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4TNV98 & 4TNE98 Diesel Engine

Section 4. Fuel System

146

Fuel System Diagram

Figure7-3

(1) Diesel Fuel Tank. (2) Fuel Filter / Water Separator. (3) Electric Fuel Pump. (4) Fuel Filter. (5) Air Bleed Orifice. (6) Fuel Supply Line.
(7) Low Pressure Gallery. (8) Pressure Control Valve. (9) Trochoid Pump. (10) Oil Seal. (11) Fuel Injection Pump Cam.
(12) Engine Crankcase. (13) Tappet. (14) High Pressure Gallery. (15) Overflow Orifice. (16) Accumulator. (17) Timer Piston.
(18) Mono-Plunger. (19) Distributor Shaft. (20) Fuel Return Line. (21) High-Pressure Fuel Injection Lines. (22) Fuel Injector.

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Summary of Contents for 4TNE98

Page 1: ...ervice Manual 4TNV98 4TNE98 Diesel Engine D20S 5 D25S 5 D30S 5 D33S 5 D35C 5 4TNV98 EM0Q3 EM0Q4 EM0Q5 D20S 5 D25S 5 D30S 5 D33S 5 D35C 5 4TNE98 EM0QC EM0QD EM0QE D20G D25G D30G 4TNE98 SB4319E00 Jan 2008 ...

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Page 3: ...following symbol WARNING Improper operation lubrication maintenance or repair of this product can be dangerous and could result in injury or death Do not operate or perform any lubrication maintenance or repair on this product until you have read and understood the operation lubrication maintenance and repair information Operations that may cause product damage are identified by NOTICE labels on t...

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Page 5: ...Units of Force 28 Units of Torque 28 Units of Pressure 28 Units of Power 28 Units of Temperature 28 Section 2 PERIODIC MAINTENANCE Before You Begin Servicing 29 Introduction 40 The Importance of Periodic Maintenance 40 Performing Periodic Maintenance 40 Yanmar Replacement Parts 40 Required EPA ARB Maintenance USA Only 40 EPA ARB Installation Requirements USA Only 40 Periodic Maintenance Schedule 4...

Page 6: ...Injection Pump 152 Checking and Adjusting Fuel Injection Timing 157 Determining the Fuel Injection Timing Specification 157 Checking Fuel Injection Timing 158 Adjusting Fuel Injection Timing 161 Fuel Injectors 163 Removal of Fuel Injectors 163 Testing of Fuel Injectors 164 Disassembly and Inspection of Fuel Injectors 165 Adjusting Fuel Injector Pressure 166 Reassembly of Fuel Injectors 167 Install...

Page 7: ...id Oil Pump 215 Oil Pump Components 215 Disassembly of Oil Pump 216 Cleaning and Inspection 216 Reassembly of Oil Pump 217 Section 7 STARTER MOTOR Before You Begin Servicing 219 Introduction 221 Starter Motor Information 221 Starter Motor Specifications 222 Starter Motor Troubleshooting 223 Starter Motor Components 224 Starter Motor 225 Removal of Starter Motor 225 Disassembly of Starter Motor 225...

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Page 9: ...ection Pump 12 Engine Oil Filter 13 Dipstick Engine Oil 14 Governor Lever 15 Intake Manifold 16 Fuel Filter 17 Fuel Inlet 18 Fuel Return to Fuel Tank 19 Top Filler Port Engine Oil 20 Rocker Arm Cover 21 Air Intake Port From Air Cleaner 22 Flywheel 23 Starter Motor 24 Exhaust Manifold 25 Alternator 4TNE98 ENGINE Figure 4 1b 1 Fuel Filter Water Separator 2 Top Filler Port Engine Oil 3 Governor Lever...

Page 10: ...tion of the engine nameplate is shown Figure 4 2 1 4 Engine Nameplate Typical Emission Control Regulations EPA ARB Regulations USA Only Yanmar engines meet Environmental Protection Agency EPA U S Federal emission control standards as well as the California Air Resources Board ARB California regulations Only engines that conform to ARB regulations can be sold in the State of California Refer to the...

Page 11: ...might find on your engine EPA ARB Labels EPA Greater than or Equal to 50 HP SAE 37kW EPA and ARB The 97 68 EC Directive Certified Engines The engines described in this manual have been certified by the 97 68 EC Directive To identify the engines that meet this certification the 97 68 EC emission control label is affixed on the engines 97 68 EC Engine Family The EPA ARB labels and the 97 68 EC label...

Page 12: ...ilter removes contaminants and sediments from the diesel fuel Periodic replacement of the fuel filter is necessary See the Periodic Maintenance Schedule on page 39 for the replacement frequency Please note that the word diesel is implied throughout this manual when the word fuel is used Fuel Filter Water Separator The fuel filter water separator removes contaminants sediments and water from the di...

Page 13: ... the engine cooling fan circulates air through the radiator the heat is transferred to the air Radiator Cap The radiator cap controls the cooling system pressure The cooling system is pressurized to raise the boiling point of the engine coolant As the engine coolant temperature rises the system pressure and the coolant volume increases When the pressure reaches a preset value the release valve in ...

Page 14: ...t not exceed 0 35 by volume Less than 0 1 is preferred The total aromatics content should not exceed 35 by volume Less than 30 is preferred The PAH polycyclic aromatic hydrocarbons content should be below 10 by volume The metal content of Na Mg Si and Al should be equal to or lower than 1 mass ppm Test analysis method JPI 5S 44 95 Lubricity The wear mark of WS1 4 should be Max 0 018 in 460 μm at H...

Page 15: ... the precautions and concerns above may affect the warranty coverage of your engine Filling The Fuel Tank DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions Only fill the fuel tank with diesel fuel Filling the fuel tank with gasoline may result in a fire and will damage the engine NEVER refuel with the engine running Wipe up all spills immediately Keep...

Page 16: ...diesel fuels recommended by Yanmar for the best engine performance to prevent engine damage and to comply with EPA ARB warranty requirements Only use clean diesel fuel NEVER remove the primary strainer if equipped from the fuel tank filler port If removed dirt and debris could get into the fuel system causing it to clog Note that a typical fuel tank is shown The fuel tank on your equipment may be ...

Page 17: ... out of the air bleed port is free of bubbles 4 Tighten the air bleed port 5 Wipe up any spills and properly dispose of fuel 6 NEVER use the starter motor to crank the engine in order to prime the fuel system This may cause the starter motor to overheat and damage the coils pinion and or ring gear To prime the fuel system on engines not equipped with an electric fuel system 1 Place an approved con...

Page 18: ...d E 5 JASO Service Category DH 1 Definitions API Classification American Petroleum Institute ACEA Classification Association des Constructeurs Européens d Automobilies JASO Japanese Automobile Standards Organization NOTE Be sure the engine oil engine oil storage containers and engine oil filling equipment arefree of sediment and water Change the engine oil after the first 50 hours of peration and ...

Page 19: ... at the top or the side engine oil filler port Figure 4 5 5 4 Wait three minutes and check the oil level 5 Add more oil if necessary 6 Reinstall the oil cap Figure 4 5 4 and hand tighten Over tightening may damage the cap Engine Oil Capacity Typical NOTE These are the engine oil capacities associated with a deep standard oil pan The oil capacity will vary dependant upon which optional oil pan is u...

Page 20: ...drain the engine coolant Hot engine coolant may splash and burn you Failure to comply could result in death or serious injury CAUTION COOLANT HAZARD Wear eye protection and rubber gloves when you handle long life or extended life engine coolant If contact with the eyes or skin should occur flush eyes and wash immediately with clean water Failure to comply may result in minor or moderate injury CAU...

Page 21: ...ontainer Water quality is important to coolant performance Yanmar recommends that soft distilled or demineralized water be used to mix with coolants NEVER mix extended or long life coolants and conventional green coolants NEVER mix different types and or colors of extended life coolants Replace the coolant every 1000 engine hours or once a year Filling Radiator with Engine Coolant Fill the radiato...

Page 22: ...ant will leak out instead of going into the reserve tank 7 Run the engine until it is at operating temperature Check the level of engine coolant in the reserve tank When the engine is running and the engine coolant is at normal temperature the coolant level in the tank should be at the FULL HOT mark Figure 4 6 6 If the engine coolant is not at the FULL HOT mark Figure 4 6 6 add additional engine c...

Page 23: ... information described in Principal Engine Specifications is for a standard engine To obtain the information for the engine installed in your driven machine please refer to the manual provided by the driven machine manufacturer Engine rating conditions are as follows SAE J1349 ISO 3046 1 Atmospheric Condition Room temperature 77 F 25 C Atmospheric pressure 29 53 in Hg 100 kPa 750 mm Hg Relative hu...

Page 24: ...em Forced Lubrication with Trochoid Pump Normal Oil Pressure at Rated Engine Speed 42 57 psi 0 29 0 39 MPa 2 96 3 98 kgf cm Normal Oil Pressure at Low Idle Speed 8 5 psi 0 06 MPa 0 6 kgf cm or greater Electric Starting Starter Motor DC12V 3 1 hp 2 3 kW Alternator DC12V 40A Starting System Recommended Battery Capacity 12V 64 Amp Hour 5h rating Dimensions L W H 28 31 x 19 61 x 29 21 in 719 x 498 x 7...

Page 25: ...adiator Lubricating System Forced Lubrication With Trochoid Pump At normal operating speeds oil pressure is 42 57 psi 0 29 0 39 MPa 3 0 4 0 kgf cm At idle oil pressure is No less than 18 5 psi 0 13 Mpa 1 3kgf cm Electric Starting Starter Motor DC12V 3 1 hp 2 3 kW Alternator DC12V 80A Starting System Recommended Battery Capacity 12V 622 CCA Cold Cranking Amps Dimensions L W H 28 0 x 20 3 x 29 8 in ...

Page 26: ... 36 kgf cm 384 414 psi 2 65 2 85 MPa 27 29 kgf cm See Troubleshooting By Measuring Compression Pressure on page 236 Compression Pressure at 250 rpm 250 min 4TNE98 425 428 psi 2 93 2 95 MPa 29 31 kgf cm 341 psi 2 35 MPa 24 kgf cm Deviation Between Cylinders 29 43 psi 0 2 0 3 MPa 2 3 kgf cm Oil Pressure Switch Operating Pressure 5 8 8 8 psi 0 04 0 06 MPa 0 4 0 6 kgf cm Max when cold 86 psi 0 59 MPa ...

Page 27: ...Applying excessive torque may damage the fastener or component and not enough torque may cause a leak or component failure CAUTION The tightening torque in the Standard Torque Chart see General Service Information section should be applied only to the bolts with a 7 head JIS strength classification 7T Apply 60 torque to bolts that are not listed Apply 80 torque when tightened to aluminum alloy ...

Page 28: ...f the value at left when the tightening part is aluminum Use 60 of the value at left for 4T bolts and lock nuts 1 8 mm 7 ft lb 87 in lb 9 8 N m 1 0 kgf m 1 4 mm 14 ft lb 173 in lb 19 6 N m 2 0 kgf m 3 8 mm 22 ft lb 29 4 N m 3 0 kgf m PT PLug 1 2 mm 43 ft lb 58 8 N m 6 0 kgf m Item Nominal Thread Diameter x Pitch Tightening Torque Remarks M8 9 12 ft lb 112 148 in lb 12 7 16 7 N m 1 3 1 7 kgf m M10 ...

Page 29: ... minute g gram gal gallon U S gal hr gallon U S per hour gal min gallon U S per minute GL gear lubricant hp horsepower U S hr hour I D inside diameter ID identification IDI indirect injection in inch in Aq inches Aqueous water in Hg inches Mercury in lb inch pound j joule JASO Japanese Automobile Standards Organization k kelvin kg kilogram kgf cm kilogram force per square centimeter kgf m kilogram...

Page 30: ... x 0 2248 lbf N x 0 1020 kgf kgf x 2 2050 lbf kgf x 9 8070 N Units of Torque ft lb x 1 3558 N m ft lb x 0 1383 kgf m in lb x 0 1130 N m in lb x 0 0115 kgf m kgf m x 7 2330 ft lb kgf m x 86 8000 in lb kgf m x 9 8070 N m N m x 0 7376 ft lb N m x 8 8510 in lb N m x 0 1020 kgf m Units of Pressure psi x 0 0689 bar psi x 6 8950 kPa psi x 0 0703 kg cm bar x 14 5030 psi bar x 100 0000 kPa bar x 29 5300 in...

Page 31: ...ine coolant will spurt out and seriously burn you Allow the engine to cool down before you attempt to remove the radiator cap Tighten the radiator cap securely after you check the radiator Steam can spurt out during engine operation if the cap is loose ALWAYS check the level of the engine coolant by observing the reserve tank Failure to comply will result in death or serious injury DANGER FIRE AND...

Page 32: ...ith the engine running Failure to comply will result in death or serious injury DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions Be sure to place the diesel fuel container on the ground when transferring the diesel fuel from the pump to the container Hold the hose nozzle firmly against the side of the container while filling it This prevents static e...

Page 33: ... under pressure and fuel could spray out when you remove any fuel system component Failure to comply will result in death or serious injury DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions Place an approved container under the air bleed port when you prime the fuel system Never use a shop rag to catch the fuel Wipe up any spills immediately ALWAYS cl...

Page 34: ... result in death or serious injury WARNING SEVER HAZARD Keep hands and other body parts away from moving rotating parts such as the cooling fan flywheel or PTO shaft Wear tight fitting clothing and keep your hair short or tie it back while the engine is running Remove all jewelry before you operate or service the machine NEVER start the engine in gear Sudden movement of the engine and or machine c...

Page 35: ...from hot engine surfaces such as the muffler exhaust pipe turbocharger if equipped and engine block during operation and shortly after you shut the engine down These surfaces are extremely hot while the engine is operating and could seriously burn you Failure to comply could result in death or serious injury WARNING ALCOHOL AND DRUG HAZARD NEVER operate the engine while you are under the influence...

Page 36: ...cid NEVER allow battery fluid to come in contact with clothing skin or eyes Severe burns could result ALWAYS wear safety goggles and protective clothing when servicing the battery If battery fluid contacts the eyes and or skin immediately flush the affected area with a large amount of clean water and obtain prompt medical treatment Failure to comply could result in death or serious injury WARNING ...

Page 37: ...meone may accidentally start the engine and not realize you are servicing it This could result in a serious injury If you must service the engine while it is operating remove all jewelry tie back long hair and keep your hands other body parts and clothing away from moving rotating parts Failure to comply could result in death or serious injury WARNING BURN HAZARD If you must drain the engine oil w...

Page 38: ...coverage cause internal engine components to seize and or shorten engine life Prevent dirt and debris from contaminating the engine oil Carefully clean the oil cap dipstick and the surrounding area before you remove the cap NEVER mix different types of engine oil This may adversely affect the lubricating properties of the engine oil NEVER overfill Overfilling may result in white exhaust smoke engi...

Page 39: ...o start and the engine oil may not flow easily Contact your authorized Yanmar industrial engine dealer or distributor if the engine will be operated outside of this standard temperature range CAUTION NEVER hold the key in the START position for longer than 15 seconds or the starter motor will overheat CAUTION For maximum engine life Yanmar recommends that when shutting the engine down you allow th...

Page 40: ...ing This may damage the starter motor pinion and or ring gear CAUTION It is important to perform daily checks Periodic maintenance prevents unexpected downtime reduces the number of accidents due to poor machine performance and helps extend the life of the engine CAUTION ALWAYS be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of...

Page 41: ...arranty coverage on your engine See Yanmar Limited Warranty in Warranty Section Consult your authorized Yanmar dealer or distributor for assistance when checking items marked with a CAUTION If the fuel filter water separator is positioned higher than the fuel level in the fuel tank water may not drip out when the fuel filter water separator drain cock is opened If this happens turn the air vent sc...

Page 42: ...e to comply could result in death or serious injury Perform periodic maintenance procedures in an open level area free from traffic If possible perform the procedures indoors to prevent environmental conditions such as rain wind or snow from damaging the machine Yanmar Replacement Parts Yanmar recommends that you use genuine Yanmar parts when replacement parts are needed Genuine replacement parts ...

Page 43: ...d to establish definitively The following should be treated only as a general guideline CAUTION Establish a periodic maintenance plan according to the engine application and make sure you perform the required periodic maintenance at the intervals indicated Failure to follow these guidelines will impair the engine s safety and performance characteristics shorten the engine s life and may affect the...

Page 44: ...ent Check Battery Check Engine Oil Level Check Engine Oil Pressure Indicator Drain and Fill Engine Oil Engine Oil Replace Engine Oil Filter 1st time 2nd and after Engine Speed Control Check and Adjust Governor Lever and Engine Speed Control Inspect Clean and Test Fuel Injectors Emission Control Warranty Inspect Crankcase Breather System Check and Refill Fuel Tank Level Check Fuel Filter Indicator ...

Page 45: ...r serious injury 0000009en 4TNE98 For D25S 5 Only WARNING HIGH PRESSURE HAZARD Avoid skin contact with high pressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line High pressure fuel can penetrate your skin and result in serious injury If you are exposed to high pressure fuel spray obtain prompt medical treatment NEVER check for a fuel leak with your hands ALWA...

Page 46: ...he scheduled periodic maintenance if the fuel filter indicator comes on The fuel filter water separator contains a sensor to detect the amount of water and contaminants This sensor sends a signal to an indicator to alert the operator Drain the fuel filter water separator as follows Figure 5 1 1 Position an approved container under the fuel filter water separator Figure5 1 1 to collect the contamin...

Page 47: ... oil specified Other engine oils may affect warranty coverage cause internal engine components to seize and or shorten engine life Prevent dirt and debris from contaminating the engine oil Carefully clean the oil cap dipstick and the surrounding area before you remove the cap NEVER mix different types of engine oil This may adversely affect the lubricating properties of the engine oil NEVER overfi...

Page 48: ...to collect waste oil Figure 5 1 6 Remove the oil drain plug Figure 5 2 1 from the engine oil pan Allow oil to drain 7 After all oil has been drained from the engine reinstall the oil drain plug Figure 5 2 1 and tighten to 139 8 47 0 ft lb 53 9 63 7 N m 5 5 6 5 kgf m 8 Dispose of used oil properly Remove the engine oil filter as follows 1 Turn the engine oil filter Figure 5 2 2 counterclockwise Fig...

Page 49: ...ny engine oil is spilled wipe it away with a clean cloth Check and Adjust Cooling Fan V Belt The V belt will slip if it does not have the proper tension This will prevent the alternator from generating sufficient power Also the engine will overheat due to the engine coolant pump pulley slipping Check and adjust the V belt tension deflection as follows 1 Press the V belt down with your thumb with a...

Page 50: ...ting run the engine for 5 minutes or more Check the tension again using the specifications for a used V belt Used V Belt Tension A B C 3 8 1 2 in 10 14 mm 1 4 3 8 in 7 10 mm 5 16 1 2 in 9 13 mm Every 50 Hours of Operation After you complete the initial 50 hour maintenance procedures perform the following procedures every 50 hours thereafter Drain Fuel Filter Water Separator Check Battery Drain Fue...

Page 51: ... are discovered The cup of the separator is made from semi transparent material In the cup is a red colored float ring The float ring will rise to the surface of the water to show how much needs to be drained Also some optional fuel filter water separators are equipped with a sensor to detect the amount of contaminants This sensor sends a signal to an indicator to alert the operator Drain the fuel...

Page 52: ... CAUTION ALWAYS be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil diesel fuel and engine coolant Consult the local authorities or reclamation facility NEVER dispose of hazardous materials irresponsibly by dumping them into a sewer on the ground or into ground water or waterways Failure to...

Page 53: ...ive Wipe up any spills immediately Wear eye protection The fuel system is under pressure and fuel could spray out when you remove any fuel system component Failure to comply will result in death or serious injury CAUTION ALWAYS be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil diesel fuel...

Page 54: ...e fins apply detergent thoroughly clean and rinse with tap water CAUTION NEVER use high pressure water or compressed air at greater than 28 psi 193 kPa 19 686 mmAq or a wire brush to clean the radiator fins Radiator fins damage easily Figure 5 10 Check and Adjust Cooling Fan V Belt Check and adjust the cooling fan V belt every 250 hours of operation after the initial 50 hour V belt maintenance See...

Page 55: ... low or high idle speed limit screw This may impair the safety and performance of the machine and shorten its life If the idle speed limit screws require adjustment see your authorized Yanmar industrial engine dealer or distributor Clean Air Cleaner Element Note that a typical air cleaner is shown in Figure 5 12 and Figure 5 13 for illustrative purposes only The engine performance is adversely aff...

Page 56: ...ER operate the engine with the air cleaner element s removed This may allow foreign material to enter the engine and damage it Every 500 Hours of Operation Perform the following maintenance every 500 hours of operation Replace Engine Oil and Engine Oil Filter Replace Air Cleaner Element Replace Fuel Filter Clean Fuel Filter Water Separator Replace Engine Oil and Engine Oil Filter CAUTION Only use ...

Page 57: ...e rag are flammable and explosive Wipe up any spills immediately Wear eye protection The fuel system is under pressure and fuel could spray out when you remove any fuel system component Failure to comply will result in death or serious injury CAUTION For maximum engine life Yanmar recommends that when shutting the engine down you allow the engine to idle without load for five minutes This will all...

Page 58: ...or leaks 4TNE98 for D25S 5 Only Replace the fuel filter at specified intervals to prevent contaminants from adversely affecting the diesel fuel flow 1 Stop the engine and allow it to cool 2 Close all fuel cocks in fuel line 3 Disconnect the fuel filter sensor connector Figure 5 14a 1 Figure 5 14a 4 Place an approved container under fuel filter 5 Carefully open the drain plug Figure 5 15a 1 to drai...

Page 59: ...stall the new fuel filter Figure 5 14 2 by turning it to the right Figure 5 14 4 until it contacts the mounting surface Tighten one additional turn 18 Open all fuel cocks in the fuel line 19 Reconnect the fuel filter sensor connector Figure 5 14 1 20 Prime the fuel system See Priming the Fuel System on page 15 21 Check for fuel leaks Applicable Fuel Filter Part No Figure 5 14 2 4TNE98 A409559 Clea...

Page 60: ...ater Separator on page 41 4 Turn the retaining ring Figure 5 15 5 to the left Figure 5 15 10 and remove the cup Figure 5 15 6 If equipped disconnect the sensor wire Figure 5 15 7 from the cup before removing the cup 5 Carefully hold the cup to prevent fuel from spilling If you spill any fuel clean up the spill completely 6 Remove the float ring Figure 5 15 8 from the cup Pour the contaminants into...

Page 61: ...on and rubber gloves when you handle long life or extended life engine coolant If contact with the eyes or skin should occur flush eyes and wash immediately with clean water Failure to comply may result in minor or moderate injury CAUTION ALWAYS be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engi...

Page 62: ...all and tighten the drain plug or close the drain cock in the radiator Reinstall and tighten the cylinder block drain plug or reconnect the coolant hose at the oil cooler 6 Fill radiator and engine with engine coolant See Filling Radiator with Engine Coolant on page 19 Adjust Intake Exhaust Valve Clearance Proper adjustment is necessary to maintain the correct timing for opening and closing the va...

Page 63: ...his procedure is considered normal maintenance and is performed at the owner s expense This procedure is not covered by the Yanmar Limited Warranty Inspect Crankcase Breather System Proper operation of the crankcase breather system is required to maintain the emission requirements of the engine The EPA ARB requires that the crankcase breather system is inspected every 1500 hours There are three di...

Page 64: ... Fuel Hoses and Engine Coolant Hoses CAUTION ALWAYS be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil diesel fuel and engine coolant Consult the local authorities or reclamation facility NEVER dispose of hazardous materials irresponsibly by dumping them into a sewer on the ground or into ...

Page 65: ...ts and clothing away from moving rotating parts Failure to comply could result in death or serious injury WARNING FUME BURN HAZARD Always read and follow safety related precautions found on containers of hazardous substances like parts cleaners primers sealants and sealant removers Failure to comply could result in death or serious injury CAUTION FLYING OBJECT HAZARD ALWAYS wear eye protection whe...

Page 66: ...dversely affect the properties of the engine coolant CAUTION Identify all parts and their location using an appropriate method It is important that all parts are returned to the same position during the reassembly process CAUTION Any part which is found defective as a result of inspection or any part whose measured value does not satisfy the standard or limit must be replaced CAUTION Any part dete...

Page 67: ...cting rod assemblies together to be returned to the same position during the reassembly process Label the parts using an appropriate method CAUTION Do not allow the honing tool to operate in one position for any length of time Damage to the cylinder wall will occur Keep the tool in constant up and down motion ...

Page 68: ...sion 4TNV98 4 Valve Head Intake Exhaust 0 0142 0 0220 in 0 36 0 56 mm 0 0138 0 0217 in 0 35 0 55 mm 0 0315 in 0 8 mm 0 0315 in 0 8 mm See Valve Recession on Page 95 and 98 Intake 120 Seat Angle Exhaust 90 Valve Seat 4 Valve Seat Correction Angle 40 150 See Valve Face and Valve Seat on Page 96 and 99 4TNE98 Engine Inspection Item Standard Limit Reference Page Combustion Surface Distortion Flatness ...

Page 69: ...nd 103 Valve Guide Installation Method Cold fitted Valve Stem Seal Projection From Cylinder Head 0 460 0 472 in 11 7 12 0 mm See Reassembly of Intake and Exhaust Valves on page 98 4TNE98 Engine Inspection Item Standard Limit Reference Page Guide Inside Diameter 0 3156 0 3161 in 8 015 8 030 mm 0 3189 in 8 10 mm Valve Stem Outside Diameter 0 3136 0 3142 in 7 965 7 980 mm 0 3110 in 7 90 mm Intake Val...

Page 70: ...nspection Item Model Standard Limit Reference Page 4TNV98 4 Valve Head 1 5630 in 39 7 mm 1 5433 in 39 2 mm Free Length 4TNE98 1 87 in 47 5 mm 4TNV98 4 Valve Head 0 0551 in 1 4 mm Squareness 4TNE98 0 05 in 1 2 mm See Inspection of Valve Springs on page 97 and 101 Camshaft and Timing Gear Train Specifications Camshaft Inspection Item Standard Limit Reference Page End Play 0 0020 0 0079 in 0 05 0 20 ...

Page 71: ...0 mm Camshaft Outside Diameter 1 9655 1 9665 in 49 925 49 950 mm 1 9642 in 49 890 mm Flywheel End Oil Clearance 0 0020 0 0039 in 0 050 0 100 mm 0 0083 in 0 210 mm See Inspection of Camshaft on page 125 Idler Gear Shaft and Bushing Inspection Item Standard Limit Reference Page Shaft Outside Diameter 1 8091 1 8100 in 45 950 45 975 mm 1 8071 in 45 900 mm Bushing Inside Diameter 1 8110 4 8120 in 46 00...

Page 72: ...Connecting Rod Journals Oil Clearance 0 0015 0 0029 in 0 038 0 074 mm 0 0059 in 0 150 mm See Inspection of Crankshaft on Page 124 Journal Outside Diameter 2 5572 2 5576 in 64 952 64 962 mm 2 5552 in 64 902 mm Bearing Inside Diameter 2 5590 2 5598 in 65 000 65 020 mm Bearing Insert Thickness 0 0785 0 0791 in 1 995 2 010 mm Main Bearing Journal Oil Clearance 0 0015 0 0027 in 0 038 0 068 mm 0 0059 in...

Page 73: ...spection Item Standard Limit Reference Page Ring Groove Width 0 0803 0 0811 in 2 040 2 060 mm Ring Width 0 0764 0 0772 in 1 940 1 960 mm 0 0756 in 1 920 mm Side Clearance 0 0031 0 0047 in 0 080 0 120 mm Top Ring End Gap 0 0098 0 0177 in 0 250 0 450 mm 0 0213 in 0 540 mm Ring Groove Width 0 0819 0 0825 in 2 080 2 095 mm 0 0864 in 2 195 mm Ring Width 0 0776 0 0783 in 1 970 1 990 mm 0 0768 in 1 950 m...

Page 74: ... page 124 Connecting Rod Big End Inspection Item Standard Limit Reference Page 4TNV98 0 0079 0 0157 in 0 20 0 40 mm Side Clearance Thrust Clearance 4TNE98 0 0051 0 0091 in See Inspection of Connecting Rod on page 124 See Special Torque Chart on page 69 for other specifications Tappet Inspection Item Standard Limit Reference Page Tappet Bore Block Inside Diameter 0 4724 0 4731 in 12 000 12 018 mm 0...

Page 75: ...m or less 0 0012 in 0 03 mm See Inspection of Cylinder Block on page 121 Special Torque Chart Torque for Bolts and Nuts Component Thread Diameter and Pitch Torque Lubricating Oil Application Thread Portion and Seat Surface Cylinder Head Bolt M11 x 1 25 mm 76 83 ft lb 103 1 112 9 N m 10 5 11 5 kgf m Applied Connecting Rod Bolt M10 x 1 0 mm 40 43 ft lb 53 9 58 8 N m 5 5 6 0 kgf m Applied Flywheel Bo...

Page 76: ... 9 127 5 N m 11 0 13 0 kgf m Applied Fuel Injector Bolt 4TNV98 M8 x 1 25 mm 17 21 ft lb 22 6 28 4 N m 2 3 2 9 kgf m Not Applied Fuel Pump Drive Gear Nut 4TNV98 M18 x 1 5 mm 83 90 ft lb 113 123 N m 11 5 12 5 kgf m Not Applied High Pressure Fuel Lines Bolt 4TNV98 M12 x 1 5 mm 174 217 in lb 19 6 24 5 N m 2 0 2 5 kgf m Not Applied Fuel Return Line Joint Bolt 4TNV98 M6 x 1 0 mm 70 86 in lb 7 8 9 8 N m ...

Page 77: ... 551 in 14 mm 0 787 in 20 mm 2 Valve Guide Tool For Installing Valve Guide Locally Manufactured L1 L2 d1 d2 0 787 in 20 mm 3 937 in 100 mm 1 181 in 30 mm 1 299 in 33 mm 4 Connecting Rod Bushing Replacer For Removal Installation of Connecting Rod Bushing Locally Manufactured 5 Valve Spring Compressor For Removal Installation of Valve Spring Yanmar Part No 129100 92630 Model d1 d2 d3 L1 L2 L3 4TNV98...

Page 78: ...Camshaft Bushing Tool For Extracting Camshaft Bushing Locally Manufactured Yanmar Part No Cylinder Bore 9 Flex Hone For Preparation of Cylinder Walls 129400 92440 3 504 3 976 in 89 101 mm 10 Piston Ring Compressor For Installing Piston Yanmar Part No 95550 002476 The Piston Insertion Tool is Applicable for 2 362 4 921 in 60 125 mm Diameter Pistons 11 Piston Ring Expander For Removal Installation o...

Page 79: ...y Available For holding the dial gauge when measuring 4 Micrometer Locally Available For measuring the outside diameters of crankshaft pistons piston pins etc 5 Cylinder Bore Gauge Locally Available For measuring the inside diameters of cylinder liners bearing bores etc 6 Calipers Locally Available For measuring outside diameters depth thickness and width 7 Depth Micrometer Locally Available For m...

Page 80: ...and valve adjustment clearance 12 Battery Coolant Tester For checking concentration of antifreeze and the battery electrolyte charge status 13 Digital Thermometer For measuring temperatures Contact Type For measuring revolution by contacting the revolving shaft Photoelectric Type For measuring revolution by sensing the reflecting mark on the outer periphery of the revolving shaft 14 Tachometer Fue...

Page 81: ...ion 15 Circuit Tester For measuring resistance voltage and continuity of electrical circuits Compression Gauge Kit For measuring compression pressureGauge Set Part No TOL 97190080 16 New Comperssion Test Adaptor Adapter for direct injection 2 valve cylinder headAdapter Part No 119802 92950 ...

Page 82: ...4TNV98 4TNE98 Diesel Engine Section 3 Engine 80 Cylinder Head Cylinder Head Components 4TNV98 Engine Figure 6 36 ...

Page 83: ... 14 Valve Adjusting Screw Lock Nut Primary 15 Rocker Arm Shaft Aligning Stud 16 Fuel Injector Retainer 17 Valve Stem Seal 18 Valve Guide 19 Cylinder Head 20 Intake Valve 21 Exhaust Valve 22 Cylinder Head Gasket 23 Fuel Injector Nozzle Protector 24 Fuel Injector Nozzle Seat 25 Valve Spring 26 Valve Bridge Guide 27 Spring Retainer 28 Valve Keepers 29 Valve Bridge 30 Valve Bridge Seat 31 Valve Adjust...

Page 84: ...ge7 31 Figure 6 37 CAUTION Remove or install the high pressure fuel injection lines as an assembly whenever possible Disassembling the high pressure fuel injection lines from the retainers or bending any of the fuel lines will make it difficult to reinstall the fuel lines 3 Disconnect the fuel return hose Figure 6 37 2 from the cylinder head 4 Disconnect the hoses Figure 6 37 3 from the cold start...

Page 85: ...se a flat blade screwdriver Figure 6 39 to remove the fuel injection line grommets Figure 6 40 1 from the valve cover Figure 6 40 3 and fuel injectors Figure 6 40 2 There is a notch at the 3 o clock position in the valve cover opening to insert the screwdriver Figure 6 39 3 Remove the valve cover nuts Figure 6 40 4 4 Remove the O ring Figure 6 40 5 on each valve cover nut Figure 6 40 5 Remove the ...

Page 86: ...6 Identify all parts so that they will be reinstalled in their original locations Figure 6 41 Disassembly of Rocker Arm Assembly NOTE Identify the rocker arms so they can be reinstalled with the original matching valve and pushrod 1 Remove the rocker arm shaft alignment studs Figure 6 42 5 from the rocker arm shaft supports Figure 6 42 6 2 Slide the supports wave washers Figure 6 42 7 rocker arms ...

Page 87: ...lts Figure 6 44 1 3 Lift the cylinder head away from the cylinder block Discard the cylinder head gasket Figure 6 44 2 Place the cylinder head on the work bench to prevent damage to the combustion surface Figure 6 44 Removal of Intake and Exhaust Valves 1 Place the cylinder head on the work bench with the combustion side down 2 Using the valve spring compressor tool compress one of the valve sprin...

Page 88: ...inal location 7 Remove the injector nozzle protectors Figure 6 46 6 and the seats Figure 6 46 7 8 Turn the cylinder head so the exhaust port side faces down Remove the intake and exhaust valves Figure 6 46 5 from the cylinder head 9 Remove the valve stem seals Figure 6 46 4 Removal of Valve Guides NOTE Removal of the valve guides should be postponed until inspection and measurement procedures have...

Page 89: ...4TNV98 4TNE98 Diesel Engine Section 3 Engine 87 4TNE98 Engine Figure 6 1 ...

Page 90: ...ap 10 Valve Keepers 11 Spring Retainer 12 Valve Spring 13 Valve Stem Seal 14 Valve Guide 15 Intake Valve 16 Exhaust Valve 17 Cylinder Head Gasket 18 Cylinder Head 19 Glow Plug 20 Glow Plug Cover 21 Push Rod 22 Support Bracket Bolt 23 Rocker Arm Shaft Spring 24 Support Bracket Stud 25 Support Bracket 26 Rocker Arm 27 Rocker Arm Shaft Retaining Ring 28 Valve Adjusting Screw Lock Nut 29 Valve Adjusti...

Page 91: ...ove the exhaust manifold bolts Figure 6 2 4 and nuts Figure 6 2 5 Remove the exhaust manifold Figure 6 2 6 Discard the exhaust manifold gasket Figure 6 2 7 3 Remove the water pump from the engine See Disassembly of Engine Coolant Pump on 205 4 Remove the fuel injectors from the cylinder head See Removal of the Fuel Injectors on page 196 Removal of Glow Plugs 1 Remove the glow plug cover Figure 6 3...

Page 92: ...r Arm Assembly 1 Remove the rocker arm shaft alignment screw Figure 6 7 1 from the support bracket that secures the rocker arm shaft Figure 6 7 2 2 Remove the retaining rings Figure 6 7 3 from the ends of the rocker arm shaft Figure 6 7 2 3 Slide the rocker arm shaft Figure 6 7 2 out of the rocker arm support brackets Figure 6 7 4 springs Figure 6 7 5 and rocker arms Figure 7 6 NOTE The rocker arm...

Page 93: ...er head bolts Figure 6 9 1 3 Lift the cylinder head away from the cylinder block Discard the cylinder head gasket Figure 6 9 2 Position the cylinder head on the work bench to prevent damage to the combustion surface Figure 6 9 Removal of Intake Exhaust Valves 1 Place the cylinder head on the work bench with the combustion side down 2 Using the valve spring compressor tool compress one of the valve...

Page 94: ...hem so they can be installed in their original location 7 Turn the cylinder head so the exhaust port side faces down Remove the intake and exhaust valves Figure 6 11 6 from the cylinder head Removal of Valve Guides 1 Using a drift pin and hammer drive the valve guides Figure 6 12 1 out of the cylinder head Figure 6 12 Cleaning of Cylinder Head Components WARNING FUME BURN HAZARD Always read and fo...

Page 95: ...vice as determined from the state of current rate of wear should be replaced even though the part currently meets the service standard limit Inspection of Push Rods Push Rod Bend 1 Place the push rods on a flat inspection block or layout bed 2 Roll the push rods until a gap can be observed between a portion of the push rod and the surface of the block or layout bed 3 Use a feeler gauge to measure ...

Page 96: ...he valve guides while they are installed in cylinder head Use a telescoping gauge and micrometer to measure the inside diameter at each end of the valve guide Measure in three places and 90 apart Figure 6 51 See Intake Exhaust Valve and Guide on page 67 for the service limit Replace the valve guides if not within specification Figure 6 51 Inspection of Cylinder Head Cylinder Head Distortion Place ...

Page 97: ...ce limit Figure 6 53 Valve Stem Bend Place the valve stem on a flat inspection block or layout bed Roll the valve until a gap can be observed between a portion of the valve stem and the surface of the block or bed Use a feeler gauge to measure the gap Figure 6 54 See Intake Exhaust Valve and Guide on page 67 for the service limit Figure 6 54 Valve Recession NOTE The valve guides must be installed ...

Page 98: ... valves and valve seats can be lapped or ground to return them to serviceable condition Severely worn or damaged components will require replacement Coat the valve seat with a thin coat of bluing compound Install the valve and rotate to distribute bluing onto the valve face The contact pattern should be approximately centered on the valve face Figure 6 57 1 and even in width Figure 6 57 Also visua...

Page 99: ...res Check for fractures on the inside and outside portions of the springs If the valve spring is fractured replace the valve spring Corrosion Check for corrosion of spring material caused by oxidation Squareness Use a flat surface and a square to check each spring for squareness Figure 6 59 See Valve Spring on page 68 for the service limit Figure 6 59 Free Length Use a caliper to measure the lengt...

Page 100: ... after removing the valve guides from the freezer insert the valve guides Figure 6 62 1 in their proper positions 4TNV98 Engine 4TNE98 Engine Figure 6 62 3 Finish installing the valve guides Figure 6 63 1 into the cylinder head to the proper height Figure 6 63 3 using the valve guide installation tool Figure 6 63 2 See Intake Exhaust Valve and Guide on page 67 Figure 6 63 Reassembly of Intake and ...

Page 101: ... its exhaust port side 4 Place all the valves Figure 6 66 5 in their proper location in the cylinder head 4TNV98 Engine 4TNE98 Engine Figure 6 66 5 Place the cylinder head on the workbench with the combustion side down Install the valve spring Figure 6 66 3 and spring retainer Figure 6 66 2 6 Using the valve spring compressor tool compress the valve spring 7 Insert the valve keepers Figure 6 66 1 ...

Page 102: ...67 2 on the cylinder block 2 Position the cylinder head on the on the cylinder head gasket 4TNV98 Engine 4TNE98 Engine Figure 6 67 3 Lightly oil the threads of the cylinder head bolts Figure 6 67 1 Tighten the bolts to the specified torque in two steps as shown in the chart below Tighten in the sequence shown in Figure 6 68 See Special Torque Chart on page 73 for specification First Step 1 2 of fi...

Page 103: ...ir original locations Figure 6 69 IMPORTANT The wave washers Figure 6 70 2 must be installed with the bow facing the rocker arms Figure 6 70 1 Figure 6 70 IMPORTANT Ensure the lubrication holes Figure 6 71 1 in the rocker arm shaft are oriented correctly with respect to the rocker arms Figure 6 71 2 Figure 6 71 3 Lubricate the rocker arm shaft Slide the rocker arm supports Figure 6 72 6 wave washe...

Page 104: ...ft Slide the rocker arm support brackets Figure 6 30 4 springs Figure 6 30 5 and rocker arms Figure 6 30 6 onto the shaft NOTE The rocker arm shaft fits tightly in the rocker arm support brackets Clamp the support bracket in a padded vise and twist the rocker arm shaft to remove Reverse this process when you reinstall the rocker arm shaft into the support brackets NOTE To properly align the rocker...

Page 105: ...ten the bolts to specification 7 Reconnect the fuel injector return hose and fuel injection pump coolant hoses 8 Reinstall the high pressure fuel line grommets into the valve cover 9 Reinstall the high pressure and fuel return lines See Installation of the Fuel Injectors on page 167 10 Reinstall the coolant pump See Reassembly of Engine Coolant Pump on page 208 11 Reinstall the alternator 12 Recon...

Page 106: ...ible in the timing port of the flywheel housing If there is no valve clearance and the cylinder is at TDC of the compression stroke extreme wear or damage to the cylinder head or valves may be possible If adjusting each cylinder individually the cylinder to be adjusted first does not have to be the No 1 cylinder Select and adjust the cylinder where the piston is nearest to the top dead center afte...

Page 107: ...r on page 103 NOTE If adjusting each cylinder individually the cylinder to be adjusted first does not have to be the No 1 cylinder Select and adjust the cylinder where the piston is nearest to the top dead center after turning and make adjustment for other cylinders in the order of firing by turning the crankshaft ...

Page 108: ...ing grid on the flywheel Position where both the intake and exhaust valves are closed 3 Make sure there is clearance Figure 6 77 5 between the valve bridge Figure 6 77 1 and the rocker arm Figure 6 77 3 IMPORTANT Do not loosen or tighten the valve adjusting screw lock nut without holding the valve bridge Always hold the valve bridge using a wrench to prevent bending of the valve stems 4 Loosen the...

Page 109: ...cations on page6 6 between the rocker arm Figure 6 82 2 and valve bridge Figure 6 82 3 Record the results and use this value as an indication of wear Figure 6 82 9 If adjustment is required proceed to the next step 10 Loosen the valve adjusting screw lock nut Figure 6 83 5 and valve adjusting screw Figure 6 83 4 on the rocker arm Figure 6 83 3 and check the clearance gap Figure 6 83 2 for evidence...

Page 110: ...gure 6 83 4 while tightening the valve adjusting screw lock nut Figure 6 83 5 Recheck the clearance 13 Apply oil to the contact surface between the adjusting screw and push rod 14 Rotate the crankshaft to measure and adjust the set of valves Continue until all valves are measured and adjusted ...

Page 111: ...4TNV98 4TNE98 Diesel Engine Section 3 Engine 109 Crankshaft and Camshaft Components Figure 6 84 ...

Page 112: ...ler Gear 18 Oil Pickup O Ring 19 Oil Pickup 20 Crankshaft 21 Parallel Pin 22 Crankshaft Gear Key 23 Crankshaft Gear 24 Crankshaft Pulley 25 Main Bearing Inserts 26 Main Bearing Cap 27 Oil Pan 28 Thrust Bearings 29 Flywheel 30 Connecting Rod Cap 31 Connecting Rod Bearing Inserts 32 Connecting Rod 33 Wrist Pin Bushing 34 Circlip 35 Wrist Pin 36 Piston 37 Oil Ring 38 Second Compression Ring 39 Top Co...

Page 113: ...gine falling during work on the engine 6 Clean the engine by washing with solvent air or steam cleaning Carefully operate so as to prevent any foreign matter or fluids from entering the engine or any fuel system or electrical components remaining on the engine 7 Drain the engine oil into a suitable container Remove the oil filter 8 Remove the cylinder head See 4 Valve Cylinder Head on page 80 9 Re...

Page 114: ...not allow the gear being checked to move axially as excess end play could cause a false reading Figure 6 86 1 Fuel Injection Pump Drive Gear 2 Camshaft Drive Gear 3 Auxiliary Drive Gear Optional 4 Crankshaft Drive Gear 5 Direction of Rotation 6 Oil Pump Drive Gear 4TNV94L 4TNV106 7 Idler Gear Measuring Idler Gear to Crankshaft Gear Backlash 1 Install a dial indicator as shown in Figure 6 87 Figure...

Page 115: ...sing a gear puller 3 Removal of the camshaft gear requires the camshaft be removed and placed in a press Do not remove the camshaft gear unless it or the camshaft is damaged and requires replacement See Removal of Camshaft on page 114 CAUTION Do not loosen or remove the four bolts retaining the fuel injection pump drive gear to the fuel injection pump hub Do not disassemble the fuel injection pump...

Page 116: ...y Method A Install a dial indicator Figure 6 92 1 on the cylinder block Move the camshaft Figure 6 92 2 back and forth to measure the end play Record the measurement See Camshaft on page 68 for the service limit Figure 6 92 Method B Use a feeler gauge to measure the clearance between the thrust plate Figure 6 93 1 and front camshaft bearing Figure 6 93 2 See Thrust Bearing on page 70 for the servi...

Page 117: ...ocation 6 Remove the camshaft drive gear Figure 6 94 4 only if the gear or camshaft require replacement Use a knife edge puller and a press to remove the gear The gear is a shrink fit and will need to be heated to 356 392 F 180 200 C to remove Removal of Gear Case or Front Plate NOTE The camshaft must be removed before the gear case front plate can be removed See Inspection of Camshaft on page 125...

Page 118: ...mpossible to remove the pistons Use a suitable ridge reamer to remove ridges and carbon prior to removing the pistons NOTE Pistons can fall from cylinder block if the engine is inverted Rotate the engine so the connecting rods are horizontal before removing the connecting rod caps 1 Using a feeler gauge measure the connecting rod side clearance as shown Figure 6 97 See Connecting Rod on page 72 fo...

Page 119: ...f Compare the width of the flattened PLASTIGAGE to the graduation marks on the package Figure 6 99 1 The mark that most closely matches the width of the flattened PLASTIGAGE will indicate the bearing oil clearance Figure 6 99 g Repeat with remaining connecting rods IMPORTANT Do not allow the connecting rod to contact the crankshaft journal during piston removal Damage to the bearing journal may re...

Page 120: ...led Removal of Crankshaft 1 Remove the flywheel Figure 6 101 1 from the crankshaft 2 Remove the bolts from the rear oil seal assembly Figure 6 101 2 3 Remove the assembly from the engine Figure 6 101 3 Before removing the main bearing caps measure the crankshaft end play Use either of the following two methods Method A Install a dial gauge Figure 6 102 1 on the cylinder block Move the crankshaft F...

Page 121: ... the markings on the main bearing caps or mark them yourself so they can be reinstalled in the same order as they were removed Do not remove the bearing inserts at this time NOTE The arrows on the main bearing caps point to the flywheel end of the engine Figure 6 104 5 Measure bearing oil clearance prior to removing the crankshaft to determine extent of wear Record the measurements a Wipe oil from...

Page 122: ... the crankshaft gear unless the gear or crankshaft are damaged and require replacement 8 If necessary remove the crankshaft gear Figure 6 107 1 parallel pin Figure 6 107 2 and key Figure 6 107 3 If using a gear puller be careful not to damage the threads in the end of the crankshaft Figure 6 107 Inspection of Crankshaft and Camshaft Components WARNING FUME BURN HAZARD Always read and follow safety...

Page 123: ...nce Oil clearance should be checked during disassembly to determine the extent of wear and during assembly to ensure long engine life The same procedure is done for both connecting rods and main bearings Inspection of Cylinder Block 1 Ensure that oil passages are clear and unobstructed 2 Check for discoloration or evidence of cracks If a fracture is suspected use the color check method or the Magn...

Page 124: ...g grooves 4 Measure the diameter of the piston skirt at 90 to the wrist pin bore as shown Figure 6 111 Measurements must be taken at a specified distance Figure 6 111 1 from the bottom of the piston based on engine model Record the measurements See Piston on page 71 for specifications Figure 6 111 5 Subtract the piston measurement from the greatest measurement acquired during cylinder inspection s...

Page 125: ...ifications Replace the piston if not within specification Figure 6 114 10 To measure piston ring end gap insert each compression piston ring Figure 6 115 1 one at a time into the cylinder Use a piston with the piston rings removed to slide the ring into the cylinder bore until it is approximately 1 18 in 30 mm Figure 6 115 2 from the bottom of the bore Remove the piston Measure the end gap Figure ...

Page 126: ...diameter See Crankshaft on page 70 for specifications Inspection of Tappets 1 Inspect the tappet contact surfaces for abnormal wear Figure 6 117 1 Normal wear will be even as shown in Figure 6 117 2 Slight surface defects can be corrected using an oilstone Figure 6 117 2 Measure the outside diameter of the tappet stem Figure 6 118 1 See Tappet on page 72 for the service limit Figure 6 118 3 Measur...

Page 127: ...cation grind the journals and install undersize bearings or replace the crankshaft Figure 6 120 Inspection of Camshaft 1 Use V blocks and a dial indicator to check camshaft bend Figure 6 121 Place the indicator on the center bearing journal Figure 6 121 2 Rotate the camshaft and observe the runout See Camshaft on page 68 for specifications 3 Measure the height of each lobe Figure 6 122 1 See Camsh...

Page 128: ...e condition Slight imperfections can be corrected by honing alone 1 Boring Significant cylinder damage may be corrected by boring the cylinder to an oversize dimension Refer to the appropriate parts catalog for available oversize pistons and piston rings Boring a cylinder should always be done in a properly equipped machine shop A bored cylinder should always be finished with a hone to properly pr...

Page 129: ... with hot water and dry with compressed air Apply clean engine oil to all steel surfaces to prevent rusting Reassembly of Crankshaft and Piston Components NOTES Proceed slowly Make no forced assemblies unless a pressing operation is called for All parts must be perfectly clean and lightly lubricated when assembled Use new gaskets seals and O rings during assembly Liberally apply clean engine oil t...

Page 130: ...ston and connecting rod are different depending on engine model Piston to Connecting Rod Orientation By Model Orient the piston identification mark stamped on top of the piston on the same side as the rod and cap match marks stamped on the connecting rod NOTE The actual appearance of the match marks on the piston and connecting rod may vary but they will always be in the same locations Figure 6 12...

Page 131: ... on Connecting Rod 4 Rod and Cap Match Marks 5 Flywheel End of Engine 6 Camshaft Side of Engine 1 Lubricate and reinstall the wrist pin Figure 6 131 3 through the piston and connecting rod 2 Reinstall the second circlip Figure 6 131 4 and ensure it is securely seated in the groove Figure 6 131 NOTE If installing new piston rings the end gap must be checked and adjusted as necessary See Inspection ...

Page 132: ...ression ring Figure 6 133 1 This ring is identified by its silver color and barrel shaped face profile IMPORTANT The oil ring expander Figure 6 133 4 end gap must be located 180 from the oil ring Figure 6 133 3 end gap Figure 6 133 6 Stagger the piston ring end gaps at 120 intervals Figure 6 134 1 2 3 Do not position the top piston ring end gap in line with the wrist pin Figure 6 134 1 Top Compres...

Page 133: ...igure6 70 3 through the piston and wrist pin bushing 6 Install the second circlip Figure6 70 4 7 Install the piston rings Use piston ring pliers to install the piston rings Install each piston ring on the piston with the punched manufacturer s mark Figure6 72 1 facing upward Figure 6 72 Install the top compression ring second compression ring and oil ring Figure 6 73 Stagger the piston ring joints...

Page 134: ...gure 6 135 1 and thrust bearing Figure 6 135 2 in the cylinder block and main bearing caps Apply a liberal coat of clean engine oil to the bearings and crankshaft journals 3 Place the crankshaft into the engine IMPORTANT The main bearing caps are numbered and have arrows for proper positioning The No 1 cap is at the flywheel end The arrows point toward the flywheel end of the engine 4 Reinstall th...

Page 135: ...page 73 for specifications Figure 6 136 Installation of Pistons IMPORTANT Do not allow the connecting rod to contact the crankshaft journal during piston installation Damage to the crankshaft bearing journal may result 4TNV98 Engine 1 Lubricate the piston piston rings and cylinder with clean engine oil or assembly lubricant 2 Rotate the crankshaft so the crankpin for the piston being installed is ...

Page 136: ...he engine and the embossed mark on the connecting rod Figure 6 138 3 must face the flywheel end Figure 6 138 5 of the engine Figure 6 138 1 Fuel Injection Pump Side of Engine 2 Piston Identification Mark 3 Embossed Mark on Connecting Rod 4 Rod and Cap Match Marks 5 Flywheel End of Engine 6 Camshaft Side of Engine 4 Reinstall the bearing inserts Figure 6 140 1 in the connecting rod and cap 5 Apply ...

Page 137: ...install the piston into No 1 cylinder Be sure the punched mark on the connecting rod is facing the fuel injector side and the embossed mark on the connecting rod is facing the flywheel Figure 6 78 4 Install the connecting rod bearing halves Figure6 79 1 and connecting rod cap Figure6 79 2 Tighten the connecting rod bolts to the specified torque Figure 6 79 5 Install the remaining pistons in their ...

Page 138: ...der block so that gravity will keep the tappets Figure 6 143 5 in place and out of the way of the camshaft lobes when the camshaft is being reinstalled NOTE If the engine is not installed on an engine repair fixture stand the engine upright on the flywheel end mounting flange NOTE The tappets are mushroom shaped and must be installed from inside the engine crankcase 3 Lubricate the tappets with cl...

Page 139: ...ward the top of the engine 6 Ensure all three timing marks Figure 6 144 A B C are aligned 7 When all gears are properly aligned tighten the idler gear retaining bolts to specified torque See Special Torque Chart on page 73 for specifications Installation of Gear Case Cover 1 Apply a continuous bead of Three Bond Liquid Gasket No 1212 Yanmar Part No 977770 01212 to the mounting area of the gear cas...

Page 140: ...lt hole 3 Reinstall the oil pan and tighten the bolts securely Figure 6 149 Final Reassembly of Engine 1 Reinstall the starter motor 2 Reinstall the cylinder head See Reassembly of Cylinder Head on page 88 for the 4 valve cylinder head 3 Reinstall the engine in the machine 4 Reconnect the fuel and coolant lines 5 Reinstall the alternator 6 Reconnect and adjust the throttle cable 7 Reconnect all el...

Page 141: ... could result in death or serious injury WARNING Never inject fuel toward you Since the fuel is injected at high pressure from the nozzle it may penetrate the skin resulting in injury Never inject fuel toward a fire source Atomized fuel is highly flammable and may cause a fire or burn skin WARNING FUME BURN HAZARD Always read and follow safety related precautions found on containers of hazardous s...

Page 142: ...before engaging the transmission or any PTOs Engaging the transmission or PTO at an elevated engine speed could result in an unexpected movement of the equipment CAUTION Remove or install the high pressure fuel injection lines as an assembly whenever possible Disassembling the high pressure fuel injection lines from the retainers or bending any of the fuel lines will make it difficult to reinstall...

Page 143: ...ith or removing these devices may void the Yanmar Limited Warranty Figure 7 1 The following describes the features of the MP fuel injection pump manufactured by Yanmar The fuel injection pump is a very important component of the engine It is capable of making very precise fuel delivery adjustments according to the varied loads applied to the engine All of the fuel injection pump components are ver...

Page 144: ...engine not continuing to run with the key switch returned to the ON or RUN position or the engine failing to stop when the key switch is turned to the OFF position Use a multimeter or continuity light to check for 12V at the stop solenoid connector in the correct sequence Cold Start Device The Yanmar TNV model engines are equipped with a cold start device CSD The cold start device is located in th...

Page 145: ...ar Nut 4TNV98 83 91 ft lb 113 123 N m 11 5 12 5 kgf m Not Applied High Pressure Fuel Injection Line Nuts 22 25 ft lb 29 34 N m 3 0 3 5 kgf m Not Applied Fuel Return Line Bolts 69 87 in lb 7 8 9 8 N m 0 8 1 0 kgf m Not Applied Fuel Injection Pump Mounting Nuts 17 21 ft lb 23 28 N m 2 3 2 9 kgf m Not Applied Fuel Injector Nozzle Case Nut 30 33 ft lb 39 2 44 1 N m 4 4 5 kgf m Not Applied Fuel Injecti...

Page 146: ... 5 MPa 5 0 kgf cm after about 5 hours of operation due to the initial break in of the engine When adjusting a new fuel injector or after it has been disassembled for service adjust the fuel injector 72 5 psi 0 5 MPa 5 0 kgf cm higher than the above standard NOTE All fuel injectors have a three character identification mark Figure7 2 1 The first character starts with V or W Figure7 2 Fuel injector ...

Page 147: ...spray pattern of fuel injection nozzle and measuring injection pressure Dial Indicator Mituotoyo 2050SB Locally Available Check and adjust fuel injection timing 2 Extension Rod Mituotoyo 303613 Locally Available 3 Fuel Injection Pump Plunger Adapter M16 4TNV98 Yanmar Part No 158090 51841 Mount dial indicator to fuel injection pump 4 Plunger Adapter Clamp Yanmar Part No 23000 013000 Clamps stem of ...

Page 148: ...lter 5 Air Bleed Orifice 6 Fuel Supply Line 7 Low Pressure Gallery 8 Pressure Control Valve 9 Trochoid Pump 10 Oil Seal 11 Fuel Injection Pump Cam 12 Engine Crankcase 13 Tappet 14 High Pressure Gallery 15 Overflow Orifice 16 Accumulator 17 Timer Piston 18 Mono Plunger 19 Distributor Shaft 20 Fuel Return Line 21 High Pressure Fuel Injection Lines 22 Fuel Injector ...

Page 149: ...Injection Pump Drive Gear Nut 9 Lock Washer 10 Fuel Injection Pump Drive Gear Assembly DO NOT remove or loosen the four bolts that fasten the injection pump drive gear to the injection pump drive gear hub 11 Coolant Lines for Cold Start Device 12 Fuel Injection Pump Insulator 13 Diesel Fuel Injection Pump 14 Rear Fuel Injection Pump Support 15 Fuel Filter Water Separator 16 Electric Fuel Supply Pu...

Page 150: ...el injection pump CAUTION Remove or install the high pressure fuel injection lines as an assembly whenever possible Disassembling the high pressure fuel injection lines from the retainers or bending any of the fuel lines will make it difficult to reinstall the fuel lines 7 Finish loosening all the fuel line nuts and remove the high pressure fuel lines as an assembly being careful not to bend any o...

Page 151: ...ure 7 9 2 from the pump IMPORTANT Take care to not damage or bend the oil line In some applications it may be preferable to remove the complete oil line assembly from the engine before proceeding NOTE On models 4TNV98 the cover is larger and retained by 7 bolts Figure 7 9 15 Remove the fuel injection pump drive gear cover Figure7 10 1 from the gear case cover Figure7 10 2 NOTE The fuel injection p...

Page 152: ...ion pump to become misaligned On 4TNV98 model engines the idler gear is visible Make a reference mark Figure 7 12 1 across both the fuel injection pump drive gear and the idler gear Figure7 12 CAUTION Do not loosen or remove the four bolts retaining the fuel injection pump drive gear to the fuel injection pump hub Do not disassemble the fuel injection pump drive gear from the hub Correct fuel inje...

Page 153: ...carefully remove the drive gear nut Figure 7 15 1 and lock washer Figure 7 15 2 Figure 7 15 22 Locate the mark stamped into the upper outside mounting boss of the fuel injection pump Highlight this mark and make a corresponding mark on the gear case or front plate Figure 7 16 1 Figure 7 16 NOTE Some model engines may require the intake manifold and fuel injection pump insulator Figure 7 17 2 be re...

Page 154: ... the fuel injection pump and governor assembly These adjustments have been made at the factory to meet all applicable emissions regulations and then sealed NEVER attempt to make any adjustments to these sealed adjustment screws If adjustments are required they can be made only by a qualified fuel injection shop that will ensure the injection pump continues to meet all applicable emissions regulati...

Page 155: ... reference marks made earlier 4TNV98 model engines Figure 7 21 1 Figure 7 21 2 If installing the fuel injection pump on an engine with the front gear case cover removed the fuel injection pump drive gear can be aligned with the idler gear by aligning the stamped marks A B C on the fuel injection pump drive gear idler gear and crankshaft drive gear Ensure all three timing marks Figure 7 22 A B C ar...

Page 156: ...and tighten the drive gear nut to the specified torque See Special Torque Chart on page 143 Figure 7 23 If reinstalling the original fuel injection pump Align the reference marks Figure 7 24 1 previously made on both the fuel injection pump mounting flange and gear case or front plate Figure 7 24 Tighten the fuel injection pump retaining nuts to specification See Special Torque Chart on page 143 I...

Page 157: ...re 7 27 1 by the calculated positive amount adjust the fuel injection pump to the calculated value If the difference between the timing index numbers is a negative number the replacement injection pump must be retarded Figure 7 27 3 rotated toward the engine by the calculated negative amount Each mark on the timing sticker represents 0 5 timing change The above calculated difference indicates that...

Page 158: ... the pump cover and tighten the cover bolts 10 Reconnect the fuel return lines fuel supply line and coolant lines to the fuel injection pump 11 Reinstall the fuel injection high pressure lines Tighten the nuts to specification See Special Torque Chart on page 143 IMPORTANT When reinstalling a new or repaired fuel injection pump it is important to add engine oil to the fuel injection pump to provid...

Page 159: ...all the cooling fan guard if equipped 16 Prime the fuel system See Priming the Fuel System on page 15 17 Operate the engine and check for fuel and coolant leaks Checking and Adjusting Fuel Injection Timing Determining the Fuel Injection Timing Specification 1 Locate and record the fuel injection pump timing index number Figure 7 34 1 stamped into the boss on the engine side of the fuel injection p...

Page 160: ...4 17 6 Fuel injection Timing Record the calculated fuel injection timing specification Checking Fuel Injection Timing NOTE Some fuel may drain from the fuel injection pump during this process Make provisions to contain any such spillage 1 Turn off the fuel valve in the fuel supply hose and the fuel return hose 2 Clamp shut the fuel injection pump fuel return hose leading to fuel filter Figure 7 36...

Page 161: ...tate the crankshaft in a clockwise direction while looking through the flywheel inspection port Figure7 39 1 Rotate the crankshaft until the injection timing marks on the flywheel are visible Figure 7 39 7 Typical flywheel markings are as shown in Figure 7 40 1 NOTE A typical flywheel will have multiple timing grids depending on the number of cylinders Any grid can be used to check the fuel inject...

Page 162: ...longer marks is approximately 2 0 cm and the distance from the TDC mark is approximately 4 0cm the answer is approximately 2 This indicates there is 10 2x5 between the TDC mark and the first longer mark on the timing grid That means the first longer mark on the timing grid indicates 10 BTDC the second longer mark indicates 15 BTDC and the third timing mark indicates 20 BTDC If the answer is 3 that...

Page 163: ... Adjusting Fuel Injection Timing on page 161 13 If the injection timing is correct remove the dial indicator and adapter Replace the pump plunger plug and its copper gasket and tighten to specifications Replace the flywheel inspection port cover Open the fuel supply valve and remove the clamp from the fuel supply hose and the fuel return hose 14 Prime the fuel system Operate the engine and check f...

Page 164: ...fuel injection pump until the dial indicator reads 2 5 mm 0 098 in 6 To advance the injection timing rotate the top of the fuel injection pump away from the engine 7 To retard the injection timing rotate the top of the fuel injection pump toward the engine 8 When the dial indicator reads 2 5 mm 0 098in of pump plunger lift and the target timing mark on the flywheel aligns with the reference mark o...

Page 165: ... 4 Remove the fuel injector mounting clamp bolts Figure7 48 2 Lift the injector mounting clamps Figure7 48 3 away from injector 5 Remove the fuel injector Figure7 48 4 from the cylinder head Figure 7 48 NOTE The fuel injectors can be removed by manually pulling them out of the fuel injector wells 6 Remove the injector nozzle protector Figure 7 48 5 and seat Figure 7 48 6 from the cylinder head Dis...

Page 166: ...s highly flammable and may cause a fire or burn skin CAUTION FLYING OBJECT HAZARD ALWAYS wear eye protection when servicing the engine and when using compressed air or high pressure water Dust flying debris compressed air pressurized water or steam may injure your eyes Failure to comply may result in minor or moderate injury Figure 7 49 4 Pump the operating lever of the tester slowly observing the...

Page 167: ...ee Adjusting Fuel Injector Pressure on page 166 Disassembly and Inspection of Fuel Injectors CAUTION Never use a steel wire brush to clean fuel injectors Damage to the nozzle and other components is likely to result 1 Clean carbon from used injectors using clean diesel fuel Hardened deposits or varnish can be cleaned using a brass wire brush Figure 7 52 1 Fuel Return Passage 2 Injector ID Location...

Page 168: ...ical pull the nozzle valve about 2 3 of the way out Figure 7 54 c Release the valve It should fall smoothly to its seat by it s own weight Figure 7 54 8 Replace the fuel injector assembly if it fails any inspection Adjusting Fuel Injector Pressure The fuel injectors open when pressure reaches a predetermined pressure threshold They close when the pressure is reduced below that threshold The pressu...

Page 169: ... vise with the nozzle end up 2 Reinstall the shims nozzle spring nozzle spring seat valve stop spacer nozzle valve and nozzle body 3 Reinstall the nozzle case nut Tighten it to specification See Special Torque Chart on page 143 Installation of the Fuel Injectors 4 Valve Cylinder Head 1 Reinsert a new nozzle seat Figure 7 57 6 and nozzle protector Figure 7 57 5 in the cylinder head for each injecto...

Page 170: ...e Fuel Injector 29 4 ft lbs 39 2 N m 4 kgf m Not Applied See Installation of Fuel Injectorson page 200 Fuel Pump Drive Gear Nut 43 5 51 0 ft lbs 59 69 N m 6 0 7 0 kgf m Not Applied See Installation of the Fuel Injection Pumpon page 192 Measuring Instruments No Tool Name Application Illustration 1 Fuel Injector Tester For measuring injection spray pattern of fuel injection nozzle and injection pres...

Page 171: ...4TNV98 4TNE98 Diesel Engine Section 4 Fuel System 169 Fuel System Components Figure 7 1 ...

Page 172: ...by the feed pump in order to feed fuel into the injection pump chamber Although the fuel pressure in the pump chamber is proportional to the pump revolution excessive fuel is returned to the suction system by the regulating valve when the pressure exceeds the specified value The fuel is then sent to the plunger via the fuel path in the distributor head The plunger applies high pressure to the fuel...

Page 173: ...4TNV98 4TNE98 Diesel Engine Section 4 Fuel System 171 Structure And Operation Of Fuel Injection Pump Figure 7 3 ...

Page 174: ...holder Governor Figure 7 5 The governor is located above the inspection pump chamber and mainly consists of a flyweight holder and governor lever assembly The flyweight holder holds four flyweights and governor sleeves and is supported by the governor shaft The drive gear engages with the flyweight holder gear to increase the revolutions of the drive shaft and to turn the flyweight holder assembly...

Page 175: ...he advance direction counter revolution direction to early the injection timing Thus the timer controls the fuel injection timing according to the fuel pressure in the pump chamber Feed Pump Vane Type Figure 7 7 The feed pump functions to feed fuel from the fuel tank to the pump chamber The feed pump consists of the rotor blade vane and liner The rotor is driven by the drive shaft The liner is loc...

Page 176: ... the fuel feeding pressure of the feed pump the fuel compresses the regulating valve spring to lift the piston The fuel is then returned to the suction side as shown by the arrow in the figure It is therefore possible to regulate the pump chamber pressure by changing the set force of the regulating valve spring Figure 7 9 Figure 7 9 shows typical relationships between pump revolutions and pump cha...

Page 177: ...activate the plunger s reciprocating operation When the inlet port of the plunger barrel being pressed into the distributor head and the inlet slit of the plunger overlap the plunger draws fuel and applies pressure to it When the outlet port of the plunger barrel and the outlet slit of the plunger align the high pressure fuel opens the delivery valve to be injected into the engine combustion chamb...

Page 178: ...njection Process Figure 7 12 Figure 7 13 The plunger begins rotating at the same time the lifting process of the cam disc begins When the inlet port of the plunger barrel is covered by the plunger pressure feeding of fuel is initiated At the same time the highly pressurized fuel presses up the delivery valve when the outlet slit of the plunger meets the outlet port of the plunger barrel The fuel i...

Page 179: ...ring so the delivery valve closes to terminate pressure feeding of fuel Uniform Pressure Process Figure 7 16 Figure 7 17 When the plunger turns a further 180 after the end of fuel injection the uniform pressure slit of the plunger meets the outlet port of the plunger barrel As a result the pump chamber is connected to the outlet port thereby making the pressure in the chamber and outlet port equal...

Page 180: ...essurized resulting in non injection state Fuel Injection Volume Adjustment Mechanism Figure 7 19 The fuel injection volume is increased or decreased by changing the control sleeve position resulting in change of the effective stroke The effective stroke represents the plunger s stroke from the time the inlet port and inlet slit close until the cutoff port overruns the control sleeve which is prop...

Page 181: ...uel in the pipe by the amount equal to the suck back stroke of the piston Delivery Valve Holder with Damping Valve Figure 7 21 The delivery valve holder with damping valve functions to prevent cavitation erosion in the pipe at high speed unstable fuel injection and secondary injection When high pressure fuel is fed from the plunger it is mainly sent to the nozzle through the outer periphery of the...

Page 182: ...es the governor sleeve and presses the governor lever assembly to the right The governor lever assembly mainly consists of the corrector leer tension lever and start lever Corrector lever fulcrum M is fixed by the pivot bolt of the pump housing Furthermore the corrector lever cannot move since it is pressed both by the spring at the bottom and the full load adjusting screw at the top The tension a...

Page 183: ...ing which is connected to the control lever Movement of the control lever is capable of changing the set force of the governor spring On the upper back of the tension lever is the idle spring The governor is controlled at all speeds by means of the start governor and idle springs Figure 7 24 Figure7 24 shows the typical injection volume control characteristics of the all speed governor ...

Page 184: ...nsion lever is pulled until it comes into contact with press in pin M3 by governor spring force At the same time the start lever is released from the tension lever by the start spring force to press the governor sleeve to the left THe flyweight then closes completely and the start lever moves the control sleeve to the start increasing position to the right with M2 being the fulcrum Thus the engine...

Page 185: ...of the governor spring becomes zero Therefore the flyweight opens outwardly even at low revolutions to move the governor sleeve to the right This makes the start lever turn clockwise with M2 being the fulcrum to move the control sleeve in the direction to reduce the fuel volume The governor sleeve stops at a point where the flyweight centrifugal and idle spring force are balanced to ensure stable ...

Page 186: ...lt the tension of the governor spring becomes maximum At this time the tension lever is fixed at the position where is contacts pin M3 being pressed into the pump housing The idle spring is completely compressed to connect the start lever and the tension lever at point A thereby holding the control sleeve at the full load position At this time the flyweight is pressed by the governor sleeve and is...

Page 187: ...s to make the governor lever assembly turn clockwise with fulcrum M2 As a result the control sleeve moves in the direction of no injection to the left for controlling speed so as not to exceed the full load maximum speed When the accelerator pedal is not pressed down fully the set force of the governor spring changes accordingly in order to achieve governor control based on the governor spring set...

Page 188: ...load position is determined by the amount the full load adjusting screw is driven When the screw is driven the corrector lever turns counterclockwise with M1 being the fulcrum to move the control sleeve to the fuel increase direction When the screw is loosened the control sleeve moves to the fuel decrease direction ...

Page 189: ... installed in the low pressure side The timer piston slides horizontally based on the balance between the spring force and changes in the pump chamber pressure The movement of the timer piston turns the roller holder assembly via the pin When pump revolutions increase and the pump chamber pressure exceeds the set force of the timer spring the timer piston moves in the direction to compress the spr...

Page 190: ... fuel path connected to the inlet port of the plunger barrel When the ignition switch is turned on power is supplied to the magnetic valve to lift the armature thus opening the fuel path On the contrary when the ignition switch is turned off the armature is powered by the force of the spring installed in the armature to close the fuel path As a result no fuel is fed to the plunger stopping the eng...

Page 191: ...g and damaging the fuel return line fitting Then loosen the high pressure fuel line nuts Figure7 32 3 on the fuel injection pump Finish loosening all the high pressure fuel line nuts and remove the fuel lines as an assembly Be careful not to bend any of the fuel lines CAUTION Remove the high pressure fuel injection lines as an assembly whenever possible Disassembling the high pressure fuel injecti...

Page 192: ...while loosening the V belt Failure to comply may result in minor or moderate injury 9 Remove the cooling fan Figure7 35 1 spacer if equipped Figure7 35 2 and V belt Figure7 35 3 Figure 7 35 10 Remove the seven bolts from the fuel injection pump cover Figure7 36 1 on the front gear case Remove the cover NOTE The cover is secured with an adhesive sealant Use a gasket scraper to separate the cover fr...

Page 193: ...drive gear retaining nut Figure7 39 1 and lock washer Figure7 39 2 Figure 7 39 13 Using a two bolt gear puller remove the injection pump drive gear Figure7 39 3 from the injection pump shaft NOTE The injection pump shaft is tapered with a woodruff key Once you have applied some pressure with the puller A slight hammer tap on the center puller bolt will help pop the gear from the shaft 14 Remove th...

Page 194: ... made on the pump drive gear with the mark you made on the idle gear See Figure7 37 Figure 7 41 3 Install the drive gear retaining nut Figure7 42 1 and washer Figure7 42 2 While holding the engine with a wrench on the crankshaft pulley bolt torque the retaining nut to 43 5 51 ft lbs 59 69 N m 5 5 4 kgf m Figure 7 42 4 Thoroughly clean all old sealant from the fuel injection pump cover Figure7 43 1...

Page 195: ... bolt Figure 7 45 2 that fastens it to the cylinder block Figure 7 45 9 Reinstall the two bolts Figure7 45 1 to the L shaped bracket that holds the injection pump at the bottom rear Tighten the two bolts and the bolt that secures the bracket to the cylinder block to specified torque 10 Reinstall the high pressure fuel lines Replace the high pressure fuel lines as an assembly Be careful not to bend...

Page 196: ...e the fuel system and check for leaks Checking Adjustment Of Fuel Injection Timing 1 Using a wrench on the front crankshaft pulley bolt rotate the engine clockwise until the timing mark on the crankshaft pulley is aligned with the O or TDC Top Dead Center mark on the timing grid of the gear case cover 2 Remove the center bolt Figure7 47 1 and sealing washer from the rear of the fuel injection pump...

Page 197: ...ey is aligned with the mark at 4 6 and 8 5 ATDC After Top Dead Center on the timing grid on the gear case cover 8 5deg ATDC 8 If the injection timing is correct the dial indicator should read 0 038 0 041 in 0 97 1 03 mm 9 If the injection timing is not correct loosen the three fuel Injection pump mounting nuts and the bolts retaining the bottom rear L shaped injection pump mounting brackets Rotate...

Page 198: ...pump Finish loosening all the high pressure fuel line nuts and remove the fuel lines as an assembly Be careful not to bend any of the fuel lines CAUTION Remove the high pressure fuel injection lines as an assembly whenever possible Disassembling the high pressure fuel injection lines from the retainers or bending any of the fuel lines will make it difficult to reinstall the fuel lines NOTE It is n...

Page 199: ...ing in injury Never inject fuel towards a fire source Atomized fuel is highly flammable and may cause fire or skin burning 4 Pump the operating lever of the tester slowly observing the pressure reading at the point where the fuel injector begins spraying fuel The fuel injectors for these engines should begin spraying fuel at 1711 1914 PSI 11 8 13 2 MPa The opening pressure may be adjusted by addin...

Page 200: ...4TNV98 4TNE98 Diesel Engine Section 4 Fuel System 198 Figure 7 54 8 If the fuel injector fails any of these tests it should be repaired or replaced as necessary ...

Page 201: ...iform Atomization is excessively one sided Although atomized the needle does not pulsate burner like shape Bar shape with excessive after drops Drops bar shape Possible Cause Normal 1 Normally caused by carbon contamination of the nozzle tip 2 Sometimes caused by flaws in or damage to the needle tip 1 Caused by excessive carbon contamination of the nozzle tip 2 Sometimes caused by contamination 1 ...

Page 202: ...injectors Torque to 29 4ft lb 39 2N m 5 Install the fuel return line fitting using new copper gaskets 6 Tighten the fuel return line retaining nuts to 32 5ft lb 44 1N m CAUTION When loosening or tightening the lines at the fuel injectors you must hold the fuel injector with a second wrench to prevent the injector from turning and damaging the fuel return line fitting 7 Reinstall the high pressure ...

Page 203: ...the engine coolant Hot engine coolant may splash and burn you Failure to comply could result in death or serious injury WARNING ENTANGLEMENT HAZARD Stop the engine before you begin to service it NEVER leave the key in the key switch when you are servicing the engine Someone may accidentally start the engine and not realize you are servicing it This could result in a serious injury If you must serv...

Page 204: ...ult in minor or moderate injury CAUTION Only use the engine coolant specified Other engine coolants may affect warranty coverage cause an internal buildup of rust and scale and or shorten engine life Prevent dirt and debris from contaminating the engine coolant Carefully clean the radiator cap and the surrounding area before you remove the cap NEVER mix different types of engine coolants This may ...

Page 205: ...oolant pump This engine coolant pump is representative of the coolant pumps used on other TNV model engines For specific part detail see the parts catalog for the engine you are working on Cooling System Diagram Figure 8 1 1 Cylinder Head 2 Thermostat 3 Engine Coolant Pump 4 Radiator 5 Coolant Recovery Tank 6 Engine Oil Cooler 7 Cylinder Block Not standard on all models ...

Page 206: ...ump Components Figure 8 2 1 Thermostat Cover 2 Thermostat Cover Gasket 3 Thermostat 4 Thermostat O Ring 5 Special O Ring 6 Engine Coolant Pump 7 Temperature Switch 8 Gasket 9 Engine Coolant Pump Gasket 10 V Belt 11 Engine Coolant Pump V Pulley 12 Spacer 13 Engine Coolant Fan ...

Page 207: ...ge Replace the coolant pump if any of these conditions are present CAUTION If the engine coolant pump must be replaced replace the engine coolant pump as an assembly only Do not attempt to repair the engine coolant pump or replace individual components IMPORTANT Make sure the engine and engine coolant are not hot 1 Before removing the engine coolant pump or thermostat it will be necessary to drain...

Page 208: ...ut of the way CAUTION PINCH HAZARD Carefully rotate the alternator toward the cylinder block while loosening the V belt Failure to comply may result in minor or moderate injury 6 Remove the engine coolant fan guard if equipped engine coolant fan Figure 8 7 1 spacer Figure 8 7 2 and engine coolant pump V pulley Figure 8 7 3 Figure 8 7 7 Disconnect the coolant hoses and the temperature switch lead w...

Page 209: ...e 8 10 1 and an accurate thermometer Figure 8 10 2 in warm water Figure 8 10 2 Slowly increase the temperature of the water using an external heat source 3 The thermostat is operating properly if it starts to open at the temperature value stamped on the flange of the thermostat and fully opens as the temperature of the water is increased Radiator Cap 1 Check for proper operation of the radiator ca...

Page 210: ...et Install a new special O ring Figure 8 12 5 on assembly between the engine coolant pump and the joint CAUTION Use a new special O ring between the engine coolant pump and the joint Be sure to use the special O ring for each engine model Although the O ring dimensions are the same as a commercially available O ring the material is different 2 Reinstall the engine coolant pump bolts Tighten the bo...

Page 211: ...se the drain cock in the radiator Reinstall and tighten the engine block drain plug or reconnect the coolant hose at the oil cooler 8 Fill the radiator and engine with engine coolant See Drain Flush and Refill Cooling System With New Coolant on page 59 CAUTION Only use the engine coolant specified Other engine coolants may affect warranty coverage cause an internal buildup of rust and scale and or...

Page 212: ... and clothing away from moving rotating parts Failure to comply could result in death or serious injury WARNING BURN HAZARD Keep your hands and other body parts away from hot engine surfaces such as the muffler exhaust pipe turbocharger if equipped and engine block during operation and shortly after you shut the engine down These surfaces are extremely hot while the engine is operating and could s...

Page 213: ...an assembly CAUTION Only use the engine oil specified Other engine oils may affect warranty coverage cause internal engine components to seize and or shorten engine life Prevent dirt and debris from contaminating the engine oil Carefully clean the oil cap dipstick and the surrounding area before you remove the cap NEVER mix different types of engine oil This may adversely affect the lubricating pr...

Page 214: ...PM At Low Idle Speed 42 57 psi 0 29 0 39 MPa 3 0 4 0 kgf cm All Models 8 8 psi 0 06 MPa 0 6 kfg cm or greater Outer Rotor Outside Clearance All Models Standard Limit Reference Page 0 0039 0 0061 in 0 100 0 155 mm 0 0098 in 0 25 mm Check Outer Rotor Outside Clearance on page 216 Outer Rotor Side Clearance All Models Standard Limit Reference Page 0 0020 0 0039 in 0 05 0 10 mm 0 0059 in 0 15 mm Check...

Page 215: ...0 0 5108 in 12 955 12 975 mm 0 5096 in 12 945 mm 4TNV98 Rotor Clearance 0 0014 0 0026 in 0 035 0 065 mm 0 0041 in 0 105 mm Check Rotor Shaft Clearance on page 216 Gear Case Bearing I D 0 5110 to 0 5126 in 12 980 13 020 mm 0 5138 in 13 05 mm Rotor Shaft O D 0 5089 to 0 5106 in 12 925 12 970 mm 0 5085 in 12 915 mm 4TNE98 Rotor Clearance 0 0004 to 0 0026 in 0 010 to 0 065 mm 0 0041 in 0 105 mm Check ...

Page 216: ...4TNV98 4TNE98 Diesel Engine Section 6 Lubrication System 214 Lubrication System Diagram Figure 9 1 ...

Page 217: ... the mechanical oil pressure test gauge indicates good oil pressure replace the faulty oil pressure switch or sending unit or faulty machine oil pressure gauge in instrument panel If the mechanical oil pressure test gauge indicates low oil pressure troubleshoot the lubrication system to locate the cause of the low oil pressure See Troubleshooting Charts on page 190 Repair as necessary Trochoid Oil...

Page 218: ...ove the oil pump assembly bolts Remove the oil pump assembly Figure 9 16 1 from the gear case housing Figure 9 16 2 Figure 9 16 Cleaning and Inspection Wash the oil pump oil pressure regulator and oil pump cavity Inspect for wear or damage Replace as necessary CAUTION If any oil pump component clearance exceeds its limit the oil pump must be replaced as an assembly Check Outer Rotor Outside Cleara...

Page 219: ...r Figure 9 19 1 Figure 9 19 Record the measurement s and see Check Outer Rotor Side Clearance on page 217 for the service limits Check Rotor Shaft Clearance Determine the rotor shaft clearance Measure the outside diameter of the rotor shaft Figure 9 20 1 and the bore diameter in the gear case housing Figure 9 20 2 Calculate the difference between the two measurements to determine the clearance Fig...

Page 220: ... 22 4 Reinstall the gear case cover and crankshaft pulley See Installation of Gear Case Cover on page 137 5 Reinstall the engine coolant pump V pulley Figure 9 23 1 spacer Figure 9 23 2 engine cooling fan Figure 9 23 3 and engine cooling fan guard if equipped Figure 9 23 6 Reinstall the V belt Tighten the V belt to the proper tension as described in Check and Adjust Cooling Fan V Belt on page 47 ...

Page 221: ...l jewelry tie back long hair and keep your hands other body parts and clothing away from moving rotating parts Failure to comply could result in death or serious injury WARNING SHOCK HAZARD Always read and follow safety related precautions found on containers of hazardous substances like parts cleaners primers sealants and sealant removers Failure to comply could result in death or serious injury ...

Page 222: ...bined total resistance of the battery cable in both directions between the starter motor and the battery is within the value indicated on the wiring diagram The starter motor will malfunction or break down if the resistance is higher than the specified value CAUTION The starter motor is water proofed according to JIS D 0203 R2 which protects the motor from rain or general cleaning Do not use high ...

Page 223: ...rocedures for a representative starter motor For specific part detail see the Yanmar Parts Catalog for the engine you are working on Starter Motor Information No Load Loaded DOOSAN Part Number Mfg Mfg Part Number Specification Terminal Voltage Amp erage Draw rpm Terminal Voltage Amp erage Draw Torque rpm A408417 Hitachi S13 204 DC12V 3 1 hp 2 3 kW 11 140A MAX 4100 7 7 400 Max 97 in lb 11 0 N m 1 1...

Page 224: ...umber of Teeth M3 9 Difference O ring Oil Seal Dry none Application Standard Spring Force 7 868 lbf 35 N 3 6 kgf Standard 0 591 in 15 mm Brush Height Limit 0 354 in 9 mm Series Coil Resistance 0 27 Ω at 68 F 20 C Magnetic Switch Shunt Coil Resistance 0 60 Ω at 68 F 20 C Standard 1 437 in 36 5 mm Outside Diameter Limit 1 398 in 35 mm Standard 0 001 in 0 03 mm Run Out Limit 0 008 in 0 2 mm Standard ...

Page 225: ...4TNV98 4TNE98 Diesel Engine Section 7 Starter Motor 223 Starter Motor Troubleshooting ...

Page 226: ...embly 5 Return Spring 6 Pinion Stop 7 Retaining Ring 8 Gear Housing 9 Shift Lever 10 Torsion Spring 11 Plunger 12 Dust Covers Shims 13 Magnetic Switch Assembly Solenoid 14 Cover 15 M6 Bolts 2 used 16 Armature Assembly 17 Field Coil Assembly 18 Positive Brushes 19 Negative Brushes 20 Brush Holder Assembly 21 Rear Cover 22 M5 Through Bolts 2 used 23 M4 Bolts 2 used ...

Page 227: ...c repair procedures are the same The following procedures are typical and may differ from the stater being serviced Removal of Starter Motor 1 Disconnect the battery cables at the battery negative cable first 2 Remove the electrical wires from the magnetic switch assembly 3 Remove the starter mounting bolts Figure 11 2 1 Remove the starter motor from the flywheel housing Figure 11 2 Disassembly of...

Page 228: ...ace On the positive side remove the brush from the brush holder assembly Figure 11 5 1 Figure 11 5 5 Remove the brush holder assembly Figure 11 6 1 from the armature assembly Figure 11 6 3 Figure 11 6 6 Pull the armature assembly Figure 11 6 3 out from the field coil assembly Figure 11 6 2 7 Remove the two M6 bolts Figure 11 7 1 retaining the magnetic switch assembly Figure 11 7 2 to the gear hous...

Page 229: ...remove the retaining ring Figure 11 10 1 from the shaft of the pinion Figure 11 10 12 Disassemble the pinion stop Figure 11 11 3 return spring Figure 11 11 4 pinion clutch assembly Figure 11 11 1 and pinion shaft Figure 11 11 5 Figure 11 11 Cleaning and Inspection Armature Commutator Surface Inspection If the commutator surface is rough polish the surface with a 500 to 600 emery cloth Figure 11 12...

Page 230: ...ated in Figure11 14 4 An abnormal commutator condition is indicated in Figure11 14 5 Figure 11 14 See Starter Motor Specifications on page 222 for the service limit Armature Coil Continuity Test Check for continuity between the commutator segments using a multimeter Figure 11 15 The multimeter should indicate continuity Figure 11 15 If the multimeter does not indicate continuity replace the armatu...

Page 231: ...l terminals using a multimeter Figure11 18 The multimeter should indicate continuity If the multimeter does not indicate continuity replace the field coil assembly Figure 11 18 Field Coil Insulation Test Check for continuity between the field coil terminal and the yoke using a multimeter Figure11 19 The multimeter should not indicate continuity If the multimeter indicates continuity replace the fi...

Page 232: ...ng a multimeter Figure11 21 The multimeter should indicate continuity If the multimeter does not indicate continuity replace the magnetic switch Figure 11 21 Series Coil Continuity Test Check for continuity between the S and M terminals using a multimeter Figure11 22 The multimeter should indicate continuity If the multimeter does not indicate continuity replace the magnetic switch Figure 11 22 Co...

Page 233: ...hould rotate freely in the drive direction and is locked by turning it in the opposite direction Replace the pinion clutch assembly if the results are different Figure 11 24 Slide the pinion clutch assembly on the shaft It should slide smoothly on the shaft Figure11 25 Rust too much grease or damage could prevent the pinion clutch from sliding smoothly If the pinion clutch assembly does not slide ...

Page 234: ...y and pinion assembly to the gear housing Reinstall and tighten the three M4 bolts 4 Apply a small amount of high temperature lithium grease obtain locally to the sliding portions of the shift lever Figure 11 28 1 Reassemble the torsion spring Figure 11 28 2 shift lever and dust cover s Figure 11 28 3 plunger Figure 11 28 4 and magnetic switch assembly Figure 11 28 5 Figure 11 28 5 Reassemble the ...

Page 235: ...hrough bolts Reconnect the wire to the magnetic switch assembly Tighten the M8 nut Reinstall the cover over the connection Figure 11 32 Check Pinion Projection Length 1 Connect the positive lead from a battery to the S terminal 2 Connect the negative lead to the M terminal 3 Lightly pull the pinion away from the gear housing 4 Turn the switch ON and measure the pinion moving distance L in the thru...

Page 236: ...11 35 5 4 Connect a voltmeter Figure 11 35 7 to the battery negative terminal Figure 11 35 5 and the main positive battery terminal Figure 11 35 3 on the starter motor 5 Install a switch Figure 11 35 6 in a circuit between the battery positive terminal Figure 11 35 2 and the starter magnetic switch solenoid terminal Figure 11 35 8 on the starter motor 6 Use a suitable tachometer to monitor the rpm...

Page 237: ...r Gauge Set Part No TOL 97190080 Adapter for direct injection 2 valve cylinder head Yanmar Adapter Part No 119802 92950 Adapter for direct injection 4 valve cylinder head for 4TNV94L 98 98T Yanmar Adapter Part No 129906 92950 Compression Gauge Kit Adapter for direct injection 4 valve cylinder head for 4TNV106 T Yanmar Adapter Part No 123907 92950 ...

Page 238: ... on page 147 CAUTION Remove or install the high pressure fuel injection lines as an assembly whenever possible Disassembling the high pressure fuel injection lines from the retainers or bending any of the fuel lines will make it difficult to reinstall the fuel lines 3 Turn off the fuel supply valve in the fuel supply line Disconnect the fuel injection pump stop solenoid at the connector This preve...

Page 239: ...ence Value Compression Pressure at 250 rpm 250 min 1 Engine Model Standard Limit Deviation Between Cylinders 4TNV98 483 513 psi 3 33 3 53 MPa 34 36 kgf cm 384 414 psi 2 65 2 85 MPa 27 29 kgf cm 29 43 psi 0 2 0 3 MPa 2 3 kgf cm Engine Speed and Compression Pressure Use for Reference Figure 14 2 ...

Page 240: ...ressure at 250 rpm 250 min 1 Engine Model Standard Limit Deviation Between Cylinders 4TNE98 426 15 psi 2 94 0 1 MPa 30 1 kgf cm 341 15 psi 2 35 0 1 MPa 24 1 kgf cm 29 to 43 psi 0 2 to 0 3 MPa 2 to 3 kgf cm Engine Speed and Compression Pressure Use for Reference Figure 13 2 ...

Page 241: ... the valve clearance Replace the gasket 4 Cylinder Head Gasket Gas leak from gasket Retighten the cylinder head bolts to the specified torque Intake Exhaust Valve Sticking valve Replace the intake exhaust valve 5 Valve Seat Gas leak due to worn valve seat or foreign matter trapped in valve Lap the valve seat Piston Piston Ring 6 Cylinder Gas leak due to scratching or wear Perform honing and use an...

Page 242: ...4TNV98 4TNE98 Diesel Engine Section 8 Troubleshooting 240 Troubleshooting Charts ...

Page 243: ...4TNV98 4TNE98 Diesel Engine Section 8 Troubleshooting 241 ...

Page 244: ...4TNV98 4TNE98 Diesel Engine Section 8 Troubleshooting 242 ...

Page 245: ...m Note The following wiring diagram is representative of a common installation using a Yanmar engine The actual installation may be equipped with a variety of electrical components and wiring harnesses Contact the machine manufacturer for specific information 4TNV98 Engine ...

Page 246: ...4TNV98 4TNE98 Diesel Engine Section 8 Troubleshooting 244 4TNE98 Engine ...

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