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Troubleshooting

• Page 1
  SB4319E00 Jan. 2008 Service 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)

• Page 3: Important Safety Information

  If a tool, procedure, work method or operating technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.

• Page 5: Table Of Contents

  Engine General Specifications ….21 Cylinder Head ……..66 Principal Engine Specifications……22 Intake / Exhaust Valve and Guide Cont… 67 4TNV98 EPA Tier 2 ……22 Push Rod……….68 4TNE98 EPA Tier 3 ……23 Rocker Arm and Shaft ……68 Engine Service Standards……..

• Page 6
  Removal of Fuel Injection Pump … 148 Judgement Criteria on Atomization Installation of Fuel Injection Pump ..152 Condition ……….199 Checking and Adjusting Fuel Injection Timing..157 Installation of Fuel Injectors….200 Determining the Fuel Injection Timing 4TNV98 & 4TNE98 Diesel Engine Index…
• Page 7
  Reassembly of Starter Motor ….232 Check Pinion Projection Length…. 233 No-Load Test ……..234 Installation of Starter Motor….234 Section 8. TROUBLESHOOTING Special Service Tools ……..235 Troubleshooting By Measuring Compression Pressure …………236 Compression Pressure Measurement 4TNV98 & 4TNE98 Diesel Engine Index…

• Page 9: Component Identification

  (7) Drain Plug (Engine Oil) (8) Engine Oil Filter Figure 4-1a (9) Dipstick (EngineOil) (10) Engine Coolant Pump (11) Alternator (12) Glow Plug (13) V-Belt (14) Crankshaft V-Pulley (15) Starter Motor 4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information…

• Page 10: Location Of Labels

  Maintenance Schedule section of this manual. Figure 4-2 The typical location of the emission control information label shown (Figure 4-2 (2), (3)). The typical location of the engine nameplate is shown (Figure 4-2 (1), (4)). 4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information…

• Page 11: Emission Control Labels

  Engine Family The EPA / ARB labels and the 97/68/EC label all have an Engine Family field. The following is an explanation of the Engine Family designation: (EPA and ARB) 4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information…

• Page 12: Function Of Major Engine Components

  The starter motor is powered by the battery. When you turn the key switch in the operator’s console to the START position, the starter motor Starter Motor engages with the ring gear installed on the flywheel and starts the flywheel in motion. 4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information…

• Page 13: Function Of Cooling System Components

  By letting the engine warm up as quickly as possible, the thermostat reduces engine wear, deposits and emissions. 4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information…

• Page 14: Diesel Fuel

  Diesel Fuel • The total aromatics content should not exceed 35% by volume. Less than 30% is preferred. Diesel Fuel Specifications • The PAH (polycyclic aromatic hydrocarbons) content should be below 10% by volume. Diesel fuel should comply with the following •…

• Page 15: Filling The Fuel Tank

  NEVER place diesel fuel or other flammable material such as oil, hay or dried grass close to the engine during engine operation or shortly after shutdown. Failure to comply will result in death or serious injury. 4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information…

• Page 16
  (3)) and stop fueling when the gauge shows the fuel tank is full. NEVER overfill the fuel tank. 4. Replace the fuel cap (Figure 4-3, (1)) and hand tighten. Over-tightening the fuel cap will damage 4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information…

• Page 17: Priming The Fuel System

  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. Figure 4-4 4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information…

• Page 18: Engine Oil

  • ACEA Service Categories E-3, E-4, and 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) Figure 4-4a 4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information…

• Page 19: Checking Engine Oil

  Yanmar engines. Dipstick Upper Engine Model Limit / Lower Limit 11.1 / 6.3 qt 4TNV98 (10.5 / 6.0 L) 9.7 / 7.6 qt 4TNE98 (9.2 / 7.2 L) Figure 4-5 4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information…

• Page 20: Engine Coolant

  BURN HAZARD! Wait until the engine cools before you drain the engine coolant. Hot engine coolant may splash and burn you. Failure to comply could result in death or serious injury. 4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information…

• Page 21: Engine Coolant Specifications

  • 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. Figure 4-7 4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information…

• Page 22: Engine Coolant Capacity (Typical)

  (Figure 4-6, (6)). If the engine coolant is not at the FULL (HOT) mark (Figure 4-6, (6)), add additional engine coolant to the reserve tank to bring the level to the FULL (HOT) mark. 4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information…

• Page 23: Engine General Specifications

  • With Cooling Fan, Air Cleaner, Muffler: Yanmar Standard • After Engine Break-In Period; Output Allowable Deviation: ± 3% • 1 PS = 0.7355 kW • 1 hp SAE (Society of Automotive Engineers) = 0.7457 kW 4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information…

• Page 24: Principal Engine Specifications

  *** Engine oil capacity for a “Deep Standard” oil pan. Refer to the operation manual provided by the driven machine manufacturer for the actual engine oil capacity of your machine. 4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information…

• Page 25: Tne98 Epa Tier 3

  ** The Intake and Exhaust condition of Max. Rated output are Air Intake Restriction : 250mmAq Exhaust Gas Restriction : 1000mmAq ***The detail specifications are refer to the Specification document which is agreed between both engineering. 4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information…

• Page 26: Engine Service Standards

  157°F — 163°F Option Above See Thermostat (70°C — 73°C) Thermostat 185°F (85°C) on page 207 0.39 in (10 mm) 176°F — 183°F Standard (80°C — 84°C) above 203°F (95°C) 4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information…

• Page 27: Tightening Torques For Standard Bolts And Nuts

  “7” head. (JIS strength classification: 7T) Apply 60% torque to bolts that are not listed. Apply 80% torque when tightened to aluminum alloy. 4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information…

• Page 28
  4.0 5.0 kgf·m) 36 — 43 ft·lb (49.0 — 58.8 N·m, 5.0 — 6.0 kgf·m) NOTE: Torque values shown in this manual are for clean, non-lubricated fasteners unless otherwise specified. 4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information…

• Page 29: Abbreviations And Symbols

  I.D. inside diameter ° degree identification indirect injection plus inch in.Aq minus inches Aqueous (water) in.Hg inches Mercury ± plus or minus in.-lb inch pound Ω joule μ micro percent 4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information…

• Page 30: Unit Conversions

  1.3410221 = hp 0.2248 = lbf 0.1020 = kgf 2.2050 = lbf 9.8070 Units of Temperature °F = (1.8 x °C) + 32 °C = 0.556 x (°F — 32) 4TNV98 & 4TNE98 Diesel Engine Section 1. General Service Information…

• Page 31: Section 2. Periodic Maintenance

  NEVER overfill the fuel tank. Fill fuel tank. Store containers containing fuel in a well-ventilated area, away from any combustibles or sources of ignition. Failure to comply will result in death or serious injury. 4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance…

• Page 32
  Diesel fuel is flammable and explosive under certain conditions. Failure to comply will result in death or serious injury. NEVER use diesel fuel as a cleaning agent. Failure to comply will result in death or serious injury. 4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance…
• Page 33
  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. 4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance…
• Page 34
  Check before starting the engine that any tools or shop rags used during maintenance have been removed from the area. Failure to comply could result in death or serious injury. 4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance…
• Page 35
  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. 4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance…
• Page 36
  NEVER check for a fuel leak with your hands. ALWAYS use a piece of wood or cardboard. Have your authorized Yanmar industrial engine dealer or distributor repair the damage. Failure to comply could result in death or serious injury. 4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance…
• Page 37
  Failure to comply could result in death or serious injury. 4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance…
• Page 38
  Be sure to use Yanmar NEVER remove primary strainer genuine replacement parts. equipped) from the fuel tank filler port. If removed, dirt and debris could get into the fuel system causing it to clog. 4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance…
• Page 39
  CAUTION NEVER hold the key in the START position for longer than 15 seconds or the starter motor will overheat. 4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance…
• Page 40
  ALWAYS keep the oil level between the upper and lower lines on the oil cap/dipstick. Periodic maintenance prevents unexpected downtime, reduces the number of accidents due to poor machine performance and helps extend the life of the engine. 4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance…
• Page 41
  Section. restriction exceeds the above mentioned value. Consult your authorized Yanmar dealer or distributor for assistance when checking items marked with a. 4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance…

• Page 42: Introduction

  EPA and ARB. Maximum Exhaust Gas Restriction shall be: EXHAUST HAZARD! NEVER operate the engine in an enclosed area • 4TNV98 : 2.22 psi (15.3 kPa; 1560mm Aq) or such as a garage, tunnel, underground room, Iess manhole ship’s…

• Page 43: Periodic Maintenance Schedule

  See Yanmar Limited Warranty in Warranty Section. Consult your authorized Yanmar dealer or distributor for assistance when checking items marked with a. 4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance…

• Page 44
  Intake and Clean or Replace Air Cleaner Element ○ ◇ Exhaust Complete Overall Visual Check Daily ○ Engine NOTE: These procedures are considered normal maintenance and are performed at the owner’s expense. 4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance…

• Page 45: Periodic Maintenance Procedures

  After draining the fuel filter/water separator, be sure to tighten • Failure to comply will result in death or serious the air vent screw. injury. 0000025en 0000009en. 4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance…

• Page 46
  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 4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance…

• Page 47: Daily

  Failure to comply could result in death or the ground, or into ground water or waterways. serious injury. Failure follow these procedures seriously harm the environment. 4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance…

• Page 48
  Applicable Engine Oil Filter Part No. 4TNV98 A408065 4TNE98 A408065 Figure 5-1 6. Remove the oil drain plug (Figure 5-2, (1)) from the engine oil pan. Allow oil to drain. 4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance…
• Page 49
  Figure 5-4 Figure 5-3 9. Reinstall the oil filler cap (Figure 5-3, (4)). If any engine oil is spilled, wipe it away with a clean cloth. 4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance…

• Page 50: Every 50 Hours Of Operation

  3. Tighten the V-belt to the proper tension. There must be clearance (Figure 5-6, (1)) between the 4TNV98 & 4TNE98 (For China) Engine V-belt and the bottom of the pulley groove. If there is no clearance (Figure 5-6, (2)) between…

• Page 51
  / water separators are page 15. equipped with a sensor to detect the amount of contaminants. This sensor sends a signal to an 7. Check for leaks. indicator to alert the operator. 4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance…
• Page 52
  If the engine still will not start after charging, have your authorized Yanmar industrial engine dealer or distributor check the battery and the engine’s starting system. 4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance…

• Page 53: Every 250 Hours Of Operation

  4. Drain the tank until clean diesel fuel with no water and dirt flows out. Reinstall and tighten the drain plug firmly. 5. Reinstall the fuel cap. 6. Check for leaks. 4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance…

• Page 54
  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. 4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance…
• Page 55
  (4)) and adjust the cable so the governor lever Failure to comply may result in minor or makes proper contact with the high / low idle moderate injury. speed limit screw. 4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance…

• Page 56: Every 500 Hours Of Operation

  Failure follow these procedures seriously harm the environment. NEVER operate the engine with the air cleaner element(s) removed. This may allow foreign material to enter the engine and damage it. 4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance…

• Page 57
  DANGER seriously harm the environment. 4TNV98 & 4TNE98 (for D25G) Only FIRE AND EXPLOSION HAZARD! Replace the fuel filter at specified intervals to Diesel fuel is flammable and explosive under prevent contaminants from adversely affecting the certain conditions.
• Page 58
  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 5-15 9. Set the drain plug aside for reinstallation. 4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance…
• Page 59
  Failure to comply will result in death or serious 20. Prime the fuel system. See Priming the Fuel injury. System on page 15. 21. Check for fuel leaks. Applicable Fuel Filter Part No. (Figure 5-14, (2)) 4TNE98 A409559 4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance…
• Page 60
  12. Close the drain cock. Reconnect the sensor wire if equipped. 13. Open the fuel cock (Figure 5-15, (3)). 14. Prime the fuel system. See Priming the Fuel System on page 15. 15. Check for leaks. Figure 5-15 4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance…

• Page 61: Every 1000 Hours Of Operation

  2. Remove the radiator cap (Figure 5-16, (1)). 3. Remove the drain plug or open the drain cock (Figure 5-16, (2)) at the lower portion of the radiator and drain the engine coolant. 4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance…

• Page 62
  4. Drain the coolant from the engine block. • On models not equipped with an oil cooler, remove the coolant drain plug (Figure 5-17, (1)) from the engine block. Figure 5-17 4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance…

• Page 63: Every 1500 Hours Of Operation

  3. Inspect the diaphragm for tears. Inspect the spring for distortion. Replace components if necessary. 4. Reinstall the diaphragm, diaphragm plate, spring and diaphragm cover. Tighten the diaphragm bolts to specified torque. 4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance…

• Page 64: Every 2000 Hours Of Operation

  NEVER dispose hazardous materials irresponsibly by dumping them into a sewer, on the ground, or into ground water or waterways. Failure follow these procedures seriously harm the environment. 4TNV98 & 4TNE98 Diesel Engine Section 2. Periodic Maintenance…

• Page 65: Before You Begin Servicing

  Section 3. ENGINE Before You Begin Servicing WARNING WARNING FUME / BURN HAZARD! To prevent possible eye injury, always wear Always read follow safety related SAFETY GLASSES while servicing the engine. precautions found on containers of hazardous substances like parts cleaners, primers, sealants and sealant removers.

• Page 66
  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. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…
• Page 67
  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. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 68: Introduction

  (1.0 mm) Inspection Valve Sink of Intake 0.024 — 0.032 in. 0.043 in. Exhaust (0.6 — 0.8 mm) (1.1 mm) Exhaust Valves on Intake 120° Valve Seat Angle page 95. Exhaust 90° 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 69: Intake / Exhaust Valve And Guide Cont

  Valve Guide Projection From Cylinder Head Valve (14.7 – 15.0 mm) Guides on page 98. Assembly of 0.66 — 0.70 in. Valve Stem Seal Projection From Cylinder Head Valve (16.7 – 17.0 mm) Guides on page 98. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 70: Push Rod

  (43.400 — 43.600 mm) (43.150 mm) Camshaft on Cam Lobe Height page 125. 1.6707 — 1.6758 in. 1.6608 in. 4TNE98 (42.435– 42.565 mm) (42.185 mm) Shaft Outside Diameter / Bearing Inside Diameter 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 71: Idler Gear Shaft And Bushing

  Pump Gear and PTO Gear (0.08 — 0.14 mm) (0.16 mm) Timing Gear Backlash on 0.0035 — 0.0059 in. 0.0067 in. Lubricating Oil Pump Gear page 112. (0.09 — 0.15 mm) (0.17 mm) 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 72: Crankshaft And Piston Specifications

  0.0051 — 0.0091 in. 0.0110 in. 4TNV98 Removal of (0.13 — 0.23 mm) (0.28 mm) Crankshaft End Play Crankshaft 0.0043 — 0.0083 in. 0.0110 in. on Page 4TNE98 (0.11 — 0.21 mm) (0.28 mm) 118. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 73: Piston

  (2.950 mm) Oil Ring 0.0010 — 0.0024 in. 0.0071 in. Side Clearance (0.025 — 0.060 mm) (0.180 mm) 0.0098 — 0.0177 in. 0.0217 in. End Gap (0.250 — 0.450 mm) (0.550 mm) 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 74: Connecting Rod

  0.4715 — 0.4720 in. 0.4707 in. Tappet Stem Outside Diameter Tappets on page (11.975 — 11.990 mm) (11.955 mm) 124. 0.0004 — 0.0017 in. 0.0033 in. Oil Clearance (0.010 — 0.043 mm) (0.083 mm) 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 75: Cylinder Block Specifications

  M10 x 1.0 mm (53.9 — 58.8 N·m; Applied 5.5 — 6.0 kgf·m) 137 — 152 ft·lb Flywheel Bolt M14 x 1.5 mm (186.2 — 205.8 N·m; Applied 19 — 21 kgf·m) 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 76
  M6 x 1.0 mm (7.8 — 9.8 N·m; Not Applied Line Joint Bolt 0.8 — 1.0 kgf·m) See Tightening Torques for Standard Bolts and Nuts on page 23 for standard hardware torque values. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 77: Special Service Tools

  Valve Spring) Model 0.598 0.827 0.472 0.465 2.559 0.157 4TNV98 (15.2 (11.8 Stem Seal Installer (for Installing Valve Stem Seal) 0.638 0.866 0.531 0.669 2.560 0.157 4TNE98 (16.2 (13.5 (17.0 Locally Manufactured 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 78
  The Piston Insertion Tool is Applicable for 2.362 — 4.921 in. (For Installing (60 — 125 mm) Diameter Pistons Piston) Piston Ring Expander (For Removal Available Locally / Installation of Piston Ring) Crankshaft Pulley Locally Manufactured Installing Tool 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 79: Measuring Instruments

  For measuring outside diameters, depth, Calipers Locally Available thickness and width Depth Locally Available For measuring of valve recession Micrometer For measuring valve spring inclination Square Locally Available and straightness of parts 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 80
  Type periphery of the revolving shaft Fuel High This measures the revolution Pressure Pipe regardless of the center or periphery Clamp Type of the revolving object 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…
• Page 81
  Circuit Tester continuity of electrical circuits For measuring compression Compression Gauge Kit pressureGauge Set Part No. TOL- 97190080 Adapter for direct injection 2-valve New Comperssion Test cylinder headAdapter Part No. 119802- Adaptor 92950 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 82: Cylinder Head

  Cylinder Head Cylinder Head Components 4TNV98 Engine Figure 6-36 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 83
  29) Valve Bridge. 30) Valve Bridge Seat. 31) Valve Adjusting Screw Lock Nut (Secondary). 32) Valve Adjusting Screw (Secondary). 33) Push Rod. 34) Rocker Arm Shaft. 35) Crankcase Breather Components. 36) Valve Cover. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 84: Disassembly Of 4-Valve Cylinder Head

  6-38, (9)). 8. Remove the exhaust manifold bolts (Figure 6-38, (7)). Remove the exhaust manifold (Figure 6-38, (6)) with the turbocharger attached. Discard the exhaust manifold gasket. (Figure 6-38, (5)). Figure 6-37 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 85
  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. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…
• Page 86
  Components for all remaining cylinders are assembled in the same order. 3. Remove the valve adjusting screw (Figure 6-42, (2)) and the lock nut (Figure 6-42, (3)) from the rocker arms. Figure 6-41 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…
• Page 87
  1. Place the cylinder head on the work bench with prevent damage to the combustion surface. the combustion side down. 2. Using the valve spring compressor tool, compress one of the valve springs (Figure 6-45). Figure 6-45 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…
• Page 88
  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)). 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 89: Tne98 Engine

  4TNE98 Engine Figure 6-1 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 90
  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 Adjusting Screw 30) Support Bracket Nut 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 91: Disassembly Of Cylinder Head

  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. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 92
  Reverse this process when you reinstall the rocker arm shaft into the support brackets. NOTE : Mark the rocker arms so they can be reinstalled with the original matching valve and pushrod. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…
• Page 93
  Position the cylinder head on the work bench to prevent damage to the combustion surface. Figure 6-10 3. Remove the valve keepers (Figure 6-11, (2)) and valve cap (Figure 6-10, (1)) from the end of the valve. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 94: Cleaning Of Cylinder Head Components

  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. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 95
  (Figure 6-49) are within the specified limits. See Rocker Arm and Shaft on page 68 for the service limit. 2. Inspect the contact areas (Figure 6-49, (1)) for excessive wear or damage. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…
• Page 96
  (combustion side up) on the bench. Use a straight edge and feeler gauge to measure cylinder head distortion (Figure 6-52). Measure diagonally and along each side. See Cylinder Head on page 66 for the service limit. Figure 6-50 Figure 6-52 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…
• Page 97
  (Figure 6-56). See Cylinder Head on page 66 for the service limit. Figure 6-55 NOTE : 2-Valve cylinder head is shown. 4-Valve cylinder head is similar. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…
• Page 98
  40° stone to make the seat diameter larger. Once the seat location has been corrected, grind and lap the seat angle (Figure 6-58, (1)) to specification. See Cylinder Head on page 66 for specifications. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…
• Page 99
  (Figure 6-61, Spring on page 68 for the service limit. (3)). See Rocker Arm and Shaft on page 68 for the service limit. Figure 6-59 Figure 6-61 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 100: Reassembly Of Cylinder Head

  1. Oil the lip of the valve stem seal (Figure 6-64, (2)). Using the valve stem seal installation tool (Figure 6-64, (1)), install a new valve stem seal on each of the valve guides (Figure 6-64, (3)). 4TNE98 Engine Figure 6-64 Figure 6-62 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 101
  6. Using the valve spring compressor tool, compress the valve spring. 7. Insert the valve keepers (Figure 6-66, (1)) and slowly release the tension in the valve spring. Repeat the steps on all the remaining valves. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…
• Page 102
  Tighten in the sequence shown in (Figure 6-68). See Special Torque Chart on page 73 for specification. First Step 1/2 of final torque Second Step Final torque 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…
• Page 103
  3. Lubricate the rocker arm shaft. Slide the rocker arm supports (Figure 6-72, (6)), wave washers (Figure 6-72, (7)), rocker arms Figure 6-69 (Figure 6-72, (8)), and fuel injector retainers (Figure 6-72, (4)) onto the shaft. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…
• Page 104
  Tighten the rocker arm shaft alignment screw. 6. Align the push rods with their respective rocker arms and adjust the valve lash. (See Measuring and Adjusting Valve Clearanceon page 104.) 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…
• Page 105
  6. Reinstall the intake manifold using a new gasket. Tighten the bolts to specification. 7. Reconnect the fuel injector return hose and fuel Figure 6-33 injection pump coolant hoses. 8. Reinstall the high-pressure fuel line grommets into the valve cover. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 106: Measuring And Adjusting Valve Clearance

  4-Cylinder Engines Cylinder No. Valve Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust No. 1 Cylinder at • • • • TDC Compression No. 4 Cylinder at • • • • TDC Compression 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 107: Tne98 Engine

  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. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 108: Tnv98 Engine

  (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)). Figure 6-79 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 109
  (Figure 6-82, (1)) of the correct thickness (See Adjustment Specifications 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. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…
• Page 110
  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. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 111: Crankshaft And Camshaft Components

  Crankshaft and Camshaft Components Figure 6-84 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 112
  (33) Wrist Pin Bushing. (34) Circlip . (35) Wrist Pin. (36) Piston. (37) Oil Ring. (38) Second Compression Ring. (39) Top Compression Ring. (40) Crankshaft Rear Seal. (41) Crankshaft Rear Seal Housing. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 113: Disassembly Of Engine

  7. Drain the engine oil into a suitable container. Remove the oil filter. 8. Remove the cylinder head. See 4-Valve Cylinder 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 114
  Figure 6-87 2. Rotate the idler gear back and forth to check the idler gear-to-crankshaft gear backlash. The total indicator reading is the backlash. Record the measurement. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…
• Page 115
  1. Invert the engine (oil pan up) on the engine stand. not remove the camshaft gear unless it or the camshaft is damaged and requires replacement. 2. Remove the oil pan (Figure 116, (1)). See Removal of Camshaft on page 114. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…
• Page 116
  • 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 service limit. Figure 6-91 Figure 6-93 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 117: Figure

  Use a knife-edge puller and a press Figure 6-95 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. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 118: Figure

  2. Measure bearing oil clearance prior to removing engine is inverted. Rotate the engine so the the pistons and connecting rods to determine connecting rods are horizontal before removing the extent of wear. Record the measurements. connecting rod caps. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• 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. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…
• Page 120
  • Method A : Install a dial gauge (Figure 6-102, (1)) on the cylinder block. Move the crankshaft (Figure 6-102, (2)) in and out to measure the end play. Record the measurement. Figure 6-102 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 121: Method B : Use A Feeler Gauge To Measure The

  Record the measurements. (a) Wipe oil from the bearing insert and crankshaft journal surfaces. (b) Place a piece of PLASTIGAGE (Figure 6-105, (1)) along the full width of each bearing insert. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 122: Components

  Replacement of Crankshaft Oil Seals 7. Remove the bearing inserts (Figure 6-104, (1)) 1. Remove the seal (Figure 6-108, (2)) from the and thrust bearings (Figure 6-104, (2)). cover (Figure 6-108, (1)). 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 123
  Gasket No. 1212 to the outside diameter of a new oil seal (Figure 6-109, (2)), and install in the housing. Apply lithium grease to the lip of the seal. Figure 6-110 Figure 6-109 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…
• Page 124
  See Piston on page 71 for specifications. Figure 6-113 8. Using a micrometer, measure the thickness of each piston ring. See Piston on page 71 for specifications. Record the measurements. Figure 6-111 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…
• Page 125
  (Figure 6-115, (2)) from the bottom of the bore. Remove the piston. Measure the end gap (Figure 6-115, (3)) of each piston ring. Record the measurements. See Piston Ring on page 71 for specifications. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…
• Page 126
  (Figure 6-117, (2)). Slight surface defects can be corrected using an oilstone. Figure 6-119 3. Rotate the crankshaft and observe runout. See Crankshaft on page 70 for specifications. Figure 6-117 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…
• Page 127
  Figure 6-122 4. Measure the diameter of the gear end (Figure 6- 123, (1)), intermediate (Figure 6-123, (2)), and flywheel end (Figure 6-123, (3)) bearing journals. See Camshaft on page 68 for specifications. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 128: Honing And Boring

  30° to 40° crosshatch pattern (Figure 6-125). This will provide the ideal surface for the proper seating of new piston rings. Figure 6-124 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 129: Components

  Be sure to align the oil holes. IMPORTANT Solvents will not adequately remove honing residue, resulting in premature piston and ring wear. Always wash cylinders using hot, soapy water. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 130
  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. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…
• Page 131
  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 6-132 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…
• Page 132
  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. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…
• Page 133
  • Stagger the piston ring joints at 120 intervals. Do not position the top piston ring joint inline with the piston wrist pin. The coil expander joint must be opposite the oil ring joint. Figure 6-71 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…
• Page 134
  The No. 1 cap is at the flywheel end. The arrows point toward the flywheel end of the engine. Figure 6-74 4. Reinstall the main bearing caps (Figure 6-135, • Repeat these steps for the remaining pistons. (3)). 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…
• Page 135
  3. Using a piston ring compressor, compress the piston rings. IMPORTANT The piston and connecting rod must be installed in the correct orientation. The orientation of the piston to the cylinder is different depending on engine model. Figure 6-136 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…
• Page 136
  (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. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…
• Page 137
  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 respective cylinders. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 138: Components

  1. Set the No. 1 piston to top dead center. and press onto the end of the camshaft. 2. Rotate the camshaft until the mark (Figure 6-144, (C)) is approximately at the 9 o’clock position. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 139
  See Special Torque Chart on 7. When all gears are properly aligned, tighten the page 73 for specifications. idler gear retaining bolts to specified torque. See Special Torque Chart on page 73 for specifications. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 140: Final Reassembly Of Engine

  5. Reinstall the alternator. 6. Reconnect and adjust the throttle cable. 7. Reconnect all electrical connections. 8. Fill the engine with oil and coolant. 9. Reconnect the battery cables, negative (-) cable ast. 4TNV98 & 4TNE98 Diesel Engine Section 3. Engine…

• Page 141: Before You Begin Servicing

  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. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 142
  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. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 143: Tnv98 Engine

  MP2 pump, is used on the 3TNV82A — 4TNV88 model engines. The larger pump, the MP4 pump, which has a larger single plunger and a more aggressive cam profile, is used on the 4TNV94L- 4TNV106T model engines. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 144: Stop Solenoid

  12V at the stop solenoid connector in the by the MP fuel injection pump. correct sequence. The use of an electric fuel supply pump is required on all TNV model engines with the MP fuel injection pump. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 145: Fuel System Specifications

  Not Applied 2.3-2.9 kgf·m) 30-33 ft·lb Fuel Injector Nozzle Case Nut (39.2-44.1 N·m; Not Applied 4-4.5 kgf·m) 30-33 ft·lb Fuel Injection Pump 4TNV98 (40-45 N·m; Not Applied Plunger Plug 4.1-4.6 kgf·m) 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 146: Test And Adjustment Specifications

  ** Fuel injector identification is critical as each engine has a unique fuel injection pressure. The fuel nozzle is specifically matched to the fuel injector by engine model and / or engine speed. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 147: Special Service Tools

  * These special service tools may also be available as an “MP Fuel Injection Pump Special Tool Set”, under a different part number, in territories serviced by Yanmar America and Yanmar Europe. Contact your authorized Yanmar dealer or distributor for details. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 148: Fuel System Diagram

  (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. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 149: Fuel System Components

  (13) Diesel Fuel Injection Pump. (14) Rear Fuel Injection Pump Support. (15) Fuel Filter / Water Separator. (16) Electric Fuel Supply Pump. (17) Fuel Filter. (18) Fuel Filter Housing. (19) Stop Solenoid. (20) Cold Start Device (CSD). (21) Trochoid Fuel Pump 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 150: Fuel Injection Pump

  10. Remove the fuel supply line (Figure 7-7, (4)). and then at the fuel injection pump. Plug the open end of the line to minimize leakage and prevent contamination. 11. Remove the throttle cable from the fuel injection pump. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 151
  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 7-10 NOTE: TNV82-88 shown.
• Page 152
  Rotating the crankshaft will cause the fuel injection 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.
• Page 153
  (Figure 7-15, (1)) and lock washer (Figure 7-15, (2)). Figure 7-17 23. If required, remove the intake manifold and fuel pump insulator to access the fuel injection pump mounting nuts. Figure 7-15 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 154: Installation Of Fuel Injection Pump

  NOTE: The MP4 fuel injection pumps (4TNV98 model engines) are fastened to the gear case with CAUTION four (4) studs and nuts. NEVER remove or attempt to remove the 24. Remove the fuel injection pump (Figure 7-17, tamper-proof devices from the full-load fuel (1)).

• Page 155
  3. Install a new O-ring on the pump mounting flange. using the reference marks made earlier. Apply grease to the O-ring to hold it in place 4TNV98 model engines (Figure 7-21, (1)). during installation of the injection pump. NOTE: Ensure the tapered surface of the fuel injection pump shaft is clean and dry.
• Page 156
  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 7-25 Figure 7-24 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…
• Page 157
  • Each mark on the timing sticker represents 0.5° timing change. Figure 7-28 Tighten the fuel injection pump mounting nuts to specification. See Special Torque Chart on page 143. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…
• Page 158
  12. If equipped, verify the fuel injection pump insulator (Figure 7-31, (2)) is not damaged. Reinstall the insulator and intake manifold if previously removed. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 159: Checking And Adjusting Fuel Injection Timing

  15. Reinstall 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. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 160: Checking Fuel Injection Timing

  NOTE: Use the Yanmar part no. 158090-51841 for the M16 adapter used on the MP4 fuel injection pumps (TNV94-106 model engines) and Yanmar part no. 23000-013000 plunger adapter clamp (Figure 7-37, (1)). 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 161
  (1) 10° BTDC (Before Top Dead Center) (2) 15° BTDC. (3) 20° BTDC (4) Direction of Rotation. (5) TDC (Top Dead Center) 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…
• Page 162
  Center) mark (Figure 7-41, (1)) on the flywheel. 9. Highlight the target timing mark (Figure 7-42, (1)) on the flywheel as calculated in Determining the Fuel Injection Timing Specification on page 141. Figure 7-42 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 163: Adjusting Fuel Injection Timing

  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 for leaks. Figure 7-43 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 164
  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 on the flywheel housing or engine back plate, the injection timing is correct. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 165: Fuel Injectors

  (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. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 166: Testing Of Fuel Injectors

  “dripping”. If fuel leaks from the return line fitting, check that the nozzle case nut is tight. Service or replace the injector if fuel continues to leak from either the return line fitting or nozzle. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 167: Injectors

  (9) Nozzle Body. (10) Nozzle Case Nut 2. Place the fuel injector in a soft-jawed vise with the nozzle pointing up. 3. Remove the nozzle case nut. 4. Carefully remove the injector from the vise. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 168: Adjusting Fuel Injector Pressure

  The injection pressure will change by approximately 275 psi (1.9 MPa; 19 kgf/cm²) for every 0.1 mm (0.004 in.) in shim thickness. Figure 7-54 8. Replace the fuel injector assembly if it fails any inspection. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 169: Reassembly Of Fuel Injectors

  See Special Torque Chart on page 143. Figure 7-57 7. Prime the fuel system. See Priming the Fuel System on page 15. 8. Operate the engine and check for fuel and coolant leaks. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 170: Tne98 Engine

  Gear Nut Injection Pumpon page 192 6.0 — 7.0 kgf·m) Measuring Instruments Tool Name Application Illustration For measuring injection spray Fuel Injector Tester pattern of fuel injection nozzle and injection pressure 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 171: Fuel System Components

  Fuel System Components Figure 7-1 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 172: Fuel System Components

  The overflow valve above the injection pump pump chamber. functions to maintain constant fuel temperature in the pump chamber and return excessive fuel to the fuel tank. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 173: Pump

  Structure And Operation Of Fuel Injection Pump Figure 7-3 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 174: Overview

  The difference between the governor spring set force and the flyweight centrifugal force determines the moving distance of the control sleeve, thereby increasing or decreasing the fuel injection volume. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 175
  Thus, the timer controls the fuel injection When the capacity decreases, it feeds fuel into the timing according to the fuel pressure in the pump chamber. pump chamber. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…
• Page 176
  It is therefore possible to regulate the pump chamber pressure by changing the set force of the regulating valve spring. Figure 7-9 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 177: Plunger Operation

  When the cutoff port reaches the control sleeve, pressure feeding from the plunger is terminated. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 178: Process

  The fuel is then injected into the engine combustion chamber via the nozzle and nozzle holder. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 179
  The suction process through the uniform pressure process are carried out for each cylinder during every injection cycle. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 180: Fuel Injection Volume Adjustment Mechanism

  (I state. increases to increase the fuel injection volume. The control sleeve position is determined according to the governor control. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 181: Delivery Valve Assembly

  4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 182: All — Speed Governor

  The tension and start turns counterclockwise around fulcrum M to move levers move around shaft M as the fulcrum fixed the control sleeve to the start offset position. on the corrector lever. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 183
  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. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 184: At Start Of Engine

  (to the right) with M being the fulcrum. Thus, the engine can be started easily by lightly pressing down on the accelerator pedal. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 185: During Idling

  The governor sleeve stops at a point where the flyweight centrifugal and idle spring force are balanced to ensure stable idling. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 186: At Full-Load Maximum Speed Control

  A, thereby holding the control sleeve at the full-load position. At this time, the flyweight is pressed by the governor sleeve and is in the completely closed state. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 187: At No-Load Maximum Speed Control

  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 force during partial load operation. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 188
  M 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. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 189: Standard Type Automatic Timer

  4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 190: Magnetic Valve (Stop Solenoid)

  As a result, no fuel is fed to the plunger, stopping the engine immediately. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 191: Removal Of Fuel Injection Pump

  • Then loosen the high pressure fuel line nuts (Figure7-32, (3)) on the fuel injection pump. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 192
  Figure 7-36 11. To aid in reassembly, mark one tooth on the idle gear and two teeth on the pump drive gear with a dot of white paint. See (Figure 7-37). 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…
• Page 193
  Figure 7-38 12. While holding the engine from turning with a wrench on the crankshaft pulley bolt, remove the pump drive gear retaining nut (Figure7-39, (1)) and lock washer (Figure7-39, (2)). 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 194: Figure

  Install the fuel injection mark you made on the idle gear. See (Figure7- pump cover on the front gear case with seven 37). bolts. Tighten the bolts to the specified torque. Figure 7-41 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 195
  8. Pivot the bracket that fastens the fuel injection pump to the cylinder back up and toward the fuel injection pump. Retighten the bolt (Figure 7-45, (2)) that fastens it to the cylinder block. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 196: Checking / Adjustment Of Fuel Injection Timing

  (Figure7-48, (1)). Install a dial indicator into the 15. Reinstall fuel supply line to the fuel injection timing tool. pump. 16. Prime the fuel system and check for leaks. Figure 7-48 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 197
  Injection pump mounting nuts and the bolts retaining the bottom / rear L-shaped injection pump mounting brackets. Rotate the injection pump to bring the dial indicator reading into the correct range. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 198: Caution

  (Figure7-50, (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. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 199
  “pop off” pressure point. Observe the injector to MPa). The opening pressure may be adjusted by see that it is sealing properly and is not adding or subtracting internal fuel injector shims. “dripping”. Figure 7-52 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…
• Page 200
  Figure 7-54 8. If the fuel injector fails any of these tests, it should be repaired or replaced as necessary. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 201: Judgement Criteria On Atomization Condition

  Possible caused by caused by worn seat. foreign matter. Cause contamination 4. Damaged or flaws in or damage to the broken needle tip. internal parts od nozzle holder. 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 202: Installation Of Fuel Injectors

  • Start all the high pressure fuel line nuts by hand, leaving those nuts on the fuel injection pump and fuel injectors untightened. • Tighten the high pressure fuel line nuts 4TNV98 & 4TNE98 Diesel Engine Section 4. Fuel System…

• Page 203: Before You Begin Servicing

  Hot engine coolant may splash sealants and sealant removers. and burn you. Failure to comply could result in death or Failure to comply could result in death or serious injury. serious injury. 4TNV98 & 4TNE98 Diesel Engine Section 5. Cooling System…

• Page 204: Pinch Hazard

  O-ring, the material is different. 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. 4TNV98 & 4TNE98 Diesel Engine Section 5. Cooling System…

• Page 205: Figure

  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. 4TNV98 & 4TNE98 Diesel Engine Section 5. Cooling System…

• Page 206: Figure

  (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 4TNV98 & 4TNE98 Diesel Engine Section 5. Cooling System…

• Page 207: Engine Coolant System Check

  Do not attempt to repair the engine coolant pump or replace individual components. IMPORTANT Figure 8-5 Make sure the engine and engine coolant are not hot. 4TNV98 & 4TNE98 Diesel Engine Section 5. Cooling System…

• Page 208
  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)). 4TNV98 & 4TNE98 Diesel Engine Section 5. Cooling System…

• Page 209: Disassembly Of Engine Coolant Pump

  Figure 8-11 2. Apply 10.8 — 14.8 psi (75 — 105 kPa; 0.75 — 1.05 kgf/cm²) to the radiator cap. The radiator cap relief valve must open within the specified range. 4TNV98 & 4TNE98 Diesel Engine Section 5. Cooling System…

• Page 210: Reassembly Of Engine Coolant Pump

  2. Reinstall the thermostat cover (Figure 8-12, (2)) and a new gasket. Tighten the thermostat cover bolts. 3. Reinstall the temperature switch (Figure 8-12, (3)) and a new gasket (Figure 8-12, (4)). Figure 8-13 4TNV98 & 4TNE98 Diesel Engine Section 5. Cooling System…

• Page 211
  Carefully clean the radiator cap and the surrounding area before you remove the cap. NEVER mix different types of engine coolants. This may adversely affect the properties of the engine coolant. 4TNV98 & 4TNE98 Diesel Engine Section 5. Cooling System…

• Page 212: Before You Begin Servicing

  FUME / BURN HAZARD! Always read 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. 4TNV98 & 4TNE98 Diesel Engine Section 6. Lubrication System…

• Page 213
  If the oil pump must be replaced, replace it as an If any oil pump component clearance exceeds its assembly only. not replace individual limit, the oil pump must be replaced as an components. assembly. 4TNV98 & 4TNE98 Diesel Engine Section 6. Lubrication System…

• Page 214: Introduction

  Introduction This section of the Service Manual describes the procedures necessary to service the 4TNV98 Trochoid oil pump. See Replace Engine Oil and Engine Oil Filter on page 51 for engine oil and engine oil filter replacement procedures. Oil Pump Service Information…

• Page 215
  0.5089 to 0.5106 in. 0.5085 in. 4TNE98 Clearance Rotor Shaft O.D. (12.925 — 12.970 mm) (12.915 mm) 0.0004 to 0.0026 in. 0.0041 in. page 216 Rotor Clearance (0.010 to 0.065 mm) (0.105 mm) 4TNV98 & 4TNE98 Diesel Engine Section 6. Lubrication System…

• Page 216: Lubrication System Diagram

  Lubrication System Diagram Figure 9-1 4TNV98 & 4TNE98 Diesel Engine Section 6. Lubrication System…

• Page 217: Checking Engine Oil Pressure

  • 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. 4TNV98 & 4TNE98 Diesel Engine Section 6. Lubrication System…

• Page 218: Disassembly Of Oil Pump

  (Figure 9-16, (1)) from the gear case housing (Figure 9-16, (2)). Figure 9-17 Record the measurement(s) and see Check Outer Rotor Outside Clearance on page 236 for the service limits. 4TNV98 & 4TNE98 Diesel Engine Section 6. Lubrication System…

• Page 219: Reassembly Of Oil Pump

  (Figure 9-21, (2)). Figure 9-19 Record the measurement(s) and see Check Outer Figure 9-21 Rotor Side Clearance on page 217 for the service limits. 4TNV98 & 4TNE98 Diesel Engine Section 6. Lubrication System…

• Page 220
  (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. 4TNV98 & 4TNE98 Diesel Engine Section 6. Lubrication System…

• Page 221: Before You Begin Servicing

  FUME / BURN HAZARD! Always read 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. 4TNV98 & 4TNE98 Diesel Engine Section 7. Starter Motor…

• Page 222
  The starter motor will malfunction or break down if the resistance is higher than the specified value. 4TNV98 & 4TNE98 Diesel Engine Section 7. Starter Motor…

• Page 223: Introduction

  Part Mfg. Part Specification Terminal Terminal erage erage Torque Number Number Voltage Voltage Draw Draw 97 in.-lb DC12V-3.1 hp 140A A408417 Hitachi S13-204 4100 (11.0 N·m; 1400 (2.3 kW) 1.1 kgf·m) 4TNV98 & 4TNE98 Diesel Engine Section 7. Starter Motor…

• Page 224: Starter Motor Specifications

  0.008 in. (0.02 mm) Limit 6903DDU Armature Front 608DDU Armature Rear Bearing Type Nominal Number Pinion Front 60004DDU 6904DDU Pinion Rear 0.012 — 0.059 in. (0.3 — 1.5 mm) Pinion Projection Length (Length L) 4TNV98 & 4TNE98 Diesel Engine Section 7. Starter Motor…

• Page 225: Starter Motor Troubleshooting

  Starter Motor Troubleshooting 4TNV98 & 4TNE98 Diesel Engine Section 7. Starter Motor…

• Page 226: Starter Motor Components

  (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) 4TNV98 & 4TNE98 Diesel Engine Section 7. Starter Motor…

• Page 227: Starter Motor

  Remove the starter motor from the flywheel housing. Figure 11-3 2. Remove the two M4 bolts (Figure 11-4, (1)) securing the rear cover (Figure 11-4, (2)) to the brush holder assembly (Figure 11-4, (3)). 4TNV98 & 4TNE98 Diesel Engine Section 7. Starter Motor…

• Page 228
  8. Disassemble the dust cover (Figure11-8, (3)) and shift the lever (Figure11-8, (4)) from the gear housing. Figure 11-5 5. Remove the brush holder assembly (Figure 11-6, (1)) from the armature assembly (Figure 11-6, (3)). Figure 11-8 4TNV98 & 4TNE98 Diesel Engine Section 7. Starter Motor…

• Page 229: Cleaning And Inspection

  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)). 4TNV98 & 4TNE98 Diesel Engine Section 7. Starter Motor…

• Page 230
  (Figure11-16). The multimeter should not indicate continuity. Figure 11-16 If the multimeter indicates continuity, replace the Figure 11-14 armature. See Starter Motor Specifications on page 222 for the service limit. 4TNV98 & 4TNE98 Diesel Engine Section 7. Starter Motor…
• Page 231
  (Figure11-18). The multimeter should indicate continuity. If the multimeter does not indicate continuity, replace the field coil assembly. Figure 11-20 See Starter Motor Specifications on page 222 for the service limit. Figure 11-18 4TNV98 & 4TNE98 Diesel Engine Section 7. Starter Motor…
• Page 232
  The multimeter should indicate continuity. If the multimeter does not indicate continuity, replace the magnetic switch. Figure 11-22 Coil Resistance Test See Starter Motor Specifications on page 222 for the service limit. Figure 11-21 4TNV98 & 4TNE98 Diesel Engine Section 7. Starter Motor…
• Page 233
  (Figure11-24). It should 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 11-26 Figure 11-24 4TNV98 & 4TNE98 Diesel Engine Section 7. Starter Motor…

• Page 234: Reassembly Of Starter Motor

  (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 11-30 (Figure 11-28, (5)). Figure 11-28 4TNV98 & 4TNE98 Diesel Engine Section 7. Starter Motor…

• Page 235: Check Pinion Projection Length

  Reinstall the the standard range. Dust covers (Figure 11-34, cover over the connection. (1)) are available in 0.020 in (0.5 mm) and 0.031 in (0.8 mm) thicknesses. Figure 11-32 Figure 11-34 4TNV98 & 4TNE98 Diesel Engine Section 7. Starter Motor…

• Page 236: No-Load Test

  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. 4TNV98 & 4TNE98 Diesel Engine Section 7. Starter Motor…

• Page 237: Special Service Tools

  Compression Gauge Kit Adapter for direct injection 4-valve cylinder head for 4TNV94L/98/98T Yanmar Adapter Part No. 129906- 92950 Adapter for direct injection 4-valve cylinder head for 4TNV106(T) Yanmar Adapter Part No. 123907- 92950 4TNV98 & 4TNE98 Diesel Engine Section 8. Troubleshooting…

• Page 238: Troubleshooting By Measuring Compression Pressure

  3. Turn off the fuel supply valve in the fuel supply line. Disconnect the fuel injection pump stop solenoid at the connector. This prevents the fuel injection pump from injecting fuel during 4TNV98 & 4TNE98 Diesel Engine Section 8. Troubleshooting…

• Page 239
  (3.33 — 3.53 MPa; (2.65 — 2.85 MPa; (0.2 — 0.3 MPa; 34 — 36 kgf/cm²) 27 — 29 kgf/cm²) 2 – 3 kgf/cm²) Engine Speed and Compression Pressure (Use for Reference) Figure 14-2 4TNV98 & 4TNE98 Diesel Engine Section 8. Troubleshooting…
• Page 240
  (2.94 ± 0.1 MPa, (2.35 ± 0.1 MPa, (0.2 to 0.3 MPa; 30 ± 1 kgf/cm²) 24 ± 1 kgf/cm²) 2 to 3 kgf/cm²) Engine Speed and Compression Pressure (Use for Reference) Figure 13-2 4TNV98 & 4TNE98 Diesel Engine Section 8. Troubleshooting…

• Page 241: Quick Reference Table For Troubleshooting

  The following table summarizes the general trouble symptoms and their causes. If any trouble symptom occurs, take corrective action before it becomes a serious problem so as not to shorten the engine service life. 4TNV98 & 4TNE98 Diesel Engine Section 8. Troubleshooting…

• Page 242: Troubleshooting Charts

  Troubleshooting Charts 4TNV98 & 4TNE98 Diesel Engine Section 8. Troubleshooting…

• Page 243
  4TNV98 & 4TNE98 Diesel Engine Section 8. Troubleshooting…
• Page 244
  4TNV98 & 4TNE98 Diesel Engine Section 8. Troubleshooting…

• Page 245: Wiring Diagram

  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 4TNV98 & 4TNE98 Diesel Engine Section 8. Troubleshooting…

• Page 246
  4TNE98 Engine 4TNV98 & 4TNE98 Diesel Engine Section 8. Troubleshooting…