft.
Push shaft against spring and install toothed washer (A).
Turn toothed washer below the shaft splines to hold
clutch in place.
M
3
6
7
6
8

-
U
N
-
2
9
A
U
G
8
8
4. Install washer (C), pinion spring (B), and pinion (A).
Be sure flange on washer is pointing outward.
M
3
6
7
6
7

-
U
N
-
2
9
A
U
G
8
8
5. Put clutch assembly in a soft jaw vise. Be sure rear
vise jaw is against shaft and front jaw is against pinion.
6. Tighten vise slowly until pinion compresses.
7. Install retainer (A) with the cupped side outward.
Install snap ring.
8. Slide the retainer over the snap ring. Hold clutch
assembly and slowly open vise.
M
3
6
7
7
5

-
U
N
-
2
9
A
U
G
8
8
9. Apply grease to pinion (A), retainer (B), and five
rollers.
10. Install retainer and five rollers.
11. Hold pinion (A) and clutch assembly with teeth
meshed. Install both into housing at the same time.
M
3
6
7
7
6

-
U
N
-
2
9
A
U
G
8
8
M21,4010R,31 -19-14JUN85
M21,4010R,32 -19-14JUN85
M21,4010R,33 -19-14JUN85
M21,4010R,34 -19-14JUN85
010897
PN=304
60
11
NOTE: Be sure steel ball is in the end of the clutch
shaft.
12. Install plunger spring (A). Assemble solenoid housing
to clutch housing.
M
3
6
7
6
4

-
U
N
-
2
9
A
U
G
8
8
13. Fasten with two screws.
M
3
6
7
6
3

-
U
N
-
2
9
A
U
G
8
8
IMPORTANT: Install both armature bearings with the
sealed side toward the armature.
14. Install new bearing on splined end of armature shaft
using a piece of 5/8-in. I.D. pipe. Be sure to drive only
on inner race. Make sure bearing is tight against
shoulder of shaft.
M
3
6
7
7
7

-
U
N
-
2
9
A
U
G
8
8
M21,4010R,35 -19-18JUN85
M21,4010R,36 -19-14JUN85
M21,4010R,37 -19-17JUL85
010897
PN=305
60
12
15. Install bearing on commutator end of armature shaft
with sealed side of bearing toward commutator. Use a
1/2 in. driver to install bearing tight against shoulder of
shaft.
M
3
6
7
7
8

-
U
N
-
2
9
A
U
G
8
8
16. Use a screwdriver to pry springs away from brush
holder. Install brushes. Replace springs to hold brushes
in place.
M
3
6
7
7
9

-
U
N
-
2
9
A
U
G
8
8
17. Use a screwdriver to pry springs away. Install field
coil brushes in brush holder. Release springs to hold
brushes in place.
M
3
6
7
8
0

-
U
N
-
2
9
A
U
G
8
8
18. Install armature in field coil. Be sure felt washer (A)
is in place on spline end of armature. Apply a light film
of grease to the felt washer.
M
3
6
7
8
1

-
U
N
-
2
9
A
U
G
8
8
M21,4010R,38 -19-14JUN85
M21,4010R,39 -19-14JUN85
M21,4010R,40 -19-14JUN85
M21,4010R,41 -19-10JUN85
010897
PN=306
60
13
19. Release brush springs to allow field coil brushes (A)
and negative side brushes (B) to contact commutator.
M
3
6
7
5
4

-
U
N
-
2
9
A
U
G
8
8
IMPORTANT: When installing end frame, be sure field
coil brush wires do not touch end
frame. Turn brush holder slightly to
take up slack in brush wires. Press
wires inward to clear the end frame.
20. Apply grease to the bearing cup inside the end
frame. Install end frame (A) and fasten with two screws.
M
3
6
7
5
3

-
U
N
-
2
9
A
U
G
8
8
21. Fasten motor to clutch assembly with two bolts (B).
22. Connect field lead (A).
23. Install starter. Tighten nuts to 88 Nm (65 lb-ft).
M
3
6
7
5
2

-
U
N
-
2
9
A
U
G
8
8
M21,4010R,42 -19-14JUN85
M21,4010R,43 -19-14JUN85
M21,4010R,44 -19-14FEB86
010897
PN=307
60
14
DISASSEMBLE AND SERVICE HITACHI 0.8
KILOWATT STARTER
1. Disconnect wire (A) from solenoid.
2. Remove the two phillips screws and two through bolts
from rear cover.
3. Pry plastic cap (B) from rear cover.
4. Remove E clip (C) and shim pack (D). Remove
cover.
ASolenoid Wire
BPlastic Cap
CE-Clip
DShim Pack
M
3
7
8
7
3

-
U
N
-
2
9
A
U
G
8
8
5. If necessary, remove cover bushing (A) with blind hole
puller.
Install new bushing with suitable size driver disks until
bushing bottoms in cover.
M
3
7
8
7
4

-
U
N
-
2
9
A
U
G
8
8
6. Pry brush spring (A) away and pull negative brush (B)
up enough to allow spring to hold in place.
7. Remove the two field coil brushes from holders and
remove brush holder assembly.
M
3
7
8
7
5

-
U
N
-
2
9
A
U
G
8
8
M21,TM360,22 -19-14AUG87
M21,TM360,23 -19-15FEB86
M21,TM360,24 -19-15FEB86
Starter/Hitachi 0.8 kW
010897
PN=308
60
15
M
3
6
7
5
6

-
U
N
-
2
9
A
U
G
8
8
M
3
6
7
5
5

-
U
N
-
2
9
A
U
G
8
8
10. Remove field coil housing from armature.
M
3
7
8
7
6

-
U
N
-
2
9
A
U
G
8
8
11. Test for grounded field winding using an ohmmeter
or test lights. Touch one probe of tester to field coil
brush and other probe to field frame. Be sure the brush
lead is not touching the frame. If there is continuity, the
coil is grounded and the field frame assembly must be
replaced.
M
3
6
7
5
7

-
U
N
-
2
9
A
U
G
8
8
M21,4010R,10 -19-14JUN85
M21,TM360,37 -19-08APR86
M21,TM360,25 -19-15FEB86
M21,TM360,39 -19-15FEB86
010897
PN=309
60
16
field coil brush, if there is not continuity, the field coil is
M
3
6
7
5
8

-
U
N
-
2
9
A
U
G
8
8
13. Remove the two solenoid attaching cap screw.
14. Remove rubber plug (A).
15. Pull solenoid (B) and armature assemblies (C) from
housing.
M
3
7
8
7
7

-
U
N
-
2
9
A
U
G
8
8
16. Use a piece of pipe or a deep well socket to drive
pinion stopper (A) down from retaining wire.
M
3
7
8
7
8

-
U
N
-
2
9
A
U
G
8
8
17. Remove retaining wire (A), pinion stopper (B) and
clutch assembly (C) from armature shaft.
18. Inspect clutch gear for damage it should rotate only
in one direction. Replace clutch assembly as needed.
M
3
7
8
7
9

-
U
N
-
2
9
A
U
G
8
8
M21,TM360,40 -19-15FEB86
M21,TM360,26 -19-15FEB86
M21,TM360,27 -19-15FEB86
M21,TM360,28 -19-15FEB86
010897
PN=310
60
17
test light.
If test shows continuity, a winding is ground and the
M
3
6
7
6
0

-
U
N
-
2
9
A
U
G
8
8
or test light.
M
3
6
7
6
1

-
U
N
-
2
9
A
U
G
8
8
copper dust or filings between tow commutator
segments.
armature.
R
W
2
1
6
8

-
U
N
-
0
1
D
E
C
8
8
M21,TM360,29 -19-15FEB86
M21,TM360,30 -19-15FEB86
M21,TM360,31 -19-15FEB86
010897
PN=311
60
18
23. Remove and inspect solenoid components.
Assemble in reverse order.
24. Replace solenoid if indicated in bench test, earlier in
this group.
AClutch Fork Pivot
BSolenoid Plunger
CSpring
DSolenoid
M
3
7
8
8
0

-
U
N
-
2
9
A
U
G
8
8
ASSEMBLE HITACHI 0.8 KILOWATT
STARTER
1. Install clutch assembly on armature.
and use two pliers to press pinion stopper (A) over
retaining wire.
M
3
7
8
3
1

-
U
N
-
2
9
A
U
G
8
8
3. Place armature with clutch assembly into housing.
4. Be sure spring pivot (A) is installed in solenoid and
install clutch fork (B) over clutch and through solenoid
plunger.
5. Install solenoid making sure spring pivot seats in
notch (C) in clutch fork.
6. Install two solenoid attaching cap screws.
M
3
7
8
8
1

-
U
N
-
2
9
A
U
G
8
8
7. Install rubber plug (A) in notched area of housing.
M
3
7
8
8
2

-
U
N
-
2
9
A
U
G
8
8
M21,TM360,32 -19-23APR86
M21,TM360,33 -19-01SEP87
M21,TM360,34 -19-15FEB86
M21,TM360,35 -19-24MAR86
010897
PN=312
60
19
8. Install field coil housing. Install field coil brushes (B) in
brush holder. Hold springs (A) back to keep brushes off
armature.
9. Install brush holder over armature and release springs
to allow brushes to seat on commutator ring.
M
3
7
8
7
5

-
U
N
-
2
9
A
U
G
8
8
10. Install rear cover two through bolts. Install two
phillips screws to secure brush holder.
11. Install wiring onto solenoid.
12. Install same number and thickness of shims as
removed.
13. Install E clip (A) and plastic cover (B).
14. Install starter on engine. Tighten hardware to 49 Nm
(36 lb-ft). M
3
7
9
2
3

-
U
N
-
2
9
A
U
G
8
8
DISASSEMBLE AND SERVICE NIPPON
DENSO 1.4 KILOWATT STARTER
1. Remove two hex-head screws and remove end cap
(A) and shims (B) as shown.
2. Remove two phillips-head screws and two
through-bolts from rear of starter. Remove rear cover.
3. Remove motor assembly from starter.
M
3
7
8
2
0

-
U
N
-
2
9
A
U
G
8
8
M21,TM360,36 -19-15FEB86
M21,TM360,38 -19-15FEB86
M21,TM360,2 -19-15AUG87
010897
PN=313
60
20
4. Use a screwdriver to pry springs away. Remove field
coil brushes (A) from brush holder.
5. Pry springs away and pull negative side brushes (B)
back about 6 mm (0.25 in.). Release springs to hold
negative brushes in place.
6. Remove brush holder assembly from field coil
assembly.
M
3
6
7
5
4

-
U
N
-
2
9
A
U
G
8
8
M
3
6
7
5
5

-
U
N
-
2
9
A
U
G
8
8
M
3
6
7
5
6

-
U
N
-
2
9
A
U
G
8
8
9. Test for grounded field winding using an ohmmeter or
test light. Touch one probe of tester to field coil brush
and other probe to field frame. Be sure the brush lead is
not touching the frame. If there is continuity, the coil is
grounded and the field frame assembly must be
replaced.
M
3
6
7
5
7

-
U
N
-
2
9
A
U
G
8
8
M21,4010R,8 -19-14JUN85
M21,4010R,9 -19-14JUN85
M21,4010R,10 -19-14JUN85
M21,4010R,11 -19-14JUN85
010897
PN=314
60
21
field coil brush. If there is no continuity, the field coil is
M
3
6
7
5
8

-
U
N
-
2
9
A
U
G
8
8
IMPORTANT: Do not clean armature with solvent.
Solvent can damage insulation on
windings. Use only mineral spirits and
a brush.
11. Inspect armature. Look for signs of dragging against
pole shoes.
12. Inspect commutator. Look for roughness, burned
bars, or any material which might cause short circuits
between bars. If necessary, clean and touch up with 400
sandpaper. NEVER use emery cloth. Clean all dust from
armature when finished.
M
3
6
7
5
9

-
U
N
-
2
9
A
U
G
8
8
test light.
If test shows continuity, a winding is grounded and the
M
3
6
7
6
0

-
U
N
-
2
9
A
U
G
8
8
M21,4010R,12 -19-14JUN85
M21,4010R,13 -19-17JUL85
M21,4010R,14 -19-14JUN85
010897
PN=315
60
22
or test light.
M
3
6
7
6
1

-
U
N
-
2
9
A
U
G
8
8
copper dust or filings between two commutator
segments.
armature.
R
W
2
1
6
8

-
U
N
-
0
1
D
E
C
8
8
17. Inspect front and rear armature bearings for smooth
quiet operation. Replace if defective.
18. Remove bearings by using a knife edge bearing
puller.
M
3
6
7
6
2

-
U
N
-
2
9
A
U
G
8
8
M21,4010R,15 -19-14JUN85
M21,4010R,16 -19-14JUN85
M21,4010R,17 -19-14JUN85
010897
PN=316
60
23
SERVICE GEAR TRAIN (NIPPON DENSO 1.4
KILOWATT)
1. Remove three cap screws (A) and remove rear
bearing housing.
M
3
7
8
2
2

-
U
N
-
2
9
A
U
G
8
8
2. Inspect bearing (A) and seal (B).
If necessary, remove bearing with a suitable blind hole
puller. Install new bearing flush with housing surface.
M
3
7
8
2
3

-
U
N
-
2
9
A
U
G
8
8
3. Remove two cap screws and remove plunger with
spring (A), shims (B), and solenoid (C).
Replace defective parts as needed.
M
3
7
8
2
4

-
U
N
-
2
9
A
U
G
8
8
4. Remove shims from ring gear shaft.
M
3
7
8
2
1

-
U
N
-
2
9
A
U
G
8
8
M21,TM360,3 -19-15AUG87
M21,TM360,4 -19-15FEB86
M21,TM360,5 -19-15FEB86
M21,TM360,6 -19-15FEB86
010897
PN=317
60
24
5. Remove clutch fork pivot bolt (A) to remove fork and
clutch assembly (B).
6. Inspect SHOES on clutch fork, replace fork as
needed.
M
3
7
8
2
5

-
U
N
-
2
9
A
U
G
8
8
7. Use a piece of pipe or suitable size deep well socket
to drive pinion stopper (A) down from retaining wire.
M
3
7
8
2
6

-
U
N
-
2
9
A
U
G
8
8
8. Remove retaining wire (A), pinion stopper (B), and
clutch assembly (C) from ring gear shaft.
9. Inspect ring gear (D) for chipped or broken teeth.
Replace as needed.
ARetaining Wire
BPinion Stopper
CClutch Assembly
DRing Gear and Shaft
M
3
7
8
2
7

-
U
N
-
2
9
A
U
G
8
8
10. Remove snap ring (A) from clutch assembly.
M
3
7
8
2
8

-
U
N
-
2
9
A
U
G
8
8
M21,TM360,7 -19-23APR86
M21,TM360,8 -19-23APR86
M21,TM360,9 -19-15FEB86
M21,TM360,10 -19-15FEB86
010897
PN=318
60
25
11. Inspect clutch parts and replace as needed.
Assemble in reverse order.
AWasher
BSpring Cap
CSpring
DClutch
M
3
7
8
2
9

-
U
N
-
2
9
A
U
G
8
8
12. Install clutch assembly on ring gear shaft.
in groove of shaft.
14. Use two pliers to press pinion stopper (A) over
retaining wire.
M
3
7
8
3
1

-
U
N
-
2
9
A
U
G
8
8
15. Inspect end frame bushing (A). Replace using
suitable size driver disks. Install new bushing flush with
face of housing.
M
3
7
8
3
0

-
U
N
-
2
9
A
U
G
8
8
ASSEMBLE NIPPON DENSO 1.4 KILOWATT
STARTER
1. Install fork (B) over clutch and install assembly into
housing.
2. Install clutch fork pivot bolt (A) and nut.
M
3
7
8
2
5

-
U
N
-
2
9
A
U
G
8
8
M21,TM360,11 -19-15FEB86
M21,TM360,12 -19-15FEB86
M21,TM360,13 -19-15FEB86
M21,TM360,14 -19-15AUG87
010897
PN=319
60
26
3. Install same number and thickness of ring gear shims
as removed.
M
3
7
8
2
1

-
U
N
-
2
9
A
U
G
8
8
4. Install plunger with spring (A), same shims (B) as
removed and solenoid (C). Secure with two cap screws.
M
3
7
8
2
4

-
U
N
-
2
9
A
U
G
8
8
5. Install rear bearing housing. Install three cap screws
(A).
M
3
7
8
2
2

-
U
N
-
2
9
A
U
G
8
8
6. Pry brush spring back and install field coil brushes
into brush holder.
M
3
6
7
8
0

-
U
N
-
2
9
A
U
G
8
8
M21,TM360,15 -19-15FEB86
M21,TM360,16 -19-15FEB86
M21,TM360,17 -19-15FEB86
M21,TM360,18 -19-15FEB86
010897
PN=320
60
27
7. Install armature (A) into field coil.
M
3
6
7
8
1

-
U
N
-
2
9
A
U
G
8
8
8. Release springs to allow brushes (A and B) to contact
commutator.
M
3
6
7
5
4

-
U
N
-
2
9
A
U
G
8
8
9. Install motor assembly onto gear train. Install the rear
cover and secure with two long through-bolts.
10. Install the two phillip-head screws.
11. Install end frame cap (A) with same number and
thickness of shims (B) as removed.
12. Install starter on engine. Tighten nut to 88 Nm (65
lb-ft).
M
3
7
8
2
0

-
U
N
-
2
9
A
U
G
8
8
M21,TM360,19 -19-15FEB86
M21,TM360,20 -19-15FEB86
M21,TM360,21 -19-15FEB86
010897
PN=321
60
28
Name Use
Volt-Ohm-Amp Meter Check continuity
13-Ton Puller Set Remove rotor shaft bearing
SPECIFICATIONS
Item Alternator Specification
Minimum Exposed All 5.5 mm (0.22 in.)
Brush Length
Maximum Exposed Nippon Denso 13.0 mm (0.50 in.)
New Brush Length 35A
Distance From Nippon Denso 33.5 mm (1.30 in.)
Stator-to- 35 A Hitachi
Rectifier 25A
Pulley Nut Torque Nippon Denso 54 Nm (40 lb-ft)
35A
Kokosan 20A 27 Nm (20 lb-ft)
Hitachi 25A
Belt Deflection All Engines 13 mm (1/2 in.) at
107 N (24 lb)
Force between
pulleys.
M21,4005R,1 -19-17JUL85
M21,TM365,14A -19-15AUG87
Group 65
Alternator
010897
PN=322
65
1
REPLACE VOLTAGE REGULATOR (NIPPON
DENSO ALTERNATOR)
1. Remove alternator from engine.
2. Remove three attaching screws as shown.
M
3
6
7
2
5

-
U
N
-
2
9
A
U
G
8
8
3. Remove nut (A) and nuts with insulators (B and C).
M
3
6
7
2
6

-
U
N
-
2
9
A
U
G
8
8
IMPORTANT: Do not pry against stator wires.
4. Use a screwdriver to pry end frame (A) from
alternator. Do not separate stator from drive end
assembly.
M
3
6
7
2
7

-
U
N
-
2
9
A
U
G
8
8
5. Use a soldering gun with at least 120 watt capacity to
disconnected terminals (A). Remove voltage regulator
(B).
6. Install new voltage regulator and solder the terminals.
NOTE: If additional solder is needed, us ONLY 6040
rosin-core solder.
M
3
6
7
2
8

-
U
N
-
2
9
A
U
G
8
8
M21,4005R,4 -19-01SEP87
M21,4005R,5 -19-15FEB86
M21,4005R,6 -19-14JUN85
M21,40054,7 -19-14JUN85
Alternator/Nippon Denso Alternator
010897
PN=323
65
2
7. Install insulting washers on terminals (B and C) before
installing end frame.
8. Install end frame.
9. Install insulators and nuts (B and C).
10. Install nut (A).
M
3
6
7
2
6

-
U
N
-
2
9
A
U
G
8
8
11. Install and tighten three screws.
M
3
6
7
2
5

-
U
N
-
2
9
A
U
G
8
8
DISASSEMBLE NIPPON DENSO
ALTERNATOR
1. Remove screws.
M
3
6
7
2
5

-
U
N
-
2
9
A
U
G
8
8
2. Use a screwdriver to separate drive end frame (A)
from stator housing (B).
M
3
6
7
2
9

-
U
N
-
2
9
A
U
G
8
8
M21,4005R,8 -19-17JUL85
M21,4005R,9 -19-17JUL85
M21,4005R,10 -19-01SEP87
M21,4005R,11 -19-14JUN85
010897
PN=324
65
3
3. Remove rotor assembly (A) from stator assembly (B).
M
3
6
7
3
0

-
U
N
-
2
9
A
U
G
8
8
DISASSEMBLE AND TEST ROTOR
1. 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.
2. Touch the probes of an ohmmeter (A) to slip rings
(B). Replace rotor if test indicates no continuity (no
needle movement).
R
W
1
0
0
3
3

-
U
N
-
0
1
D
E
C
8
8
3. Touch the probes of the ohmmeter (A) to the shaft (B)
and one of the slip rings (C). Repeat for other slip ring.
Replace rotor if test shows continuity (needle movement).
R
W
1
0
0
3
4

-
U
N
-
0
1
D
E
C
8
8
M21,4005R,12 -19-14JUN85
M21,4005R,13 -19-14JUN85
M21,4005R,14 -19-14JUN85
010897
PN=325
65
4
4. Inspect rotor shaft rear bearing by spinning bearing on
shaft. Listen for any sounds indicating bearing failure.
Replace bearing if defective.
5. To replace bearing, pull bearing from shaft.
M
3
6
7
3
1

-
U
N
-
2
9
A
U
G
8
8
6. Inspect rotor shaft front bearing by spinning rotor in
housing. Listen for any sounds indicating bearing failure.
Replace bearing is defective.
7. To replace bearing, put rotor in a soft-jaw vise.
Remove nut (A), lock washer, pulley (B), and fan (C).
R
W
2
1
2
6

-
U
N
-
0
1
D
E
C
8
8
8. If necessary, put front frame on open jaws of vise.
Use a soft hammer to remove rotor shaft.
R
W
1
0
0
3
8

-
U
N
-
0
1
D
E
C
8
8
M21,4005R,15 -19-14JUN85
M21,4005R,16 -19-14JUN85
M21,4005R,17 -19-15AUG87
010897
PN=326
65
5
9. Remove spacer from rotor shaft.
M
3
6
7
3
2

-
U
N
-
2
9
A
U
G
8
8
10. Remove three screws to remove bearing retainer (A).
M
3
6
7
3
3

-
U
N
-
2
9
A
U
G
8
8
11. Remove retainer (A), bearing (B), washer (C), felt
washer (D), and bushing (E) from front frame (F).
Inspect bearing for tight spots in rotation. Replace if
defective.
Inspect other parts and service as necessary.
ARetainer DFelt Washer
BBearing EBushing
CWasher FFront Frame
M
3
6
7
3
4

-
U
N
-
2
9
A
U
G
8
8
DISASSEMBLE AND TEST STATOR AND
RECTIFIER
1. Remove nut (A).
2. Remove nuts and insulators (B and C).
3. Use a screwdriver to pry end frame from stator.
M
3
6
7
2
6

-
U
N
-
2
9
A
U
G
8
8
M21,4005R,18 -19-14JUN85
M21,4005R,19 -19-14JUN85
M21,4005R,20 -19-14JUN85
M21,4005R,21 -19-14JUN85
010897
PN=327
65
6
4. Inspect brush holder and brushes for damage.
Brushes must slide freely and the springs must hold the
brushes firmly against the slip ring of the rotor.
5. Measure brushes for wear. Minimum exposed length
must be 5.5 mm (0.22 in.) Replace.
6. Use an ohmmeter or a test light to check for
continuity. Check between the two brushes (A) and
between each brush and ground (B). There should be no
continuity. Replace brush holder-rectifier assembly if
there is no continuity.
M
3
6
7
3
6

-
U
N
-
2
9
A
U
G
8
8
7. To replace brushes, melt solder from brush lead
connections (A) and remove brushes and springs.
8. Inspect springs to be sure they are not broken
collapsed. Replace as needed.
M
3
6
7
3
7

-
U
N
-
2
9
A
U
G
8
8
IMPORTANT: Do not heat connections longer than
necessary to melt solder as excess
heat will damage rectifier assembly.
9. Melt solder joints (A) to remove voltage regulator (B).
Use soldering gun with at least a 120 watt capacity.
M21,4005R,22 -19-14JUN85
M21,4005R,23 -19-14JUN85
M21,4005R,24 -19-14JUN85
M21,4005R,25 -19-14JUN85
010897
PN=328
65
7
NOTE: Stator must be removed from rectifier to test.
10. Melt solder inside the connecting pipes. While solder
is hot, open the flattened pipe with a needle nose pliers.
Pull stator wire from pipe.
M
3
6
7
3
9

-
U
N
-
2
9
A
U
G
8
8
11. 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.
12. Touch the probes of an ohmmeter to each pair of
stator wires. Equal continuity readings should be
observed between each pair of leads. If readings are not
equal, replace stator.
M
3
6
7
4
0

-
U
N
-
2
9
A
U
G
8
8
13. Touch one probe of the ohmmeter to the bare metal
surface of stator and the other probe to a bare stator
lead wire. Repeat for each wire. Replace stator if test
indicates continuity.
M
3
6
7
4
1

-
U
N
-
2
9
A
U
G
8
8
NOTE: The three inner terminals (A) are connected by a
printed circuit in the rectifier.
14. Test the three inner terminals (A) using an
ohmmeter. Move probes so all terminals are cross
checked. Replace the rectifier if test shows no continuity.
M
3
6
7
4
2

-
U
N
-
2
9
A
U
G
8
8
M21,4005R,26 -19-14JUN85
M21,4005R,27 -19-14JUN85
M21,4005R,28 -19-14JUN85
M21,4005R,29 -19-14JUN85
010897
PN=329
65
8
NOTE: Each of the three outer terminals (B) on the
rectifier is connected to two diodes permitting
current flow in only one direction.
15. Test the diodes by touching probes to output post
(A) and the three outer terminals (B).
16. Switch the probes and check each terminal again.
There should be continuity in only one direction between
each terminal (B) and the output post (A).
M
3
6
7
4
3

-
U
N
-
2
9
A
U
G
8
8
17. Test the diodes by touching probes to ground post
There should be continuity in only one direction between
each terminal (B) and the ground post (A).
A shorted diode would have continuity in both directions.
An open diode would have no continuity in either
direction. Replace the rectifier if any of the six diodes
are defective.
M
3
6
7
4
4

-
U
N
-
2
9
A
U
G
8
8
M21,4005R,30 -19-14JUN85
M21,4005R,31 -19-17JUL85
010897
PN=330
65
9
ASSEMBLE STATOR AND RECTIFIER
(NIPPON DENSO ALTERNATOR)
1. 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 (A)
is on side of brush holder with raised lip (B).
2. Hold brushes in position so that exposed length is 13
mm (0.50 in.)
3. Solder brush leads in this position. Cut off excess
length of leads (C).
4. Be sure insulating washers (D) and insulator (E) are
in place.
ABrush
BBrush Holder
CBrush Lead
DWashers
EInsulator
M
3
6
7
4
5

-
U
N
-
2
9
A
U
G
8
8
NOTE: The three pair of lead wires on the stator are not
evenly spaced. Rotate the rectifier until the
terminal pipes align with the stator leads.
5. Install the three outer lead wires on stator through
outer terminal pipes. Install the three inner lead wires on
stator through inner terminal pipes.
6. Adjust the length of the stator lead wires 33.5 mm
(1.30 in.) from stator to rectifier. Connect the six
terminals using a soldering gun with at least a 120 watt
capacity.
If additional solder is needed, use ONLY 60-40 rosin
core solder.
M
3
6
7
4
6

-
U
N
-
2
9
A
U
G
8
8
M21,4005R,32 -19-01SEP87
M21,4005R,33 -19-14JUN85
010897
PN=331
65
10
7. Install voltage regulator (B). Connect and solder joints
(A).
M
3
6
7
3
8

-
U
N
-
2
9
A
U
G
8
8
IMPORTANT: Be sure six stator lead wires do not
contact end frame when installed.
8. Install end frame. Fasten with nut (A).
9. Install insulators and nuts (B and C).
M
3
6
7
2
6

-
U
N
-
2
9
A
U
G
8
8
ASSEMBLE ROTOR (NIPPON DENSO
ALTERNATOR)
1. Apply a small amount of grease to the felt washer (D).
Install bushing (E) in felt washer (D). Install bushing and
felt washer in front frame (F).
2. Install washer (C), bearing (B), and retainer (A).
ARetainer
BBearing
CWasher
DFelt Washer
EBushing
FFront Frame
M
3
6
7
3
4

-
U
N
-
2
9
A
U
G
8
8
M21,4005R,34 -19-14JUN85
M21,4005R,35 -19-14JUN85
M21,4005R,36 -19-15AUG87
010897
PN=332
65
11
3. Fasten retainer (A) with three screws.
M
3
6
7
3
3

-
U
N
-
2
9
A
U
G
8
8
4. Install bushing on rotor shaft.
M
3
6
7
3
2

-
U
N
-
2
9
A
U
G
8
8
5. Install rotor shaft in front frame assembly.
6. Install fan (C), pulley (B), lock washer, and nut (A).
7. Hold rotor in a soft-jaw vise. Tighten nut (A) to 54
Nm (40 lb-ft).
R
W
2
1
2
6

-
U
N
-
0
1
D
E
C
8
8
8. Apply a thin film of grease to the bearing. Install
bearing on rotor shaft until bearing is flush with end of
shaft. Press only on inner race of bearing.
M
3
6
7
4
7

-
U
N
-
2
9
A
U
G
8
8
M21,4005R,37 -19-17JUL85
M21,4005R,38 -19-14JUN85
M21,4005R,39 -19-14JUN85
M21,4005R,40 -19-14JUN85
010897
PN=333
65
12
9. Push alternator brushes (A) into brush holder. Install a
wire (B) through access hole in rear of end frame to lock
brushes in place.
M
3
6
7
4
8

-
U
N
-
2
9
A
U
G
8
8
10. Apply a small amount of grease on the rear of the
rotor shaft.
11. Assemble the rotor assembly to the stator assembly
and fasten with three screws (A).
12. Remove wire (B) from rear of end frame.
13. Install alternator on engine and adjust belt tension.
M
3
6
7
4
9

-
U
N
-
2
9
A
U
G
8
8
SERVICE 20A KOKOSAN ALTERNATOR
2. Clamp pulley in a soft jaw vise. Remove nut (A) and
washers.
M
4
6
0
5
9

-
U
N
-
3
1
A
U
G
8
8
3. Support alternator on open jaws of vise. Use a soft
hammer to tap shaft and flywheel from body.
R
W
1
1
7

-
U
N
-
2
9
N
O
V
8
8
M21,4005R,41 -19-01SEP87
M21,4005R,42 -19-15AUG87
M21,TM365,1 -19-01SEP87
M21,TM365,2 -19-15FEB86
Alternator/Service 20A Kokosan Alternator
010897
PN=334
65
13
4. Inspect magnets (A) in flywheel. Replace flywheel if
magnets are missing or damaged.
5. Inspect bearing (B) for damage or tight spots in
rotation.
R
W
1
2
0

-
U
N
-
1
5
D
E
C
8
8
6. If necessary to replace bearing, support flywheel on
press and push shaft from bearing and flywheel.
M
3
7
8
1
4

-
U
N
-
2
9
A
U
G
8
8
7. Support flywheel on press. Install shaft with pulley
until pulley bottoms on flywheel face.
M
3
7
8
1
5

-
U
N
-
2
9
A
U
G
8
8
8. Install washer and spacer over shaft.
M
3
7
8
1
6

-
U
N
-
2
9
A
U
G
8
8
M21,TM365,3 -19-15FEB86
M21,TM365,4 -19-15FEB86
M21,TM365,5 -19-15FEB86
M21,TM365,6 -19-15FEB86
010897
PN=335
65
14
9. Support flywheel on press. Use a 9/16 in., 1/2 in.-
drive deep socket TURNED UPSIDE DOWN to press
new bearing onto shaft until it bottoms on spacer.
M
3
7
8
1
7

-
U
N
-
2
9
A
U
G
8
8
10. If necessary to replace coil plate bearing, use a
press and a spark plug socket to remove bearing.
NOTE: Bearing will be damaged when removed, always
install a new bearing.
M
3
7
8
1
8

-
U
N
-
2
9
A
U
G
8
8
11. Support coil plate on press. Use a 1 in. socket to
press new bearing into coil plate until it bottoms in bore.
M
3
7
8
1
9

-
U
N
-
2
9
A
U
G
8
8
12. If necessary to replace stator, remove harness clamp
(A) and remove connector (B) from leads.
M
4
6
0
6
1

-
U
N
-
0
8
S
E
P
8
8
M21,TM365,7 -19-15FEB86
M21,TM365,8 -19-15FEB86
M21,TM365,9 -19-23APR86
M21,TM365,10 -19-17AUG87
010897
PN=336
65
15
13. Remove two screws and remove stator.
R
W
1
2
1

-
U
N
-
1
5
D
E
C
8
8
14. Install stator with two screws and install harness
connector.
15. Install flywheel onto coil plate. Install two washers
and tighten nut to 27 Nm (20 lb-ft).
16. Test alternator output as instructed in Section 240 of
the Machine Technical Manual.
REPLACE VOLTAGE REGULATOR (HITACHI
24V/25A ALTERNATOR)
2. Remove four attaching screws as shown.
M
5
1
5
9
4

-
U
N
-
3
1
A
U
G
8
8
3. Remove four nuts (A) and nut (B) with insulator.
M
5
1
5
9
5

-
U
N
-
3
1
A
U
G
8
8
M21,TM365,11 -19-15FEB86
M21,TM365,12 -19-15FEB86
M21,TM365,13 -19-17AUG87
M21,TM365,14 -19-17AUG87
Alternator/Hitachi 24V/25A Alternator
010897
PN=337
65
16
4. Use a screwdriver to pry end frame (A) from
alternator. Do not separate stator from drive end
assembly.
M
3
6
7
2
7

-
U
N
-
2
9
A
U
G
8
8
5. Use a soldering gun with at least 120 watt capacity to
disconnect five terminals (A). Push two capscrews (C)
out of brush housing to remove IC regulator (B). Remove
insulator (D).
6. Install new regulator and solder terminals.
NOTE: If additional solder is needed, use ONLY 60-40
rosin-care solder.
ARegulator Terminals
BRegulator
CCap Screws
DInsulator
M
5
1
6
0
2

-
U
N
-
3
1
A
U
G
8
8
7. Install insulating washer on terminal (B) before
installing end frame.
8. Install end frame.
9. Install insulator and nut (B).
10. Install four nuts (A).
M
5
1
5
9
5

-
U
N
-
3
1
A
U
G
8
8
M21,4005R,6 -19-14JUN85
M21,TM365,15 -19-17AUG87
M21,TM365,16 -19-17AUG87
010897
PN=338
65
17
11. Install and tighten four screws.
M
3
6
7
2
5

-
U
N
-
2
9
A
U
G
8
8
DISASSEMBLE HITACHI 24V/25A
ALTERNATOR
1. Remove four screws.
M
3
6
7
2
5

-
U
N
-
2
9
A
U
G
8
8
2. Use a screwdriver to separate drive end frame (A)
from stator housing (B).
M
3
6
7
2
9

-
U
N
-
2
9
A
U
G
8
8
3. Remove rotor assembly (A) from stator assembly (B).
M
3
6
7
3
0

-
U
N
-
2
9
A
U
G
8
8
M21,TM365,17 -19-17AUG87
M21,TM365,18 -19-17AUG87
M21,4005R,11 -19-14JUN85
M21,4005R,12 -19-14JUN85
010897
PN=339
65
18
DISASSEMBLE AND TEST ROTOR
1. 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.
2. Touch the probes of an ohmmeter (A) to slip rings
(B). Replace rotor if test indicates no continuity (no
needle movement).
R
W
1
0
0
3
3

-
U
N
-
0
1
D
E
C
8
8
3. Touch the probes of the ohmmeter (A) to the shaft (B)
and one of the slip rings (C). Repeat for other slip ring.
Replace rotor if test shows continuity (needle movement).
R
W
1
0
0
3
4

-
U
N
-
0
1
D
E
C
8
8
4. Inspect rotor shaft rear bearing by spinning bearing on
shaft. Listen for any sounds indicating bearing failure.
5. To replace bearing, pull bearing from shaft.
M
3
6
7
3
1

-
U
N
-
2
9
A
U
G
8
8
M21,4005R,13 -19-14JUN85
M21,4005R,14 -19-14JUN85
M21,4005R,15 -19-14JUN85
010897
PN=340
65
19
6. Inspect rotor shaft front bearing by spinning rotor in
housing. Listen for sounds indicating bearing failure.
7. To replace bearing, put rotor in a soft-jaw vise.
Remove nut (A), lock washer, pulley (B), and fan (C).
Remove bushing from shaft.
R
W
2
1
2
6

-
U
N
-
0
1
D
E
C
8
8
M
5
1
5
9
6

-
U
N
-
3
1
A
U
G
8
8
8. If necessary, put front frame on open jaws of vise.
Use a soft hammer to remove rotor shaft.
R
W
1
0
0
3
8

-
U
N
-
0
1
D
E
C
8
8
9. Remove spacer from rotor shaft.
M
3
6
7
3
2

-
U
N
-
2
9
A
U
G
8
8
M21,TM365,19 -19-17AUG87
M21,4005R,17 -19-15AUG87
M21,4005R,18 -19-14JUN85
010897
PN=341
65
20
10. Remove three screws to remove bearing retainer (A).
M
3
6
7
3
3

-
U
N
-
2
9
A
U
G
8
8
11. Remove retainer (A) and bearing (B) from front
frame (C).
Inspect bearing for tight spots in rotation. Replace if
defective.
M
5
1
5
9
7

-
U
N
-
3
1
A
U
G
8
8
DISASSEMBLE AND TEST STATOR AND
RECTIFIER
1. Remove four nuts (A).
2. Remove nut and insulator (B).
3. Use a screwdriver to pry end frame from stator.
M
5
1
5
9
5

-
U
N
-
3
1
A
U
G
8
8
4. 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.
5. Measure brushes for wear. Minimum exposed length
must be 5.5 mm (0.22 in.) or to wear limit line on
brushes. Replace brushes as necessary.
M
3
6
7
3
5

-
U
N
-
2
9
A
U
G
8
8
M21,4005R,19 -19-14JUN85
M21,TM365,20 -19-17AUG87
M21,TM365,21 -19-17AUG87
M21,TM365,22 -19-17AUG87
010897
PN=342
65
21
6. Use an ohmmeter or a test light to check for
continuity. Check between the two brushes (A) and
between each brush and ground (B). There should be no
continuity. Replace brush holder-rectifier assembly if
there is no continuity.
M
3
6
7
3
6

-
U
N
-
2
9
A
U
G
8
8
7. To replace brushes, melt solder from connection (A).
Remove IC regulator (B) if necessary. See Replace
Voltage Regulator in this group.
M
5
1
6
0
3

-
U
N
-
3
1
A
U
G
8
8
IMPORTANT: Do not heat connections longer than
necessary to melt solder as excess
heat will damage rectifier assembly.
8. Melt five solder joints (A) to remove voltage regulator
(B). Use soldering gun with at least a 120 watt capacity.
M
5
1
6
0
4

-
U
N
-
3
1
A
U
G
8
8
NOTE: Stator must be removed from rectifier to test.
9. Melt solder at three connections (A) to remove
rectifier.
M
5
1
6
0
5

-
U
N
-
3
1
A
U
G
8
8
M21,4005R,23 -19-14JUN85
M21,TM365,23 -19-17AUG87
M21,TM365,24 -19-17AUG87
M21,TM365,25 -19-01SEP87
010897
PN=343
65
22
10. 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.
11. Touch probes of an ohmmeter to wires of stator in
three possible combinations. Continuity should read
approximately 0.26 ohms. If readings are not equal,
replace stator.
M
5
1
5
9
8

-
U
N
-
3
1
A
U
G
8
8
12. Touch one probe of the ohmmeter to the bare metal
surface of stator and the other probe to a bare stator
lead wire. Repeat for each wire. Replace stator if test
indicates continuity.
M
5
1
5
9
9

-
U
N
-
3
1
A
U
G
8
8
13. Test the diodes by touching probes to ground post
There should be continuity in only one combination of
each terminals (B) and the ground post (A).
M
5
1
6
0
0

-
U
N
-
3
1
A
U
G
8
8
M21,TM365,26 -19-17AUG87
M21,TM365,27 -19-17AUG87
M21,TM365,28 -19-17AUG87
010897
PN=344
65
23
15. Test the diodes by touching probes to output post
There should be continuity in only one combination of
each terminal (B) and the output post (A).
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.
M
5
1
6
0
1

-
U
N
-
3
1
A
U
G
8
8
ASSEMBLE STATOR AND RECTIFIER
(HITACHI 24V/25A ALTERNATOR)
1. Adjust the length of the stator lead wires 33.5 mm
(1.30 in.) from stator to rectifier. Connect the three
terminals using a soldering gun with at least a 120 watt
capacity.
If additional solder is needed, use ONLY 60-40 rosin
care solder.
M
5
1
6
0
5

-
U
N
-
3
1
A
U
G
8
8
2. If IC regulator (B) was removed, install and solder five
connections (A).
M
5
1
6
0
4

-
U
N
-
3
1
A
U
G
8
8
M21,TM365,29 -19-17AUG87
M21,TM365,30 -19-01SEP87
M21,TM365,31 -19-17AUG87
010897
PN=345
65
24
IMPORTANT: Be sure stator lead wires do not
contact end frame when installed.
3. Install end frame. Fasten with four nuts (A).
4. Install insulator and nut (B).
M
5
1
5
9
5

-
U
N
-
3
1
A
U
G
8
8
ASSEMBLE ROTOR (HITACHI 24V/25A
ALTERNATOR)
1. Install bearing (B) in front frame (C).
2. Install retainer (A).
M
5
1
5
9
7

-
U
N
-
3
1
A
U
G
8
8
3. Fasten retainer (A) with three screws.
M
3
6
7
3
3

-
U
N
-
2
9
A
U
G
8
8
4. Install bushing on rotor shaft.
M
3
6
7
3
2

-
U
N
-
2
9
A
U
G
8
8
M21,TM365,32 -19-12AUG87
M21,TM365,33 -19-17AUG87
M21,4005R,37 -19-17JUL85
M21,4005R,38 -19-14JUN85
010897
PN=346
65
25
5. Install rotor shaft in front frame assembly. Install
bushing.
M
5
1
5
9
6

-
U
N
-
3
1
A
U
G
8
8
6. Install fan (C), pulley (B), lock washer, and nut (A).
7. Hold rotor in a soft-jaw vice. Tighten nut (A) to 54
Nm (40 lb-ft).
R
W
2
1
2
6

-
U
N
-
0
1
D
E
C
8
8
8. Apply a thin film of grease to the bearing. Install
bearing on rotor shaft until bearing is flush with end of
shaft. Press only on inner race of bearing.
M
3
6
7
4
7

-
U
N
-
2
9
A
U
G
8
8
9. Push alternator brushes (A) into brush holder. Install a
wire (B) through access hole in rear of end frame to lock
brushes in place.
M
3
6
7
4
8

-
U
N
-
2
9
A
U
G
8
8
M21,TM365,34 -19-17AUG87
M21,TM365,35 -19-01SEP87
M21,4005R,40 -19-14JUN85
M21,4005R,41 -19-01SEP87
010897
PN=347
65
26
10. Apply a small amount of grease on the rear of the
rotor shaft.
11. Assemble the rotor assembly to the stator assembly
and fasten with three screws (A).
12. Remove wire (B) from rear of end frame.
13. Install alternator on engine and adjust belt tension.
M
3
6
7
4
9

-
U
N
-
2
9
A
U
G
8
8
M21,4005R,42 -19-15AUG87
010897
PN=348
65
27
010897
PN=349
65
28

Yanmar Diesel

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Yanmar Diesel

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Yanmar Diesel

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3TN and 4TN Series

To seal camshaft plug

Thread Lock Apply to threads of crankshaft

Measure connecting rod bearing clearance

Measure crankshaft bearing

Thread Lock Apply to threads of crankshaft

Thread Lock Apply on threads of fuel shut-off

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