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GM 4.3 LITRE V6 AND 5.

7 LITRE V8 ENGINES
This section has the description and the repair instruc- 5. Remove the capscrews that hold the cylinder head to
tions for the GM 4.3 litre V6 and the 5.7 Litre V8 en- the block. Loosen the capscrews in the reverse order of
gines. Checks and Adjustments, Troubleshooting pro- the tightening sequence shown in FIGURE 5. Remove
cedures and Specifications are also included in this sec- the cylinder head and the gasket.
tion.
6. Remove the nuts and balls for the rocker arms. Re-
move the rocker arms. Keep the parts for each rocker
DESCRIPTION
arm assembly together.
The arrangement of the cylinders is in a V shape. The
cylinder block is made of cast iron. The V8 engine has 7. Use a valve spring compressor and remove the valves
five main bearings for the crankshaft. The V6 engine and springs. Put the valves in a rack so that they can be
has four main bearings. 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 mech-
anism 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 11700

is in the section for THE FRAME for each model of lift


truck. See the sections for the TRANSMISSION to sep- 1. CYLINDER HEAD 4. PUSH ROD
arate the transmission from the engine. 2. CYLINDER BLOCK 5. ROCKER ARM
3. CAM FOLLOWER 6. CAMSHAFT
CYLINDER HEAD FIGURE 1. CYLINDER HEAD
Removal And Disassembly (See FIGURE 1.)
Cleaning And Inspection
WARNING Clean the carbon from the ports and chambers in the cyl-
Disconnect the battery cables before making repairs inder head. Clean the carbon and oil from the valves,
to the engine. push rods and rocker arms.

1. Drain the coolant from the engine. Inspect the cylinder head for cracks in the ports and
chambers. Inspect the valves for cracks in the heads or
2. Disconnect and remove the coolant hose from the damaged stems.
housing for the thermostat.
Repairs, Valve Guides and Seats
3. Remove the air cleaner, carburetor, distributor, intake
Measure the clearance between the valve stem and the
manifold and the exhaust manifolds. Loosen the drive
guide as shown in FIGURE 2. The maximum clearance
belts and remove the bracket for the fan mount from the
for the intake valves is 0.094 mm (0.0037 in). The maxi-
cylinder heads.
mum clearance for the exhaust valves is 0.119 mm
4. Remove the rocker arm cover. (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 CAUTION
normal service procedures when grinding the valve Do not attempt to install an oversize stud without
seats. See the Specifications for dimensions. 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 in-
stallation. 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 2
damaged stud. See FIGURE 3.

FIGURE 4. INSTALLATION OF A STUD FOR A


ROCKER ARM

Valve Springs (See FIGURE 38.)


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 ten-
FIGURE 3. REMOVE A STUD FOR A ROCKER sion. Replace valve springs that are not within 44 N (10
ARM lbf) of specifications.

2
ASSEMBLY AND INSTALLATION 5. Install the intake manifold and gaskets. Tighten the
capscrews in the sequence shown in FIGURE 6. On the
1. Install each valve in the correct port. Install the shim V6 engines, tighten the capscrews to 47 N.m (35 lbf ft).
and valve springs. Compress the spring and install the On the V8 engines, tighten the capscrews to 41 N.m
oil seal in the lower groove. On the exhaust valves, (30 lbf ft).
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 cor-
rect height shown in Specifications. The installed height
of the valve spring must not be less than the minimum
height.

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 V6 ENGINE


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.

V8 ENGINE

V8 ENGINE 11682

FIGURE 6. TIGHTENING SEQUENCE, INLET


MANIFOLD

6. Install the push rods, making sure they are in the seat
FAN END
of the cam follower. Lubricate the rocker arms and rock-
V6 ENGINE
er arm balls with a molybdenum grease. Install the rock-
er arms, balls and nuts. Tighten the nuts and adjust the
valve clearance as described in Checks and Adjust-
ments.
7. Use a new gasket and install each valve cover. On the
V6 engines, tighten the capscrews to 10 N.m (7 lbf ft).
11700
On the V8 engines, tighten the capscrews to 5 N.m (4
lbf ft).
FIGURE 5. TIGHTENING SEQUENCE,
CYLINDER HEAD 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 ex- PISTON BORE PREPARATION
haust manifolds to 27 N.m (20 lbf ft). On the V6 en- Use a hone in the piston bores when installing new rings.
gines, tighten the capscrews at the center port to 35 N.m Use the hone as follows:
(26 lbf ft). Tighten the capscrews at the outer ports to 27
N.m (20 lbf ft). 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
V6 ENGINE
until the entire length of the bore has this pattern.
3. After using the hone, clean the cylinder block with hot
water and detergent. Make sure all metal particles are re-
moved 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);
V8 ENGINE
H150275H, 50 N.m (37 lbf ft).

LUBRICATION SYSTEM
Oil Pump, Removal and Disassembly
(See FIGURE 8.)
11700 1. Remove the oil sump.
2. Remove the capscrew at the mount for the pump. Re-
move the oil pump and shaft.
FIGURE 7. VALVE COVERS
3. Remove the cover for the oil pump. Put marks on the
gear teeth to show their correct location during assem-
9. Install the coolant hose to the housing for the thermo- bly.
stat. Fill the coolant system with coolant. See PERIOD-
IC MAINTENANCE. 4. Do not remove the tube and screen assembly unless it
is damaged. The tube and screen must be replaced as an
CYLINDER BLOCK, CLEANING AND assembly.
INSPECTION
Cleaning and Inspection
After the engine is disassembled, clean the cylinder
Clean the parts of the oil pump in solvent and dry with
block in solvent. Make sure all of the oil passages are
compressed air. Inspect the gears, shaft and body of the
clean. Remove the gaskets from the surface of the block.
pump for wear or damage. If any of the parts are worn or
Inspect the bores for the pistons for wear or damage. damaged the oil pump must be replaced. Separate parts
Measure the bores and check the dimensions shown in are not available.
Specifications. Repair the cylinder block as necessary. Oil Pump, Assembly and Installation
(See FIGURE 8.)
NOTE: It is important that the piston bores are prepared
correctly before new piston rings are installed. Incorrect NOTE: There are some variations in the oil pumps
preparation can cause the parts to wear quickly. installed during the years of manufacture of these en-

4
gines, but the design is the same. The repair procedures as follows: 1/420 capscrews, 10 N.m (7 lbf ft); 5/1618
are the same. See the PARTS MANUAL for each oil capscrews, 19 N.m (14 lbf ft).
pump.

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 as-
sembly is parallel to the bottom surface of the cylinder
block.
1. OIL SUMP
2. GASKET
1. HOUSING V6 ENGINE 3. SEAL
2. COVER 4. PLATE
3. RETAINER PIN
4. SPRING
5. RELIEF VALVE

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, re-
move the drive shaft at the crankshaft pulley.

6. CAPSCREW
2. Remove the crankshaft pulley and vibration damper.
AND WASHER Use a tool that pulls on the center of the vibration damp-
7. SCREEN 9. RETAINER er. Do not pull on the outside diameter of the vibration
8. CAPSCREW 10. SHAFT damper.
FIGURE 8. OIL PUMP 3. Remove the timing cover.
4. Carefully remove the oil seal from the cover.
2. Install the gears in the body of the pump. Make sure to
align the identification marks. Make sure that the Installation (See FIGURE 10.)
smooth side of the idler gear is toward the cover. Install
1. Install a new oil seal in the cover. Make sure the open
the cover for the oil pump and tighten the capscrews to 5
side of the seal is toward the inside of the cover.
N.m (40 lbf in). Turn the shaft for the oil pump and check
for smooth operation. 2. Use a sealant on the new gasket for the cover. During
installation of the cover, use a special tool to align the oil
3. Install the oil pump assembly to the engine. Make sure seal with the crankshaft. The vibration damper will
the shaft is aligned with the slot in the distributor shaft. damage the oil seal if it is not installed correctly. Tighten
Tighten the capscrew at the mount on the bearing cap to the capscrews for the cover to 9 N.m (7 lbf ft).
47 N.m (35 lbf ft).
3. Use a special tool to install the vibration damper.
4. Install new gasket(s) and the oil sump. Use a sealant Tighten the capscrew for the damper to 81 N.m (60 lbf
on the gasket(s). Tighten the capscrews for the oil sump ft).

5
4. Install the crankshaft pulley, drive shaft, belts and fan
assembly.

11699

1. TIMING
FIGURE 11. TIMING MARKS
COVER
2. GASKET
3. TOOL FOR Camshaft, Removal
VIBRATION 1. Remove the intake manifold, push rods and cam fol-
DAMPER lowers. Remove the fuel pump.
4. VIBRATION
DAMPER 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.
4. If necessary, use a special tool as shown in
FIGURE 12. to remove the camshaft bearings. Remove
11699
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 crank-
shaft 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 1. TOOL FOR CAMSHAFT BEARINGS
sure the marks are aligned as shown in FIGURE 11.
Tighten the capscrews to the camshsft sprocket to 27 FIGURE 12. CAMSHAFT BEARINGS
N.m (20 lbf ft).
Camshaft, Inspection
2. Lubricate the chain and sprockets with engine oil. Measure the diameter of each bearing surface on the
Install the timing cover. camshaft. Do the measurement at different positions on

6
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 1. LIFTER BODY
sure the plug is even with or 0.80 mm (0.03 in) below the 2. PLUNGER
surface of the block. 3. PUSH ROD SEAT
4. SPRING
2. Lubricate the camshaft lobes with a molybdenum lu- 5. CHECK BALL ASSEMBLY
6. METERING VALVE
bricant. Lubricate the camshaft bearings with engine 7018
7. RETAINER, PUSH ROD SEAT
oil. Carefully install the camshaft in the cylinder block.
FIGURE 13. HYDRAULIC VALVE LIFTER
3. Install the timing sprockets, chain and cover as de-
scribed in Timing Cover. 4. See FIGURE 14. Use a small screwdriver as a prybar
to remove the check ball retainer from the plunger.
4. Lubricate the cam followers with a molybdenum lu-
bricant. Install the cam folowers in the block. Install the
push rods and adjust the valve mechanism as described
in Checks and Adjustments.

Hydraulic Valve Lifters, Removal


1. The hydraulic valve lifters normally do not need re-
pair 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 posi- FIGURE 14. REMOVE THE CHECK BALL
tion in the engine. ASSEMBLY

Hydraulic Valve Lifters, Disassembly Hydraulic Valve Lifters, Cleaning And


Inspection
1. See FIGURE 13. Hold the plunger (2) down with a Clean all parts in a cleaning solvent and inspect them
push rod. Use the blade of a small screwdriver to remove carefully. If any parts are damaged or worn, the com-
the retainer for the push rod seat (7). plete hydraulic valve lifter must be replaced. If the body
2. Remove the push rod seat (3) and the metering valve of the hydraulic valve lifter is worn, also inspect the bore
(6). in the cylinder block. If the bottom of the hydraulic
valve lifter is worn or damaged, inspect the camshaft
3. Remove the plunger (2), check ball assembly (5), and lobe for wear and damage. The bottom of the lifter must
the plunger spring (4). be convex for correct rotation during engine operation.

7
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 un-
1. OIL SEAL
til the holes for oil are aligned. See FIGURE 16. Now 2. THRUST BEARING
put a 1.6 mm (1/16 inch) drift through the holes to hold 11698
3. MAIN BEARING CAP
the plunger. Remove the 3 mm (1/8 inch) drift and fill the 4. CRANKSHAFT
assembly again with SAE 10 oil. FIGURE 17. CRANKSHAFT

5. Install the metering valve (3) and push rod seat (2). 1. Remove the oil pan, oil pump and flywheel. On V6
See FIGURE 13. Install the retainer, push rod seat (6). engines, remove the rear seal retainer.
Push down the push rod seat to loosen the 1.6 mm (1/16 2. Use a special tool to remove the vibration damper.
inch) drift and remove the drift. The hydraulic valve lift-
er is now ready for installation. 3. Remove the caps for the connecting rods.

8
4. Remove the caps for the main bearings. Make sure both the upper and lower half of the bearing must be re-
that there are identification marks on the caps during re- placed.
moval.
When the crankshaft is assembled by the manufacturer,
5. Carefully remove the crankshaft. the main bearings are specially selected to obtain close
tolerances. For this reason, you can find onehalf of a
Inspection and Repair
standard size insert with onehalf of a 0.001 in under-
1. Clean the crankshaft with solvent and dry it with com- size insert. This combination will decrease the clearance
pressed air. 0.0005 in from using a full standard bearing.
2. Inspect the crankshaft for cracks or other damage. When a production crankshaft can not be fitted with this
method, the main journal is then ground 0.009 in under-
3. Inspect the crankshaft for wear and damage. See
size. Only those main bearing journals that can not be
FIGURE 18. Use a micrometer to measure the journals
fitted with standard, 0.001 in or 0.002 in undersize main
for the bearings of the crankshaft. Do the measurement
bearing will be ground. A 0.009 in and a 0.010 in under-
at different positions to see if the surface of the bearing is
size bearings will be selected as described to obtain
round. The correct sizes are given in the ENGINE
close tolerances.
SPECIFICATIONS.
A production crankshaft that has been ground will have
the following identification:
9741

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
1. Use PlastigageR or equivalent to check the clearance.
The procedure is similar for both connecting rod bear-
ings 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 cor-
rectly. If the engine is still in the lift truck, the crankshaft
9734 must have a support to remove any additional clearance
FIGURE 18. CRANKSHAFT INSPECTION between the upper bearing half and its journal.
2. All main bearing caps must be installed and their
4. If the crankshaft journals must be repaired, they can
capscrews tightened to the specifications.
be ground to the following diameters smaller (under-
size) than the original size: 3. Check the rear main bearing first. Remove the cap for
0.25 mm (0.010 in) the rear main bearing. The procedure for checking the
0.50 mm (0.020 in) clearance of the other bearings is similar.
NOTES ABOUT MAIN BEARINGS: Main bearings 4. Clean the oil from the bearing half and journal to be
are an insert bearing that does not use shims for adjust- checked. Put a piece of Plastigage across the full width
ment. Main bearings are available in a standard size and of the bearing journal as shown in FIGURE 21. Do not
the following undersizes: 0.001 in, 0.002 in, 0.009 in, rotate the crankshaft when the Plastigage is between the
0.010 in, and 0.020 in. If a bearing on a journal is worn, main bearing and its journal.

9
5. Install the main bearing cap and tighten the 10. Check the axial clearance between the rear main
capscrews. (See TORQUE SPECIFICATIONS FOR bearing and the thrust surface. Push the crankshaft for-
CAPSCREWS AND BOLTS.) The capscrews must be ward. See FIGURE 19. Measure the clearance between
tightened to their final torque or there will be an error in the crankshaft and the thrust surface of the rear bearing.
the measurement. The correct clearance is 0.05 to 0.15 mm (0.002 to 0.006
inch).
6. Remove the main bearing cap. The Plastigage will be
compressed and wider and will adhere to either the bear-
Installation
ing or its journal. Use the scale on the envelope for the
Plastigage to measure the width of the plastic at its wid- 1. On engines with a twopiece rear seal, install the seal
est point. The scale will indicate the clearance in milli- halves so that the lips are towards the fan end of the en-
metres or thousandths of an inch. See FIGURE 22. gine. Apply engine oil to the seal during installation. Do
7. If the clearance is greater than the specifications, se- not get any oil on the ends of the seal.
lect a new undersize bearing set and install it. Measure
NOTE: With the use of special tools, the main bearings
the clearance again. If the clearance can not meet speci-
and the rear crankshaft seal (twopiece) can be replaced
fications with the available undersize bearings, the bear-
without removing the crankshaft.
ing journal must be ground to a new undersize. If the
bearing journal is already at the maximum undersize, 2. Install the main bearings in the cylinder block and the
the crankshaft must be replaced. bearing caps. Lubricate the bearings with engine oil and
8. If the clearance is within specifications, lubricate the carefully install the crankshaft in the cylinder block.
bearing with engine oil and install the main bearing and
3. Install the bearing caps. Make sure the arrows on the
bearing cap. Tighten the capscrews on the main bearing
bearing caps are towards the front (fan end) of the en-
cap to the correct specifications.
gine. Push the crankshaft forward and measure the
9. Turn the crankshaft to make sure it rotates smoothly. 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 bear-


ing caps to 70 N.m (52 lbf ft). On the V8 engines, tight-
en the capscrews for all of the bearing caps except the
rear bearing cap to 95 N.m (70 lbf ft). Tighten the cap-
screws 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.

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


1. MEASURE CLEARANCE
the seal in the retainer. Use a sealant between the seal re-
FIGURE 19. MEASURE THE AXIAL tainer and the cylinder block, then install the seal retain-
CLEARANCE OF THE CRANKSHAFT er (See FIGURE 20.)

10
size, the crankshaft must be replaced. See the ENGINE
SPECIFICATIONS, Crankshaft.
5. If the bearing journal is within specifications, mea-
sure the clearance between the new bearing and the
crankshaft. Use Plastigage or equivalent to check the
clearance:
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
4 between the bearing and its journal.
11695
2 3
1
1. CRANKSHAFT 3. SEAL RETAINER
2. OIL SEAL 4. ENGINE BLOCK

FIGURE 20. REAR SEAL

PISTON AND CONNECTING ROD


ASSEMBLIES
Connecting Rod Bearings, Replacement
NOTE: Connecting rod bearings are insert bearings that FIGURE 21. PLASTIGAGE ON A BEARING
do not use shims for adjustment. These bearings are JOURNAL
available in a standard size and the following under-
b. Remove the bearing cap. The Plastigage will be
sizes: 0.001 in, 0.002 in, 0.010 in, and 0.020 in. If a bear-
compressed and wider and will adhere to either
ing on a journal is worn, both the upper and lower half of
the bearing or its journal. Use the scale on the en-
the bearing must be replaced.
velope for the Plastigage to measure the width of
1. Remove the oil sump and the oil pump. the plastic at its widest point. The scale will indi-
cate the clearance in millimetres or thousandths
2. Before the cap for the connecting rod is removed, of an inch. See FIGURE 22.
mark the connecting rod and cap with the cylinder num-
ber so that the parts will be installed again in their origi-
nal positions. Remove the cap for the connecting rod
bearing and the lower bearing half.

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 specifica-
tions:
FIGURE 22. MEASURE THE PLASTIGAGE ON
Outofround less than 0.0254 mm (0.001 in) A BEARING JOURNAL
Taper less than 0.0254 mm (0.001 in)
c. If the clearance is greater than the specifications,
If the bearing journals are not within specifications, the select a new undersize bearing set and install it.
crankshaft must be removed and the bearing journal Measure the clearance again. If the clearance can
ground to an undersize. If the bearing journal can not be not meet specifications with the available under-
repaired so that the bearing journal is a correct under- size bearings, the bearing journal must be ground

11
to a new undersize. If the bearing journal is al- 5. Put an identification mark on the top of each piston.
ready at the maximum undersize, the crankshaft
must be replaced. 6. Remove the caps and bearings from each connecting
rod. Keep the caps and bearings with their original pis-
d. If the clearance is within specifications, lubricate ton assemblies. Mark the caps so that they will be in-
the bearing with engine oil and install the bearing stalled again in their original positions. Do not mix the
and bearing cap. Tighten the nuts on the bearing parts.
cap. (See TORQUE SPECIFICATIONS FOR
CAPSCREWS AND BOLTS.) 7. Push the connecting rod and piston from the cylinder.
Temporarily install the bearing cap on the connecting
6. When all of the rod bearings have been replaced, use rod to keep the parts together.
the following procedure to check the side clearances be-
tween the connecting rods and the crankshaft: Disassembly

a. Use a hammer to lightly hit the connecting rod CAUTION


parallel to the crankshaft journal to make sure The pistons are aluminum alloy and can be damaged
there is a clearance. if they are hit with a hard object. The grooves for the
b. Measure the clearance between the caps for the piston rings are machined to close tolerances. Use a
connecting rods and the crankshaft. See tool made to clean the grooves of the piston rings. Do
FIGURE 23. 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 crank-
shaft 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 cylin-
der.
FIGURE 24. PISTON PIN REMOVAL
4. Clean the carbon from the top of each cylinder.

12
2. Use solvent to clean the pistons and connecting rods. chine will make a more accurate cylinder bore. The hone
Use compressed air to dry the parts. Make sure that the is then used to finish the surface of the cylinder bore.
holes for oil passages are clean.

Piston, Cleaning And Inspection


Inspect the pistons for wear, cracks, and damage. Re-
place 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 SPECIFI- FIGURE 26. PATTERN FOR NORMAL
CATIONS. The piston pin will normally fall from the CYLINDER WEAR
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.

Cylinder Bores, Inspection And Repair


Inspect the cylinder bores for wear and damage. Mea-
sure 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 cyl-
inder that is outofround greater than 0.05 mm (0.002
in) must be repaired.

FIGURE 27. GAUGE POINTS FOR PISTON AND


FIGURE 25. MEASURE THE CYLINDER BORE CYLINDER BORE

Measure the cylinder bore in positions from top to bot- A cylinder bore that has been repaired with a hone or a
tom to find any taper from wear. A normal wear pattern boring machine must be fitted with a piston that is the
for a cylinder bore is shown in FIGURE 26. A cylinder correct size. Measure the outer diameter of the piston
that has a taper [measurement A that is 0.127 mm and the inner diameter of the cylinder bore as shown in
(0.005 in) greater than measurement B] must have a FIGURE 27. Using different oversize pistons in the en-
new bore. A tool called a hone can be used to remove a gine does not affect the dynamic balance of the engine.
small amount of taper from a cylinder bore. Use a boring Replacement pistons from standard size to 0.030 inch
machine to repair a badly worn cylinder. The boring ma- oversize normally have the same weight. The clearance

13
specifications between a piston and its cylinder bore is Replace the piston if the clearances are greater than the
shown in the ENGINE SPECIFICATIONS. specifications.

Piston Rings 2. Measure the end clearance of each piston ring as


shown in FIGURE 29. The end clearances are shown in
NOTE: Check the clearance of the piston rings in the
the ENGINE SPECIFICATIONS. Install the piston ring
cylinder after the surface of the cylinder has been fin-
into the cylinder where it will be used. Use a thickness
ished with a hone. New piston rings are available for the
gauge to measure the amount of end clearance. Replace
following piston sizes: standard size, and 0.005 in,
the piston if the clearances are greater than the specifica-
0.010 in, 0.020 in, and 0.030 in oversize. The piston
tions.
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 para-
graphs.

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 nor-
mally 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 pis-
tons 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 op-
posite 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
FIGURE 30. CONNECTING ROD
IDENTIFICATION
1. Measure the clearance between the piston ring and the
groove in the piston as shown in FIGURE 28. The clear- 1. Assemble the connecting rod to the piston. Make sure
ances are shown in the ENGINE SPECIFICATIONS. the orientation of the connecting rod and piston are cor-

14
rect as described in the NOTE above. Use a press to in- FLYWHEEL AND FLYWHEEL HOUSING
stall the piston pin into the piston and connecting rod.
Lubricate the piston pin with engine oil during installa- Flywheel Repair For V6 Engines
tion. 1. Replace the ring gear on the flywheel. During remov-
al or installation, do not heat the gear to more than
2. Check the clearances of the piston rings as described
230C (450F).
in Piston Rings. Install the piston rings on the piston
as shown in FIGURE 31. 2. During installation, push the ring gear fully against
the flywheel.

3. The bearing in the flywheel can be replaced. Push the


FAN END OF ENGINE old bearing from the flywheel and push in a new bear-
ing.
B
Flywheel For V6 Engines, Installation
C A D H3.505.00XL (H70110XL)

B When installing the flywheel on these units, refer to the


section on the HYDRAULIC PUMP DRIVE AS-
A POSITION OF THE GAP FOR THE SEMBLY.
SPACER OF THE OIL RING
B POSITION OF THE GAP FOR THE H6.007.00XL (H135155XL)
OIL RING
C POSITION OF THE GAP FOR THE
SECOND COMPRESSION RING Make sure the dowel pin is installed in the crankshaft.
D POSITION OF THE GAP FOR THE Install the flywheel.
FIRST COMPRESSION RING
FIGURE 31. ARRANGEMENT OF THE PISTON Units with a manual transmission: make sure the O
RINGS ON THE PISTON ring is installed between the flywheel and the crank-
shaft. Use a sealant (Hyster Part No. 246108) on the
heads of the capscrews. Tighten the capscrews for the
Piston And Connecting Rod Assemblies, flywheel to 79 N.m (58 lbf ft).
Installation
Units with a powershift transmission: tighten the cap-
1. Lubricate the assembly with engine oil during instal-
screws to 79 N.m (58 lbf ft).
lation. Arrange the piston rings on the piston as shown in
FIGURE 31. Install a ring compressor on the piston.
Flywheel Housing, H3.505.00XL (H70110XL)
2. Make sure that the notch in the piston is toward the fan The flywheel housing on these units has the parts for the
end of the engine. Install the piston and connecting rod hydraulic pump drive assembly. When doing any ser-
assemblies in the cylinder bores. vice to the housing, refer to the section for the HY-
DRAULIC PUMP DRIVE ASSEMBLY.
3. Install the bearings and the caps for the connecting
rods. Tighten the nuts. (See TORQUE SPECIFICA- Engine Adapter, H6.007.00XL (H135155XL)
TIONS FOR CAPSCREWS AND BOLTS.) Check the (See FIGURE 32.)
side clearance of each connecting rod after the bearing
cap is installed. See the procedure in the paragraphs un- The engine adapter is used on engines with a manual
der Connecting Rod Bearings, Replacement. transmission. When the seal in the adapter is replaced,
use a sealant (Hyster Part No. 246108) between the seal
4. Install the cylinder head as described in Cylinder and the adapter. When installing the adapter on the en-
Head, Installation. gine, make sure the Orings are installed under the
washers. Tighten the capscrews for the adapter to 47
5. Install the oil sump and the oil pump. N.m (35 lbf ft).

15
12009
11696

1. FLYWHEEL
2. SEAL
3. ORING (EARLIER PRODUCTION
1. ENGINE ADAPTER
SEALANT (LATER PRODUCTION)
2. ENGINE
4. CAPSCREW
3. FLYWHEEL
5. BEARING
4. PILOT BEARING
6. DOWEL
5. SEAL
6. CAPSCREW FIGURE 33. FLYWHEEL MOUNT
7. WASHER
8. ORING
9. ORING

FIGURE 32. ENGINE ADAPTER Flywheel For V8 Engines, Flywheel Housing


(See FIGURE 34.)

The flywheel housing must be checked for alignment


Ring Gear Replacement (Flywheel) For V8 during its installation. Check the alignment as follows:
Engines (See FIGURE 33.)
1. Install the dowel pins in the cylinder block. Install the
1. During removal or installtion, do not heat the gear to flywheel housing on the cylinder block. Tighten the cap-
more than 230C (450F). screws for the housing to 31 N.m (23 lbf ft).
2. During installation, push the ring gear fully against 2. Install a dial indicator on the crankshaft so that it indi-
the flywheel. cates on the flywheel housing as shown in FIGURE 33.
3. The bearing in the flywheel can be replaced. Push the Rotate the crankshaft and check the movement of the
old bearing from the flywheel and push in a new bear- needle. If the total movement of the needle is 0.38 mm
ing. (0.015 in) or less, the housing can be installed without
adjustment. Follow the procedures in step 1 when instal-
4. When used, make sure the dowel pin is installed in the ling the housing. If the total movement of the needle is
crankshaft. When installing the flywheel, tighten the more that 0.38 mm (0.015 in), adjust the housing as de-
capscrews to 81 N.m (60 lbf ft). scribed in step 3.

16
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 PE-
RIODIC 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
1
to 20 Nm (15 lbf ft).
2

11691
87.78 mm
(3.45 in)
5
2
9

3 3 4 5
3
4
V6 ENGINE
1. DIAL INDICATOR
2. FLYWHEEL HOUSING
3. DOWEL PINS
4. CRANKSHAFT 6305
3 4
FIGURE 34. ADJUST THE FLYWHEEL 2
HOUSING, V8 ENGINE ONLY 1

3. Remove the flywheel housing. Rotate the dowel pins


so that the position of the housing is moved toward the 5
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,
6861
check that the dowel pins are installed correctly. V8 ENGINE
6 7 8
4. On units with a manual transmission, a seal is 1. FAN SHAFT
installed in the flywheel housing. When the seal in the 2. INNER SNAP RING 6. SNAP RING
flywheel housing is replaced, use a sealant (Hyster Part 3. SNAP RING 7. IDLER PULLEY
4. FAN MOUNT 8. IDLER BRACKET
No. 246108) between the seal and the flywheel housing. 5. BEARING 9. FAN BOLTS
When installing the flywheel housing, tighten the cap-
screws to 31 N.m (23 lbf ft). FIGURE 35. FAN MOUNT

17
CHECKS AND ADJUSTMENTS aligned. On V6 engines, the valves on the No. 4 cylin-
der will be closed. On V8 engines, the valves on the
Valve Clearance Adjustment No. 6 cylinder will be closed. When the engine is in this
(See FIGURE 36.)
position, adjust the valves for the following cylinders:
1. Disconnect the negative cable at the battery. Remove
V6: Inlet Valves for Numbers. 4, 5, 6 and Exhaust
the valve covers.
Valves for Numbers. 2, 3, 4,
2. Rotate the engine until the mark on the vibration
damper or crankshaft pulley is aligned with the 0 tim- V8: Inlet Valves for Numbers. 3, 4, 6, 8 and Exhaust
ing mark on the timing tab. Make sure the valves for the Valves for Numbers. 2, 5, 6, 7
No. 1 cylinder are closed. If the valves are moving as the 6. Install the valve covers. Connect the battery cable.
0 timing mark is reached, the engine is in the wrong Start the engine and check for correct operation.
position.
3. When the engine is in the No. 1 firing position, adjust
11695
the valves for the following cylinders:
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 tight-
ening the nut. When there is no clearance at the push rod,
tighten the nut for the rocker arm one full turn. The addi-
tional 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 en-
FIGURE 36. ADJUST THE VALVE CLEARANCE
gine one full turn. Make sure the timing marks are

ENGINE SPECIFICATIONS
Engine Data Bore 101.58 to 101.71 mm
(3.9995 to 4.0045 in)
GM 4.3 litre V6 Stroke 88..39 mm (3.480 in)
Number of cylinders 6 Displacement 5.7 litre (350 in3)Governor
Firing order 165432 speed See the PERIODIC
Bore 101.58 to 101.71 mm MAINTENANCE section
(3.9995 to 4.0045 in) for each model of lift truck
Stroke 88..39 mm (3.480 in)
Displacement 4.3 litre (262.4 in3 Cylinder head
Governor speed See the PERIODIC Valve seat specifications: See FIGURE 37.
MAINTENANCE section Valve seat width (inlet valves):
for each model of lift truck 0.78 to 1.57 mm
(0.031 to 0.062 in)
GM 5.7 litre V8 Valve seat width (exhaust valves):
Number of cylinders 8 1.57 to 2.36 mm
Firing order 18436572 (0.062 to 0.093 in)

18
Clearance between inlet valve and guide:
1. CYLINDER HEAD 0.02 to 0.09 mm (0.001 to 0.0037 in)
2. MINIMUM THICKNESS
OF VALVE HEAD IS Clearance between exhaust valve and guide
0.80 mm (0.031 in) 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)
Valve spring force (installed and valve is open):
880 to 930 N @ 31.75 mm
FIGURE 37. VALVE SEAT SPECIFICATIONS (194 to 206 pounds @ 1.25 in)
FOR INLET AND EXHAUST VALVES
Hydraulic Valve Lifter
Leak rate: 12 to 90 seconds
A
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
9715 B (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
Bearing journals, diameter (All engines)
47.45 to 47.48 mm
A. VARIATION FROM VERTICAL (1.8682 to 1.8692 in)
Production less than 1.5 mm (0.06 in) Bearing journals, clearance
Service limit 2.5 mm (0.984 in) 0.01778 to 0.9685 mm
B. INSTALLATION HEIGHT: (0.0007 to 0.0027 in)
THE VALVE SPRINGS NEED A MINIMUM FORCE Variation of a bearing journal in either diameter or axial
OF 347 to 383 N (76 to 86 lbf) TO COMPRESS THEM direction: 0.03 mm (0.001 in)
TO A HEIGHT OF 43 mm (1.69 in)
Axial Clearance (All Engines)
0.10 to 0.30 mm (0.004 to 0.0012 in)
Lobe lift (V6)
Inlet 9.06 mm (0.357 in)
Exhaust 9.90 mm (3.90 in)
Lobe lift (V8)
Inlet 6.60 mm (0.260 in)
Exhaust 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)
Clearance at bottom of cylinder:
FIGURE 38. VALVE SPRING SPECIFICATIONS 0.068 mm (0.0027 in)

19
Piston ring to groove clearance for piston rings (see V8
FIGURE 28.) Diameter of connecting rod journals:
Compression rings No. 1 and No. 2: 53.31 to 53.33 mm (2.0988 to 2.0998 in)
0.030 to 0.081 mm (0.0012 to 0.0032 in)
Outofround of bearing journal (maximum)
Oil ring to groove clearance:
Production Limit 0.0127 mm (0.0005 in)
0.051 to 0.18 mm (0.002 to 0.007 in)
Service Limit 0.0254 mm (0.001 in)
Piston ring end clearance (see FIGURE 29.)
Compression rings No. 1 and No. 2: Taper of bearing journal (maximum)
0.25 to 0.76 mm (0.010 to 0.030 in) Production Limit 0.0127 mm (0.0005 in)
Oil ring 0.38 to 1.40 mm (0.015 to 0.055 in) Service Limit 0.0254 mm (0.001 in)
Piston pin to piston clearance: Clearance between crankshaft journals and connecting rod
0.006 to 0.011 mm (0.00025 to 0.00045 in) bearings 0.03 to 0.08 mm (0.0013 to 0.0035 in)
Piston pin to connecting rod clearance: Available undersize connecting rod bearings:
Press fit 0.0254 mm (0.001 in)
0.0508 mm (0.002 in)
Crankshaft
0.254 mm (0.010 in)
Diameter of main bearing journal 0.508 mm (0.020 in)
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) Side clearance of connecting rod to crankshaft:
Number 5 62.15 to 62.19 mm (2.4471 to 2.4488 in) 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) Cooling System
Service Limit 0.0254 mm (0.001 in) Thermostat: 82C (180F)
Taper of main bearing journal (maximum)
Production Limit 0.0051 mm (0.0002 in) Lubrication System
Service Limit 0.0254 mm (0.001 in) Oil pressure @ 2500 rpm
Clearance between journals and main bearings 170 to 241 kPa
Number 1 0.020 to 0.050 mm (0.0008 to 0.0020 in) (25 to 35 psi)
Number 2, 3, 4 0.027 to 0.058 mm (0.0011 to 0.0023 in Minimum oil pressure @ idle rpm
Number 5 0.043 to 0.081 mm (0.0017 to 0.0032 in 48 kPa (7 psi)
Available undersize main bearings:
Oil pressure switch ON @
0.0254 mm (0.001 in)
20 to 39 kPa
0.0508 mm (0.002 in)
(2.9 to 5.7 psi)
0.2285 mm (0.009 in
0.25 mm (0.010 in)
0.50 mm (0.020 in) CAUTION
Axial Clearance (crankshaft to thrust surface main bearing): Fuel System Note: Lift trucks that have the V6 en-
0.15 to 0.254 mm (0.006 to 0.010 in) gine with fuel injection have an electric fuel pump
Connecting Rods and a fuel shutoff valve. Do not close the fuel shut
V6 off valve when the engine is running. This action can
Diameter of connecting rod journals: cause high pressure at the fuel pump and break the
57.12 to 57.14 mm (2.2487 to 2.2497 in) connector hose.

20
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 POSSIBLE CAUSE
When the ignition switch is in the START The battery has a problem.
position, the starter does not operate. 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 POSSIBLE CAUSE
There is noise inside the engine. 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 The spark plugs are dirty.
acceleration. 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