1989–1993 John Deere Series 220 Diesel Engines Component Technical Manual (CTM3)

John Deere Component Technical Manual CTM3 covers repair and adjustment of the listed 1989–1993 3TN/4TN diesel engines and Series 220 OEM power units. The August 10, 1993 edition replaces the November 28, 1989 edition.

Text search and navigation: Service text and specification tables are searchable, with embedded bookmarks for engine families, service groups, and the index. Labels within wiring diagrams are not searchable; small terminal numbers and wire-color codes are easiest to read with zoom.

• Engine repair: Cylinder head and valve service, piston and connecting rod inspection, crankshaft and main bearing checks, camshaft service, and timing gear adjustment.

• Fuel system: Injection-pump removal, static timing, governor-linkage service, pintle- and hole-type nozzle testing, fuel-system bleeding, and shutoff-solenoid adjustment.

• Lubrication and cooling: Oil pump and water pump service, oil cooler checks, engine oil pressure testing, thermostat testing, radiator bubble tests, and cooling system pressure tests.

• Starting and charging: Hitachi and Nippondenso starter repair, Kokosan, Hitachi, and Nippondenso alternator coverage, starter amp-draw/RPM tests, and alternator amperage testing.

• Turbocharger service: RHB3 and wastegated RHB5 disassembly, rotor shaft play inspection, reassembly, failure analysis charts, and dealer-fabricated measuring tools.

• Electrical schematics: Separate 3009 and 3011/3014/4019 power unit circuits for starting, fuel shutoff, preheat, charging, indicators, and optional gauges.

This manual is written for experienced technicians and identifies the special tools required for the covered service work.

Engine Applications and Serial Differences

Application charts connect 3009 with 3TNA72, 3011 with 3TNC78, 3014 with 3TN84, and 4019D/4019T with 4TN84/4TN84T. TN-series and OEM engines can share parts while using different specifications; the OEM units are not tractor repower engines.

The early and later 3TNA72 sections distinguish timing gear layouts, oil pumps, and fuel control linkages. The 655 oil pan serial change also affects mounting hardware, helping you match the repair information to the assembly on the bench.

Machine-specific engine removal, installation, and access procedures require the corresponding machine technical manual.

Internal Engine Repair and Inspection

Teardown instructions cover rocker arms, valves, pistons, connecting rods, flywheels, and crankshaft seals. The 4TN82RJK and 4TN84RJK coverage adds balancer assembly service; lubrication sections distinguish oil cooler and piston cooling nozzle applications.

Standard dimensions and wear limits for valve guide bores, piston ring grooves, and main bearings support inspection of parts before reassembly. Component torque data, clearances, and adjustment specifications are grouped by engine. Special-tool references include the D15001NU magnetic follower holder for camshaft work.

Valve seat grinding and lapping procedures include a warning that cutting the seats can damage their sealing surfaces and cause leakage or valve/seat failure.

Fuel-System Diagnosis and Repair Limits

The Engine and Fuel System Troubleshooting Chart links starting trouble, smoke, power loss, and overheating to checks and possible causes. Cylinder compression testing and nozzle chatter, leakage, opening-pressure, and spray-pattern checks provide further diagnostic detail, with injector cross-sections and spray-pattern diagrams.

The manual covers injection-pump removal and timing but assigns internal pump repair to qualified fuel-injection specialists. The 3TN66/3TNA72 section permits delivery-valve service and covers the separate governor linkage; direct-injection pump and governor repairs require specialist service.

Turbocharger, Accessories, and Electrical Reference

Turbocharger Failure Analysis and the seven-step inspection distinguish compressor, turbine, lubrication, and center-housing faults. Drawings specify dealer-made DFRG1 and DFRG2 indicator tips for rotor shaft measurements. Accessory removal and installation details cover air cleaners, mufflers, radiators, and engine electrical components.

Repair notes explain how oil migration through the turbocharger when an engine is rolled on a stand can cause hydraulic lock and severe engine damage.

Fuel Injection Pump Operation cross-sections show plunger action, while the Lubrication System Operation drawing traces oil routing. Engine Electrical Components and Instrument Panel Components views support the power unit wiring diagrams. Complete tractor, mower, loader, or excavator wiring requires the machine-specific manual.

Follow the manual’s precautions for engine lifting, rotating machinery, and high-pressure fuel before service.

Printable PDF and Included Pages

Supplied as one printable, English-language, 718-page PDF. The total includes two cover pages, the one-page dealer revision notice, and 18 blank or header-only pages.