Part of the Yanmar Repair Manuals.
Set the crankshaft in the block and you will want main bearing clearances, endplay limits, and the rod bolt torque before anything else goes back together. This 175 page Yanmar service manual covers the 3TN100E, 4TN100E, and turbocharged 4TN100TE industrial diesels of the TN 100 series, delivered as a PDF download under factory publication 0000AOC1927 T 8905.
The chapters follow the engine from the inside out: cylinder block, head, pistons, connecting rods, crankshaft, and timing gear in Basic Engine, then full disassembly, reassembly, and inspection of the governor and fuel injection pump, followed by the lubricating, cooling, air induction, and electrical systems, including a wiring diagram, starter, alternator, and starting aids.
Whether the engine drives a generator, a pump, or something else entirely, you are usually working on it alone. The closing Disassembly and Reassembly chapter puts the bolt and nut tightening torques in one table so the rebuild goes together right the first time.
What's Inside This Yanmar 3TN100E, 4TN100E, 4TN100TE Manual
| System | Pages | Key Topics |
|---|---|---|
| Yanmar Service Manual | 1 | - |
| Preface | 2-3 | - |
| General | 4-19 | Specifications, Performance Curves, Cross Sectional Views, Dimensions, Maintenance |
| Basic Engine | 20-52 | Cylinder Block, Cylinder Head, Piston and Piston Pins, Connecting Rod, Crankshaft and Main Bearing, Camshaft and Tappets, Timing Gear, Flywheel |
| Fuel Injection Equipment | 53-96 | Fuel Supply System, Disassembly, Reassembly and Inspection of Governor, Reassembly and Inspection of Fuel Injection Pump |
| Lubricating System | 97-109 | Lubrication System, Lube Oil Pump, Lube Oil Filter & Oil Pressure Control Valve, Oil Cooler, Piston Cooling Nozzle, Oil Pressure Control Valve |
| Cooling System | 110-119 | Radiator Fan Belt, Thermostat, Cooling Water Pump |
| Air Induction System | 120-136 | Air Cleaner, Turbocharger |
| Electrical System | 137-158 | Wiring Diagram, Starter Motor, Alternator, Starting Aids |
| Disassembly and Reassembly | 159-174 | Disassembly, Reassembly, Bolt/Nut Tightening Torque |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Nozzle opening pressure | 200 - 210 kg/cm² | p. 87 |
| Fuel injection nozzle retainer nut tightening torque (to cylinder head) | 0.4 ~ 0.5 kg-m (2.9 ~ 3.6 ft-lb) | p. 171 |
| Fuel injection pump driving gear nut torque | 11.5 ~ 12.5 kg-m | p. 174 |
| Water pump impeller to body clearance (Standard) | 0.3 ~ 0.7 mm | p. 117 |
| Cooling water pump support tightening torque | 1.8 ~ 2.3 kg-m (13 ~ 16.7 ft-lb) | p. 171 |
| Valve clearance (Intake and exhaust) | 0.27 – 0.33 mm (0.0106 – 0.0130 in) | p. 32 |
| Radiator cap working pressure | 0.9 kg/cm² (0.98/12.8 PSI) | p. 112 |
| Alternator nominal output | 12V-40A | p. 149 |
| Connecting rod clamping bolt torque | 11.5 – 12.5 kg-m | p. 174 |
Yanmar 3TN100E, 4TN100E, 4TN100TE Common Problems This Manual Covers
Hard starting, especially in cold weather
Air drawn into the fuel lines, a clogged filter, or poor fuel delivery will keep a TN 100 from lighting off. The Fuel Injection Equipment chapter covers the fuel supply system so you can trace and bleed the circuit properly.
Manual Section: Fuel Injection Equipment p. 53Sudden shutdown under load
Fuel starvation from a faulty injection pump or governor can stop the engine without warning. The manual walks through disassembly, reassembly, and inspection of both the governor and the injection pump.
Manual Section: Fuel Injection Equipment p. 53Low oil pressure at operating temperature
A worn lube oil pump, blocked filter, or sticking oil pressure control valve will starve the bearings long before a gauge makes it obvious. This chapter covers the pump, filter, control valve, oil cooler, and piston cooling nozzles.
Manual Section: Lubricating System p. 97Overheating or rising coolant temperature
A lazy thermostat, slipping fan belt, or worn water pump impeller will push the temperature up fast on these engines. The manual gives inspection procedures for the thermostat, belt, and cooling water pump, including the standard impeller to body clearance of 0.3 to 0.7 mm.
Manual Section: Cooling System p. 110Power loss on the turbocharged 4TN100TE
A restricted air cleaner or a tired turbocharger shows up as smoke and weak output under load. The Air Induction System chapter covers both the air cleaner and turbocharger service.
Manual Section: Air Induction System p. 120Slow cranking or charging failure
A dragging starter motor, weak alternator, or bad wiring leaves you chasing electrical gremlins with a test light. This chapter includes the wiring diagram plus starter motor, alternator, and starting aid procedures.
Manual Section: Electrical System p. 137Valve noise or falling compression
Worn valve train parts and drifting lash cost compression and add clatter. The Basic Engine chapter covers the cylinder head, camshaft, and tappets, with the intake and exhaust valve clearance specified at 0.27 to 0.33 mm.
Manual Section: Basic Engine p. 20Frequently Asked Questions
Which engine models does this manual cover?
It covers the Yanmar 3TN100E, 4TN100E and 4TN100TE industrial diesels of the TN 100 series. The turbocharged 4TN100TE is included, with turbocharger service starting on page 120 in the Air Induction System chapter.
What is the valve clearance for the Yanmar 3TN100E, 4TN100E, 4TN100TE, TN 100 series engines?
Intake and exhaust valve clearance is 0.27 to 0.33 mm (0.0106 to 0.0130 in). The Basic Engine chapter covers the cylinder head, camshaft, and tappets where you set it. p. 32
Does it cover injection pump and injector service?
Yes. The Fuel Injection Equipment chapter covers disassembly, reassembly, and inspection of the fuel injection pump and governor, and lists the nozzle opening pressure at 200 to 210 kg/cm² for testing injectors. p. 87
Are tightening torque specifications included?
Yes. The Disassembly and Reassembly chapter ends with a bolt and nut tightening torque table, including values like 11.5 to 12.5 kg-m for the connecting rod clamping bolts, so you have the numbers before final assembly. p. 174
Do I get instant access to this Service Manual?
This is a 175-page searchable PDF (12 MB) ready for immediate download. Works on any device, so pull it up on your phone while you're under the hood. No shipping, no waiting.
Am I able to print pages from this manual?
Yes. The PDF has no DRM restrictions, so print any page or section you need for your shop. Works with any standard printer.
Does this Yanmar 3TN100E manual have electrical schematics?
Yes. The Electrical System chapter carries the wiring diagram, along with starter motor, alternator, and starting aid procedures — the alternator is specified there at 12V-40A on page 149.
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