Pulling an old marine diesel out of the bilge is hard enough without guessing at the rebuild specs, which is why this 182-page Yanmar 2TM, 3TM, 4TM Service Manual PDF (OEM #000/AVA200-3107) breaks down every cylinder, gear, and fuel system procedure. You get full factory wiring diagrams, complete troubleshooting charts for diagnosing fuel delivery issues, and step-by-step teardown instructions for the reduction and reversing gear systems. Open to any chapter and find detailed piping diagrams, clear component exploded views, and page after page of factory specifications. Verify your piston ring end gap is sitting perfectly between 0.25 and 0.45 mm, then torque the main bearing bolts to exactly 138-152 lb-ft before closing up the bottom end. Stop wasting time searching for marine engine specs online. Grab this bookmarked file on your tablet, head straight to the engine room, and get your boat running right.
What's Inside This Yanmar 2TM, 3TM, 4TM Manual
| System | Pages | Key Topics |
|---|---|---|
| Chapter 1 General | 4-24 | 1.External Veiw, 2.Specifications, 3.Performance Curves, 4.Engine Cross-Section, 5.Piping Diagram, 6.Disassembly and Reassembly Tools |
| Chapter 2 Basic Engine | 25-65 | Cylinder Block, Cylinder Liner, Cylinder Head, Piston, Connecting Rod, Crankshaft, Camshaft, Timing Gears |
| Chapter 3 Fuel System | 66-88 | 1.Fuel Supply System, 2.Injection Pump, 3.Governor and Linkage, 4.Fuel Injection Nozzle, 5.Fuel Feed Pump, 6.Fuel Filter, 7.Water Separator, 8.Fuel Tank (Option) |
| Chapter 4 Intake and Exhaust System | 89-91 | 1.Intake and Exhaust System |
| Chapter 5 Lubrication System | 92-104 | 1.Lubrication System, 2.Oil Pump, 3.Oil Filter, 4.Oil Cooler |
| Chapter 6 Cooling System | 105-113 | 1.Cooling System, 2.Water Pump, 3.Kingston Cock, 4.Sea Water Filter (Option) |
| Chapter 7 Chain Overdrive Hand-Operated System | 114-116 | 1.Chain Overdrive Hand-Operated System |
| Chapter 8 Reduction and Reversing Gear | 117-143 | For Model 2TM and 3TM (Construction, Disassembly, Servicing, Reassembly, Adjustment), For Model 4TM (Construction |
| Chapter 9 Electrical System | 144-168 | 1.Composition, 2.Battery, 3.Starter Motor, 4.Alternator, Option |
| Chapter 10 Stern Equipment | 169-171 | 1.Stern Arrangement (Yanmar Standard), 2.Stern Bearings |
| Chapter 11 Troubleshooting | 172-176 | 1.Troubleshooting |
| Chapter 12 Inspection and Servicing | 177-181 | 1.Periodic Inspections and Servicing, 2.Specifications, 3.Tightening Torque |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Cylinder head fixing nut tightening torque | 13.5 ~ 14.5 kg-m (97.8 ~ 105 lb-ft) | p. 180 |
| Fuel injection pump fixing nut tightening torque | 0.9 ~ 1.1 kg-m (6.5 ~ 8.0 lb-ft) | p. 180 |
| Main bearing bolt tightening torque | 19 ~ 21 kg-m (138 ~ 152 lb-ft) | p. 180 |
| Allowable error between cylinders (Fuel injection volume) | ±0.5cc/1000 st. | p. 72 |
| Piston ring end gap (No. 1,2,3) - Standard | 0.25 ~ 0.45 mm (0.0098 ~ 0.0177 in.) | p. 179 |
| Piston ring end gap (Oil ring) - Standard | 0.20 ~ 0.40 mm (0.0079 ~ 0.0157 in.) | p. 179 |
| Filter type | Paper type | p. 85 |
| Filtration area | 4000cm² | p. 85 |
| Cylinder Head Bolt Tightening Torque | 13.5 ~ 14.5 kg-m | p. 28 |
| Main Bearing Cap Bolt Tightening Torque | 19 ~ 21 kg-m | p. 54 |
| Nozzle Valve Opening Pressure | 200 ~ 205 kg/cm² | p. 79 |
Yanmar 2TM, 3TM, 4TM Common Problems This Manual Covers
Yanmar 2TM, 3TM, and 4TM marine diesel engine fails to start or cranks without ignition. p. 173
Replace the paper type fuel filter element every 500 hours as shown on page 85. Bleed air from the fuel lines. Test the injection pump delivery volume. Verify the allowable error between cylinders remains within ±0.5cc/1000 st. as specified on page 72.
Manual Section: Engine Cranks but Doesn't StartRapid loss of power under heavy load accompanied by high engine and cooling water temperature. p. 175
Inspect the cooling water flow and clean the dirty cooling system. Check for gas leakage into the crankcase. If removing the head to inspect passages, torque the cylinder head bolts to 13.5 ~ 14.5 kg-m during reassembly as instructed on page 28.
Manual Section: High Engine/Cooling Water TemperatureExcessive engine oil consumption accompanied by continuous blue exhaust smoke during regular operation. p. 174
Remove the cylinder head and pull the pistons to inspect the rings. Measure the piston ring end gap for rings 1, 2, and 3. Replace the rings if the gap exceeds the standard 0.25 ~ 0.45 mm specification listed on page 179.
Manual Section: Abnormal Exhaust Gas ColorLoud metallic engine knocking noise that increases in frequency with engine RPM. p. 175
Measure the bearing and crankpin clearance. Inspect the connecting rod and flywheel bolts for looseness. When reassembling the bottom end, tighten the main bearing cap bolts strictly to 19 ~ 21 kg-m as specified on page 54 to prevent further knocking.
Manual Section: Engine KnocksFrequently Asked Questions
What are the torque specs for the YANMAR 2TM, 3TM, and 4TM cylinder head bolts?
The tightening torque for the cylinder head fixing nuts on YANMAR 2TM, 3TM, and 4TM engines is specified as 13.5 to 14.5 kg-m (98 to 105 ft-lb). These bolts have a screw diameter of M14 x 1.5 and a 22 mm bolt head side-to-side dimension.
How do I adjust valve clearance on a YANMAR 2TM, 3TM, or 4TM?
Valve clearance adjustment should be performed when the engine is cold. First, remove the valve rocker arm cover. Then, check and adjust the intake and exhaust valve head clearances of the No. 1 piston to the maintenance standard of 0.25 mm (0.010 in.) using a feeler gauge, loosening the lock nut, adjusting the screw, and retightening the lock nut. The procedure is then repeated for the remaining pistons as per the provided table.
What is the crankshaft main bearing bolt torque for the 2TM, 3TM, or 4TM?
The tightening torque for the crankshaft main bearing bolts on YANMAR 2TM, 3TM, and 4TM engines is specified as 19 to 21 kg-m (137.42 to 151.68 ft-lb).
How often should the fuel filter be replaced on the 2TM, 3TM, or 4TM?
Replace the paper-type fuel filter element every 500 hours, then bleed air from the fuel lines (page 85).
Document Quality
This document is a scanned PDF, not a native digital file. You can search the full text, as it includes an OCR layer, and the text is generally crisp and readable despite minor scan artifacts. Diagrams and illustrations are raster images, so they show some pixelation when zoomed, but their labels remain clear. Pages are mostly clean, though some exhibit slight skewing and faint background noise. Be aware that there are several blank pages throughout the document, often marking the end of sections.
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