Hyster H1.50XM Operating instructions

0$='$ (1*,1(
M4-2.0G AND M4-2.2G
H1.50-1.75XM (S/H25-35XM)
[C010, D001, D010, E001];
H2.00XMS (S/H40XMS)
[C010, D001, D010, E001]; S/H2.00-3.20XM
(S/H40-65XM)
[D177, D187, H177]
PART NO. 897477 600 SRM 496

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
•When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
•Do not lift heavy parts by hand, use a lifting mechanism.
•Wear safety glasses.
•DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks.
•Disconnect the battery ground cable on internal combustion lift trucks.
•Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.
•Keep the unit clean and the working area clean and orderly.
•Use the correct tools for the job.
•Keep the tools clean and in good condition.
•Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
•Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
•Always fasten a DO NOT OPERATE tag to the controls of theunit when making repairs,
or if the unit needs repairs.
•Be sure to follow the WARNING and CAUTION notes in the instructions.
•Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
•Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!

Mazda Engine Table of Contents
TABLE OF CONTENTS
General............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Engine Removal and Installation ..................................................................................................................... 1
Cylinder Head, Camshaft, and Valve Mechanism Repair............................................................................... 2
Remove........................................................................................................................................................... 2
Clean .............................................................................................................................................................. 3
Inspect and Repair......................................................................................................................................... 4
Cylinder Head............................................................................................................................................ 4
Rocker Shaft Assembly ............................................................................................................................. 4
Camshaft.................................................................................................................................................... 4
Valve Guides.............................................................................................................................................. 5
Valve Seats................................................................................................................................................. 6
Valves......................................................................................................................................................... 6
Valve Springs............................................................................................................................................. 7
Install ............................................................................................................................................................. 7
Crankshaft and Main Bearings Repair ............................................................................................................ 10
Remove........................................................................................................................................................... 10
Inspect and Repair......................................................................................................................................... 10
Crankshaft................................................................................................................................................. 10
Main Bearings ........................................................................................................................................... 10
Install ............................................................................................................................................................. 11
Pistons and Connecting Rods Repair................................................................................................................ 12
Remove and Disassemble.............................................................................................................................. 12
Clean .............................................................................................................................................................. 12
Inspect and Repair......................................................................................................................................... 12
Pistons........................................................................................................................................................ 12
Piston Rings............................................................................................................................................... 12
Connecting Rods and Bearings................................................................................................................. 13
Assemble and Install..................................................................................................................................... 13
Cylinder Block Repair........................................................................................................................................ 15
Oil Pump Repair ................................................................................................................................................ 15
Remove........................................................................................................................................................... 15
Disassemble ................................................................................................................................................... 16
Clean .............................................................................................................................................................. 16
Inspect............................................................................................................................................................ 17
Assemble ........................................................................................................................................................ 17
Install ............................................................................................................................................................. 18
Cooling System Repair ...................................................................................................................................... 18
Thermostat..................................................................................................................................................... 18
Replace....................................................................................................................................................... 18
Fan Assembly................................................................................................................................................. 18
Remove and Disassemble.......................................................................................................................... 18
Assemble and Install................................................................................................................................. 19
Water Pump ................................................................................................................................................... 19
Remove and Disassemble.......................................................................................................................... 19
Assemble and Install................................................................................................................................. 20
Distributor Repair.............................................................................................................................................. 21
Remove........................................................................................................................................................... 21
Install ............................................................................................................................................................. 21
Flywheel and Ring Gear Repair S/H2.00-3.20XM (S/H40-65XM)................................................................... 22
Remove........................................................................................................................................................... 22
©2002 HYSTER COMPANY i

Table of Contents Mazda Engine
TABLE OF CONTENTS (Continued)
Ring Gear, Replace ........................................................................................................................................ 22
Install............................................................................................................................................................. 22
Flywheel Repair H1.50-175XM, H2.00XMS (S/H25-35XM, S/H40XMS)........................................................ 23
Remove........................................................................................................................................................... 23
Install............................................................................................................................................................. 23
Valve Adjustment............................................................................................................................................... 24
Compression Pressure Check............................................................................................................................ 25
Engine Timing Adjustment............................................................................................................................... 25
Throttle Linkage Adjustment............................................................................................................................ 26
Gasoline Engines........................................................................................................................................... 26
LPG Engines (IMPCO).................................................................................................................................. 26
LPG Engines (AISAN)................................................................................................................................... 26
Engine Specifications......................................................................................................................................... 26
Engine Data................................................................................................................................................... 26
Thermostat..................................................................................................................................................... 26
Cylinder Head................................................................................................................................................ 26
Valve Mechanism........................................................................................................................................... 27
Camshaft........................................................................................................................................................ 27
Crankshaft ..................................................................................................................................................... 27
Connecting Rods ............................................................................................................................................ 28
Cylinder Block ............................................................................................................................................... 28
Pistons............................................................................................................................................................ 28
Oil Pump ........................................................................................................................................................ 28
Torque Specifications......................................................................................................................................... 29
Troubleshooting.................................................................................................................................................. 30
This section is for the following models:
H1.50-1.75XM (S/H25-35XM) [C010, D001, D010, E001];
H2.00XMS (S/H40XMS) [C010, D001, D010, E001];
S/H2.00-3.20XM (S/H40-65XM) [D177, D187, H177]
ii

600 SRM 496 Engine Removal and Installation
General
This section has the instructions for removal, disas-
sembly, repair, assembly, installation, checks, adjust-
ments, and troubleshooting for the Mazda M4-2.0G
and M4-2.2G engines. The engine specifications are
given at the end of the section.
Additional information on engine components can be
found in the sections for Gasoline Fuel System,
LPG Fuel System,andElectrical System.
Description
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 de-
scribed below.
•Make sure the gasketmaterial is wetwith wa-
ter or oil to prevent particles in the air.
•Use a hand scraper to remove old gasket ma-
terial. 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 mate-
rial 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 sys-
tem can be damaged if the following cautions
are not followed:
•Do not disconnect the battery when the en-
gine is running. The voltage surge can dam-
age the diodes and resistors.
•Do not disconnect an electric wire before the
engine is stopped and the key switch is OFF.
•Do not cause a short circuit by connection
of the electric wires to the wrong terminals.
Make sure a correct identification of the wire
is made wire before it is connected.
•Make sure a battery is thecorrect voltage and
polarity before it is connected.
•Do not check for current flow by making a
spark because the transistors can be dam-
aged.
The Mazda M4-2.0G and M4-2.2G engines have
four cylinders. The displacement of the M4-2.0G
is 1998 cm3(121.9 in.3). The displacement of the
M4-2.2G is 2184 cm3(133.2 in.3). The firing order is
1–3–4–2.They are both available with either a
gasoline or LPG fuel system. The No. 1 cylinder is
toward the end of the engine with the cooling fan.
The overhead camshaft is driven by a cog belt. The
camshaft operates the rocker arms that actuate the
valves.
The crankshaft has five main bearings. The main
bearing in the center of the crankshaft is also the
thrust bearing.
The pistons are aluminum alloy and have three pis-
ton 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.
Engine Removal and Installation
The removal and installation procedures for the engine are not included in this section. For model
units H1.50-1.75 (S/H25-35XM) and H2.00 (S/H40XMS), see the section Frame 100 SRM 545. For model
units S/H2.00-3.20 (S/H40-65XM), see the section Frame 100 SRM 505.
1

Cylinder Head, Camshaft, and Valve Mechanism Repair 600 SRM 496
Cylinder Head, Camshaft, and Valve Mechanism Repair
REMOVE
1. Disconnect connections at battery.
2. Drain cooling system.
3. Remove air cleaner, carburetor linkage, inlet,
and exhaust manifolds.
4. Remove coolant hoses.
5. Remove bracket for cooling fan.
6. Remove upper and lower timing belt covers. See
Figure 1.
1. LOWER TIMING BELT COVER
2. UPPER TIMING BELT COVER
Figure 1. Timing Belt Covers
7. Loosen capscrews for timing belt tensioner and
remove spring. Remove capscrews and timing
belt tensioner.
8. Use chalk to mark direction of timing belt rota-
tion. See Figure 2. Remove timing belt.
Figure 2. Timing Belt
9. Put labels on wires to aid in correct installation.
Disconnect wires at distributor. Remove cap-
screw for distributor mount and pull distributor
from front housing.
10. Remove camshaft pulley. Keep pulley from rotat-
ing and loosen capscrew. Remove capscrew and
pulley. See Figure 3.
Figure 3. Camshaft Gear Removal
11. Remove nuts and capscrews for front housing.
Then remove housing. See Figure 4.
2

600 SRM 496 Cylinder Head, Camshaft, and Valve Mechanism Repair
1. FRONT HOUSING
2. GASKET 3. OIL SEAL
Figure 4. Front Housing
12. Remove valve cover.
13. Loosen capscrews for rocker shaft supports in
proper sequence. See Figure 5. Remove rocker
shaft assembly and camshaft.
Figure 5. Rocker Assembly Removal Sequence
14. Remove capscrews forcylinder head in proper se-
quence. See Figure 6.
15. Lift cylinder head from the block.
Figure 6. Cylinder Head Removal Sequence
16. Use valve spring compressor to remove valve re-
tainers, springs, and valves from head. See Fig-
ure 7.
Figure 7. Valve Removal
CLEAN
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the solvent
manufacturer’s recommended safety proce-
dures.
Cleanallpartsinsolvent.Makesurealloilpassages
are clean and all machined surfaces are smooth.
3

Cylinder Head, Camshaft, and Valve Mechanism Repair 600 SRM 496
INSPECT AND REPAIR
Cylinder Head
Use straight edge and thickness gauge to check bot-
tom surface of cylinder head for distortion. Do the
measurements at the positions shown in Figure 8.
Maximum amount of distortion is 0.15 mm
(0.0059 in.). If grinding of cylinder head is nec-
essary, maximum amount of correction is 0.2 mm
(0.008 in.).
Figure 8. Cylinder Head Inspection
Rocker Shaft Assembly
1. Disassemble rocker shaft assembly. Put marks
on rocker arms so they can be installed on correct
shafts.
2. Clean oil passages in rocker shafts and rocker
arms.
3. Check clearance between rocker arms and
rocker shafts. Maximum clearance is 0.10 mm
(0.004 in.).
Correct dimension for inside diameter of rocker
armis16.000to16.027 mm (0.6299to0.6311in.).
Correct dimension for outside diameter of
rocker shaft is 15.966 to 15.984 mm (0.6286 to
0.6293 in.). If components do not meet specifica-
tions, replace rocker arm(s) or rocker shaft(s) as
necessary.
Camshaft
1. Check camshaft for cracks or damage.
2. Use dial indicator on end of camshaft to check
movement of camshaft in cylinder head. See
Figure 9. Maximum movement is 0.20 mm
(0.008 in.).
Figure 9. Camshaft Check
3. Measureheightofcamshaftlobes. SeeFigure10.
Minimum height of intake and exhaust lobes is
36.902 mm (1.4528 in.).
4. Measure camshaft journals at four points (A-D)
asshowninFigure10.Minimumdimensionsfor
the journals are as follows:
Front and Rear Journals (Nos. 1 and 5) -
31.940 to 31.965 mm (1.2575 to 1.2585 in.)
Center Journals (Nos. 2, 3 and 4) - 31.910 to
31.935 mm (1.2563 to 1.2573 in.)
Front Oil Seal Surface - 33.961 to 34.000 mm
(1.3371 to 1.3386 in.)
Fuel Pump Lobe - 37.1 mm (1.46 in.)
5. Check camshaft for straightness. Put front and
rear journals in V blocks and rotate camshaft one
completeturn. SeeFigure11. Maximumamount
that the dial indicator should indicate is 0.03 mm
(0.0012 in.).
4

600 SRM 496 Cylinder Head, Camshaft, and Valve Mechanism Repair
6. Measureclearancebetweencamshaftandborein
cylinder head as follows:
a. Install camshaft in cylinder head.
b. Put plastic gauge material between each
camshaft journal and cap. Do not allow
camshaft to rotate.
c. Tightencapscrewsforcapsto18to27N•m
(13 to 20 lbf ft). See Figure 12.
Correct clearance for journals No. 1 and 5
is 0.035 to 0.085 mm (0.0014 to 0.0033 in.).
Correct clearance for journals No. 2, 3, and
4 is 0.065 to 0.115 mm (0.0026 to 0.0045 in.).
If any clearances are greater than 0.15 mm
(0.0059 in.), replace cylinder head assembly.
7. Replace camshaft if there is any damage or if it
does not meet specifications.
1. FRONT OIL SEAL SURFACE
2. FRONT JOURNAL (NO. 1)
3. CENTER JOURNALS (NOS. 2, 3, AND 4)
4. REAR JOURNAL (NO. 5)
5. FUEL PUMP LOBE
Figure 10. Camshaft Inspection
Figure 11. Camshaft Check
1. PLASTIC GAUGE 2. SCALE
Figure 12. Camshaft Clearance Measurement
Valve Guides
1. Measure clearance between valve stems and
valve guides. Normal clearance is 0.025 to
0.060 mm (0.001 to 0.002 in.).
If clearance is more than 0.20 mm (0.008 in.),
replace valve or valve guide.
2. If replacement is necessary, remove seal from
valve guide(s). Then use tool to remove valve
guide(s).
3. To install valve guide, install retaining ring on
valve guide. Use tool to install valve guide so
that retaining ring contacts cylinder head. See
Figure 13.
Correct height of valve guide above valve spring
seat is 19.1 to 19.6 mm (0.75 to 0.77 in.).
5

Cylinder Head, Camshaft, and Valve Mechanism Repair 600 SRM 496
1. CYLINDER HEAD
2. RETAINING RING 3. VALVE GUIDE
Figure 13. Valve Guide Inspection
Valve Seats
1. Inspect condition of valve seats. If valve seats
have cracks, cylinder head must be replaced.
2. If valve seats are in good condition, check contact
pattern of valve and valve seat. Use valve seat
grinder to make sure valve seats are within spec-
ifications shown in Figure 14. Use valve com-
pound to make sure valves fit seats.
A. EXHAUST B. INTAKE
1. VALVE SEAT
WIDTH
2. EXHAUST VALVE
SEAT
3. INTAKE VALVE
SEAT
Figure 14. Valve Seat Specifications
Valves
1. Inspect stem of each valve for wear. Use microm-
eter to measure outside diameter of stem. See
Figure 15.
Minimum dimension for intake valve is
7.980 mm (0.3142 in.). Minimum dimension
for exhaust valve is 7.975 mm (0.3140 in.).
2. Inspect valves for cracks, burned faces, and dis-
tortion. Inspect seat face of valves for wear and
damage.
3. Measure thickness of valve head. Minimum
thickness for intake valve is 0.5 mm (0.020 in.).
Minimum thickness for exhaust valve is 1.0 mm
(0.040 in.).
If valves need grinding, correct surface angle is
30 for both intake and exhaust valves.
1. DIAMETER 2. THICKNESS,
VALVE HEAD
Figure 15. Valve Inspection
6

600 SRM 496 Cylinder Head, Camshaft, and Valve Mechanism Repair
Valve Springs
1. Check valve springs for damage.
2. Measurefreelengthofoutervalvesprings. See
Figure 16.
Minimum length of intake spring is 44.3 mm
(1.74 in.). Minimum length of exhaust spring is
50.8 mm (2.00 in.).
3. Check outer valve springs for squareness. See
Figure 16.
Ifmeasurementismore than1.81mm (0.071in.),
replace valve spring(s).
A. MEASURE HERE
Figure 16. Valve Springs Inspection
INSTALL
1. Clean surface of cylinder head and surface of en-
gine block.
2. Install new gasket and cylinder head on engine
block.
3. Install capscrews and washers for cylinder
head. Tighten capscrews to 82 to 88 N•m(60to
65 lbf ft) in proper sequence. See Figure 17.
4. Apply gasket sealer to areas shown by arrows.
Lubricate camshaft with clean engine oil. Then
install camshaft. Make sure dowel pin is at top
of camshaft. See Figure 18.
Figure 17. Cylinder Head Installation
1. DOWEL PIN 2. APPLY SEALANT
HERE
Figure 18. Camshaft Installation
5. Assemble rocker shaft assembly. See Figure 19.
Lubricate rocker arms and shafts engine oil. Put
capscrews in rocker shaft supports. Then install
assembly on cylinder head.
7

Cylinder Head, Camshaft, and Valve Mechanism Repair 600 SRM 496
A. NO. 1 AND NO. 3 ARE THE SAME
B. NO. 2 AND NO. 4 ARE THE SAME
Figure 19. Rocker Shaft Assembly
6. Tighten capscrews forrockershaft supports to 18
to27N•m(13to20lbfft)inpropersequence. See
Figure 20.
Figure 20. Rocker Shaft Assembly Installation
7. If necessary, install oil seal in front housing. See
Figure21. Usenewgasketandinstallfronthous-
ing on cylinder head. Tighten capscrews for front
housing to 19 to 26 N•m (14 to 19 lbf ft).
8. With dowel pin at top of camshaft, install
camshaft pulley. Check that letter A on pulley is
aligned with timing mark on front housing. See
Figure 22.
9. Install capscrew and washer for camshaftpulley.
See Figure 22. Keep pulley from turning and
tightencapscrewto48to66N•m (35 to 49 lbf ft).
1. FRONT HOUSING
2. GASKET 3. OIL SEAL
Figure 21. Front Housing
1. TIMING MARKS 2. CAMSHAFT
PULLEY
Figure 22. Camshaft Pulley Installation
8

600 SRM 496 Cylinder Head, Camshaft, and Valve Mechanism Repair
10. Align timing marks for crankshaft pulley. See
Figure 23. Install crankshaft pulley, tapered
ring, and capscrew. Tighten capscrew to 160 to
170 N•m (118 to 125 lbf ft).
1. CRANKSHAFT
PULLEY 2. TIMING MARK
Figure 23. Timing Belt Installation
11. Install timing belt tensioner and spring. Move
tensioner fully toward intake side of engine and
temporarily tighten lock bolt.
12. Clean any oil or grease from pulleys. Install tim-
ingbeltsothatitgoesinsamedirectionasmark
made during removal.
13. Loosen lockbolt andapplyspring tension on belt.
Rotate crankshaft pulley clockwise two complete
turns and check timing marks.
If timing marks are correct, tighten lock bolt for
tensioner to 20 to 35 N•m (15 to 26 lbf ft). Check
movement on tension side of timing belt. If ten-
sion is correct, belt will move 12 to 14 mm (0.47
to 0.55 in.) with 10 kg (20 lb) of force. See Fig-
ure 24.
14. Install lower timing belt cover and gasket.
Tighten capscrews to 7 to 8 N•m(5to6lbfft).
Install upper timing belt cover and gasket.
Tightencapscrewsto8to12N•m(6to9lbfft).
See Figure 25.
15. Install distributor. See Distributor Repair for
procedures.
1. TENSIONER
2. SPRING 3. LOCK BOLT 4. TENSION SIDE
Figure 24. Timing Belt Installation
1. LOWER TIMING BELT COVER
2. UPPER TIMING BELT COVER
Figure 25. Timing Belt Covers
9

Crankshaft and Main Bearings Repair 600 SRM 496
Crankshaft and Main Bearings Repair
REMOVE
1. Remove bracket for cooling fan.
2. Remove six capscrews and plate from crankshaft
pulley. Remove six capscrews that hold crank-
shaft pulley to timing pulley.
3. Removecapscrewfromtimingpulley. Installspe-
cial tool on crankshaft to remove timing pulley.
Rotate tool until it touches front of crankshaft.
Hittoolwith hammertoloosentimingpulley. Re-
move pulley, dowel pin, and tapered ring. Re-
move tool.
4. Remove oil pan and oil strainer.
5. Remove rear cover. Remove front cover with oil
pump.
6. Remove caps for connecting rods. Put identifica-
tion mark on each cap so they will be installed in
correct location.
7. Before removing crankshaft, measure clearance
between crankshaft and flange of center main
bearing. See Figure 26. Push crankshaft fully
forward before making measurement.
Maximum clearance is 0.30 mm (0.012 in.). If
clearance is greater than specification, replace
center main bearing or crankshaft.
1. CENTER MAIN BEARING
Figure 26. Crankshaft Clearance Measurement
8. Put identification markson bearingcaps. Loosen
capscrews for main bearing caps in steps. Then
remove capscrews, caps, and crankshaft.
INSPECT AND REPAIR
Crankshaft
1. Inspect crankshaft for wear, cracks, or other
damage. Replace crankshaft if it has cracks.
2. Use micrometer to measure diameter of journals
for crankshaft. See Figure 27. Make measure-
ment at several locations for each journal. Cor-
rect dimensions for journals are as follows:
Main Journal Diameter - 59.937 to 59.995 mm
(2.3597 to 2.3620 in.)
Connecting Rod Journals - 50.940 to
50.955 mm (2.0055 to 2.0061 in.)
RearOilSealSurface-89.946to90.000mm
(3.5412 to 3.5433 in.)
Front Oil Seal Surface - 33.961 to 34.000 mm
(1.3371 to 1.3386 in.)
If measurements are less than specifications,
grind crankshaft and install undersize bearings.
3. Check crankshaft for straightness. See Fig-
ure 27. Put front and rear journals in V blocks
and rotate crankshaft one complete turn. Maxi-
mum amount that dial indicator should indicate
is 0.03 mm (0.0012 in.).
4. Check oil passages crankshaft. Make sure pas-
sages are clean and have no restrictions.
Main Bearings
NOTE: Do not clean main bearings. If any bearings
are too dirty, replace all main bearings.
1. Inspect main bearings for damage. If any main
bearing is damaged, all main bearings must be
replaced.
2. To inspect main bearings for wear, measure
clearance between main bearings and crank-
shaft.SeeFigure28.
a. Install crankshaft in cylinder block.
10

600 SRM 496 Crankshaft and Main Bearings Repair
1. REAR OIL SEAL
SURFACE
2. CONNECTING
ROD JOURNALS
3. MAIN BEARING
JOURNALS
4. FRONT OIL SEAL
SURFACE
Figure 27. Crankshaft Inspection
b. Put plastic gauge material on journals and
install main bearing caps. Tighten cap-
screws for bearing caps to 84 to 90 N•m(62
to 66 lbf ft).
c. Removebearingcaps. Plasticgaugematerial
will adhere to journals or bearing caps.
d. Use graduations on scale to measure width
of plastic gauge material at its widest point.
Correct clearance is 0.031 to 0.049 mm
(0.0012 to 0.0019 in.). If any clearance is
greater than specification, replace all main
bearings.
1. PLASTIC GAUGE
MATERIAL 2. SCALE
Figure 28. Main Bearings Clearance Check
INSTALL
1. Clean areas of cylinder block around main bear-
ings. Carefully install bottom half of new main
bearings if necessary. Lubricate bearings with
clean engine oil.
2. Install crankshaft.
3. Install top half of main bearings in caps and
lubricate with oil. Use identification marks to
install main bearing caps in correct locations.
Tighten capscrews for main bearing caps to 84
to 90 N•m (62 to 66 lbf ft).
4. Install pistons and connecting rods as described
in Pistons and Connecting Rods Repair.
5. Make sure O-ring is in oil pump housing. Lubri-
cateoilsealwithengineoil. Useadhesivesealant
to install housing to cylinder block. Make sure
there is no sealant in oil port. Tighten M10 cap-
screws to 38 to 53 N•m (28 to 39 lbf ft). Tighten
M8 capscrews to 19 to 26 N•m (14 to 19 lbf ft).
6. Lubricate surfaces of oil seal with engine oil. Use
presstoinstalloilsealinrearcover. Installalign-
ment pin in cylinder block.
7. Install gasket and rear cover. See Figure 29.
Make sure dowel pin is installed. Tighten cap-
screwsto8to12N•m(6to9lbfft). Cutoff
part of gasket that extends past bottom of cylin-
der block.
11

Pistons and Connecting Rods Repair 600 SRM 496
8. Install oil strainer. Tighten M6 capscrews to 8 to
12 N•m (6 to 9 lbf ft). Tighten M8 capscrews to
16 to 23 N•m (12 to 17 lbf ft).
9. Install gasket and oil pan. Tighten capscrews to
7to12N•m(5to9lbfft).
1. REAR COVER
2. OIL SEAL 3. CRANKSHAFT
Figure 29. Rear Cover
Pistons and Connecting Rods Repair
REMOVE AND DISASSEMBLE
1. Remove cylinder head as described in Cylinder
Head, Camshaft, and Valve Mechanism Repair.
2. Remove oil pan and oil strainer.
3. Put identification mark on top of each piston.
4. Clean carbon from top of each cylinder bore.
5. Remove caps and bearings from each connecting
rod. Keep caps and bearings with correct piston
assemblies.
6. Push connecting rod and piston from cylinder
block.
7. Carefully remove piston rings from pistons. Use
tool to push piston pin from connecting rod.
CLEAN
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow solvent man-
ufacturer’s recommended safety procedures.
Clean all parts in solvent. Make sure all oil passages
and grooves are clean. Make sure all machined sur-
faces are smooth.
INSPECT AND REPAIR
Pistons
1. Inspect pistons for wear and cracks. Replace any
piston that is damaged.
2. Measure outside diameter of piston. See
Figure 30. Correct dimension is 85.944 to
85.964 mm (3.3836 to 3.3844 in.). Maximum
clearance between piston and cylinder bore is
0.15 mm (0.0059 in.).
Figure 30. Piston Measurement
Piston Rings
1. Install piston ring into cylinder bore where it will
beused. Usethicknessgaugetomeasure amount
12

600 SRM 496 Pistons and Connecting Rods Repair
of end clearance of each piston ring. See Fig-
ure 31. Correct dimensions are as follows:
Top Piston Ring - 0.20 to 0.35 mm (0.008 to
0.014 in.)
2nd Piston Ring - 0.15 to 0.30 mm (0.006 to
0.012 in.)
Oil Ring - 0.30 to 0.90 mm (0.012 to 0.035 in.)
Maximum clearance is 1.0 mm (0.039 in.)
2. Measure clearance between piston ring and
groove in piston. See Figure 31. Correct dimen-
sions are as follows:
Top Piston Ring - 0.03 to 0.07 mm (0.0012 to
0.0028 in.)
2nd Piston Ring - 0.03 to 0.07 mm (0.0012 to
0.0028 in.)
Maximum clearance is 0.15 mm (0.0059 in.)
1. PISTON RING END CLEARANCE
2. PISTON RING GROOVE CLEARANCE
Figure 31. Piston Rings Measurement
Connecting Rods and Bearings
1. Use alignment tool to check connecting rods for
straightness. Maximumamountofdistortionper
100 mm (4.0 in.) is 0.04 mm (0.0016 in.).
If amount of distortion is greater than specifica-
tion, install new rod or use press to straighten
connecting rod.
2. Clean rod bearings and crankshaft journals. To
check bearings for wear, measure clearance be-
tween rod bearings and journals. See Figure 32.
a. Put plastic gauge material on crankshaft
journals and install rod caps. Tighten cap-
screws for rod caps to 51 to 56 N•m(38to
41 lbf ft). Do not rotate connecting rod.
b. Remove rod caps. Plastic gauge material will
adhere to journals or rod caps.
c. Usegraduationsonscaletomeasurewidth
of plastic gauge material at its widest point.
Correct clearance is 0.027 to 0.067 mm
(0.0011 to 0.0026 in.). If any clearance is
greater than specification, replace all rod
bearings.
1. BEARING 2. PLASTIC GAUGE
Figure 32. Connecting Rod Bearings Clearance
Check
ASSEMBLE AND INSTALL
1. Align oil port on large end of connecting rod with
F mark on piston. See Figure 33. Lubricate pis-
tonpinandboreinpistonwithengineoil.
2. Use press to install piston pin. Amount of force
required to push pin into piston must be 500 to
1500 kg (1102 to 3306 lb). If force is not correct,
replace piston pin and/or connecting rod.
Use special tool to make sure piston pin is in-
stalled to correct depth. After installation, check
that piston moves freely on piston pin.
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Pistons and Connecting Rods Repair 600 SRM 496
1. F MARK 2. OIL PORT
Figure 33. Connecting Rod and Piston
3. Install piston rings on pistons. During instal-
lation, writing on each piston ring must be to-
ward top of piston. Check that rings rotate freely.
Then put ends of rings in positions shown in Fig-
ure 34. Make sure ends of upper and lower oil
control rings are each 30 from piston pin. Also
make sure that top and second rings are each 30
from piston pin. Lubricate rings with engine oil.
4. Apply clean engine oil to piston assembly. Install
bearings for connecting rods. Install piston into
correct cylinder, making sure F is toward front
(timing belt end) of engine. See Figure 35.
5. Apply clean engine oil to bearing. Then install
each cap to correct connecting rod. During in-
stallation of caps, make sure to align identifi-
cation marks that were made during disassem-
bly. Tighten nuts for caps to 51 to 56 N•m(38to
41 lbf ft).
A. OIL CONTROL RING
B. TOP AND SECOND RINGS
1. EXPANDER RING
2. OIL RING (UPPER)
3. OIL RING (LOWER)
4. TOP RING
5. SECOND RING
Figure 34. Piston Rings
1. F MARK
Figure 35. Piston Installation
14

600 SRM 496 Oil Pump Repair
Cylinder Block Repair
1. After cylinder block is cleaned, check its surface
for distortion. See Figure 36.
If amount of distortion is greater than 0.15 mm
(0.0059in.), grind surface of cylinder block. Max-
imum amount of correction permitted is 0.20 mm
(0.008 in.).
2. Check cylinder bores for wear and damage. Mea-
sure each bore. Correct dimension is 86.00 to
86.019 mm (3.3858 to 3.3866 in.). Wear limit
above this dimension is 0.015 mm (0.001 in.).
Repair cylinder block or use bigger pistons as
necessary.
Figure 36. Cylinder Block Insepction
Oil Pump Repair
Before removing oil pump, replace sending unit with
pressure gauge and check oil pressure. Minimum oil
pressure at governed rpm is approximately 275 kPa
(40 psi). If pressure is less than specification, oil
pump or engine bearings need repair.
REMOVE
1. Remove bracket for cooling fan.
2. Remove upper and lower timing belt covers. See
Figure 37.
3. Loosen capscrews for timing belt tensioner and
remove spring. Remove capscrews and timing
belt tensioner.
4. Use chalk to mark direction of rotation of timing
belt. See Figure 38. Remove timing belt.
5. Remove six capscrews and plate from crankshaft
pulley. Remove six capscrews that hold crank-
shaft shaft pulley to timing pulley.
6. Removecapscrewfromtimingpulley. Installspe-
cial tool on crankshaft to remove timing pulley.
Rotate tool until it touches the front of crank-
shaft. Hit tool with hammer to loosen timing pul-
ley. Remove pulley, dowel pin, and tapered ring.
Remove tool.
7. Remove capscrews that hold oil pan to cylinder
block. Remove oil pan.
8. Remove capscrews that hold front cover (pump
housing) to cylinder block. Remove front cover
and oil pump assembly.
1. UPPER TIMING BELT COVER
2. LOWER TIMING BELT COVER
Figure 37. Timing Belt Covers
Figure 38. Timing Belt
15

Oil Pump Repair 600 SRM 496
DISASSEMBLE
1. Remove screws and pump cover. See Figure 39.
1. SCREW
2. COVER
3. OUTER GEAR
4. INNER GEAR
5. FRONT COVER
(HOUSING)
6. OIL SEAL
7. PLUNGER
8. SNAP RING
Figure 39. Oil Pump
2. Removeoutergearandinnergearfrompump
body.
3. Remove snap ring and plunger assembly from
housing.
CLEAN
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the solvent
manufacturer’s recommended safety proce-
dures.
Clean all parts in solvent. Make sure all machined
surfaces are smooth.
16