GM 4.3 LITRE V6 AND 5.

7 LITRE V8 ENGINES
This section has the description and the repair instructions for the GM 4.3 litre V6 and the 5.7 Litre V8 engines. Checks and Adjustments, Troubleshooting procedures and Specifications are also included in this section.

DESCRIPTION
The arrangement of the cylinders is in a V shape. The
cylinder block is made of cast iron. The V8 engine has
five main bearings for the crankshaft. The V6 engine
has four main bearings.

5. Remove the capscrews that hold the cylinder head to

the block. Loosen the capscrews in the reverse order of
the tightening sequence shown in FIGURE 5. Remove
the cylinder head and the gasket.
6. Remove the nuts and balls for the rocker arms. Remove the rocker arms. Keep the parts for each rocker
arm assembly together.
7. Use a valve spring compressor and remove the valves
and springs. Put the valves in a rack so that they can be
installed in their original positions.

The cylinder head is cast iron and has an intake valve

and an exhaust valve for each cylinder. The valve mechanism is actuated by push rods and rocker arms from the
camshaft.
The camshaft has five bearings on the V8 and four
bearings on the V6. The camshaft is driven by a chain
from the crankshaft. Hydraulic cam followers are used
to actuate the push rods.
The pistons are made of cast aluminum and have two
compression rings and one oil control ring.

ENGINE, REMOVAL AND INSTALLATION

The Removal and Installation procedures for the engine
is in the section for THE FRAME for each model of lift
truck. See the sections for the TRANSMISSION to separate the transmission from the engine.

CYLINDER HEAD
Removal And Disassembly (See FIGURE 1.)

WARNING
Disconnect the battery cables before making repairs
to the engine.
1. Drain the coolant from the engine.
2. Disconnect and remove the coolant hose from the
housing for the thermostat.

11700

1. CYLINDER HEAD
2. CYLINDER BLOCK
3. CAM FOLLOWER

4. PUSH ROD
5. ROCKER ARM
6. CAMSHAFT

FIGURE 1. CYLINDER HEAD

Cleaning And Inspection
Clean the carbon from the ports and chambers in the cylinder head. Clean the carbon and oil from the valves,
push rods and rocker arms.
Inspect the cylinder head for cracks in the ports and
chambers. Inspect the valves for cracks in the heads or
damaged stems.
Repairs, Valve Guides and Seats

3. Remove the air cleaner, carburetor, distributor, intake

manifold and the exhaust manifolds. Loosen the drive
belts and remove the bracket for the fan mount from the
cylinder heads.
4. Remove the rocker arm cover.

Measure the clearance between the valve stem and the

guide as shown in FIGURE 2. The maximum clearance
for the intake valves is 0.094 mm (0.0037 in). The maximum clearance for the exhaust valves is 0.119 mm
(0.0047 in). If the clearance is more than the maximum
1

amount, oversize valves must be installed. Use a reamer

of the correct size when installing oversize valves. Use
normal service procedures when grinding the valve
seats. See the Specifications for dimensions.

CAUTION
Do not attempt to install an oversize stud without
reaming the stud hole to the new size. Installation of
an oversize stud without reaming the stud hole can
cause cracks in the cylinder head.
2. Use a reamer of the correct size for the new oversize
stud. Apply SAE 90 lubricant to the new stud during installation. Install the new stud as shown in FIGURE 4.

11700

1. VALVE STEM
2. DIAL INDICATOR

FIGURE 2. VALVE STEM CLEARANCE

1. REAMER
2. INSTALLATION TOOL
11700

Studs For The Rocker Arms

Replace a stud that has damaged threads or is loose in the
cylinder head. New studs are available in the following
oversizes: 0.003 inch and 0.013 inch.
1. Remove the old stud. Install a spacer, flat washer, and
nut to the damaged stud. Use a wrench to remove the
damaged stud. See FIGURE 3.

FIGURE 4. INSTALLATION OF A STUD FOR A

ROCKER ARM
Valve Springs (See FIGURE 38.)

FIGURE 3. REMOVE A STUD FOR A ROCKER

ARM
2

Use a special tool to check the tension of the valve

springs. Compress the spring to the correct height and
check the tension. See Specifications for the correct tension. Replace valve springs that are not within 44 N (10
lbf) of specifications.

ASSEMBLY AND INSTALLATION

1. Install each valve in the correct port. Install the shim
and valve springs. Compress the spring and install the
oil seal in the lower groove. On the exhaust valves,
install the valve rotators. Install the valve retainer cap
and retainers. Measure the height of the valve spring as
shown in FIGURE 38. Measure from the top of the shim
to the top of the retainer cap. Install shims to get the correct height shown in Specifications. The installed height
of the valve spring must not be less than the minimum
height.

5. Install the intake manifold and gaskets. Tighten the

capscrews in the sequence shown in FIGURE 6. On the
V6 engines, tighten the capscrews to 47 N.m (35 lbf ft).
On the V8 engines, tighten the capscrews to 41 N.m
(30 lbf ft).

2. Clean the surface of the cylinder head and the top of

the cylinder block. Make sure the threads in the block
are clean.
3. Install the cylinder head gasket and cylinder head. If a
steel gasket is used, use a sealant on both sides of the
gasket. Do not use a sealant when a steel and asbestos
gasket is used. Make sure the cylinder head is aligned
with the pins in the block.
4. Use a sealant on the threads of the capscrews for the
cylinder head. Install the capscrews and tighten them in
steps until the final torque is reached. The final torque is
88 N.m (65 lbf ft). Use the tightening sequence shown in
FIGURE 5.

V6 ENGINE

V8 ENGINE
V8 ENGINE

11682

FIGURE 6. TIGHTENING SEQUENCE, INLET

MANIFOLD
6. Install the push rods, making sure they are in the seat
of the cam follower. Lubricate the rocker arms and rocker arm balls with a molybdenum grease. Install the rocker arms, balls and nuts. Tighten the nuts and adjust the
valve clearance as described in Checks and Adjustments.

FAN END
V6 ENGINE

11700

FIGURE 5. TIGHTENING SEQUENCE,

CYLINDER HEAD

7. Use a new gasket and install each valve cover. On the

V6 engines, tighten the capscrews to 10 N.m (7 lbf ft).
On the V8 engines, tighten the capscrews to 5 N.m (4
lbf ft).
8. Install the exhaust manifolds. Use new gaskets when
they are required. Do not use a sealant on the gaskets. On
3

the V8 engines, tighten all of the capscrews for the exhaust manifolds to 27 N.m (20 lbf ft). On the V6 engines, tighten the capscrews at the center port to 35 N.m
(26 lbf ft). Tighten the capscrews at the outer ports to 27
N.m (20 lbf ft).

PISTON BORE PREPARATION

Use a hone in the piston bores when installing new rings.
Use the hone as follows:
1. Use a hone with a 280 grit stone. Make sure the stone
is clean and will not damage the bore.
2. Move the hone quickly (approximately 60 times per
minute) up and down in the bore. Make sure the hone
makes a cross pattern of 45 to 60 degrees. Use the hone
until the entire length of the bore has this pattern.

V6 ENGINE

3. After using the hone, clean the cylinder block with hot
water and detergent. Make sure all metal particles are removed from the block. Dry the bores and lubricate them
with engine oil.

ENGINE MOUNTS
If the engine mount was removed from the cylinder
block, tighten the capscrews for the mount as follows:
H3.505.00XL (H70110XL), 31 N.m (23 lbf ft);
H6.007.00XL (H135155XL), 50 N.m (37 lbf ft);
H150275H, 50 N.m (37 lbf ft).

V8 ENGINE

LUBRICATION SYSTEM
Oil Pump, Removal and Disassembly
(See FIGURE 8.)
11700

FIGURE 7. VALVE COVERS

9. Install the coolant hose to the housing for the thermostat. Fill the coolant system with coolant. See PERIODIC MAINTENANCE.

CYLINDER BLOCK, CLEANING AND

INSPECTION
After the engine is disassembled, clean the cylinder
block in solvent. Make sure all of the oil passages are
clean. Remove the gaskets from the surface of the block.
Inspect the bores for the pistons for wear or damage.
Measure the bores and check the dimensions shown in
Specifications. Repair the cylinder block as necessary.
NOTE: It is important that the piston bores are prepared
correctly before new piston rings are installed. Incorrect
preparation can cause the parts to wear quickly.
4

1. Remove the oil sump.

2. Remove the capscrew at the mount for the pump. Remove the oil pump and shaft.
3. Remove the cover for the oil pump. Put marks on the
gear teeth to show their correct location during assembly.
4. Do not remove the tube and screen assembly unless it
is damaged. The tube and screen must be replaced as an
assembly.
Cleaning and Inspection
Clean the parts of the oil pump in solvent and dry with
compressed air. Inspect the gears, shaft and body of the
pump for wear or damage. If any of the parts are worn or
damaged the oil pump must be replaced. Separate parts
are not available.
Oil Pump, Assembly and Installation
(See FIGURE 8.)
NOTE: There are some variations in the oil pumps
installed during the years of manufacture of these en-

gines, but the design is the same. The repair procedures

are the same. See the PARTS MANUAL for each oil
pump.

as follows: 1/420 capscrews, 10 N.m (7 lbf ft); 5/1618

capscrews, 19 N.m (14 lbf ft).

1. Use a sealant when replacement of the tube and screen

assembly is necessary. Do not damage the tube during
installation. Make sure that the surface of the screen assembly is parallel to the bottom surface of the cylinder
block.

1.
2.
3.
4.
5.

HOUSING
COVER
RETAINER PIN
SPRING
RELIEF VALVE

V6 ENGINE

1.
2.
3.
4.

OIL SUMP
GASKET
SEAL
PLATE

11699

V8 ENGINE

FIGURE 9. OIL SUMP

TIMING COVER, TIMING SPROCKETS,

CAMSHAFT AND CAM FOLLOWERS
Timing Cover, Removal
1. Remove the fan assembly and belts. If installed, remove the drive shaft at the crankshaft pulley.
6. CAPSCREW
AND WASHER
7. SCREEN
8. CAPSCREW

9. RETAINER
10. SHAFT

FIGURE 8. OIL PUMP

2. Install the gears in the body of the pump. Make sure to
align the identification marks. Make sure that the
smooth side of the idler gear is toward the cover. Install
the cover for the oil pump and tighten the capscrews to 5
N.m (40 lbf in). Turn the shaft for the oil pump and check
for smooth operation.
3. Install the oil pump assembly to the engine. Make sure
the shaft is aligned with the slot in the distributor shaft.
Tighten the capscrew at the mount on the bearing cap to
47 N.m (35 lbf ft).
4. Install new gasket(s) and the oil sump. Use a sealant
on the gasket(s). Tighten the capscrews for the oil sump

2. Remove the crankshaft pulley and vibration damper.

Use a tool that pulls on the center of the vibration damper. Do not pull on the outside diameter of the vibration
damper.
3. Remove the timing cover.
4. Carefully remove the oil seal from the cover.
Installation (See FIGURE 10.)
1. Install a new oil seal in the cover. Make sure the open
side of the seal is toward the inside of the cover.
2. Use a sealant on the new gasket for the cover. During
installation of the cover, use a special tool to align the oil
seal with the crankshaft. The vibration damper will
damage the oil seal if it is not installed correctly. Tighten
the capscrews for the cover to 9 N.m (7 lbf ft).
3. Use a special tool to install the vibration damper.
Tighten the capscrew for the damper to 81 N.m (60 lbf
ft).
5

4. Install the crankshaft pulley, drive shaft, belts and fan

assembly.

11699

1. TIMING
COVER
2. GASKET
3. TOOL FOR
VIBRATION
DAMPER
4. VIBRATION
DAMPER

FIGURE 11. TIMING MARKS

Camshaft, Removal
1. Remove the intake manifold, push rods and cam followers. Remove the fuel pump.
2. Remove the timing cover. Align the timing marks and
then remove the timing chain and sprockets.
3. Carefully remove the camshaft from the cylinder
block. All of the camshaft bearings are the same size. Do
not damage bearings or camshaft during removal.

11699

4. If necessary, use a special tool as shown in

FIGURE 12. to remove the camshaft bearings. Remove
the front and rear bearings last.

FIGURE 10. TIMING COVER

Timing Sprockets, Removal

Remove the timing cover. Remove the capscrews for the
camshaft sprocket. Use a puller to remove the crankshaft sprocket. Make sure the timing chain is removed
with the sprockets.
Timing Sprockets, Installation
(See FIGURE 11.)
11698

1. Install the chain on the camshaft sprocket. Install the

camshaft sprocket and the crankshaft sprocket. Make
sure the marks are aligned as shown in FIGURE 11.
Tighten the capscrews to the camshsft sprocket to 27
N.m (20 lbf ft).

Camshaft, Inspection

2. Lubricate the chain and sprockets with engine oil.

Install the timing cover.

Measure the diameter of each bearing surface on the

camshaft. Do the measurement at different positions on

1. TOOL FOR CAMSHAFT BEARINGS

FIGURE 12. CAMSHAFT BEARINGS

the surface of the bearing to see if they are round. If the

difference of the readings for each bearing is more than
0.025 mm (0.001 in), replace the camshaft.
Camshaft, Installation
1. Use a special tool as shown in FIGURE 12. to install
the camshaft bearings. Install the front and rear bearings
first. Make sure the oil holes in the bearings are aligned
with the oil holes in the block. Use a sealant on the rear
camshaft plug and install the plug in the block. Make
sure the plug is even with or 0.80 mm (0.03 in) below the
surface of the block.
2. Lubricate the camshaft lobes with a molybdenum lubricant. Lubricate the camshaft bearings with engine
oil. Carefully install the camshaft in the cylinder block.
3. Install the timing sprockets, chain and cover as described in Timing Cover.
4. Lubricate the cam followers with a molybdenum lubricant. Install the cam folowers in the block. Install the
push rods and adjust the valve mechanism as described
in Checks and Adjustments.

1.
2.
3.
4.
5.
6.
7.

LIFTER BODY
PLUNGER
PUSH ROD SEAT
SPRING
CHECK BALL ASSEMBLY
METERING VALVE
RETAINER, PUSH ROD SEAT

7018

FIGURE 13. HYDRAULIC VALVE LIFTER

4. See FIGURE 14. Use a small screwdriver as a prybar
to remove the check ball retainer from the plunger.

Hydraulic Valve Lifters, Removal

1. The hydraulic valve lifters normally do not need repair unless varnish or dirty engine oil has caused them to
malfunction. The hydraulic valve lifters must be clean
to operate correctly. If a hydraulic valve lifter must be
disassembled, make sure the small parts are handled
carefully to prevent loss or damage.
2. The push rods must be removed as described under
Cylinder Head, Removal. Remove the side cover
from the cylinder block.
3. Remove the hydraulic valve lifters and put them in a
rack so that they can be installed again in the same position in the engine.

FIGURE 14. REMOVE THE CHECK BALL

ASSEMBLY

Hydraulic Valve Lifters, Disassembly

Hydraulic Valve Lifters, Cleaning And

Inspection

1. See FIGURE 13. Hold the plunger (2) down with a

push rod. Use the blade of a small screwdriver to remove
the retainer for the push rod seat (7).

Clean all parts in a cleaning solvent and inspect them

carefully. If any parts are damaged or worn, the complete hydraulic valve lifter must be replaced. If the body
of the hydraulic valve lifter is worn, also inspect the bore
in the cylinder block. If the bottom of the hydraulic
valve lifter is worn or damaged, inspect the camshaft
lobe for wear and damage. The bottom of the lifter must
be convex for correct rotation during engine operation.

2. Remove the push rod seat (3) and the metering valve
(6).
3. Remove the plunger (2), check ball assembly (5), and
the plunger spring (4).

Hydraulic Valve Lifters, Assembly

1. Assemble the check ball assembly. Put the check ball
on the small hole in the bottom of the plunger. Install the
check ball spring in the seat of the check ball retainer.
Put the check ball retainer over the check ball so that the
check ball spring is on the check ball. Carefully press the
check ball retainer into position in the plunger. See
FIGURE 15.
3. See FIGURE 13. Put the plunger spring (9) over the
check ball retainer (5) and slide the lifter body (1) over
the spring and plunger.

FIGURE 16. ASSEMBLY, HYDRAULIC VALVE

LIFTER

CRANKSHAFT
Removal (See FIGURE 17.)

FIGURE 15. INSTALL THE CHECK BALL

ASSEMBLY

4. Fill the assembly with SAE 10 engine oil. Put a 3 mm

(1/8 inch) drift into the plunger and push the plunger until the holes for oil are aligned. See FIGURE 16. Now
put a 1.6 mm (1/16 inch) drift through the holes to hold
the plunger. Remove the 3 mm (1/8 inch) drift and fill the
assembly again with SAE 10 oil.
5. Install the metering valve (3) and push rod seat (2).
See FIGURE 13. Install the retainer, push rod seat (6).
Push down the push rod seat to loosen the 1.6 mm (1/16
inch) drift and remove the drift. The hydraulic valve lifter is now ready for installation.
8

11698

1.
2.
3.
4.

OIL SEAL
THRUST BEARING
MAIN BEARING CAP
CRANKSHAFT

FIGURE 17. CRANKSHAFT

1. Remove the oil pan, oil pump and flywheel. On V6
engines, remove the rear seal retainer.
2. Use a special tool to remove the vibration damper.
3. Remove the caps for the connecting rods.

4. Remove the caps for the main bearings. Make sure

that there are identification marks on the caps during removal.
5. Carefully remove the crankshaft.
Inspection and Repair
1. Clean the crankshaft with solvent and dry it with compressed air.
2. Inspect the crankshaft for cracks or other damage.
3. Inspect the crankshaft for wear and damage. See
FIGURE 18. Use a micrometer to measure the journals
for the bearings of the crankshaft. Do the measurement
at different positions to see if the surface of the bearing is
round. The correct sizes are given in the ENGINE
SPECIFICATIONS.

9741

both the upper and lower half of the bearing must be replaced.
When the crankshaft is assembled by the manufacturer,
the main bearings are specially selected to obtain close
tolerances. For this reason, you can find onehalf of a
standard size insert with onehalf of a 0.001 in undersize insert. This combination will decrease the clearance
0.0005 in from using a full standard bearing.
When a production crankshaft can not be fitted with this
method, the main journal is then ground 0.009 in undersize. Only those main bearing journals that can not be
fitted with standard, 0.001 in or 0.002 in undersize main
bearing will be ground. A 0.009 in and a 0.010 in undersize bearings will be selected as described to obtain
close tolerances.
A production crankshaft that has been ground will have
the following identification:
The crankshaft journal that has been ground will

have a 9 marked in the metal of the crankshaft

next to the journal. A spot of light green paint is
also added to the crankshaft.
The main bearing cap is also marked with green

paint.
How To Check The Clearance Between The
Main Bearings And Their Journals

9734

FIGURE 18. CRANKSHAFT INSPECTION

4. If the crankshaft journals must be repaired, they can
be ground to the following diameters smaller (undersize) than the original size:
0.25 mm (0.010 in)
0.50 mm (0.020 in)
NOTES ABOUT MAIN BEARINGS: Main bearings
are an insert bearing that does not use shims for adjustment. Main bearings are available in a standard size and
the following undersizes: 0.001 in, 0.002 in, 0.009 in,
0.010 in, and 0.020 in. If a bearing on a journal is worn,

1. Use PlastigageR or equivalent to check the clearance.

The procedure is similar for both connecting rod bearings and main bearings. If the engine has been removed
from the lift truck put the engine so that the crankshaft is
up. The weight of the crankshaft is against the upper
bearing half and the total clearance can be measured correctly. If the engine is still in the lift truck, the crankshaft
must have a support to remove any additional clearance
between the upper bearing half and its journal.
2. All main bearing caps must be installed and their
capscrews tightened to the specifications.
3. Check the rear main bearing first. Remove the cap for
the rear main bearing. The procedure for checking the
clearance of the other bearings is similar.
4. Clean the oil from the bearing half and journal to be
checked. Put a piece of Plastigage across the full width
of the bearing journal as shown in FIGURE 21. Do not
rotate the crankshaft when the Plastigage is between the
main bearing and its journal.
9

5. Install the main bearing cap and tighten the

capscrews. (See TORQUE SPECIFICATIONS FOR
CAPSCREWS AND BOLTS.) The capscrews must be
tightened to their final torque or there will be an error in
the measurement.
6. Remove the main bearing cap. The Plastigage will be
compressed and wider and will adhere to either the bearing or its journal. Use the scale on the envelope for the
Plastigage to measure the width of the plastic at its widest point. The scale will indicate the clearance in millimetres or thousandths of an inch. See FIGURE 22.
7. If the clearance is greater than the specifications, select a new undersize bearing set and install it. Measure
the clearance again. If the clearance can not meet specifications with the available undersize bearings, the bearing journal must be ground to a new undersize. If the
bearing journal is already at the maximum undersize,
the crankshaft must be replaced.
8. If the clearance is within specifications, lubricate the
bearing with engine oil and install the main bearing and
bearing cap. Tighten the capscrews on the main bearing
cap to the correct specifications.
9. Turn the crankshaft to make sure it rotates smoothly.

10. Check the axial clearance between the rear main

bearing and the thrust surface. Push the crankshaft forward. See FIGURE 19. Measure the clearance between
the crankshaft and the thrust surface of the rear bearing.
The correct clearance is 0.05 to 0.15 mm (0.002 to 0.006
inch).
Installation
1. On engines with a twopiece rear seal, install the seal
halves so that the lips are towards the fan end of the engine. Apply engine oil to the seal during installation. Do
not get any oil on the ends of the seal.
NOTE: With the use of special tools, the main bearings
and the rear crankshaft seal (twopiece) can be replaced
without removing the crankshaft.
2. Install the main bearings in the cylinder block and the
bearing caps. Lubricate the bearings with engine oil and
carefully install the crankshaft in the cylinder block.
3. Install the bearing caps. Make sure the arrows on the
bearing caps are towards the front (fan end) of the engine. Push the crankshaft forward and measure the
clearance at the front side of the rear main bearing. The
correct clearance is 0.050.15 mm (0.0020.006 in).
(See FIGURE 19.)
4. On the V6 engine, tighten the capscrews for the bearing caps to 70 N.m (52 lbf ft). On the V8 engines, tighten the capscrews for all of the bearing caps except the
rear bearing cap to 95 N.m (70 lbf ft). Tighten the capscrews for the rear bearing cap to 14 N.m (10 lbf ft).
Move the crankshaft forward and backward to align the
rear main bearing. Tighten the capscrews for all bearing
caps to 95 N.m (70 lbf ft).
5. Install the connecting rods, oil pump and oil pan.
Install the flywheel and other parts.

1. MEASURE CLEARANCE

FIGURE 19. MEASURE THE AXIAL

CLEARANCE OF THE CRANKSHAFT

10

6. On late model engines with a onepiece seal, install

the seal in the retainer. Use a sealant between the seal retainer and the cylinder block, then install the seal retainer (See FIGURE 20.)

size, the crankshaft must be replaced. See the ENGINE

SPECIFICATIONS, Crankshaft.
5. If the bearing journal is within specifications, measure the clearance between the new bearing and the
crankshaft. Use Plastigage or equivalent to check the
clearance:

4
11695

1
1. CRANKSHAFT
2. OIL SEAL

a. Put a piece of Plastigage across the full width of

the bearing journal as shown in FIGURE 21. Do
not rotate the crankshaft when the Plastigage is
between the bearing and its journal.

3. SEAL RETAINER
4. ENGINE BLOCK

FIGURE 20. REAR SEAL

PISTON AND CONNECTING ROD

ASSEMBLIES
Connecting Rod Bearings, Replacement
NOTE: Connecting rod bearings are insert bearings that
do not use shims for adjustment. These bearings are
available in a standard size and the following undersizes: 0.001 in, 0.002 in, 0.010 in, and 0.020 in. If a bearing on a journal is worn, both the upper and lower half of
the bearing must be replaced.
1. Remove the oil sump and the oil pump.
2. Before the cap for the connecting rod is removed,
mark the connecting rod and cap with the cylinder number so that the parts will be installed again in their original positions. Remove the cap for the connecting rod
bearing and the lower bearing half.

FIGURE 21. PLASTIGAGE ON A BEARING

JOURNAL
b. Remove the bearing cap. The Plastigage will be
compressed and wider and will adhere to either
the bearing or its journal. Use the scale on the envelope for the Plastigage to measure the width of
the plastic at its widest point. The scale will indicate the clearance in millimetres or thousandths
of an inch. See FIGURE 22.

3. Push the connecting rod away from the crankshaft and

remove the upper bearing half. Wipe the oil from the
bearing halves and the bearing journal.
4. Use a micrometer to measure the bearing journal. The
bearing journal must be within the following specifications:
Outofround less than 0.0254 mm (0.001 in)
Taper less than 0.0254 mm (0.001 in)
If the bearing journals are not within specifications, the
crankshaft must be removed and the bearing journal
ground to an undersize. If the bearing journal can not be
repaired so that the bearing journal is a correct under-

FIGURE 22. MEASURE THE PLASTIGAGE ON

A BEARING JOURNAL
c. If the clearance is greater than the specifications,
select a new undersize bearing set and install it.
Measure the clearance again. If the clearance can
not meet specifications with the available undersize bearings, the bearing journal must be ground
11

to a new undersize. If the bearing journal is already at the maximum undersize, the crankshaft
must be replaced.
d. If the clearance is within specifications, lubricate
the bearing with engine oil and install the bearing
and bearing cap. Tighten the nuts on the bearing
cap. (See TORQUE SPECIFICATIONS FOR
CAPSCREWS AND BOLTS.)
6. When all of the rod bearings have been replaced, use
the following procedure to check the side clearances between the connecting rods and the crankshaft:
a. Use a hammer to lightly hit the connecting rod
parallel to the crankshaft journal to make sure
there is a clearance.
b. Measure the clearance between the caps for the
connecting rods and the crankshaft. See
FIGURE 23.

5. Put an identification mark on the top of each piston.

6. Remove the caps and bearings from each connecting
rod. Keep the caps and bearings with their original piston assemblies. Mark the caps so that they will be installed again in their original positions. Do not mix the
parts.
7. Push the connecting rod and piston from the cylinder.
Temporarily install the bearing cap on the connecting
rod to keep the parts together.
Disassembly

CAUTION
The pistons are aluminum alloy and can be damaged
if they are hit with a hard object. The grooves for the
piston rings are machined to close tolerances. Use a
tool made to clean the grooves of the piston rings. Do
not use a wire brush to clean a piston.
1. Remove the piston rings from the pistons. Use a press
to remove the piston pins from the piston. See
FIGURE 24.

FIGURE 23. MEASURE THE SIDE

CLEARANCE, CONNECTING RODS
Piston And Connecting Rod Assemblies,
Removal
1. Remove the oil sump and the oil pump.
2. Remove the cylinder head as described in Cylinder
Head, Removal.
3. If the engine has been in service for many hours, a
ridge can be worn in the top of the cylinder. This ridge
can be removed with a ridge reamer tool. Turn the crankshaft to lower the piston to the bottom of the stroke in its
cylinder. Put a cloth on top of the piston for a collector of
metal particles. Remove the ridge at the top of the cylinder.
4. Clean the carbon from the top of each cylinder.
12

FIGURE 24. PISTON PIN REMOVAL

2. Use solvent to clean the pistons and connecting rods.

Use compressed air to dry the parts. Make sure that the
holes for oil passages are clean.

chine will make a more accurate cylinder bore. The hone

is then used to finish the surface of the cylinder bore.

Piston, Cleaning And Inspection

Inspect the pistons for wear, cracks, and damage. Replace a piston that is worn or damaged.
NOTE: If the cylinder bore must be repaired the piston
must be changed to the correct oversize. Check the
clearance of the piston in its cylinder after the surface of
the cylinder bore has been finished with a hone.
Check the clearance of the piston pin in the piston. The
normal clearance is shown in the ENGINE SPECIFICATIONS. The piston pin will normally fall from the
hole in the piston by its own weight. The piston pin is a
press fit in the connecting rod. The piston and piston pin
are a matched set and must be replaced as a unit if the
clearances are greater than the specifications.

FIGURE 26. PATTERN FOR NORMAL

CYLINDER WEAR

Cylinder Bores, Inspection And Repair

Inspect the cylinder bores for wear and damage. Measure the cylinder bores in several positions as shown in
FIGURE 25. Measure the cylinder bore at right angles
to the centerline to find any distortion from wear. A cylinder that is outofround greater than 0.05 mm (0.002
in) must be repaired.

FIGURE 25. MEASURE THE CYLINDER BORE

FIGURE 27. GAUGE POINTS FOR PISTON AND

CYLINDER BORE

Measure the cylinder bore in positions from top to bottom to find any taper from wear. A normal wear pattern
for a cylinder bore is shown in FIGURE 26. A cylinder
that has a taper [measurement A that is 0.127 mm
(0.005 in) greater than measurement B] must have a
new bore. A tool called a hone can be used to remove a
small amount of taper from a cylinder bore. Use a boring
machine to repair a badly worn cylinder. The boring ma-

A cylinder bore that has been repaired with a hone or a

boring machine must be fitted with a piston that is the
correct size. Measure the outer diameter of the piston
and the inner diameter of the cylinder bore as shown in
FIGURE 27. Using different oversize pistons in the engine does not affect the dynamic balance of the engine.
Replacement pistons from standard size to 0.030 inch
oversize normally have the same weight. The clearance
13

specifications between a piston and its cylinder bore is

shown in the ENGINE SPECIFICATIONS.

Replace the piston if the clearances are greater than the

specifications.

Piston Rings

2. Measure the end clearance of each piston ring as

shown in FIGURE 29. The end clearances are shown in
the ENGINE SPECIFICATIONS. Install the piston ring
into the cylinder where it will be used. Use a thickness
gauge to measure the amount of end clearance. Replace
the piston if the clearances are greater than the specifications.

NOTE: Check the clearance of the piston rings in the

cylinder after the surface of the cylinder has been finished with a hone. New piston rings are available for the
following piston sizes: standard size, and 0.005 in,
0.010 in, 0.020 in, and 0.030 in oversize. The piston
rings must match the size of the piston on which they are
installed. Check the side clearance and the end clearance
of the piston rings as described in the following paragraphs.
Each compression ring has a mark on one surface. This
mark must be toward the top of the cylinder when the
piston ring is installed. The No. 1 compression ring normally has a chrome or molybdenum surface.
The oil control ring has three pieces. There are two thin
steel rings separated by a spacer.

A593

FIGURE 29. CHECK THE END CLEARANCE OF

THE PISTON RINGS
Assembly
NOTE: There are notches cast in the top of all pistons to
indicate the correct assembly and installation. The pistons must always be installed with this notch toward the
fan end of the engine. See FIGURE 31.
The connecting rods have a notch cast in the bearing
journal as shown in FIGURE 30. This notch must be opposite the notch on the top of the piston when the piston
and connecting rod are assembled.

A595

FIGURE 28. CHECK THE CLEARANCE

BETWEEN THE PISTON RING AND THE
GROOVE
1. Measure the clearance between the piston ring and the
groove in the piston as shown in FIGURE 28. The clearances are shown in the ENGINE SPECIFICATIONS.
14

FIGURE 30. CONNECTING ROD

IDENTIFICATION
1. Assemble the connecting rod to the piston. Make sure
the orientation of the connecting rod and piston are cor-

rect as described in the NOTE above. Use a press to install the piston pin into the piston and connecting rod.
Lubricate the piston pin with engine oil during installation.
2. Check the clearances of the piston rings as described
in Piston Rings. Install the piston rings on the piston
as shown in FIGURE 31.

FAN END OF ENGINE

FLYWHEEL AND FLYWHEEL HOUSING

Flywheel Repair For V6 Engines
1. Replace the ring gear on the flywheel. During removal or installation, do not heat the gear to more than
230C (450F).
2. During installation, push the ring gear fully against
the flywheel.
3. The bearing in the flywheel can be replaced. Push the
old bearing from the flywheel and push in a new bearing.

Flywheel For V6 Engines, Installation

C

B
A POSITION OF THE GAP FOR THE
SPACER OF THE OIL RING
B POSITION OF THE GAP FOR THE
OIL RING
C POSITION OF THE GAP FOR THE
SECOND COMPRESSION RING
D POSITION OF THE GAP FOR THE
FIRST COMPRESSION RING

FIGURE 31. ARRANGEMENT OF THE PISTON

RINGS ON THE PISTON

Piston And Connecting Rod Assemblies,

Installation
1. Lubricate the assembly with engine oil during installation. Arrange the piston rings on the piston as shown in
FIGURE 31. Install a ring compressor on the piston.
2. Make sure that the notch in the piston is toward the fan
end of the engine. Install the piston and connecting rod
assemblies in the cylinder bores.
3. Install the bearings and the caps for the connecting
rods. Tighten the nuts. (See TORQUE SPECIFICATIONS FOR CAPSCREWS AND BOLTS.) Check the
side clearance of each connecting rod after the bearing
cap is installed. See the procedure in the paragraphs under Connecting Rod Bearings, Replacement.
4. Install the cylinder head as described in Cylinder
Head, Installation.
5. Install the oil sump and the oil pump.

H3.505.00XL (H70110XL)
When installing the flywheel on these units, refer to the
section on the HYDRAULIC PUMP DRIVE ASSEMBLY.
H6.007.00XL (H135155XL)
Make sure the dowel pin is installed in the crankshaft.
Install the flywheel.
Units with a manual transmission: make sure the O
ring is installed between the flywheel and the crankshaft. Use a sealant (Hyster Part No. 246108) on the
heads of the capscrews. Tighten the capscrews for the
flywheel to 79 N.m (58 lbf ft).
Units with a powershift transmission: tighten the capscrews to 79 N.m (58 lbf ft).
Flywheel Housing, H3.505.00XL (H70110XL)
The flywheel housing on these units has the parts for the
hydraulic pump drive assembly. When doing any service to the housing, refer to the section for the HYDRAULIC PUMP DRIVE ASSEMBLY.
Engine Adapter, H6.007.00XL (H135155XL)
(See FIGURE 32.)
The engine adapter is used on engines with a manual
transmission. When the seal in the adapter is replaced,
use a sealant (Hyster Part No. 246108) between the seal
and the adapter. When installing the adapter on the engine, make sure the Orings are installed under the
washers. Tighten the capscrews for the adapter to 47
N.m (35 lbf ft).
15

12009
11696

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

ENGINE ADAPTER
ENGINE
FLYWHEEL
PILOT BEARING
SEAL
CAPSCREW
WASHER
ORING
ORING

FIGURE 32. ENGINE ADAPTER

Ring Gear Replacement (Flywheel) For V8

Engines (See FIGURE 33.)
1. During removal or installtion, do not heat the gear to
more than 230C (450F).
2. During installation, push the ring gear fully against
the flywheel.
3. The bearing in the flywheel can be replaced. Push the
old bearing from the flywheel and push in a new bearing.
4. When used, make sure the dowel pin is installed in the
crankshaft. When installing the flywheel, tighten the
capscrews to 81 N.m (60 lbf ft).
16

1. FLYWHEEL
2. SEAL
3. ORING (EARLIER PRODUCTION
SEALANT (LATER PRODUCTION)
4. CAPSCREW
5. BEARING
6. DOWEL

FIGURE 33. FLYWHEEL MOUNT

Flywheel For V8 Engines, Flywheel Housing

(See FIGURE 34.)
The flywheel housing must be checked for alignment
during its installation. Check the alignment as follows:
1. Install the dowel pins in the cylinder block. Install the
flywheel housing on the cylinder block. Tighten the capscrews for the housing to 31 N.m (23 lbf ft).
2. Install a dial indicator on the crankshaft so that it indicates on the flywheel housing as shown in FIGURE 33.
Rotate the crankshaft and check the movement of the
needle. If the total movement of the needle is 0.38 mm
(0.015 in) or less, the housing can be installed without
adjustment. Follow the procedures in step 1 when installing the housing. If the total movement of the needle is
more that 0.38 mm (0.015 in), adjust the housing as described in step 3.

COOLANT PUMP
If any parts of the coolant pump are worn or damaged,
replace the coolant pump. Parts for the coolant pump are
not available separately. During installation, apply a
sealant to the gasket for the coolant pump. Tighten the
capscrews for the coolant pump to 41 N.m (30 lbf ft).
Adjust the tension of the belt as described in the PERIODIC MAINTENANCE section.

FAN MOUNT (See FIGURE 35.)

The fan mount has the shaft and bearings for the fan. On
some units the mount has an idler pulley for adjustment
of the fan belt. When the fan is installed, tighten the bolts
to 20 Nm (15 lbf ft).

1
2

11691

87.78 mm
(3.45 in)
5

1
3
3

5
3

4
1.
2.
3.
4.

DIAL INDICATOR
FLYWHEEL HOUSING
DOWEL PINS
CRANKSHAFT

V6 ENGINE

6305

FIGURE 34. ADJUST THE FLYWHEEL

HOUSING, V8 ENGINE ONLY
3. Remove the flywheel housing. Rotate the dowel pins
so that the position of the housing is moved toward the
direction of minimum needle movement. Install the
housing and check the alignment as described in step 2.
If the housing can not be adjusted to specifications,
check that the dowel pins are installed correctly.
4. On units with a manual transmission, a seal is
installed in the flywheel housing. When the seal in the
flywheel housing is replaced, use a sealant (Hyster Part
No. 246108) between the seal and the flywheel housing.
When installing the flywheel housing, tighten the capscrews to 31 N.m (23 lbf ft).

6861

V8 ENGINE
1.
2.
3.
4.
5.

FAN SHAFT
INNER SNAP RING
SNAP RING
FAN MOUNT
BEARING

6
6.
7.
8.
9.

SNAP RING
IDLER PULLEY
IDLER BRACKET
FAN BOLTS

FIGURE 35. FAN MOUNT

17

CHECKS AND ADJUSTMENTS

Valve Clearance Adjustment
(See FIGURE 36.)
1. Disconnect the negative cable at the battery. Remove
the valve covers.
2. Rotate the engine until the mark on the vibration
damper or crankshaft pulley is aligned with the 0 timing mark on the timing tab. Make sure the valves for the
No. 1 cylinder are closed. If the valves are moving as the
0 timing mark is reached, the engine is in the wrong
position.
3. When the engine is in the No. 1 firing position, adjust
the valves for the following cylinders:

aligned. On V6 engines, the valves on the No. 4 cylinder will be closed. On V8 engines, the valves on the
No. 6 cylinder will be closed. When the engine is in this
position, adjust the valves for the following cylinders:
V6: Inlet Valves for Numbers. 4, 5, 6 and Exhaust
Valves for Numbers. 2, 3, 4,
V8: Inlet Valves for Numbers. 3, 4, 6, 8 and Exhaust
Valves for Numbers. 2, 5, 6, 7
6. Install the valve covers. Connect the battery cable.
Start the engine and check for correct operation.

11695

V6: Inlet Valves for Numbers. 1, 2, 3 and Exhaust

Valves for Numbers. 1, 5, 6
V8: Inlet Valves for Numbers. 1, 2, 5, 7 and Exhaust
Valves for Numbers. 1, 3, 4, 8
4. Adjust the valve clearance by loosening the nut for the
rocker arm until the push rod is loose. Tighten the nut for
the rocker are until there is no clearance at the push rod.
Check the clearance by rotating the push rod while tightening the nut. When there is no clearance at the push rod,
tighten the nut for the rocker arm one full turn. The additional turn of the nut will put the push rod in the seat of
the cam follower.
5. After the valves are adjusted in step 3, rotate the engine one full turn. Make sure the timing marks are

FIGURE 36. ADJUST THE VALVE CLEARANCE

ENGINE SPECIFICATIONS
Engine Data
GM 4.3 litre V6
Number of cylinders
Firing order
Bore
Stroke
Displacement
Governor speed

GM 5.7 litre V8
Number of cylinders
Firing order
18

Bore

6
165432
101.58 to 101.71 mm
(3.9995 to 4.0045 in)
88..39 mm (3.480 in)
4.3 litre (262.4 in3
See the PERIODIC
MAINTENANCE section
for each model of lift truck

8
18436572

101.58 to 101.71 mm
(3.9995 to 4.0045 in)
Stroke
88..39 mm (3.480 in)
Displacement
5.7 litre (350 in3)Governor
speed
See the PERIODIC
MAINTENANCE section
for each model of lift truck
Cylinder head
Valve seat specifications: See FIGURE 37.
Valve seat width (inlet valves):
0.78 to 1.57 mm
(0.031 to 0.062 in)
Valve seat width (exhaust valves):
1.57 to 2.36 mm
(0.062 to 0.093 in)

1. CYLINDER HEAD
2. MINIMUM THICKNESS
OF VALVE HEAD IS
0.80 mm (0.031 in)

Clearance between inlet valve and guide:

0.02 to 0.09 mm (0.001 to 0.0037 in)
Clearance between exhaust valve and guide
0.02 to 0.12 mm (0.001 to 0.0047 in)
Valve spring, free length (See FIGURE 38.
52.8 mm (2.08 in)
Valve spring force (installed and valve is closed):
347 to 383 N @ 43 mm
(78 to 86 pounds @ 1.69 in)

FIGURE 37. VALVE SEAT SPECIFICATIONS

FOR INLET AND EXHAUST VALVES

Valve spring force (installed and valve is open):

880 to 930 N @ 31.75 mm
(194 to 206 pounds @ 1.25 in)

Hydraulic Valve Lifter

A

9715

Leak rate:

12 to 90 seconds
with 50 lb load

Body diameter

21.3868 to 21.4046 mm
(0.8420 to 0.8427 in)

Plunger travel:

3.175 mm (0.125 in)

Clearance in bore:

0.0635 mm (0.0025 in)

Lifter bore diameter: 21.425 to 21.450 mm

(0.8435 to 0.8445 in)

Camshaft
Variation from front to rear of a cam lobe:
Taper with larger dimension away from No. 1 piston

A. VARIATION FROM VERTICAL

Production
less than 1.5 mm (0.06 in)
Service limit
2.5 mm (0.984 in)
B. INSTALLATION HEIGHT:
THE VALVE SPRINGS NEED A MINIMUM FORCE
OF 347 to 383 N (76 to 86 lbf) TO COMPRESS THEM
TO A HEIGHT OF 43 mm (1.69 in)

Bearing journals, diameter (All engines)

47.45 to 47.48 mm
(1.8682 to 1.8692 in)
Bearing journals, clearance
0.01778 to 0.9685 mm
(0.0007 to 0.0027 in)
Variation of a bearing journal in either diameter or axial
direction:
0.03 mm (0.001 in)
Axial Clearance (All Engines)
0.10 to 0.30 mm (0.004 to 0.0012 in)
Lobe lift (V6)
Inlet
Exhaust

9.06 mm (0.357 in)

9.90 mm (3.90 in)

Lobe lift (V8)

Inlet
Exhaust

6.60 mm (0.260 in)

6.94 mm (0.2733 in)

Pistons
Piston diameter (see gauge points in FIGURE 27.)
Cylinder Bore Outof round (see FIGURE 25.):
0.0508 mm (0.002 in)
Maximum cylinder taper: 0.025 mm (0.001 in)

FIGURE 38. VALVE SPRING SPECIFICATIONS

Clearance at bottom of cylinder:

0.068 mm (0.0027 in)
19

Piston ring to groove clearance for piston rings (see

FIGURE 28.)
Compression rings No. 1 and No. 2:
0.030 to 0.081 mm (0.0012 to 0.0032 in)
Oil ring to groove clearance:
0.051 to 0.18 mm (0.002 to 0.007 in)

V8
Diameter of connecting rod journals:
53.31 to 53.33 mm (2.0988 to 2.0998 in)
Outofround of bearing journal (maximum)
Production Limit 0.0127 mm (0.0005 in)
Service Limit
0.0254 mm (0.001 in)

Piston ring end clearance (see FIGURE 29.)

Compression rings No. 1 and No. 2:
0.25 to 0.76 mm (0.010 to 0.030 in)
Oil ring
0.38 to 1.40 mm (0.015 to 0.055 in)

Taper of bearing journal (maximum)

Production Limit 0.0127 mm (0.0005 in)
Service Limit
0.0254 mm (0.001 in)

Piston pin to piston clearance:

0.006 to 0.011 mm (0.00025 to 0.00045 in)

Clearance between crankshaft journals and connecting rod

bearings
0.03 to 0.08 mm (0.0013 to 0.0035 in)

Piston pin to connecting rod clearance:

Press fit

Available undersize connecting rod bearings:

0.0254 mm (0.001 in)
0.0508 mm (0.002 in)
0.254 mm (0.010 in)
0.508 mm (0.020 in)

Crankshaft
Diameter of main bearing journal
Number 1
62.16 to 62.21 mm (2.4474 to 2.4493 in)
Number 2, 3, 4 62.15 to 62.20 mm (2.4471 to 2.4490 in)
Number 5
62.15 to 62.19 mm (2.4471 to 2.4488 in)

Side clearance of connecting rod to crankshaft:

0.20 to 0.35 mm (0.008 to 0.014 in)

Outofround of main bearing journal (maximum)

Production Limit 0.0051 mm (0.0002 in)
Service Limit
0.0254 mm (0.001 in)

Cooling System

Taper of main bearing journal (maximum)

Production Limit 0.0051 mm (0.0002 in)
Service Limit
0.0254 mm (0.001 in)

Lubrication System

Clearance between journals and main bearings

Number 1
0.020 to 0.050 mm (0.0008 to 0.0020 in)
Number 2, 3, 4 0.027 to 0.058 mm (0.0011 to 0.0023 in
Number 5
0.043 to 0.081 mm (0.0017 to 0.0032 in
Available undersize main bearings:
0.0254 mm (0.001 in)
0.0508 mm (0.002 in)
0.2285 mm (0.009 in
0.25 mm (0.010 in)
0.50 mm (0.020 in)
Axial Clearance (crankshaft to thrust surface main bearing):
0.15 to 0.254 mm (0.006 to 0.010 in)

Connecting Rods
V6
Diameter of connecting rod journals:
57.12 to 57.14 mm (2.2487 to 2.2497 in)

20

Thermostat:

82C (180F)

Oil pressure @ 2500 rpm

170 to 241 kPa
(25 to 35 psi)
Minimum oil pressure @ idle rpm
48 kPa (7 psi)
Oil pressure switch ON @
20 to 39 kPa
(2.9 to 5.7 psi)

CAUTION
Fuel System Note: Lift trucks that have the V6 engine with fuel injection have an electric fuel pump
and a fuel shutoff valve. Do not close the fuel shut
off valve when the engine is running. This action can
cause high pressure at the fuel pump and break the
connector hose.

TORQUE SPECIFICATIONS FOR CAPSCREWS AND BOLTS

Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 N.m (65 lbf ft)
Inlet Manifold To Cylinder Head . . . . . . . . . . . . . . . . . . . . 54 N.m (40 lbf ft)
Exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 N.m (30 lbf ft)
Exhaust Manifold To Inlet Manifold . . . . . . . . . . . . . . . . . 61 N.m (45 lbf ft)
Main Bearing Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 N.m (70 lbf ft)
Connecting Rod Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 N.m (32 lbf ft)
Vibration Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 N.m (60 lbf ft)
Flywheel Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 N.m (35 lbf ft)
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 N.m (60 lbf ft)
Chain Control Block For Hydraulic Pump Drive . . . . . . . 19 N.m (14 lbf ft) with adhesive sealant
Camshaft Thrust Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 N.m (7 lbf ft)
Cooling Fan To Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N.m (18 lbf ft)
Coolant Pump To Engine Block . . . . . . . . . . . . . . . . . . . . 10 N.m (7 lbf ft)
Thermostat Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N.m (20 lbf ft)
Rocker Arm Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N.m (6 lbf ft)
Side Cover To Engine Block . . . . . . . . . . . . . . . . . . . . . . . 10 N.m (7 lbf ft)
Oil Pump To Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 N.m (22 lbf ft)
Oil Screen Support To Crankcase . . . . . . . . . . . . . . . . . . 50 N.m (37 lbf ft)
Oil Sump To Crankcase (1/420) . . . . . . . . . . . . . . . . . . . 10 N.m (7 lbf ft)
Oil Sump To Crankcase (1/1618) . . . . . . . . . . . . . . . . . . . 19 N.m (14 lbf ft)
Oil Sump To Timing Cover . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N.m (6 lbf ft)
Oil Pump Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 N.m (10 lbf ft)
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N.m ( 20 lbf ft)
Alternator pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 N.m (45 lbf ft)
Distributor Mount Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 N.m (25 lbf ft)
Motor Mount to Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 N.m (35 lbf ft)
Motor Mount to Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 N.m (39 lbf ft)

21

TROUBLESHOOTING
PROBLEM
When the ignition switch is in the START
position, the starter does not operate.

POSSIBLE 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 has a problem.
The starter system has a problem.
There are damaged parts in the engine.

The engine will not start.

The fuel tank is empty.

The battery is not fully charged.
The valves are worn or damaged.
The piston rings are worn or have damage.
The ignition system has a problem.
The fuel system has a problem.
The ignition timing is wrong.
The choke system has a problem.

The engine does not run smoothly.

The valves are not adjusted correctly.

The head gasket has a leak.
The cylinder head has cracks.
There is a leak in the intake system.
The spark plugs have a problem.
The ignition system has problems. (See the sections for the
electrical components in the SERVICE MANUAL for more
information.

The engine does not have enough power.

The air filter is dirty.

The fuel is the wrong type.
The ignition timing is not correct.
The valve mechanism needs adjustment or is worn.
The piston assemblies are worn or 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.

22

TROUBLESHOOTING
PROBLEM
There is noise inside the engine.

POSSIBLE 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 valve lifter has a problem.
The valves are not adjusted correctly.

There is noise in the engine during

acceleration.

The spark plugs are dirty.

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

The engine gets too hot.

There is not enough coolant in the cooling system.

The belt for the water pump is worn or not adjusted correctly.
The thermostat has damage.
The cooling system has restrictions.
The water pump has damage.
The radiator is dirty.
The exhaust system has restrictions.

The bearings in the engine are damaged.

There is not enough oil in the engine.

The oil in the engine is the wrong type.
The oil pump has damage.
The connecting rods have damage.
The camshaft is worn or damaged.
The passages for oil have restrictions.
The bearings are not installed correctly.
The oil in the engine is dirty.

23