Part of the Yanmar Repair Manuals.
Before a cylinder head goes back on a Yanmar 2TD, you need the fixing nut torque and the tightening sequence, not a figure someone half-remembers at the dock. This 184-page Yanmar service manual (publication A0A1 748-8806) covers the 2TD, 3TD, and 4TD marine diesel engines end to end: cylinder block, liners, head, pistons, connecting rods, crankshaft, camshaft, and timing gears, then the full fuel system with injection pump, governor, nozzles, feed pump, and filters.
It continues through the lubrication and cooling systems, the reduction and reversing gear (with separate disassembly and reassembly procedures for the 2TD/3TD and the 4TD), the electrical system, stern equipment, and closes with troubleshooting and inspection tables.
It is a downloadable PDF with 72 bookmarks, so the torque and clearance tables are a click away whether you are at the bench, aboard, or at the parts counter.
What's Inside This Yanmar 2TD, 3TD, 4TD Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 4-24 | External View, Specifications, Performance Curve, Engine Cross-Section, Piping Diagram, Disassembly and Reassembly Tools |
| Basic Engine | 25-65 | Cylinder Block, Cylinder Liner, Cylinder Head, Piston, Connecting Rod, Crankshaft, Camshaft, Timing Gears |
| Fuel System | 66-88 | Fuel Supply System, Injection Pump, Governor and Linkage, Fuel Injection Nozzle, Fuel Feed Pump, Fuel Filter, Water Separator, Fuel Tank (Option) |
| Intake and Exhaust System | 89-91 | Intake Port, Exhaust Pipe, Exhaust Silencer, Exhaust Manifold, Cylinder Head, Gasket Packing |
| Lubrication System | 92-104 | Oil Pump, Oil Filter, Oil Cooler |
| Cooling System | 105-115 | Water Pump, Kingston Cock, Bilge Pump, Sea Water Filter (Option) |
| Chain Overdrive Hand-Operated System | 116-118 | Sprocket Wheel, Camshaft Gear, Crankshaft Gear, Roller Chain, Starting Shaft Support |
| Reduction and Reversing Gear | 119-145 | Governor, Reversing Gear Upper Case, Reversing Gear Shaft, Clutch Housing, Reversing Gear Box, Thrust Shaft, Thrust Gear |
| Electrical System | 146-170 | Composition, Battery, Starter Morter, Alternator, Option |
| Stern Equipment | 171-173 | Stern Arrangement (Yanmar Standard), Stern Bearings |
| Troubleshooting | 174-178 | Flywheel, Engine, Fuel System, Governor, Piston, Bearings, Fuel Filter, Fuel Injection Pump |
| Inspection and Servicing | 179-183 | Fuel Oil, Lube Oil, Cooling Water, Fuel Injection Pump, Fuel Injection Valve, Cylinder Head, Electrical Equipment, Marine Gear |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Cylinder head fixing nut torque | 13.5 ~ 14.5 kg-m (98 ~ 105 ft-lb) | p. 182 |
| Nozzle valve opening pressure | 200 ~ 205 kg/cm² | p. 79 |
| Nozzle nut tightening torque | 6.5 ~ 7.5 kg-m (47.0 ~ 54.2 ft-lb) | p. 81 |
| Fuel feed pump head | 0.5 m | p. 83 |
| Fuel filter pressure loss | 3 ~ 5 mmHg | p. 86 |
| Fuel filter max. passing particle size | 10 μ | p. 86 |
| Oil filter filtration mesh | 150 mesh | p. 100 |
| Oil filter max. flow capacity | 1050 L/hr | p. 100 |
| Minimum battery capacity | 12V, 120AH | p. 148 |
| Fully charged battery specific gravity | 1.280 | p. 148 |
| Cooling Water Capacity (at 2,100 rpm) | 1,350 L/hr | p. 8 |
| Connecting Rod Tightening Bolt Torque | 9.5 ~ 10.5 kg-m | p. 182 |
Yanmar 2TD, 3TD, 4TD Common Problems This Manual Covers
Hard starting after winter layup
Air drawn into the fuel lines, stale fuel, or a clogged filter will keep a TD-series engine cranking without firing. The fuel supply system layout, feed pump, filter, and water separator procedures show where to trace and cure the problem.
Manual Section: Chapter 3 Fuel System p. 66Rough running and excessive smoke
Worn or fouled injection nozzles upset combustion and show up as low power, stalling under load, and smoke. The manual gives nozzle service procedures with a verified opening pressure of 200 to 205 kg/cm2, so you can test and reset rather than guess.
Manual Section: Chapter 3 Fuel System p. 66Overheating under load
Restricted raw water flow from a fouled Kingston cock, a tired water pump, or a blocked sea water filter drives temperatures up fast. This chapter covers the water pump, Kingston cock, bilge pump, and optional sea water filter.
Manual Section: Chapter 6 Cooling System p. 105Low oil pressure or oil contamination
Falling oil pressure points to the oil pump, a plugged filter, or internal wear, and running on while it drops costs bearings. The lubrication chapter covers the oil pump, filter, and cooler with inspection procedures.
Manual Section: Chapter 5 Lubrication System p. 92Starter will not crank the engine
A weak battery or failing starter motor leaves you dead at the mooring. The electrical chapter covers battery care, including the 12V 120AH minimum capacity and electrolyte checks, plus starter motor and alternator service.
Manual Section: Chapter 9 Electrical System p. 146Reversing gear slips or shifts hard
Clutch and thrust gear wear in the marine gear shows up as slipping under power or harsh engagement. The manual gives separate construction, disassembly, inspection, reassembly, and adjustment procedures for the 2TD/3TD gear and the 4TD gear.
Manual Section: Chapter 8 Reduction and Reversing Gear p. 119Low compression from worn liners
High hours bring worn cylinder liners, rings, and valves, felt as hard starting and blow-by. The basic engine chapter covers liner, piston, connecting rod, crankshaft, and cylinder head measurement and reconditioning for a proper rebuild.
Manual Section: Chapter 2 Basic Engine p. 25Frequently Asked Questions
Which engines does this manual cover?
It covers the Yanmar 2TD, 3TD, and 4TD marine diesel engines. It is the factory service manual, publication A0A1 748-8806, 184 pages, in English, and includes procedures specific to each model where they differ, such as the reduction and reversing gear.
What is the cylinder head torque for the Yanmar 2TD, 3TD, 4TD marine diesel engines?
The manual specifies 13.5 to 14.5 kg-m (98 to 105 ft-lb) for the M14 x 1.5 cylinder head fixing nuts, listed in the Chapter 12 Inspection and Servicing tables. Connecting rod bolt torque is given there as well. p. 182
Does it cover the fuel injection pump and injectors?
Yes. Chapter 3 Fuel System covers the injection pump, governor and linkage, injection nozzles, feed pump, fuel filter, and water separator. Nozzle valve opening pressure is specified at 200 to 205 kg/cm2, with nozzle nut tightening torque included. p. 66
Does it include the marine gear and stern equipment?
Yes. Chapter 8 covers the reduction and reversing gear with separate disassembly, inspection, reassembly, and adjustment procedures for the 2TD/3TD and the 4TD. Chapter 10 covers the Yanmar standard stern arrangement and stern bearings. p. 119
Is this manual a PDF I download?
Immediate download of the complete 184-page searchable Service Manual. Access it on any device, from a laptop at your desk to a phone in the field.
Can I print this manual?
The PDF is DRM-free. Print whatever sections you need to take out to the shop. Standard letter or A4 paper works.
Can I find wiring schematics in this Yanmar 2TD manual?
Yes. You'll find full electrical schematics with wire routing diagrams, connector identification, and circuit descriptions.
Reviews
There are no reviews yet.