Mazda m4-121g Engine [PDF]

Zitiervorschau

MAZDA M4–121G ENGINE

2

1 3 1. FILL CAP FOR ENGINE OIL 2. ROCKER ARM COVER 3. VALVES AND HEAD ASSEMBLY 4. CYLINDER BLOCK 5. CAMSHAFT 6. CRANKSHAFT 7. PISTON AND CONNECTING ROD ASSEMBLY 8. FLYWHEEL HOUSING 9. OIL SUMP 10. DRAIN PLUG, ENGINE OIL 11. FAN

4 5 7

8

11

9

6

10 10016

FIGURE 1. MAZDA ENGINE

GENERAL This section has the repair instructions for the engine. Removal, disassembly, repair, assembly, installation, checks and adjustments, and trouble–shooting are included. The specifications are given at the end of the section. Additional information about the fuel system can found in the following sections: THE CARBURETOR, 900 SRM 129 THE LPG FUEL SYSTEM, 900 SRM 15 Mazda engines installed in lift trucks before April 1990 all have distributors with contact points. Some Mazda engines installed in lift trucks after April 1990 have a high energy ignition (HEI) distributor which does not have contact points. Additional information about the electrical system can be found in the section MAZDA ELECTRICAL SYSTEM, 2200 SRM 132.

WARNING Some gaskets used in this engine can contain dangerous fibers. Breathing dust from these fibers is a cancer or lung disease hazard. Do not create dust!

Use vacuum equipment for asbestos or follow the cleaning procedure described below.

• Make sure the gasket material is wet with water or oil to prevent particles in the air.

• Use a hand scraper to remove old gasket material. Do not use a power tool or compressed air.

• Discard all asbestos material in a closed container while it is still wet. Put a “DANGEROUS FIBERS” warning label on the container. Discard dangerous fiber material safely.

CAUTION Disconnect the battery cables before doing any disassembly and repair to the engine or parts of the electrical system. The diodes and resistors in the electrical system can be damaged if the following cautions are not followed: • Do not disconnect the battery when the engine

is running. The voltage surge can damage the diodes and resistors. • Do not disconnect an electric wire before the

engine is stopped and the switches are “OFF”. 1

• Do not cause a short circuit by connection of

the electric wires to the wrong terminals. Make sure a correct identification is made of the wire before it is connected.

5. Remove the coolant pump as described in COOLANT PUMP, Removal. 6. See FIGURE 2. Remove the rocker arm cover.

• Make sure a battery is the correct voltage and

polarity before it is connected. 5

• Do not check for current flow by making a

6 7

spark because the transistors can be damaged.

DESCRIPTION

4

The Mazda engine is a four cylinder engine that has a displacement of 1985 cm3 (121.1 in3). The firing order is 1–3–4–2. It is available with either a gasoline or an LPG fuel system. The number one cylinder is toward the end of the engine with the cooling fan. The serial number of the engine is found near the bottom of the crankcase and near the fuel pump. A camshaft in the cylinder block operates the overhead valves with push rods. The valve seats and valve guides can be replaced during an engine overhaul.

3

8 9

2 1

10

The crankshaft has three main bearings. The main bearing in the center of the crankshaft is also the thrust bearing. The pistons are aluminum alloy and have three piston rings. Each of the two compression rings have a special shape designed for its position on the piston. The third piston ring is the oil control ring.

REMOVAL AND INSTALLATION OF THE ENGINE NOTE: The removal and installation procedures for the engine are not included in this section. See the section for THE FRAME for more information.

CYLINDER HEAD AND VALVE MECHANISM Cylinder Head, Removal 1. Disconnect the connections at the battery. 2. Drain the coolant system.

12 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

11 CYLINDER HEAD VALVE GUIDE VALVE SEAL (INLET) COOLANT DISTRIBUTION TUBE BRACKET BREATHER ROCKER ARM COVER GASKET PUSH ROD TUBE O–RING CYLINDER HEAD GASKET MANIFOLD GASKET

10015

FIGURE 2. CYLINDER HEAD

7. Remove the rocker arm assembly and the push rods. Keep the push rods in the correct order so that they will be installed in the same positions.

3. Remove the air cleaner, the carburetor linkage, the inlet and exhaust manifolds.

8. Remove the bolts that hold the cylinder head to the crankcase. Remove the bolts in the sequence shown in FIGURE 3.

4. Remove the coolant hoses.

9. Lift the cylinder head from the crankcase.

2

Rocker Arm Assembly 4 5

1

9

12

Disassemble the rocker arm assembly as shown in FIGURE 4. Measure the clearance between the rocker arm shaft and the bushings for the rocker arms. See the ENGINE SPECIFICATIONS. If the clearance is greater than the specification, replace the bushings in the rocker arm or the rocker arm shaft.

10 8

To replace a bushing for the rocker arm, push the old bushing out of the rocker arm and push in a new bushing. During replacement of the bushings, make sure the holes for oil passages are aligned. 2

6

11

7

3 10007

FIGURE 3. SEQUENCE FOR REMOVAL OF THE CYLINDER HEAD Cylinder Head, Inspection And Repairs Check the surface of the cylinder head for distortion. Do the measurements at the positions shown in the ENGINE SPECIFICATIONS, FIGURE 48. If the amount of distortion is greater than the specification, the cylinder head needs repair. When grinding the cylinder head, the maximum amount of correction is 0.2 mm (0.008 in).

Valve Guides Measure the clearance between the valves and the valve guides as shown in ENGINE SPECIFICATIONS, FIGURE 50. NOTE: Use a special tool (HYSTER part number 327686) to replace the valve guides. Apply clean engine oil to the valve guide during installation. Use the special tool and the adapter to install the valve guide. Install the valve guide until the adapter touches the cylinder head. See FIGURE 5.

5 2

4

1 3

4

1 1

2 1. 2. 3. 4. 5.

ROCKER ARM SPRING SHAFT SUPPORT WASHER RETAINER

9993

FIGURE 4. ROCKER ARM ASSEMBLY

3

3. If the valves need grinding, see the ENGINE SPECIFICATIONS, FIGURE 49.

1. VALVE GUIDE INSTALLATION TOOL 2. ADAPTER

Valve Springs Check the valve springs for damage. The specifications for the valve springs are shown in ENGINE SPECIFICATIONS, FIGURE 53. Check the installation height of the valve springs. If the pressure at the installation height is less than the specifications, replace the valve spring. NOTE: See FIGURE 6. The retainers for the valve springs are different. The ends of the retainers for the exhaust valves come together when they are installed. The retainers for the inlet valves do not come together when they are installed.

1

2

INLET

EXHAUST

12799

FIGURE 5. INSTALLATION OF VALVE GUIDES 3

1

Valve Seats 1. Inspect the condition of the valve seats. If the valve seats have cracks, uneven wear or other damage, they must be repaired. If the condition of the valve seats is good, check the depth of the valves as shown in ENGINE SPECIFICATIONS, FIGURE 52. If dimension “A” is 48.5 to 49 mm (1.911 to 1.931 in), put shims under the valve springs. If dimension “A” is greater than 50.50 mm (1.99 in) replace the cylinder head. 2. To repair a valve seat, see the ENGINE SPECIFICATIONS, FIGURE 49. After repair is made to the valve seat, check the contact pattern of the valve and the valve seat. Make sure the valves are within the measurements of the specifications. Valves 1. Inspect the stem of each valve for wear. Use a micrometer to measure the outside diameter of the stem. See the ENGINE SPECIFICATIONS. 2. Inspect the valve for cracks, burned faces, and distortion. Inspect the seating face of the valves for wear and damage. 4

2

10011

1. CLEARANCE AT THE ENDS OF THE RETAINERS 2. VALVE SEAL (INLET) 3. VALVE SEAL (EXHAUST)

FIGURE 6. VALVE SPRING RETAINERS Cylinder Head, Installation 1. Clean the surface of the cylinder head and the surface of the crankcase. 2. Install a new cylinder head gasket to the crankcase. 3. Install the cylinder head. 4. Install the bolts for the cylinder head. Tighten the bolts to 88 N.m (65 lbf ft) in the sequence shown in FIGURE 7.

7. Adjust the valves as described in CHECKS AND ADJUSTMENTS.

11 10

12

6

2

3

7

8. Tighten the cylinder head bolts again as described in step 4 after the engine is warm.

TIMING GEAR CASE, REMOVAL NOTE: The timing cover must be removed to replace the seal. 1. Remove the drive belts from the engine. 2. Remove the water pump. 9

5

1

4

8 10007

FIGURE 7. INSTALLATION OF THE CYLINDER HEAD 5. Install the push rods. 6. Install the rocker arm assembly. Align the flat surface of the balls in the rocker arms with the stems of the valves during installation. See FIGURE 8. Tighten the capscrews for the rocker arm assembly to 35 N.m (25 lbf ft).

3. Remove the pulley from the crankcase. 4. Remove the timing case cover. 5. Check the tension of the drive chain as shown in FIGURE 9. If measurement “A” is more than 19 mm (0.741 in), replace the drive chain.

A

10012

THE FLAT SURFACE ON THE BALL MUST ALIGN WITH THE STEM OF THE VALVE

FIGURE 8. ROCKER ARM

12832

FIGURE 9. CHECK THE DRIVE CHAIN

5

6. Remove the drive chain assembly as shown in FIGURE 10.

3. Install the drive chain assembly. See FIGURE 10. Apply clean engine oil to the sprockets and the chain during installation. 4. Install the snap ring behind the bearing at the location for the hydraulic pump. 5. Install a new oil seal into the timing gear cover. Apply a thin layer of oil to the lip of the seal. 6. Install the timing gear cover. 7. Install the crankshaft pulley. Tighten the bolt to 175 N.m (130 lbf ft).

CAMSHAFT Removal 1. Remove the timing chain as described in TIMING GEAR CASE, Removal. 2. Remove the rocker arm assembly, the push rods, and the cam followers. 12832

FIGURE 10. REMOVE THE DRIVE CHAIN 7. Check the clearance between the crankshaft gear and the camshaft gear. The maximum clearance between the gears is 0.2 mm (0.008 in).

3. Turn the camshaft to get access to the bolts for the thrust plate. See FIGURE 11. 4. Remove the bolts that hold the thrust plate to the crankcase. 5. Carefully pull the camshaft from the crankcase.

CAUTION Do not turn the camshaft when the crankshaft gear is removed and the valve mechanism is installed. Remove the rocker arm assembly when working on the timing gears to prevent damage to the valve mechanism. 8. Remove the camshaft as described in CAMSHAFT, Removal. 9. Remove the crankshaft gear and the key. 10. Remove the gear housing.

TIMING GEAR CASE, INSTALLATION 1. Use a new gasket to install the timing gear housing. Put a sealant on both sides of the gasket during installation. 2. Install the camshaft as described in CAMSHAFT, Installation. 6

12800

FIGURE 11. THRUST PLATE FOR THE CAMSHAFT

Inspection 1. Measure the amount of clearance between the thrust plate and the camshaft as shown in FIGURE 12. If the clearance is greater than 1.2 mm (0.008 in), replace the thrust plate. 9745

1. SPACER GAUGE 2. THRUST PLATE 3. CAMSHAFT JOURNAL

3 1

2

FIGURE 12. CHECK THE CLEARANCE BETWEEN THRUST PLATE AND THE CAMSHAFT 2. Use a micrometer to check the wear of the camshaft. Measure the areas of the camshaft shown in the ENGINE SPECIFICATIONS, FIGURE 54. If any of the measurements are less than the specifications, replace the camshaft.

2. Apply clean engine oil to the camshaft bearings and the camshaft. 3. Carefully install the camshaft into the crankcase. 4. Install the thrust plate and the thrust washer. 5. Install the camshaft gear. Align the mark on the camshaft gear with the mark on the crankshaft gear. See FIGURE 13. 6. Install the washer and the nut that holds the gear to the camshaft. Tighten the nut to a torque of 130 N.m (95 lbf ft). 7. Turn the camshaft to get access to the bolts for the thrust plate. Tighten the bolts evenly to a torque of 20 N.m (15 lbf ft). 8. Apply clean engine oil to the cam followers. Install the cam followers. 9. Install the push rods and the rocker arm assembly as described in Installation of the Cylinder Head.

1

3

2

3. Check the camshaft as shown in ENGINE SPECIFICATIONS, FIGURE 55. Rotate the camshaft and look at the dial indicator. If the difference between the highest and lowest indication is greater than 0.03 mm (0.002 in), replace the camshaft. 4. Check the clearance between the bearing surfaces of the camshaft and the bearing surfaces in the cylinder block. See the ENGINE SPECIFICATIONS. If maximum clearance is greater than the specification, replace the camshaft. Cam Followers, Inspection Inspect the contact surface of the cam follower for damage and wear. Replace a cam follower as necessary. Measure the amount of clearance between the cam follower and the guide for the cam follower. See the ENGINE SPECIFICATIONS. If the clearance is greater than specifications, replace the cam follower. Installation 1. Turn the crankshaft so that the number one piston is at TDC.

1. CRANKSHAFT GEAR 2. CAMSHAFT GEAR 3. TIMING MARKS

12800

FIGURE 13. CAMSHAFT INSTALLATION

CRANKSHAFT AND MAIN BEARINGS Crankshaft, Removal 1. Remove the flywheel and the flywheel housing. 2. Remove the timing gear case as described in TIMING GEAR CASE, REMOVAL. 3. Remove the oil sump. 7

4. Remove the set screw from the crankcase that holds the shaft of the oil pump. See FIGURE 14. Remove the oil pump.

1

12831

FIGURE 15. CHECK THE CRANKSHAFT CLEARANCE

7. Remove the two plates that hold the rear oil seal for the crankshaft in position. 8. Remove the caps for the main bearings. 9. Remove the crankshaft. Keep the main bearings for the crankshaft in their correct order.

2 1. SET SCREW 2. LOCK SCREW

12829

FIGURE 14. REMOVE THE OIL PUMP

5. Remove the caps for the connecting rods. Put a mark of identification on each cap so that they will be installed to the same location. 6. Before removing the crankshaft, measure the clearance between the crankshaft and the flange of the center main bearing. See FIGURE 15. Push the crankshaft fully forward before making the measurement. The maximum clearance is 0.25 mm (0.009 in). If the clearance is greater than the specification, replace the center main bearing or the crankshaft.

8

Crankshaft, Inspection And Repair 1. Visually inspect the crankshaft for wear, cracks or other damage. Replace the crankshaft if it has cracks. 2. Use a micrometer to measure the diameter of the journals for the crankshaft. Make the measurement at several locations for each journal. See the ENGINE SPECIFICATIONS. If the measurements are less than the specifications, grind the crankshaft and install undersize bearings. 3. Check the crankshaft as shown in FIGURE 16. Rotate the crankshaft one turn and check the reading on the dial indicator. If the difference between the highest and the lowest reading is more than 0.03 mm (0.002 in), repair or replace the crankshaft. 4. Check the passages for oil in the crankshaft. Use a wire and compressed air to clean the passages.

12831

FIGURE 16. CRANKSHAFT INSPECTION Main Bearings 1. Visually inspect the main bearings for wear and damage. Replace the bearings as necessary. 2. Measure the clearance between the main bearings and the crankshaft. See the ENGINE SPECIFICATIONS. If the clearance is greater than the specifications, replace the main bearings. Crankshaft, Installation 1. Clean the main bearings and the areas at the crankcase for the main bearings.

12830

FIGURE 17. INSTALL THE OIL SEAL 6. Install the pistons and the connecting rods as described in PISTONS AND THE CONNECTING RODS, Installation. 7. Apply a sealant to the two square seals for the number three bearing cap. Install the seals so that the holes of the seal are toward the front or rear of the engine. See FIGURE 18. 8. Install the two plates (oil seal retainers) that hold the rear oil seal in position as shown in FIGURE 19.

2. Apply grease to the lip of the rear oil seal for the crankshaft. Assemble the oil seal as shown in FIGURE 17. The lip of the seal must be toward the front of the engine. Put the oil seal in position so that the ends of the seal will be toward the cylinder head during installation of the crankshaft. Connect the ends of the spring and then install the spring in the oil seal. Apply a sealant to the outer edge of the seal. 3. Apply clean engine oil to the main bearings and the journals of the crankshaft. 4. Install the crankshaft. 5. Install the main bearing caps. Tighten the bolts for the main bearing caps to a torque of 88 N.m (65 lbf ft).

12829

FIGURE 18. INSTALL THE OIL SEAL

9

6. Push the connecting rod and piston from the crankcase.

1

4 2

3 2

FIGURE 19. OIL SEAL RETAINERS 5

9. See FIGURE 20. Install the flywheel housing. Tighten the capscrews 28 to 41 N.m (20 to 30 lbf ft). 10. Install the oil pump as described in OIL PUMP, Installation.

6 7

11. Install the oil sump.

8 9994

9

10

12670

FIGURE 20. FLYWHEEL HOUSING

PISTONS AND CONNECTING RODS Removal 1. Remove the cylinder head as described in Cylinder Head, Removal. 2. Remove the oil sump. 3. Put a mark for identification on the top of each piston. 4. Clean the carbon from the top of each cylinder. 5. Remove the caps and bearings from each connecting rod. Keep the caps and bearings with the correct piston assemblies. 10

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

PISTON RINGS SNAP RING BUSHING PISTON BUSHING CONNECTING ROD CONNECTING ROD CAP WASHER SPECIAL BOLT BEARINGS

FIGURE 21. PISTON AND CONNECTING ROD Disassembly During disassembly of the piston assemblies, keep the parts with the correct assembly. Remove the snap rings at each end of the piston pin. Heat the piston and connecting rod in oil that is 150°C (300°F). After five minutes, push the pin from the piston. Pistons, Inspection And Repair 1. Visually inspect the pistons for wear and cracks. Replace a piston that has damage.

2. Check the clearance between the piston and the cylinder liner. The correct clearance is 0.03 to 0.07 mm (0.001 to 0.003 in). If the clearance is greater than 0.15 mm (0.006 in), replace the piston or the cylinder liner.

3. Check the clearance between each connecting rod assembly and the crankshaft as shown in FIGURE 22. The maximum amount of clearance is 0.20 mm (0.008 in). If the clearance is greater than the specification, replace the connecting rod or the crankshaft.

Piston Rings 10032

1. Measure the end clearance of each piston ring as shown in the ENGINE SPECIFICATIONS, FIGURE 58. Install the piston ring into the cylinder where it will be used. Use a thickness gauge to measure the amount of end clearance. 2. Measure the clearance between the piston ring and the groove in the piston as shown in the ENGINE SPECIFICATIONS, FIGURE 57. Piston Pin and Bushing 1. Measure the clearance between the piston pin and the bushing. See the correct clearance in the ENGINE SPECIFICATIONS. 2. If the piston pin bushing must be replaced, push the old bushing from the connecting rod. Install the new bushing. Align the holes for oil passages during installation. Connecting Rods and Bearings, Inspection 1. Use a special machine to check the alignment of the connecting rods. The maximum amount of distortion per 13 cm (5 in) is 0.05 mm (0.002 in). If the amount of distortion is greater than the specification, use a press to straighten the connecting rod. NOTE: The weight of each connecting rod is marked in the connecting rod. During replacement of a connecting rod, make sure the weight of all the connecting rods is the same. 2. Check the clearance between the rod bearings and the journals of the crankshaft. Clean the rod bearings and journals. Install the connecting rod assemblies to the crankshaft. Tighten the bolts for the caps to a torque of 45 N.m (35 lbf ft). The maximum amount of clearance between the rod bearings and the crankshaft is 0.10 mm (0.004 in). If the clearance is greater than the specifications, install undersize bearings and grind the crankshaft.

FIGURE 22. CHECK THE CLEARANCE OF THE CONNECTING ROD Pistons And Connecting Rods, Assembly 1. Install one snap ring into the piston. Heat the piston to 100 to 150_C (200 to 300_F). Make sure the assembly of the piston and connecting rod is the arrangement shown in FIGURE 23. Install the connecting rod in the piston. Push the piston pin through the piston and connecting rod. Install the snap ring.

DURING INSTALLATION OF THE CONNECTING ROD, THE HOLE
FOR OIL MUST BE OPPOSITE THE MARK ”F” 

 10032


FIGURE 23. CONNECTING ROD AND PISTON 2. Install the piston rings on the pistons as shown in FIGURE 24. During installation, the writing on each piston ring must be toward the top of the piston. Put the ends of the rings in the positions shown in FIGURE 24. 11

1. POSITION OF THE CLEARANCE FOR THE NO. 2 PISTON RING 2. POSITION OF THE CLEARANCE FOR THE NO. 1 PISTON RING 3. POSITION OF THE CLEARANCE FOR PART ”A” OF THE NO. 3 PISTON RING 4. POSITION OF THE CLEARANCE FOR THE SPRING 5. POSITION OF THE CLEARANCE FOR PART ”B” OF THE NO. 3 PISTON RING

A B

2

3 60°

30° 30°

1

4 5 10009

FIGURE 24. PISTON RING INSTALLATION Pistons And Connecting Rods, Installation 1. Apply clean engine oil to the piston assembly. Install the assembly into the correct cylinder as shown in FIGURE 25. 2. Install the connecting rod bearings into the caps. Apply clean engine oil to the bearing then install the cap to the correct connecting rod. During installation of the caps, make sure to align the identification marks that were made during disassembly. 3. Tighten the bolts for the caps to a torque of 47 N.m (35 lbf ft). 4. Install the cylinder head as described in Cylinder Head, Installation. 5. Install the oil pump and the oil sump.

1. PISTON 10010 2. CRANKCASE 3. DURING INSTALLATION OF THE PISTON ASSEMBLY, THE “F” MARK MUST BE TOWARD THE FRONT OF THE ENGINE

FIGURE 25. PISTON AND CONNECTING ROD INSTALLATION

CYLINDER BLOCK AND CYLINDER LINERS Cylinder Block, Repairs After the cylinder block is cleaned , check its surface for distortion. If the amount of distortion is greater than 0.15 mm (0.006 in), grind the surface of the cylinder block. The maximum amount of correction that is permitted is 0.4 mm (0.016 in). Cylinder Liners 1. Check the cylinder liners for wear and damage. Measure each liner at six positions as shown in the ENGINE

12

SPECIFICATIONS, FIGURE 56. If the difference between any of the measurements is greater than specifications, replace the cylinder liner. NOTE: Use a special tool to remove a cylinder liner. The HYSTER part numbers for the two pieces of the removal tool are 327688 and 327689. 2. Use the special tool to remove a cylinder liner as shown in FIGURE 26. Remove the O–rings. 12801

FIGURE 27. MEASURE THE CYLINDER LINER POSITION

DISTRIBUTOR NOTE: This section has only the removal and installation procedures for the distributor. The service procedures for the ignition system are found in THE ELECTRICAL SYSTEM, 2200 SRM 132. Removal 1. Remove the wires from the distributor. 2. Remove the two capscrews from the flange of the distributor shaft housing. 3. Lift the distributor assembly from the engine. Installation 1. Rotate the crankshaft until the number one piston is at approximately 0° BTDC on the compression stroke. See FIGURE 28. See the ENGINE SPECIFICATIONS on page 22 for the correct timing for your engine. 2

12803

FIGURE 26. REMOVE THE CYLINDER LINER

3. Install the new O–rings into the grooves at the bottom of the cylinders. Apply a lubricant to the O–rings during installation. 4. Install the cylinder liner. Push the cylinder liner until its surface is 0.03 to 0.14 mm (0.002 to 0.005 in) above the surface of the cylinder block. See FIGURE 27.

4

5

13

1. 2. 3. 4. 5.

TDC INDICATOR 9° BTDC 13° BTDC 18° BTDC

9569

FIGURE 28. TIMING MARKS, MAZDA ENGINES 13

2. Use a screwdriver to turn the shaft for the oil pump so that its groove is parallel with the engine. The punch mark on the shaft must be toward the engine. See FIGURE 29. 3. Install a new gasket for the distributor shaft housing. During installation, make sure the holes for oil align.

FRONT OF ENGINE

9995

10030

1

FIGURE 29. ALIGNMENT OF THE OIL PUMP SHAFT 2

4. Before installation of the distributor shaft housing, put its shaft in position (1) as shown in FIGURE 30. The distributor shaft will rotate approximately 40 degrees as it engages the camshaft gear. 5. See FIGURE 29. Install the distributor shaft housing. During installation, make sure the holes for oil align. After installation of the distributor shaft housing, check the position of the groove in the shaft. The groove in the shaft must be parallel with the engine. Also the punch mark on the top of the shaft must be toward the engine.

1. GROOVE OF THE DISTRIBUTOR SHAFT (BEFORE INSTALLATION) 2. GROVE OF OIL PUMP SHAFT (“XX”) 3. GROVE OF DISTRIBUTOR SHAFT (AFTER INSTALLATION) 4. PUNCH MARK MUST BE TOWARD ENGINE

3

4

6. Install the capscrews that hold the distributor shaft housing to the engine. 7. Check the ignition timing as described in THE ELECTRICAL SYSTEM, 2200 SRM 132.

10007

FIGURE 30. DISTRIBUTOR INSTALLATION

14

pressure at 3000 rpm is shown in the ENGINE SPECIFICATIONS. The minimum oil pressure at engine idle is 40 kPa (6 psi). If the pressure is less than the specification, the oil pump or the engine bearings need repair.

21 22

1

1. Drain the oil from the crankcase. 2 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

BODY PLUNGER SPRING SEAT PIN SHAFT PIN COVER STUD GASKET

3

4 5

2. Remove the sump pan. 3. Remove the tubes from the oil pump. 4. Remove the capscrews that hold the oil pump assembly to the crankcase. Remove the two set screws that are in the side of the crankcase. See FIGURE 14.

7

5. Remove the oil pump.

6

Repairs

8

NOTE: See the ENGINE SPECIFICATIONS for the correct clearances. 13 12 11 10 9 11

20 19

16 17

1. Check the clearance between the inner and outer rotor as shown in FIGURE 32. If the clearance is greater than the specifications, replace both rotors.

12 14 18

11. 11. 12. 13. 14. 15. 16.

15

CAPSCREW (SHORT) (2) CAPSCREW (LONG) (2) WASHER (6) WASHER (4) NUT (2) SCREEN GASKET (2)

17. 18. 19. 20. 21. 22.

CAPSCREW PIPE CAPSCREW WASHER (5) SCREW SCREW

FIGURE 31. OIL PUMP

12826

FIGURE 32. CHECK THE CLEARANCE BETWEEN THE ROTORS

OIL PUMP (See FIGURE 31.) Removal 1. Before the engine is disassembled, check the operation of relief valve in the oil pump. The minimum oil

2. Check the clearance between the outer rotor and the pump body as shown in FIGURE 33. If the clearance is greater than the specifications, replace the pump body or the outer rotor.

15

Installation 1. Install the oil pump. 2. Install the capscrews that hold the oil pump assembly to the crankcase. Install the two set screws that are in the side of the crankcase. See FIGURE 14. 3. Install the tubes to the oil pump. 4. Install the oil sump. 12826

FIGURE 33. CHECK THE CLEARANCE BETWEEN THE ROTOR AND BODY 3. Check the clearance between the rotors and the pump cover. First, measure the clearance between the rotors and the surface of the pump body as shown in FIGURE 34. Make a note of the reading. Then measure the clearance between the surface of the pump cover and the center of the pump cover. Add the measurements. The result is the clearance between the rotors and the pump cover. If the clearance between the parts is greater than the specifications, use lapping compound on the pump cover.

5. When the work is complete, fill the crankcase with the correct engine oil.

GOVERNOR Description The governor prevents the engine speeds greater than the specifications. It is driven by the fan belt. Since it is driven by a belt, the belt must be checked at regular intervals. The throttle pedal connects to the governor speed lever. The throttle plate in the carburetor connects to the governor control lever. When the engine operates at less than the setting, the control lever moves the same amount as the speed lever. When the engine speed approaches the limit, centrifugal force causes the weights in the governor to move away from the shaft. This movement of the weight mechanism causes the control lever to close the throttle plate in the carburetor. The idle speed and maximum speed of the engine are adjusted at the governor. Removal 1. Disconnect the linkage from the governor.

12801

FIGURE 34. CHECK THE CLEARANCE OF THE ROTORS 4. If the oil pressure is less than the specifications and the oil pump is not worn, shims can be added between the spring and the seat of the relief valve. Do not increase the relief pressure greater than the specifications shown in the ENGINE SPECIFICATIONS. 16

2. Loosen the bolt that holds the idler pulley to the bracket. Loosen the bolt that controls the tension of the drive belt for the fan and governor. Remove the drive belt. 3. Remove the pulley from the governor. 4. Remove the governor from the bracket.

2

4 3

1

2

3

1

5 6

5 7 7

6

10

8

9

9 11 1. 2. 3. 4. 5. 6. 7. 8. 9

13

4

8 SCREW GOVERNOR CONTROL SHAFT FORK SPEED LEVER SPRING LINKAGE LEVER (TO THROTTLE PEDAL) PINS SPEED CONTROL SHAFT

9998

9996

FIGURE 36. DISASSEMBLY OF THE GOVERNOR

12 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

GOVERNOR CONTROL SHAFT WEIGHT MECHANISM BEARING OIL SEAL HUB PULLEY COVER SPEED CONTROL SHAFT GOVERNOR BODY LEVER (T0 CARBURETOR) LEVER (TO THROTTLE PEDAL) ADJUSTMENT SCREW (MAXIMUM SPEED) ADJUSTMENT SCREW (IDLE SPEED)

5. Remove the lever from the speed control shaft. Rotate the speed control shaft (9) to get access to the pins that hold the speed lever (4) to the shaft. Pull the shaft out approximately 13 mm (0.5 in) then remove the pins. Remove the speed control shaft and the speed lever. 6. See FIGURE 37. Give support to the cover (1). Use a brass hammer and lightly hit the shaft to remove it from the cover. Remove the oil seal from the cover.

FIGURE 35. GOVERNOR 1

Disassembly

2

1. Remove the drain plug to drain the oil from the governor. 2. Use a puller to remove the hub from the shaft. 3. Remove the four bolts that hold the cover to the housing. Separate the parts. 4. See FIGURE 36. Remove the screw (1) then pull the control shaft (2) from the fork (3). Remove the fork and the spring (5).

9999

1. COVER 2. SHAFT ASSEMBLY

FIGURE 37. COVER ASSEMBLY 17

7. See FIGURE 38. Compress the spring (3) to remove the pin (5) from the shaft. Remove the parts from the shaft.

1

2

4

3

5

10001

1. WEIGHT ASSEMBLY 2. COLLAR

3. SPRING 4. RETAINER 5. PIN

5. Assemble the speed control shaft as shown in FIGURE 40. After assembly, check the clearance between the pin (5) and the housing. The maximum clearance is 0.2 mm (0.008 in). If necessary, install shims between the pin and the housing to get the correct clearance. Adjust the bolt (6) of the linkage to get the correct length as shown in FIGURE 40.

1. O–RING 2. SPEED CONTROL SHAFT 3. SPEED LEVER 4. PINS 5. PIN 6. BOLT

6

FIGURE 38. SHAFT ASSEMBLY A

8. Remove the bearing from the shaft as shown in FIGURE 39.

“A” = 45.05 mm (1.774 in)

5 10002

2

FIGURE 39. REMOVE THE BEARING Assembly 1. Install a new oil seal into the cover.

1

1 4

10005

3

2. Assemble the shaft assembly as shown in FIGURE 38. During assembly, check the distance of compression for the spring. If the distance is more than 10 mm (0.40 in), replace the spring.

FIGURE 40. ASSEMBLE THE SPEED CONTROL ARM

3. Install the weight assembly into the cover.

6. Assemble the governor control arm as shown in FIGURE 36.

4. Install the key then press the hub on the shaft. Tighten the nut to 25 N.m (20 lbf ft).

7. Use a new gasket and install the housing assembly to the cover assembly.

18

8. Measure the movement of the shaft as shown in FIGURE 41. If the amount of movement is more than 0.3 mm (0.012 in), install shims at area “A”.

A

12799

“A”

FIGURE 42. ADJUST THE DRIVE BELT

10004

4

2

FIGURE 41. CHECK THE MOVEMENT OF THE SHAFT

Installation

6

1. Install the governor.

1

2. Install the drive belt. 3. Adjust the tension of the drive belt by turning the adjustment bolt at the idler pulley. The correct tension is 9 mm (0.375 in) of movement at area “A” of the belt. See FIGURE 42. When the tension is correct, tighten the locknut for the adjustment bolt then tighten the bolt for the idler pulley.

3

5 1. 2. 3. 4. 5. 6.

THROTTLE CABLE CLEVIS PIN SPRING SPEED CONTROL ARM GOVERNOR

10006

FIGURE 43. THROTTLE LINKAGE

COOLANT PUMP Removal

4. Connect the throttle linkage to the governor as shown in FIGURE 43. Adjust the linkage as described in Checks and Adjustments. 5. Remove the breather and fill the governor with 200 cm (0.42 pt) of clean engine oil. Remove the plug from the side of the governor to check the level of the oil.

1. Drain the cooling system. 2. Remove the fan. 3. Loosen the bolt that holds the idler pulley to the bracket. Then loosen the bolt that controls the tension of the drive belt for the fan and governor. Remove the drive belt. 19

4. Remove the drive belt for the alternator and the coolant pump. 5. Remove the coolant hoses. 8

6. Remove the bracket assembly for the fan.

7 5

7. Remove the coolant pump.

5 4

4

1

3 2

1

8 2

3

12828

1. 2. 3. 4.

6 HUB BUSHING SNAP RING SHAFT

5. 6. 7. 8.

BEARINGS HOUSING WASHER SNAP RING

FIGURE 45. BRACKET ASSEMBLY 9997

6 5

1. 2. 3. 4.

7 HUB IMPELLER SEAL ASSEMBLY SNAP RING

5. 6. 7. 8.

SHAFT COVER SEAL BEARINGS

FIGURE 44. COOLANT PUMP

Disassembly and Repair 1. If the bearings in the bracket assembly need service, disassemble the bracket assembly as shown in FIGURE 45. 2. Remove the thermostat housing and the thermostat. 3. Test the operation of the thermostat. The thermostat must begin to open at 76°C (168°F). 10031

4. Remove the cover from the pump body. 5. Use a puller to remove the hub from the shaft. 6. Remove the snap ring from the front of the bearing assembly. 7. Remove the shaft and bearing assembly as shown in FIGURE 46. 8. Remove the impeller and the seal assembly. 20

FIGURE 46. REMOVE THE SHAFT AND BEARING ASSEMBLY Assembly 1. Assemble the parts of the bracket assembly as shown in FIGURE 45. 2. Install the bearing assembly and the shaft in the pump body. Install the snap ring.

3. Use a press to push the hub on the shaft. Push the hub until its surface is even with the end of the shaft.

a. During removal or installation, do not heat the ring gear greater than 230°C (450°F).

4. Install the seal assembly in the pump body.

b. During installation, push the ring gear fully against the shoulder of the flywheel.

5. Use a press to push the impeller on the shaft. Push the impeller until its surface is even with the end of the shaft. 6. Install the cover. Use a new gasket during installation. 7. Install the thermostat and the housing for the thermostat. 8. Install the pulley. Installation 1. Install the coolant pump. Use a new gasket during installation. 2. Install the bracket assembly. 3. Install the drive belts. Adjust the tension of the drive belts as described in CHECKS AND ADJUSTMENTS.

c. The pilot bearing in the flywheel can be replaced. Push the old bearing from the flywheel and push in a new bearing. Installation 1. Install the end plate. Tighten the bolts that hold the flywheel housing to the crankcase to 28 to 41 N.m (20 to 30 lbf ft). 2. Install the flywheel on the crankshaft. On early models be sure to align the marks on the crankshaft and flywheel as shown in FIGURE 47. Tighten the bolts that hold the flywheel to the crankshaft to 58 to 64 N.m (43 to 47 lbf ft).

4. Install the coolant hoses. 5. Fill the coolant system with coolant. 6. Start the engine and check the coolant system for leaks.

WARNING DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator cap is removed, the pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns. DO NOT remove the cover for the radiator when the engine is running. 7. After the engine has been operated, stop the engine. If the coolant is hot, give the engine time to cool. Check the coolant level.

FLYWHEEL 10031

Repairs 1. Use the following procedure to replace the ring gear on the flywheel:

FIGURE 47. INSTALLATION OF THE FLYWHEEL

CHECKS AND ADJUSTMENTS ADJUST THE VALVES 1. Rotate the crankshaft until the number one piston is at TDC on the compression stroke. Now adjust the clear-

ance of the valves for the number one cylinder. The correct clearance for all the valves is 0.3 mm (0.012 in). To 21

adjust the clearance, loosen the lock nut and turn the adjustment screw. NOTE: During adjustment of the valves, check the position of the balls that are in the ends of the rocker arms. The flat surface of the ball must be in contact with the stem of the valve. See FIGURE 8.

4. Rotate the crankshaft clockwise 180 degrees. Now adjust the valves for the number two cylinder. 5. If the valves are adjusted when the engine is cold, check the adjustments again after the engine is warm.

2. Rotate the crankshaft clockwise 180 degrees. Now adjust the valves for the number three cylinder.

ADJUST THE THROTTLE LINKAGE

3. Rotate the crankshaft clockwise 180 degrees. Now adjust the valves for the number four cylinder.

See THE CARBURETOR, 900 SRM 129 for the adjustment of the throttle linkage

ENGINE SPECIFICATIONS Engine Data Type

4 – stroke, gasoline or LPG

Firing order

1–3–4–2

Displacement

1985 cm# (121.12 in#)

Bore

82 mm (3.22 in)

Stroke

94 mm (3.70 in)

(Lift trucks with serial codes A177 and A187) Compression ratio 8.0 : 1 (Lift trucks with serial codes A177 and A187) Compression pressure @ 200 rpm: 1075 kPa (156 psi) (Lift trucks with serial codes B177, C177 and B187) Compression ratio 8.5 : 1

9742

A E

(Lift trucks with serial codes B177, C177 and B187) Ignition timing 9° BTDC (gasoline) @ 625 rpm 18° BTDC (LPG) @ 625 rpm (Governor speed 2600 to 2700 rpm [when installed in S/H1.25–1.75XL (S/H25–35XL) lift trucks] (Governor speed 2700 to 2800 rpm [when installed in S2.00–3.00XL (S40–60XL) lift trucks] (Governor speed 2900 to 3000 rpm [when installed in H2.00–3.00XL (H40–60XL) lift trucks] Idle speed

Cooling System 82°C (180°F)

Cylinder Head And Valve Mechanism Maximum distortion of cylinder head. (See FIGURE 48.) 0.15 mm (0.006 in)

22

D B

FIGURE 48. CHECK THE CYLINDER HEAD FOR DISTORTION Valve seat specifications: See FIGURE 49. 1

600–650 rpm

Valve clearance adjustment (warm engine) Inlet 0.30 mm (0.012 in) Exhaust 0.30 mm (0.012 in)

Thermostat

F C

(Lift trucks with serial codes A177 and A187) Ignition timing 13° BTDC @ 625 rpm

2

45 0

1. CYLINDER HEAD 2. VALVE SEAT

75 0 9717

NOTE: Inlet valves have 45° and 75° angles on the valve seats. Exhaust valves only have a 45° on the valve seats.

FIGURE 49. VALVE SEAT SPECIFICATIONS

Clearance between inlet valve and guide See FIGURE 50. – Production Limit 0.025 to 0.070 mm (0.001 to 0.003 in) – Service Limit 0.20 mm (0.008 in) maximum Clearance between exhaust valve and guide See FIGURE 50. – Production Limit 0.050 to 0.095 mm (0.002 to 0.004 in) – Service Limit 0.20 mm (0.008 in)

9719

Measure The Diameter Of The Valve Stem

A 9764

B A= CONTACT WIDTH INLET VALVES = 1.75 mm (0.07 in) EXHAUST VALVES = 1.4 mm (0.06 in) B=THICKNESS OF VALVE HEAD Production Limit = 1.5 mm (0.059 in) Service Limit = 1.0 mm (0.039 in)

FIGURE 51. VALVE SPECIFICATIONS

Angle of valve face:

12686

45 degrees

Depth of valve below cylinder head: Dimension “A” (See FIGURE 52.) – Production Limit 49.00 mm (1.93 in) – Service Limit 50.50 mm (1.99 in)

FIGURE 50. CHECK THE CLEARANCE BETWEEN VALVE GUIDE AND VALVE

Diameter of inlet valve stem (SeeFIGURE 51.): – Production Limit 8.030 to 8.045 mm (0.316 to 0.317 in) – Service Limit 7.980 mm (0.313 in) Diameter of exhaust valve stem (SeeFIGURE 51.): – Production Limit 8.005 to 8.020 mm (0.315 to 0.316 in) – Service Limit 7.955 mm (0.313 in) Valve head thickness (margin): – Production Limit 1.5 mm (0.059 in) – Service Limit 1.0 mm (0.039 in) Valve head diameter: – Inlet 39.4 to 39.6 mm (1.55 to 1.56 in) – Exhaust 29.9 to 30.1 mm (1.18 to 1.19 in)

10013

FIGURE 52. MEASURE THE DEPTH OF THE VALVES

23

Valve spring, free length (See FIGURE 53.) – Production Limit 49.1 mm (1.933 in) – Service Limit 47.6 mm (1.874 in)

A

B 9715

C

(0.0003 to 0.0024 in) – Service Limit 0.10 mm (0.004 in) Cam followers (tappets), outside diameter – Production Limit 22.959 to 22.980 mm (0.905 to 0.906 in) Bore for cam followers in cylinder block: 23.000 to 23.033 mm (0.906 to 0.907 in) Clearance between cam followers and bore in cylinder block: – Production Limit 0.020 to 0.074 mm (0.001 to 0.003 in) – Service Limit 0.01 mm (0.004 in)

Camshaft (See FIGURE 54.) 9740

A. 1.0 mm (0.039 in) MAXIMUM B. FREE LENGTH 49.1 mm (1.83 in) 47.6 mm (1.87 in) MINIMUM C. INSTALLATION HEIGHT: THE VALVE SPRINGS NEED A MINIMUM FORCE OF 323 N (73 lbf) TO COMPRESS THEM TO A HEIGHT OF 42 mm (1.65 in)

12631

CAM LOBE (X) = 41.39 mm (1.629 in) MINIMUM JOURNAL DIAMETER (AA) or (BB): FIRST = 49.93 mm (1.965 in) MINIMUM SECOND = 48.92 mm (1.926 in) MINIMUM THIRD = 44.93 mm (1.769 in) MINIMUM MAXIMUM VARIATION BETWEEN (AA) AND (BB) OR ACROSS SURFACE = 0.05 mm (0.002 in)

FIGURE 54. CAMSHAFT SPECIFICATIONS

FIGURE 53. VALVE SPRING SPECIFICATIONS Rocker arm shaft, diameter – Production Limit 18.972 to 18.993 mm (0.747 to 0.748 in) Rocker arm bore, diameter – Production Limit 19.000 to 19.033 mm (0.748 to 0.749 in) Clearance between rocker arms and shaft – Production limit 0.007 to 0.061 mm

24

Cam lobes – Production Limit 41.592 mm (1.638 in) – Service limit 41.395 mm (1.630 in) Bearing journal No. 1, diameter – Production Limit 49.977 to 49.990 mm (1.9679 to 1.9684 in) – Service limit 49.94 mm (1.9664 in) Bearing journal No. 2, diameter – Production Limit 48.967 to 48.980 mm (1.9279 to 1.9284 in) – Service limit 48.93 mm (1.9264 in) Bearing journal No. 3, diameter – Production Limit 44.977 to 48.990 mm (1.7708 to 1.7713 in) – Service limit 44.927 mm (1.7693 in)

Variation from front to rear of a cam lobe or a bearing journal: – Production Limit less than 0.03 mm (0.001 in) – Service limit 0.05 mm (0.002 in)

Available undersize bearings: –0.25 mm (–0.010 in) –0.50 mm (–0.020 in) –0.75 mm (–0.030 in)

Clearance between journals and bore – Production Limit 0.06 to 0.12 mm (0.002 to 0.005 in) – Service Limit 0.15 mm (0.006 in)

Axial Clearance – Production Limit

Axial Clearance – Production Limit

Connecting Rods

– Service Limit

– Service Limit

0.020 to 0.180 mm (0.001 to 0.007 in) 0.2 mm (0.008 in)

Small end bore:

0.0254 to 0.2286 mm (0.001 to 0.009 in) 0.305 mm (0.012 in)

22.003 to 22.014 mm (0.866 to 0.867 in)

Clearance between piston pin and bushing: – Production Limit 0.003 to 0.021 mm (0.0001 to 0.0008 in) – Service Limit 0.3 mm (0.001 in)

Camshaft “run–out” (See FIGURE 55.) – Production Limit less than 0.03 mm (0.0012 in) – Service Limit 0.06 mm (0.0024 in)

Clearance between crankshaft journals and connecting rod bearings – Production Limit 0.030 to 0.080 mm (0.001 to 0.003 in) – Service Limit 0.10 mm (0.004 in) Available undersize bearings: –0.25 mm (–0.010 in) –0.50 mm (–0.020 in) –0.75 mm (–0.030 in)

Cylinder Liners 9748

FIGURE 55. CAMSHAFT INSPECTION Timing Gear Clearance between timing gear and crankshaft gear: – Production Limit 0.00 to 0.05 mm (0.00 to 0.002 in) – Service Limit more than 0.2 mm (0.008 in)

Crankshaft Crankshaft “run–out” – Production Limit less than 0.03 mm (0.0012 in) Clearance between journals and main bearings – Production Limit 0.041 to 0.071 mm (0.002 to 0.003 in) – Service Limit 0.08 mm (0.003 in) Diameter of main bearing journal – Production Limit 62.940 to 62.955 mm (2.478 to 2.479 in) – Service Limit 62.905 mm (2.474 in) – Grinding Limit 62.19 mm (2.448 in) Diameter of connecting rod journal – Production limit 52.940 to 52.955 mm (2.084 to 2.085 in) – Service Limit 52.89 mm (2.083 in) – Grinding Limit 52.19 mm (2.055 in)

Diameter – Production Limit – Service Limit

82.000 to 82.019 mm (3.228 to 3.229 in) 81.87 mm (3.223 in)

Extension above cylinder block: 0.03 to 0.14 mm (0.001 to 0.006 in)

ÉÉ ÉÉ ÉÉ ÉÉ ÉÉ ÉÉ ÉÉ ÉÉ

ÉÉ ÉÉ ÉÉ ÉÉ ÉÉ ÉÉ ÉÉ ÉÉ

Y

X

X

Y 10008

FIGURE 56. MEASUREMENT OF THE CYLINDER LINER

Pistons Piston diameter [measured at 90_ to pin bore axis and 54.5 mm (2.15 in) from bottom of piston] 81.945 to 81.965 mm (3.226 to 3.227 in) 25

Clearance between pistons and liner 0.035 to 0.074 mm (0.001 to 0.003 in) Piston pin diameter

21.982 to 21.990 mm (0.865 to 0.855 in)

Piston pin hole bore

21.985 to 21.996 mm (0.8656 to 0.8660 in)

Groove width for Piston Rings No. 1 and 2 2.020 to 2.034 mm (0.0795 to 0.0801 in) Groove width for Oil Control Ring 4.520 to 4.532 mm (0.1780 to 0.1784 in)

9739

COMPRESSION RINGS 0.3 to 0.5 mm (0.012 to 0.020 in)

Thickness for Piston Rings No. 1 and 2 1.97 to 1.99 mm (0.0776 to 0.0783 in)

OIL CONTROL RING 0.2 to 1.2 mm (0.008 to 0.047 in)

FIGURE 58. CHECK THE END CLEARANCE OF THE PISTON RINGS

Thickness for Oil Control Ring 4.480 to 4.532 mm (0.176 to 0.178 in)

Lubrication System

Piston Rings No. 1 and 2 clearance in groove – Production Limit 0.03 to 0.06 mm (0.001 to 0.002 in) – Service Limit 0.15 mm (0.006 in)

Piston ring end clearance – Piston rings 0.3 to 0.5 mm (0.012 to 0.020 in)

Capacity with filter 5.2 liter (5.5 qt) Oil pump, clearance between outer rotor and body – Production Limit 0.20 to 0.27 mm (0.008 to 0.011 in) – Service Limit 0.30 mm (0.012 in) Oil pump, clearance between rotor lobes – Production Limit 0.04 to 0.15 mm (0.002 to 0.006 in) – Service Limit 0.25 mm (0.01 in) Oil pump, rotor axial clearance – Production Limit 0.04 to 0.10 mm (0.002 to 0.004 in) – Service Limit 0.15 mm (0.006 in) Oil pump, clearance between shaft and body – Production Limit 0.012 to 0.049 mm (0.0005 to 0.004 in) – Service Limit 0.10 mm (0.004 in) Oil pressure @ 3000 rpm 345 to 441 kPa (50 to 64 psi) Oil pump capacity @ 2000 rpm 12.5 litres/min (13 quarts/min) Oil pressure @ 2600 rpm 290 to 360 kPa (42 to 52 psi) Oil pressure switch “ON” @ 20 to 39 kPa (2.9 to 5.7 psi)

– Oil control ring

Fuel Pump

Oil Control Ring Clearance in Groove – Production Limit 0.03 to 0.06 mm (0.001 to 0.002 in) – Service Limit 0.15 mm (0.006 in)

9738

FIGURE 57. CLEARANCE BETWEEN THE PISTON RING AND THE GROOVE

– Service Limit (all)

26

0.2 to 1.2 mm (0.008 to 0.047 in) 1.0 mm (0.039 in)

Pressure

19.3 to 25 kPa (2.8 to 3.6 psi)

TORQUE SPECIFICATIONS Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . 81 to 88 N.m (60 to 65 lbf ft) Inlet manifold . . . . . . . . . . . . . . . . . . . . . . . . 30 to 51 N.m (22 to 38 lbf ft) Exhaust manifold . . . . . . . . . . . . . . . . . . . . . 30 to 51 N.m (22 to 38 lbf ft) Main Bearing Cap . . . . . . . . . . . . . . . . . . . . 81 to 88 N.m (60 to 65 lbf ft) Connecting Rod Cap . . . . . . . . . . . . . . . . . . 48 to 52 N.m (35 to 38 lbf ft) Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . . 137 to 157 N.m (101 to 116 lbf ft) Flywheel Housing . . . . . . . . . . . . . . . . . . . . 28 to 41 N.m (20 to 30 lbf ft) Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 to 64 N.m (43 to 47 lbf ft) Camshaft Gear . . . . . . . . . . . . . . . . . . . . . . . 118 to 137 N.m (87 to 101 lbf ft) Camshaft Thrust Plate . . . . . . . . . . . . . . . . . 16 to 23 N.m (12 to 17 lbf ft) Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . 16 to 23 N.m (12 to 17 lbf ft) Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . 16 to 23 N.m (12 to 17 lbf ft) Rocker Arm Brackets . . . . . . . . . . . . . . . . . . 28 to 41 N.m (21 to 30 lbf ft) Oil Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 to 9 N.m (5 to 7 lbf ft) Oil Pressure Switch . . . . . . . . . . . . . . . . . . . 12 to 17 N.m (9 to 13 lbf ft) Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . 16 to 23 N.m (12 to 17 lbf ft) Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 to 20 N.m (18 to 27 lbf ft) Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 to 117 N.m (64 to 87 lbf ft) Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . 7 to 9 N.m (5 to 7 lbf ft) Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . 15 to 23 N.m (11 to 17 lbf ft) Motor Mount to Engine . . . . . . . . . . . . . . . . 56 N.m (41 lbf ft) Motor Mount to Frame . . . . . . . . . . . . . . . . 53 N.m (39 lbf ft)

27

TROUBLESHOOTING PROBLEM When the ignition switch is in the “START” position, the crankshaft does not operate.

CAUSE The battery has a problem. The battery is not fully charged. The connections at the battery are loose or they have corrosion. The ignition switch is worn or damaged. The starter system has a problem. There is a seizure of parts in the engine.

The engine will not start.

The fuel tank is empty. The battery is not fully charged. The valves are damaged. The piston rings are worn or damaged. The ignition system has a problem. The fuel system is not operating. The ignition timing is not correct. The choke system does not work.

The engine does not run smoothly.

The valves are not adjusted correctly. The head gasket leaks. The cylinder head has cracks. There is a leak in the inlet system. The spark plugs have a problem. The ignition system has a problem. (See THE ELECTRICAL SYSTEM, 2200 SRM 132 for more information.

The engine does not have enough power.

The air filter is dirty. The fuel is the wrong type. The ignition timing is not correct. The valve mechanism needs adjustment. The piston assemblies are damaged. The spark plugs are the wrong type or they are not installed correctly. The valve timing is not correct. The exhaust system has restrictions.

28

TROUBLESHOOTING PROBLEM There is noise inside the engine.

CAUSE The main bearings are worn or damaged. The bearings for the connecting rods are worn or damaged. The pistons are worn or damaged. The engine is too hot. There is not enough oil in the engine. The flywheel is loose. A connecting rod is bent. There is a leak in the exhaust system. A cam follower has a problem. The valves are not adjusted correctly.

There is noise in the engine during acceleration.

The spark plugs are dirty. The spark plugs are the wrong type. The ignition timing is not correct. The fuel is the wrong type. There is too much carbon in the combustion chamber. The engine is too hot. The carburetor is not adjusted correctly.

The engine gets too hot.

There is not enough coolant in the cooling system. The belt for the water pump is worn or not adjusted correctly. The thermostat does not open correctly. The cooling system has restrictions. The water pump does not operate correctly The radiator is dirty. The exhaust system has restrictions.

The bearings in the engine are damaged.

There is not enough oil in the engine. The oil in the engine is the wrong type. The oil pump is worn or damaged. The connecting rod(s) are bent or damaged. The camshaft is damaged. The passages for oil have restrictions. The bearings are not installed correctly. The oil in the engine is dirty. 29

NOTES

30

31