MAZDA M4–121G ENGINE

1 2

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

9 10
6 10016

FIGURE 1. MAZDA ENGINE

GENERAL Use vacuum equipment for asbestos or follow the

This section has the repair instructions for the engine.
Removal, disassembly, repair, assembly, installation,
checks and adjustments, and trouble–shooting are in-
cluded. 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!
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 mate-
rial. Do not use a power tool or compressed air.
• Discard all asbestos material in a closed con-
tainer 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 5. Remove the coolant pump as described in COOL-
the electric wires to the wrong terminals. ANT PUMP, Removal.
Make sure a correct identification is made of
the wire before it is connected. 6. See FIGURE 2. Remove the rocker arm cover.

• Make sure a battery is the correct voltage and

polarity before it is connected.
5 6
• Do not check for current flow by making a
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 num- 8
3
ber of the engine is found near the bottom of the crank- 9
case and near the fuel pump. 2
A camshaft in the cylinder block operates the overhead 10
1
valves with push rods. The valve seats and valve guides
can be replaced during an engine overhaul.

The crankshaft has three main bearings. The main bear-

ing in the center of the crankshaft is also the thrust bear-
ing.

The pistons are aluminum alloy and have three piston 12 11

rings. Each of the two compression rings have a special 10015
1. CYLINDER HEAD
shape designed for its position on the piston. The third 2. VALVE GUIDE
piston ring is the oil control ring. 3. VALVE SEAL (INLET)
4. COOLANT DISTRIBUTION TUBE
5. BRACKET
REMOVAL AND INSTALLATION OF THE 6. BREATHER
ENGINE 7. ROCKER ARM COVER
8. GASKET
9. PUSH ROD TUBE
NOTE: The removal and installation procedures for the
10. O–RING
engine are not included in this section. See the section 11. CYLINDER HEAD GASKET
for THE FRAME for more information. 12. MANIFOLD GASKET
FIGURE 2. CYLINDER HEAD
CYLINDER HEAD AND VALVE
MECHANISM

Cylinder Head, Removal 7. Remove the rocker arm assembly and the push rods.
Keep the push rods in the correct order so that they will
1. Disconnect the connections at the battery. be installed in the same positions.
2. Drain the coolant system. 8. Remove the bolts that hold the cylinder head to the
3. Remove the air cleaner, the carburetor linkage, the in- crankcase. Remove the bolts in the sequence shown in
let and exhaust manifolds. FIGURE 3.

4. Remove the coolant hoses. 9. Lift the cylinder head from the crankcase.

2
 Rocker Arm Assembly
4
5 9 12 10 8 Disassemble the rocker arm assembly as shown in
1
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.

To replace a bushing for the rocker arm, push the old

2 6 11
FIGURE 3. SEQUENCE FOR REMOVAL OF
THE CYLINDER HEAD
Cylinder Head, Inspection And Repairs
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.
7 3
10007
Valve Guides
Measure the clearance between the valves and the valve
guides as shown in ENGINE SPECIFICATIONS,
FIGURE 50.

Check the surface of the cylinder head for distortion. Do
the measurements at the positions shown in the EN-
GINE SPECIFICATIONS, FIGURE 48. If the amount
of distortion is greater than the specification, the cylin-
der head needs repair. When grinding the cylinder head,
the maximum amount of correction is 0.2 mm (0.008
in).
NOTE: Use a special tool (HYSTER part number
327686) to replace the valve guides.
Apply clean engine oil to the valve guide during instal-
lation. 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
4
2
1

3 4

1 2
1. ROCKER ARM
2. SPRING
3. SHAFT SUPPORT
4. WASHER
5. RETAINER

9993

FIGURE 4. ROCKER ARM ASSEMBLY

3
 3. If the valves need grinding, see the ENGINE SPECI-
FICATIONS, FIGURE 49.
1. VALVE GUIDE
INSTALLATION Valve Springs
TOOL
2. ADAPTER Check the valve springs for damage. The specifications
for the valve springs are shown in ENGINE SPECIFI-
CATIONS, 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
1 springs are different. The ends of the retainers for the ex-
haust valves come together when they are installed. The
retainers for the inlet valves do not come together when
2 they are installed.

INLET EXHAUST

12799

FIGURE 5. INSTALLATION OF VALVE GUIDES

3
1

Valve Seats 2

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 EN-
GINE SPECIFICATIONS, FIGURE 52. If dimension 10011
“A” is 48.5 to 49 mm (1.911 to 1.931 in), put shims un-
der the valve springs. If dimension “A” is greater than
50.50 mm (1.99 in) replace the cylinder head. 1. CLEARANCE AT THE ENDS OF THE
RETAINERS
2. To repair a valve seat, see the ENGINE SPECIFICA- 2. VALVE SEAL (INLET)
3. VALVE SEAL (EXHAUST)
TIONS, FIGURE 49. After repair is made to the valve
seat, check the contact pattern of the valve and the valve FIGURE 6. VALVE SPRING RETAINERS
seat. Make sure the valves are within the measurements
of the specifications. Cylinder Head, Installation

Valves
1. Inspect the stem of each valve for wear. Use a mi-
crometer to measure the outside diameter of the stem.
See the ENGINE SPECIFICATIONS.
2. Inspect the valve for cracks, burned faces, and distor-
tion. Inspect the seating face of the valves for wear and
damage.
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.

4
 7. Adjust the valves as described in CHECKS AND AD-
11 JUSTMENTS.
10 6 2 3
12 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 3. Remove the pulley from the crankcase.
10007

FIGURE 7. INSTALLATION OF THE CYLINDER 4. Remove the timing case cover.

HEAD
5. Check the tension of the drive chain as shown in
5. Install the push rods. FIGURE 9. If measurement “A” is more than 19 mm
(0.741 in), replace the drive chain.
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).
A

10012

THE FLAT SURFACE ON THE BALL MUST

12832
ALIGN WITH THE STEM OF THE VALVE
FIGURE 8. ROCKER ARM FIGURE 9. CHECK THE DRIVE CHAIN

5
6. Remove the drive chain assembly as shown in 3. Install the drive chain assembly. See FIGURE 10.
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.
3. Turn the camshaft to get access to the bolts for the
12832 thrust plate. See FIGURE 11.
FIGURE 10. REMOVE THE DRIVE CHAIN
4. Remove the bolts that hold the thrust plate to the
crankcase.
7. Check the clearance between the crankshaft gear and
the camshaft gear. The maximum clearance between the 5. Carefully pull the camshaft from the crankcase.
gears is 0.2 mm (0.008 in).

CAUTION
Do not turn the camshaft when the crankshaft gear is
removed and the valve mechanism is installed. Re-
move the rocker arm assembly when working on the
timing gears to prevent damage to the valve mecha-
nism.

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 installa-
tion. 12800

2. Install the camshaft as described in CAMSHAFT, In- FIGURE 11. THRUST PLATE FOR THE
stallation. CAMSHAFT

6
Inspection 2. Apply clean engine oil to the camshaft bearings and
the camshaft.
1. Measure the amount of clearance between the thrust
plate and the camshaft as shown in FIGURE 12. If the 3. Carefully install the camshaft into the crankcase.
clearance is greater than 1.2 mm (0.008 in), replace the
4. Install the thrust plate and the thrust washer.
thrust plate.
5. Install the camshaft gear. Align the mark on the cam-
9745
1. SPACER shaft gear with the mark on the crankshaft gear. See
GAUGE FIGURE 13.
2. THRUST PLATE
3. CAMSHAFT 6. Install the washer and the nut that holds the gear to the
JOURNAL
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
3 N.m (15 lbf ft).
2
1 8. Apply clean engine oil to the cam followers. Install
the cam followers.
FIGURE 12. CHECK THE CLEARANCE
BETWEEN THRUST PLATE AND THE 9. Install the push rods and the rocker arm assembly as
CAMSHAFT described in Installation of the Cylinder Head.

2. Use a micrometer to check the wear of the camshaft. 2

3
Measure the areas of the camshaft shown in the EN- 1
GINE SPECIFICATIONS, FIGURE 54. If any of the
measurements are less than the specifications, replace
the camshaft.
3. Check the camshaft as shown in ENGINE SPECIFI-
CATIONS, FIGURE 55. Rotate the camshaft and look
at the dial indicator. If the difference between the high-
est 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 maxi-
mum clearance is greater than the specification, replace
the camshaft. 1. CRANKSHAFT GEAR
2. CAMSHAFT GEAR
Cam Followers, Inspection 3. TIMING MARKS 12800

Inspect the contact surface of the cam follower for dam- FIGURE 13. CAMSHAFT INSTALLATION
age and wear. Replace a cam follower as necessary.
Measure the amount of clearance between the cam fol- CRANKSHAFT AND MAIN BEARINGS
lower and the guide for the cam follower. See the EN-
GINE SPECIFICATIONS. If the clearance is greater Crankshaft, Removal
than specifications, replace the cam follower. 1. Remove the flywheel and the flywheel housing.
Installation 2. Remove the timing gear case as described in TIM-
ING GEAR CASE, REMOVAL.
1. Turn the crankshaft so that the number one piston is at
TDC. 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.
2 the crankshaft in their correct order.
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 clear-
ance 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 clear-
ance is greater than the specification, replace the center
main bearing or the crankshaft.
8
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
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 jour-
nals for the crankshaft. Make the measurement at sev-
eral locations for each journal. See the ENGINE SPEC-
IFICATIONS. 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 12830

FIGURE 17. INSTALL THE OIL SEAL

Main Bearings

1. Visually inspect the main bearings for wear and dam-
age. 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.
6. Install the pistons and the connecting rods as de-
scribed 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 instal-
lation 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.

12829
5. Install the main bearing caps. Tighten the bolts for the
main bearing caps to a torque of 88 N.m (65 lbf ft). FIGURE 18. INSTALL THE OIL SEAL

9
 6. Push the connecting rod and piston from the crank-
case.

1 4

3
2

FIGURE 19. OIL SEAL RETAINERS

5
9. See FIGURE 20. Install the flywheel housing. Tight-
en the capscrews 28 to 41 N.m (20 to 30 lbf ft).
10. Install the oil pump as described in OIL PUMP, In- 6
stallation.
7
11. Install the oil sump.
8
9994
9

10

1. PISTON RINGS
2. SNAP RING
3. BUSHING
4. PISTON
12670 5. BUSHING
6. CONNECTING ROD
FIGURE 20. FLYWHEEL HOUSING 7. CONNECTING ROD CAP
8. WASHER
9. SPECIAL BOLT
PISTONS AND CONNECTING RODS 10. BEARINGS

FIGURE 21. PISTON AND CONNECTING ROD

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.
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 con-
necting rod in oil that is 150°C (300°F). After five min-
utes, push the pin from the piston.
Pistons, Inspection And Repair
1. Visually inspect the pistons for wear and cracks. Re-
place a piston that has damage.

10
2. Check the clearance between the piston and the cylin-
der 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.
Piston Rings
3. Check the clearance between each connecting rod as-
sembly 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.

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 SPECIFI-
CATIONS, 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.
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
2. If the piston pin bushing must be replaced, push the
100 to 150_C (200 to 300_F). Make sure the assembly of
old bushing from the connecting rod. Install the new
the piston and connecting rod is the arrangement shown
bushing. Align the holes for oil passages during installa-
in FIGURE 23. Install the connecting rod in the piston.
tion.
Push the piston pin through the piston and connecting
rod. Install the snap ring.
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 DURING INSTALLATION
OF THE CONNECTING
distortion is greater than the specification, use a press to
ROD, THE HOLE

straighten the connecting rod.
FOR OIL MUST BE
OPPOSITE THE MARK
NOTE: The weight of each connecting rod is marked in ”F” 
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 10032
journals of the crankshaft. Clean the rod bearings and

journals. Install the connecting rod assemblies to the
FIGURE 23. CONNECTING ROD AND PISTON
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 2. Install the piston rings on the pistons as shown in
(0.004 in). If the clearance is greater than the specifica- FIGURE 24. During installation, the writing on each
tions, install undersize bearings and grind the crank- piston ring must be toward the top of the piston. Put the
shaft. 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
A THE SPRING
5. POSITION OF THE CLEARANCE FOR
B PART ”B” OF THE NO. 3 PISTON RING
2 3

30°
60° 4
30°
1 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. Ap-
ply 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.

CYLINDER BLOCK AND CYLINDER

1. PISTON
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
LINERS
10010
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 per-
mitted is 0.4 mm (0.016 in).
Cylinder Liners
1. Check the cylinder liners for wear and damage. Meas-
ure each liner at six positions as shown in the ENGINE

12
SPECIFICATIONS, FIGURE 56. If the difference be-
tween any of the measurements is greater than specifica-
tions, replace the cylinder liner.

NOTE: Use a special tool to remove a cylinder liner.

The HYSTER part numbers for the two pieces of the re-
moval 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 installa-

tion procedures for the distributor. The service proce-
dures for the ignition system are found in THE ELEC-
TRICAL SYSTEM, 2200 SRM 132.
Removal
1. Remove the wires from the distributor.
2. Remove the two capscrews from the flange of the dis-
tributor 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.

12803 2
4
5
FIGURE 26. REMOVE THE CYLINDER LINER
13

3. Install the new O–rings into the grooves at the bottom

of the cylinders. Apply a lubricant to the O–rings during 1. TDC
installation. 2. INDICATOR
3. 9° BTDC
4. 13° BTDC
9569
4. Install the cylinder liner. Push the cylinder liner until 5. 18° BTDC
its surface is 0.03 to 0.14 mm (0.002 to 0.005 in) above FIGURE 28. TIMING MARKS,
the surface of the cylinder block. See FIGURE 27. 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 1. GROOVE OF THE DISTRIBUTOR SHAFT
distributor shaft will rotate approximately 40 degrees as (BEFORE INSTALLATION)
it engages the camshaft gear. 2. GROVE OF OIL PUMP SHAFT (“XX”)
3. GROVE OF DISTRIBUTOR SHAFT (AFTER
INSTALLATION)
5. See FIGURE 29. Install the distributor shaft housing.
4. PUNCH MARK MUST BE TOWARD ENGINE
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 4
3
mark on the top of the shaft must be toward the engine.

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 SPECI-
21 22
FICATIONS. The minimum oil pressure at engine idle
is 40 kPa (6 psi). If the pressure is less than the specifica-
tion, the oil pump or the engine bearings need repair.
1
1. Drain the oil from the crankcase.
2
3 2. Remove the sump pan.
4
5
1. BODY 3. Remove the tubes from the oil pump.
2. PLUNGER
3. SPRING 4. Remove the capscrews that hold the oil pump assem-
4. SEAT 7
bly to the crankcase. Remove the two set screws that are
5. PIN
6. SHAFT in the side of the crankcase. See FIGURE 14.
7. PIN
8. COVER 6 5. Remove the oil pump.
9. STUD
10. GASKET Repairs
8
NOTE: See the ENGINE SPECIFICATIONS for the
correct clearances.
13 16
12 1. Check the clearance between the inner and outer rotor
11 as shown in FIGURE 32. If the clearance is greater than
20 10 17
19 9 the specifications, replace both rotors.
11
12
14
18
15

11. CAPSCREW (SHORT) (2)

11. CAPSCREW (LONG) (2) 17. CAPSCREW
12. WASHER (6) 18. PIPE
13. WASHER (4) 19. CAPSCREW
14. NUT (2) 20. WASHER (5)
15. SCREEN 21. SCREW
16. GASKET (2) 22. SCREW 12826

FIGURE 31. OIL PUMP

OIL PUMP (See FIGURE 31.)
Removal
1. Before the engine is disassembled, check the opera-
tion of relief valve in the oil pump. The minimum oil
FIGURE 32. CHECK THE CLEARANCE
BETWEEN THE ROTORS
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

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.
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 in-
crease the relief pressure greater than the specifications
shown in the ENGINE SPECIFICATIONS.
16
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.
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 in-
tervals. 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 ap-
proaches 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.
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.
 4 3 2 2 1 3

5 6

7 8 9 9
6 11 4
9998
8
1. SCREW
2. GOVERNOR CONTROL SHAFT
3. FORK
4. SPEED LEVER
10 13 5. SPRING
6. LINKAGE
7. LEVER (TO THROTTLE PEDAL)
8. PINS
9 SPEED CONTROL SHAFT
9996
FIGURE 36. DISASSEMBLY OF THE
12 GOVERNOR
1. GOVERNOR CONTROL SHAFT
2. WEIGHT MECHANISM
3. BEARING 5. Remove the lever from the speed control shaft. Rotate
4. OIL SEAL
the speed control shaft (9) to get access to the pins that
5. HUB
6. PULLEY hold the speed lever (4) to the shaft. Pull the shaft out ap-
7. COVER proximately 13 mm (0.5 in) then remove the pins. Re-
8. SPEED CONTROL SHAFT move the speed control shaft and the speed lever.
9. GOVERNOR BODY
10. LEVER (T0 CARBURETOR) 6. See FIGURE 37. Give support to the cover (1). Use a
11. LEVER (TO THROTTLE PEDAL)
12. ADJUSTMENT SCREW (MAXIMUM SPEED) brass hammer and lightly hit the shaft to remove it from
13. ADJUSTMENT SCREW (IDLE SPEED) 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 gover-
nor.

2. Use a puller to remove the hub from the shaft.

3. Remove the four bolts that hold the cover to the hous-
ing. Separate the parts.
1. COVER
4. See FIGURE 36. Remove the screw (1) then pull the 9999 2. SHAFT ASSEMBLY
control shaft (2) from the fork (3). Remove the fork and
the spring (5). FIGURE 37. COVER ASSEMBLY

17
7. See FIGURE 38. Compress the spring (3) to remove 5. Assemble the speed control shaft as shown in
the pin (5) from the shaft. Remove the parts from the FIGURE 40. After assembly, check the clearance be-
shaft. tween the pin (5) and the housing. The maximum clear-
ance is 0.2 mm (0.008 in). If necessary, install shims be-
tween the pin and the housing to get the correct clear-
2
1 3 4 ance. Adjust the bolt (6) of the linkage to get the correct
5 length as shown in FIGURE 40.

1. O–RING
2. SPEED CONTROL
SHAFT 6
10001 3. SPRING 3. SPEED LEVER
1. WEIGHT ASSEMBLY 4. RETAINER 4. PINS
2. COLLAR 5. PIN 5. PIN
6. BOLT
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

FIGURE 39. REMOVE THE BEARING 2

Assembly
1 10005
1. Install a new oil seal into the cover. 1

2. Assemble the shaft assembly as shown in 4 3

FIGURE 38. During assembly, check the distance of FIGURE 40. ASSEMBLE THE SPEED CONTROL
compression for the spring. If the distance is more than ARM
10 mm (0.40 in), replace the spring.
6. Assemble the governor control arm as shown in
3. Install the weight assembly into the cover. FIGURE 36.
4. Install the key then press the hub on the shaft. Tighten 7. Use a new gasket and install the housing assembly to
the nut to 25 N.m (20 lbf ft). 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”.

12799
“A”
FIGURE 42. ADJUST THE DRIVE BELT

10004
4

3
2
FIGURE 41. CHECK THE MOVEMENT OF
THE SHAFT

Installation 6

1. Install the governor. 5

1
1. THROTTLE CABLE
2. Install the drive belt. 2. CLEVIS
3. PIN
4. SPRING
3. Adjust the tension of the drive belt by turning the ad- 5. SPEED CONTROL ARM
justment bolt at the idler pulley. The correct tension is 9 6. GOVERNOR 10006

mm (0.375 in) of movement at area “A” of the belt. See FIGURE 43. THROTTLE LINKAGE
FIGURE 42. When the tension is correct, tighten the
locknut for the adjustment bolt then tighten the bolt for COOLANT PUMP
the idler pulley.
Removal
4. Connect the throttle linkage to the governor as shown 1. Drain the cooling system.
in FIGURE 43. Adjust the linkage as described in
2. Remove the fan.
Checks and Adjustments.
3. Loosen the bolt that holds the idler pulley to the
5. Remove the breather and fill the governor with 200 bracket. Then loosen the bolt that controls the tension of
cm (0.42 pt) of clean engine oil. Remove the plug from the drive belt for the fan and governor. Remove the drive
the side of the governor to check the level of the oil. belt.

19
4. Remove the drive belt for the alternator and the cool-
ant pump.

5. Remove the coolant hoses.

8
7
6. Remove the bracket assembly for the fan.

7. Remove the coolant pump. 5 5

4 3 1
2

1 4 8
12828
2 6
1. HUB 5. BEARINGS
2. BUSHING 6. HOUSING
3 3. SNAP RING 7. WASHER
4. SHAFT 8. SNAP RING
FIGURE 45. BRACKET ASSEMBLY

9997
6

5
7
1. HUB 5. SHAFT
2. IMPELLER 6. COVER
3. SEAL ASSEMBLY 7. SEAL
4. SNAP RING 8. 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.

FIGURE 46. REMOVE THE SHAFT AND
5. Use a puller to remove the hub from the shaft. BEARING ASSEMBLY
6. Remove the snap ring from the front of the bearing as-
Assembly
sembly.
1. Assemble the parts of the bracket assembly as shown
7. Remove the shaft and bearing assembly as shown in in FIGURE 45.
FIGURE 46.
2. Install the bearing assembly and the shaft in the pump
8. Remove the impeller and the seal assembly. body. Install the snap ring.

20
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.
4. Install the seal assembly in the pump body.
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 thermo-
stat.
8. Install the pulley.
Installation
1. Install the coolant pump. Use a new gasket during in-
stallation.
2. Install the bracket assembly.
3. Install the drive belts. Adjust the tension of the drive
belts as described in CHECKS AND ADJUSTMENTS.
4. Install the coolant hoses.
5. Fill the coolant system with coolant.
6. Start the engine and check the coolant system for
leaks.
a. During removal or installation, do not heat the
ring gear greater than 230°C (450°F).
b. During installation, push the ring gear fully
against the shoulder of the flywheel.
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 mod-
els be sure to align the marks on the crankshaft and fly-
wheel 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).

WARNING
DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator cap is re-
moved, 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 ra-
diator 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
FIGURE 47. INSTALLATION OF THE
1. Use the following procedure to replace the ring gear FLYWHEEL
on 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 cor-
rect clearance for all the valves is 0.3 mm (0.012 in). To
21
adjust the clearance, loosen the lock nut and turn the ad- 4. Rotate the crankshaft clockwise 180 degrees. Now
justment screw. adjust the valves for the number two cylinder.
NOTE: During adjustment of the valves, check the po-
5. If the valves are adjusted when the engine is cold,
sition of the balls that are in the ends of the rocker arms.
check the adjustments again after the engine is warm.
The flat surface of the ball must be in contact with the
stem of the valve. See FIGURE 8.
2. Rotate the crankshaft clockwise 180 degrees. Now ADJUST THE THROTTLE LINKAGE
adjust the valves for the number three cylinder.
3. Rotate the crankshaft clockwise 180 degrees. Now See THE CARBURETOR, 900 SRM 129 for the ad-
adjust the valves for the number four cylinder. justment 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) 9742

Compression pressure @ 200 rpm:

1075 kPa (156 psi)
(Lift trucks with serial codes B177, C177 and B187) A
Compression ratio 8.5 : 1 E F
(Lift trucks with serial codes A177 and A187) C D
Ignition timing 13° BTDC @ 625 rpm B
(Lift trucks with serial codes B177, C177 and B187)
Ignition timing 9° BTDC (gasoline) @ 625 rpm
18° BTDC (LPG) @ 625 rpm FIGURE 48. CHECK THE CYLINDER HEAD
(Governor speed 2600 to 2700 rpm [when installed in FOR DISTORTION
S/H1.25–1.75XL (S/H25–35XL) lift trucks]
Valve seat specifications: See FIGURE 49.
(Governor speed 2700 to 2800 rpm [when installed in
S2.00–3.00XL (S40–60XL) lift trucks]
1 2
(Governor speed 2900 to 3000 rpm [when installed in
H2.00–3.00XL (H40–60XL) lift trucks]
Idle speed 600–650 rpm
45 0
Valve clearance adjustment (warm engine)
Inlet 0.30 mm (0.012 in)
75 0
Exhaust 0.30 mm (0.012 in) 1. CYLINDER
HEAD 9717
Cooling System 2. VALVE SEAT
Thermostat 82°C (180°F) NOTE: Inlet valves have 45° and 75° angles on the
Cylinder Head And Valve Mechanism valve seats.
Exhaust valves only have a 45° on the valve seats.
Maximum distortion of cylinder head.
(See FIGURE 48.) 0.15 mm (0.006 in) FIGURE 49. VALVE SEAT SPECIFICATIONS

22
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. 9719
Measure The Diameter Of The Valve Stem
– Production Limit 0.050 to 0.095 mm
(0.002 to 0.004 in)
– Service Limit 0.20 mm (0.008 in)

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: 45 degrees

Depth of valve below cylinder head:
Dimension “A” (See FIGURE 52.)
– Production Limit 49.00 mm (1.93 in)
12686 – 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): 10013

– 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) FIGURE 52. MEASURE THE DEPTH OF THE
– Exhaust 29.9 to 30.1 mm VALVES
(1.18 to 1.19 in)

23
Valve spring, free length (See FIGURE 53.) (0.0003 to 0.0024 in)
– Production Limit 49.1 mm (1.933 in) – Service Limit 0.10 mm (0.004 in)
– Service Limit 47.6 mm (1.874 in) Cam followers (tappets), outside diameter
– Production Limit 22.959 to 22.980 mm
(0.905 to 0.906 in)
A 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)
B – Service Limit 0.01 mm (0.004 in)
9715 C
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
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
FIGURE 53. VALVE SPRING SPECIFICATIONS (1.9679 to 1.9684 in)
– Service limit 49.94 mm (1.9664 in)
Rocker arm shaft, diameter
Bearing journal No. 2, diameter
– Production Limit 18.972 to 18.993 mm
– Production Limit 48.967 to 48.980 mm
(0.747 to 0.748 in)
(1.9279 to 1.9284 in)
Rocker arm bore, diameter – Service limit 48.93 mm (1.9264 in)
– Production Limit 19.000 to 19.033 mm Bearing journal No. 3, diameter
(0.748 to 0.749 in) – Production Limit 44.977 to 48.990 mm
Clearance between rocker arms and shaft (1.7708 to 1.7713 in)
– Production limit 0.007 to 0.061 mm – Service limit 44.927 mm (1.7693 in)

24
Variation from front to rear of a cam lobe or a bearing jour- Available undersize bearings:
nal: –0.25 mm (–0.010 in)
– Production Limit less than 0.03 mm (0.001 in) –0.50 mm (–0.020 in)
– Service limit 0.05 mm (0.002 in) –0.75 mm (–0.030 in)
Clearance between journals and bore Axial Clearance
– Production Limit 0.06 to 0.12 mm – Production Limit 0.0254 to 0.2286 mm
(0.002 to 0.005 in) (0.001 to 0.009 in)
– Service Limit 0.15 mm (0.006 in) – Service Limit 0.305 mm (0.012 in)
Axial Clearance Connecting Rods
– Production Limit 0.020 to 0.180 mm
(0.001 to 0.007 in) Small end bore: 22.003 to 22.014 mm
– Service Limit 0.2 mm (0.008 in) (0.866 to 0.867 in)
Camshaft “run–out” (See FIGURE 55.) Clearance between piston pin and bushing:
– Production Limit less than 0.03 mm (0.0012 in) – Production Limit 0.003 to 0.021 mm
– Service Limit 0.06 mm (0.0024 in) (0.0001 to 0.0008 in)
– Service Limit 0.3 mm (0.001 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 Diameter
– Production Limit 82.000 to 82.019 mm
FIGURE 55. CAMSHAFT INSPECTION (3.228 to 3.229 in)
– Service Limit 81.87 mm (3.223 in)
Timing Gear
Extension above cylinder block:
Clearance between timing gear and crankshaft gear: 0.03 to 0.14 mm
– Production Limit 0.00 to 0.05 mm (0.001 to 0.006 in)
(0.00 to 0.002 in)

ÉÉ ÉÉ
– Service Limit more than 0.2 mm (0.008 in)
Y
Crankshaft
ÉÉ ÉÉ
Crankshaft “run–out”
ÉÉ ÉÉ
– Production Limit less than 0.03 mm (0.0012 in)
ÉÉ ÉÉ
ÉÉ ÉÉ
Clearance between journals and main bearings X X

ÉÉ ÉÉ
– Production Limit 0.041 to 0.071 mm

ÉÉ ÉÉ
(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 ÉÉ ÉÉ
FIGURE 56. MEASUREMENT OF THE
Y
10008

(2.478 to 2.479 in)

– Service Limit 62.905 mm (2.474 in) CYLINDER LINER
– Grinding Limit 62.19 mm (2.448 in)
Diameter of connecting rod journal Pistons
– Production limit 52.940 to 52.955 mm Piston diameter [measured at 90_ to pin bore axis and 54.5
(2.084 to 2.085 in) mm (2.15 in) from bottom of piston]
– Service Limit 52.89 mm (2.083 in) 81.945 to 81.965 mm
– Grinding Limit 52.19 mm (2.055 in) (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)
Thickness for Piston Rings No. 1 and 2
1.97 to 1.99 mm
(0.0776 to 0.0783 in)
Thickness for Oil Control Ring
4.480 to 4.532 mm
(0.176 to 0.178 in)
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)
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
Piston ring end clearance
– Piston rings 0.3 to 0.5 mm
(0.012 to 0.020 in)
– Oil control ring 0.2 to 1.2 mm
(0.008 to 0.047 in)
– Service Limit (all) 1.0 mm (0.039 in)
26
9739
COMPRESSION RINGS
0.3 to 0.5 mm (0.012 to 0.020 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
Lubrication System
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)
Fuel Pump
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.
The engine will not start.
The engine does not run smoothly.
The engine does not have enough power.
28
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 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 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 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.
 TROUBLESHOOTING
PROBLEM
There is noise inside the engine.
There is noise in the engine during
acceleration.
The engine gets too hot.
The bearings in the engine are damaged.
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.
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.
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.
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

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