Yale GDP16-20AF Guide

Maintenance
0$='$ (1*,1(
FE AND F2
GP/GLP/GDP16-20AF/BF
(GP/GLP/GDP030-040AF/BF) [A810];
GC/GLC030-040AF [B809];
GLP/GDP16-20AF
(GP/GLP/GDP030-040AF) [B810];
GP/GLP/GDP2.00-3.00RF/TF
(GP/GLP/GDP040-060RG/TG/ZG) [A875];
GC/GLC040-065TF/RF [E187]
PART NO. 524158742 600 YRM 496

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
•When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fas-
tened, 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 Maintenance 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 YALE 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
forcetoremoveparts.
•Always fasten a DO NOT OPERATE tag to the controls of the unit 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.................................................................................................................................................... 15
Clean............................................................................................................................................................... 16
Inspect............................................................................................................................................................. 16
Assemble ........................................................................................................................................................ 16
Install............................................................................................................................................................... 17
Cooling System Repair........................................................................................................................................ 17
Thermostat...................................................................................................................................................... 17
Replace....................................................................................................................................................... 17
Fan Assembly.................................................................................................................................................. 18
Remove and Disassemble.......................................................................................................................... 18
Assemble and Install................................................................................................................................... 18
Water Pump .................................................................................................................................................... 18
Remove and Disassemble.......................................................................................................................... 18
Assemble and Install................................................................................................................................... 19
Distributor Repair................................................................................................................................................. 20
Remove........................................................................................................................................................... 20
Install............................................................................................................................................................... 20
Flywheel and Ring Gear Repair .......................................................................................................................... 21
Remove........................................................................................................................................................... 21
©2002 Yale Materials Handling Corp. i

Table of Contents Mazda Engine
TABLE OF CONTENTS (Continued)
Ring Gear, Replace......................................................................................................................................... 21
Install............................................................................................................................................................... 21
Flywheel Repair................................................................................................................................................... 22
Remove........................................................................................................................................................... 22
Install............................................................................................................................................................... 22
Valve Adjustment................................................................................................................................................. 23
Compression Pressure Check............................................................................................................................. 24
Engine Timing Adjustment................................................................................................................................... 24
Throttle Linkage Adjustment................................................................................................................................ 25
Gasoline Engines............................................................................................................................................ 25
LPG Engines (IMPCO).................................................................................................................................... 25
LPG Engines (AISAN)..................................................................................................................................... 25
Engine Specifications.......................................................................................................................................... 25
Engine Data .................................................................................................................................................... 25
Thermostat...................................................................................................................................................... 25
Cylinder Head ................................................................................................................................................. 26
Valve Mechanism............................................................................................................................................ 26
Camshaft......................................................................................................................................................... 26
Crankshaft....................................................................................................................................................... 27
Connecting Rods............................................................................................................................................. 27
Cylinder Block................................................................................................................................................. 27
Pistons ............................................................................................................................................................ 27
Oil Pump ......................................................................................................................................................... 27
Torque Specifications .......................................................................................................................................... 28
Troubleshooting................................................................................................................................................... 29
This section is for the following models:
GP/GLP/GDP16-20AF/BF (GP/GLP/GDP030-040AF/BF) [A810];
GC/GLC030-040AF [B809];
GLP/GDP16-20AF (GP/GLP/GDP030-040AF) [B810];
GP/GLP/GDP2.00-3.00RF/TF (GP/GLP/GDP040-060RG/TG/ZG) [A875];
GC/GLC040-065TF/RF [E187]
ii

600 YRM 496 Engine Removal and Installation
General
This section has the instructions for removal, disassem-
bly, repair, assembly, installation, checks, adjustments,
and troubleshooting for the FE and F2 engines. The en-
gine 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, and Electrical System.
Description
WARNING
Some gaskets used in this engine can contain dan-
gerous 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 toremove old gasket material.
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 anydis-
assembly 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 en-
gine 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
acorrectid
entificationofthewireismadewire
before it is connected.
•Make sure a battery is the correct voltage and po-
larity before it is connected.
•Do not check for current flow by making a spark
because the transistors can be damaged.
The Mazda FE and F2 engines have four cylinders. The
displacement of the FE is 1998 cm3(121.9 in.3). The
displacement of the F2 is 2184 cm3(133.2 in.3). The
firing orderis1–3–4–2. Theyarebothavailable
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 bear-
inginthecenterof the crankshaft isalsothethrust bear-
ing.
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.
Engine Removal and Installation
The removal and installation procedures for the engine
are not included in this section. For model units
GP/GLP/GDP16-20AF/BF (GP/GLP/BDP030-040AF/
BF), GC/GLC030-040AF, and GLP/GDP16-20AF
(GP/GLP/GDP030-040AF), see the section Frame 100
YRM 545. For model units GP/GLP/GDP2.0-3.0RF/TF
(GP/GLP/GDP040-060RG/TG/ZG) and GC/GLC040-
065TF/RF, see the section Frame 100 YRM 505.
1

Cylinder Head, Camshaft, and Valve Mechanism Repair 600 YRM 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 re-
move spring. Remove capscrews and timing belt
tensioner.
8. Use chalk to mark direction of timing belt rotation.
SeeFigure2.Removetimingbelt.
Figure 2. Timing Belt
9. Put labels on wires to aid in correct installation.
Disconnect wires at distributor. Remove capscrew
for distributor mount and pull distributor from front
housing.
10. Remove camshaft pulley. Keep pulley from rotating
and loosen capscrew. Remove capscrew and pul-
ley.SeeFigure3.
Figure 3. Camshaft Gear Removal
11. Remove nuts and capscrews for front housing.
Then remove housing. See Figure 4.
2

600 YRM 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 for cylinder 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 procedures.
Clean all parts in solvent. Make sure all oil passages
are clean and all machined surfaces are smooth.
3

Cylinder Head, Camshaft, and Valve Mechanism Repair 600 YRM 496
INSPECT AND REPAIR
Cylinder Head
Use straight edge and thickness gauge to check bottom
surface of cylinder head for distortion. Do the measure-
ments at the positions shown in Figure 8.
Maximum amount of distortion is 0.15 mm (0.0059 in.).
If grinding of cylinder head is necessary, 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
arm is 16.000 to 16.027 mm (0.6299 to 0.6311 in.).
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 specifications, 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 Fig-
ure 9. Maximum movement is 0.20 mm (0.008 in.).
Figure 9. Camshaft Check
3. Measure height of camshaft lobes. See Figure 10.
Minimum height of intake and exhaust lobes is
36.902 mm (1.4528 in.).
4. Measure camshaft journals at four points (A-D) as
shown in Figure 10. Minimum dimensions for 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
complete turn. See Figure 11. Maximum amount
that the dial indicator should indicate is 0.03 mm
(0.0012 in.).
6. Measure clearance between camshaft and bore in
cylinder head as follows:
a. Install camshaft in cylinder head.
4

600 YRM 496 Cylinder Head, Camshaft, and Valve Mechanism Repair
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.). Cor-
rect 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.), re-
place valve or valve guide.
2. If replacement isnecessary, removeseal 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 retain-
ing 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 YRM 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 compound
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 microme-
ter to measure outside diameter of stem. See Fig-
ure 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 distor-
tion. Inspect seat face of valves for wear and dam-
age.
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 YRM 496 Cylinder Head, Camshaft, and Valve Mechanism Repair
Valve Springs
1. Check valve springs for damage.
2. Measure free length of outer valve springs. 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 Fig-
ure 16.
If measurement is more than 1.81 mm (0.071 in.),
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 (60 to 65 lbf ft)
in proper sequence. See Figure 17.
4. Apply gasket sealer to areas shown by arrows. Lu-
bricate camshaft with clean engine oil. Then in-
stall 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 YRM 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 for rocker shaft supports to 18
to 27 N•m (13 to 20 lbf ft) in proper sequence. See
Figure 20.
Figure 20. Rocker Shaft Assembly Installation
7. If necessary, install oil seal in front housing. See
Figure 21. Use new gasket and install front hous-
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 camshaft pulley.
SeeFigure22. Keeppulleyfromturningandtighten
capscrew to 48 to 66 N•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 YRM 496 Cylinder Head, Camshaft, and Valve Mechanism Repair
10. Align timing marks for crankshaft pulley. See Fig-
ure 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 ten-
sioner fully toward intake side of engine and tem-
porarily tighten lock bolt.
12. Clean any oil or grease from pulleys. Install timing
belt so that it goes in same direction as mark made
during removal.
13. Loosen lock bolt and apply spring tension on belt.
Rotate crankshaft pulley clockwise two complete
turns and check timing marks.
If timing marks are correct, tighten lock bolt for ten-
sioner to 20 to 35 N•m (15to26lbfft). Check move-
ment on tension side of timing belt. If tension is cor-
rect,beltwillmove12to14mm(0.47to0.55in.)
with 10 kg (20 lb) of force. See Figure 24.
14. Install lower timing belt cover and gasket. Tighten
capscrewsto7to8N•m (5 to 6 lbf ft). Install upper
timing belt cover and gasket. Tighten capscrews to
8to12N•m(6to9lbfft).SeeFigure25.
15. Install distributor. See Distributor Repair for proce-
dures.
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 YRM 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 crankshaft
pulley to timing pulley.
3. Removecapscrewfromtiming pulley. Installspecial
tool on crankshaft to remove timing pulley. Rotate
tool until it touches front of crankshaft. Hit tool with
hammer to loosen timing pulley. Remove pulley,
dowel pin, and tapered ring. Remove tool.
4. Remove oil pan and oil strainer.
5. Remove rear cover. Remove front cover with oil
pump.
6. Removecapsforconnectingrods. Putidentification
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 clear-
ance is greater than specification, replace center
main bearing or crankshaft.
1. CENTER MAIN BEARING
Figure 26. Crankshaft Clearance Measurement
8. Put identification marks on bearing caps. 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 dam-
age. Replace crankshaft if it has cracks.
2. Use micrometer to measure diameter of journals for
crankshaft. See Figure 27. Make measurement at
several locations for each journal. Correct dimen-
sions 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.)
Rear Oil Seal Surface - 89.946 to 90.000 mm
(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 Figure 27.
Put front and rear journals in V blocks and rotate
crankshaft one complete turn. Maximum 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 re-
placed.
2. To inspect main bearings for wear, measure clear-
ance between main bearings and crankshaft. See
Figure 28.
a. Install crankshaft in cylinder block.
10

600 YRM 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 in-
stall main bearing caps. Tighten capscrews for
bearing caps to 84 to 90 N•m (62 to 66 lbf ft).
c. Remove bearing caps. Plastic gauge material
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 bear-
ings if necessary. Lubricate bearings with clean en-
gine oil.
2. Install crankshaft.
3. Install top half of main bearings in caps and lu-
bricate 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
(62to66lbfft).
4. Install pistons and connecting rods as described in
Pistons and Connecting Rods Repair.
5. Make sure O-ring is in oil pump housing. Lubricate
oil seal with engine oil. Use adhesive sealant to
install housing to cylinder block. Make sure there is
no sealant in oil port. Tighten M10 capscrews 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
press to install oil seal in rear cover. Install align-
ment pin in cylinder block.
7. Install gasket and rear cover. See Figure 29. Make
sure dowel pin is installed. Tighten capscrews to 8
to 12 N•m (6 to 9 lbf ft). Cut off part of gasket that
extends past bottom of cylinder block.
11

Pistons and Connecting Rods Repair 600 YRM 496
8. Install oil strainer. Tighten M6 capscrews to 8 to
12 N•m(6to9lbfft).TightenM8capscrewsto16
to 23 N•m (12 to 17 lbf ft).
9. Install gasket and oil pan. Tighten capscrews to 7
to 12 N•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 connectingrodand pistonfrom cylinderblock.
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 sol-
vents, always follow solvent manufacturer’srecom-
mended 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. Measureoutsidediameterof piston. SeeFigure 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 be
used. Use thickness gauge to measure amount of
12

600 YRM 496 Pistons and Connecting Rods Repair
end clearance of each piston ring. See Figure 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 dimensions 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. Maximum amount of distortion per
100 mm (4.0 in.) is 0.04 mm (0.0016 in.).
If amount of distortion is greater than specification,
installnewrodorusepresstostraightenconnecting
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 jour-
nals and install rod caps. Tighten capscrews
for rod caps to 51 to 56 N•m (38 to 41 lbf ft).
Do not rotate connecting rod.
b. Remove rod caps. Plastic gauge material will
adhere to journals or rod caps.
c. Use graduations on scale to measure width 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 bear-
ings.
1. PLASTIC GAUGE 2. SCALE
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 piston
pin and bore in piston with engine oil.
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 installed
to correct depth. After installation, check that piston
moves freely on piston pin.
13

Pistons and Connecting Rods Repair 600 YRM 496
1. F MARK 2. OIL PORT
Figure 33. Connecting Rod and Piston
3. Install piston rings on pistons. During installation,
writingoneachpistonringmustbetowardtopof
piston. Check that rings rotate freely. Then put
ends of rings in positions shown in Figure 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. Lu-
bricate rings with engine oil.
4. Apply clean engine oil to piston assembly. Install
bearings for connecting rods. Install piston into cor-
rect 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 installation of
caps, make sure to align identification marks that
were made during disassembly. Tighten nuts for
caps to 51 to 56 N•m(38to41lbfft).
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 YRM 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
(0.0059 in.), 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 nec-
essary.
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 re-
move spring. Remove capscrews and timing belt
tensioner.
4. Usechalktomarkdirectionofrotationoftimingbelt.
See Figure 38. Remove timing belt.
5. Remove six capscrews and plate from crankshaft
pulley. Remove six capscrews that hold crankshaft
shaft pulley to timing pulley.
6. Remove capscrew from timing pulley. Install spe-
cial tool on crankshaft to remove timing pulley. Ro-
tate tool until it touches the front of crankshaft. Hit
tool with hammer to loosen timing pulley. 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
DISASSEMBLE
1. Remove screws and pump cover. See Figure 39.
15

Oil Pump Repair 600 YRM 496
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. Remove outer gear and inner gear from pump 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 procedures.
Clean all parts in solvent. Make sure all machined sur-
faces are smooth.
INSPECT
1. Check front cover (pump housing) and pump cover
for wear or damage. Check plunger spring for dam-
age.
2. Measure parts of oil pump. See Figure 40.
a. Measure clearance between gears and cres-
cent. Correct clearance is 0.20 to 0.32 mm
(0.008 to 0.013 in.). If clearance is more than
0.35 mm (0.014 in.), repair as necessary.
b. Measure clearance between crescent and
teeth of inner gear. Correct clearance is 0.267
to 0.380 mm (0.0105 to 0.0150 in.). If clear-
ance is more than 0.40 mm (0.0157 in.), repair
as necessary.
c. Use straight edge to measure side clearance
of gears. Correct clearance is 0.03 to 0.63 mm
(0.0012to 0.0248 in.). Ifclearanceis more than
0.10 mm (0.004 in.), repair as necessary.
d. Measure clearance between body and outer
gear. Correct clearance is 0.090 to 0.184 mm
(0.0035to 0.0072 in.). Ifclearanceis more than
0.20 mm (0.008 in.), repair as necessary.
ASSEMBLE
1. Install oil seal in oil pump housing. Make sure front
edge of oil seal is even with outer edge of housing.
See Figure 39.
2. Lubricate gears with engine oil. Then install gears
in housing.
3. Install pump cover. Apply thread-locking compound
on screws for pump cover. Then install screws.
4. Install plunger assembly and snap ring.
16