GM ENGINE REPAIR

GM 2.4 LITER ENGINE

S2.0-3.5FT (S40-70FT, S55FTS) [F187];
H2.0-3.5FT (H40-70FT) [L177]

PART NO. 1580503 600 SRM 1121

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the prod-
uct. Updated technical service information may be available from your local authorized Hyster® dealer. Service
Manuals provide general guidelines for maintenance and service and are intended for use by trained and expe-
rienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service
Manual could result in damage to the products, personal injury, property damage or death.

• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load
being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the
load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.
Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON
BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the
specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs
repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure
to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make
sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this
manual:

WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
GM Engine Repair Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Engine Serial Number ....................................................................................................................................... 1
Engine Removal and Installation ..................................................................................................................... 3
Intake Manifold.................................................................................................................................................. 3
Remove ........................................................................................................................................................... 3
Clean and Inspect .......................................................................................................................................... 4
Install ............................................................................................................................................................. 4
Exhaust Manifold............................................................................................................................................... 5
Remove ........................................................................................................................................................... 5
Clean and Inspect .......................................................................................................................................... 5
Install ............................................................................................................................................................. 5
Camshaft and Cylinder Head Repair ............................................................................................................... 6
Rocker Arm Cover.......................................................................................................................................... 6
Remove....................................................................................................................................................... 6
Install ......................................................................................................................................................... 6
Camshaft Timing Pulley and/or Front Seal ................................................................................................. 7
Remove....................................................................................................................................................... 7
Install ......................................................................................................................................................... 7
Camshaft Carrier and Cylinder Head .......................................................................................................... 8
Remove....................................................................................................................................................... 8
Disassemble ............................................................................................................................................... 9
Camshaft Carrier .................................................................................................................................. 9
Cylinder Head ....................................................................................................................................... 10
Clean and Inspect...................................................................................................................................... 11
Camshaft Carrier .................................................................................................................................. 11
Cylinder Head ....................................................................................................................................... 12
Valve and Valve Seat................................................................................................................................. 14
Assemble .................................................................................................................................................... 14
Cylinder Head ....................................................................................................................................... 14
Camshaft Carrier .................................................................................................................................. 15
Install ......................................................................................................................................................... 15
Timing Belt......................................................................................................................................................... 16
Timing Belt Front Cover ............................................................................................................................... 16
Remove....................................................................................................................................................... 16
Install ......................................................................................................................................................... 17
Timing Belt and Timing Belt Tensioner....................................................................................................... 17
Remove....................................................................................................................................................... 17
Install ......................................................................................................................................................... 19
Timing Belt Rear Cover................................................................................................................................. 19
Remove....................................................................................................................................................... 19
Install ......................................................................................................................................................... 19
Lubrication System Repair................................................................................................................................ 20
Oil Pan............................................................................................................................................................ 20
Remove....................................................................................................................................................... 20
Install ......................................................................................................................................................... 20
Oil Pump ........................................................................................................................................................ 22
Remove....................................................................................................................................................... 22
Clean and Inspect...................................................................................................................................... 23
Install ......................................................................................................................................................... 24
Piston and Piston Rod Assemblies Repair........................................................................................................ 25
Piston Rod Bearings, Replace ....................................................................................................................... 25

©2012 HYSTER COMPANY i

Table of Contents GM Engine Repair

TABLE OF CONTENTS (Continued)

Piston and Piston Rod Assemblies................................................................................................................ 27
Remove....................................................................................................................................................... 27
Disassemble ............................................................................................................................................... 28
Pistons, Clean and Inspect........................................................................................................................ 28
Cylinder Bores, Inspect and Repair ......................................................................................................... 29
Piston Rings, Inspect................................................................................................................................. 30
Assemble .................................................................................................................................................... 31
Install ......................................................................................................................................................... 31
Crankshaft and Main Bearings......................................................................................................................... 32
Crankshaft Timing Pulley and/or Front Seal .............................................................................................. 32
Remove....................................................................................................................................................... 32
Install ......................................................................................................................................................... 33
Crankshaft Rear Main Oil Seal .................................................................................................................... 34
Remove....................................................................................................................................................... 34
Install ......................................................................................................................................................... 34
Crankshaft/RPM Sensor ............................................................................................................................... 34
Remove....................................................................................................................................................... 34
Install ......................................................................................................................................................... 35
Crankshaft Reluctor Wheel........................................................................................................................... 35
Remove and Install ................................................................................................................................... 35
Crankshaft and Main Bearings .................................................................................................................... 35
Remove....................................................................................................................................................... 35
Inspect and Repair .................................................................................................................................... 36
Bearing Selection ...................................................................................................................................... 37
Main Bearings and Journal Clearance, Check ........................................................................................ 38
Install ......................................................................................................................................................... 39
Flywheel and Flywheel Housing ....................................................................................................................... 41
Remove ........................................................................................................................................................... 41
Install ............................................................................................................................................................. 41
Cooling System Repair ...................................................................................................................................... 42
Serpentine Belt .............................................................................................................................................. 42
Remove....................................................................................................................................................... 42
Inspect........................................................................................................................................................ 42
Install ......................................................................................................................................................... 42
Water Pump ................................................................................................................................................... 43
Remove....................................................................................................................................................... 43
Inspect........................................................................................................................................................ 45
Install ......................................................................................................................................................... 45
Thermostat..................................................................................................................................................... 46
Remove....................................................................................................................................................... 46
Check.......................................................................................................................................................... 47
Install ......................................................................................................................................................... 47
Thermostat Housing...................................................................................................................................... 48
Remove....................................................................................................................................................... 48
Clean and Inspect...................................................................................................................................... 48
Install ......................................................................................................................................................... 48
Sensors and Switches ........................................................................................................................................ 50
Crankshaft Position (CKP) Sensor ............................................................................................................... 50
Remove....................................................................................................................................................... 50
Install ......................................................................................................................................................... 50
Camshaft Position (CMP) Sensor ................................................................................................................. 50

ii
GM Engine Repair Table of Contents

TABLE OF CONTENTS (Continued)

Remove for Lift Trucks Built Before January, 2010................................................................................ 50
Assembly................................................................................................................................................ 50
Sensor Only ........................................................................................................................................... 51
Install for Lift Trucks Built Before January, 2010 .................................................................................. 51
Assembly................................................................................................................................................ 51
Sensor Only ........................................................................................................................................... 52
Remove for Lift Trucks Built After January, 2010 .................................................................................. 52
Install for Lift Trucks Built After January, 2010 .................................................................................... 52
Oil Pressure Sensor ....................................................................................................................................... 52
Remove....................................................................................................................................................... 52
Install ......................................................................................................................................................... 53
Ignition System .................................................................................................................................................. 53
Spark Plug Wire Inspection .......................................................................................................................... 53
Spark Plug Wire Replacement ...................................................................................................................... 53
Remove....................................................................................................................................................... 53
Install ......................................................................................................................................................... 54
Spark Plug Replacement ............................................................................................................................... 54
Remove....................................................................................................................................................... 54
Install ......................................................................................................................................................... 54
Spark Plug Inspection ................................................................................................................................... 55
Usage.......................................................................................................................................................... 55
Inspect........................................................................................................................................................ 55
Visual Inspection ....................................................................................................................................... 57
Coil Pack......................................................................................................................................................... 57
Remove....................................................................................................................................................... 57
Install ......................................................................................................................................................... 57
Alternator Repair............................................................................................................................................... 58
Alternator....................................................................................................................................................... 58
Remove....................................................................................................................................................... 58
Install ......................................................................................................................................................... 58
Alternator Fuse, Replace............................................................................................................................... 58
Starter Repair .................................................................................................................................................... 59
Remove ........................................................................................................................................................... 59
Install ............................................................................................................................................................. 59
Engine Specifications......................................................................................................................................... 60
Engine Data ................................................................................................................................................... 60
Cylinder Bore ................................................................................................................................................. 60
Piston.............................................................................................................................................................. 60
Piston Rings ................................................................................................................................................... 60
Wrist Pin ........................................................................................................................................................ 61
Crankshaft ..................................................................................................................................................... 61
Piston Rod ...................................................................................................................................................... 61
Camshaft and Camshaft Carrier .................................................................................................................. 62
Valve System.................................................................................................................................................. 62
Cylinder Head Warpage ................................................................................................................................ 63
Lubrication System ....................................................................................................................................... 63
Cooling System .............................................................................................................................................. 63
Torque Specifications ......................................................................................................................................... 63
Special Tools ....................................................................................................................................................... 65

iii
Table of Contents GM Engine Repair

TABLE OF CONTENTS (Continued)

This section is for the following models:

S2.0-3.5FT (S40-70FT, S55FTS) [F187];

H2.0-3.5FT (H40-70FT) [L177]

iv
600 SRM 1121 Engine Serial Number

General
This section has the repair instructions for the GM
2.4 liter engine.

Engine Serial Number

The location of the engine serial number is shown in
Figure 1 and Figure 2.

1. ENGINE SERIAL NUMBER

Figure 1. Engine Serial Number Prior to January, 2010

1
Engine Serial Number 600 SRM 1121

1. ENGINE SERIAL NUMBER

Figure 2. Engine Serial Number After January, 2010

2
600 SRM 1121
Engine Removal and Installation
CAUTION
Disconnect the battery cables before doing any
disassembly and repair to the engine or parts
of the electrical system.
The diodes and resistors in the electrical sys-
tem can be damaged if the following cautions
are not followed:
• Do not disconnect the battery when the en-
gine is running. The voltage surge can dam-
age the diodes and resistors.
• Do not disconnect an electric wire before the
engine is stopped and the switches are OFF.
• Do not cause a short circuit by connection
of the electric wires to the wrong terminals.
Make sure a correct identification is made of
the wire before it is connected.
• Make sure a battery is the correct voltage and
polarity before it is connected.
Intake Manifold
REMOVE
NOTE: Step 1 is for gasoline engines only.
1. Disconnect the electrical connector from the fuel
pump.
NOTE: Step 2 is for LPG fuel systems only.
2. Close the fuel valve on the propane tank.
3. Start the engine and let it idle until the engine
shuts down from the lack of fuel.
NOTE: Step 4 is for gasoline engines only.
4. Crank the engine for approximately five seconds
for full pressure relief from the fuel system.
5. Disconnect the negative battery cable.
6. Remove the left rear side cover. Refer to the sec-
tion Frame 100 SRM 1120.
7. Disconnect the air intake hoses from the air filter
assembly.
NOTE: The ECM assembly must be disconnected
from the air filter assembly before removing the air
filter assembly. For gasoline engines, refer to the
section Gasoline Fuel System, GM 2.4L Engine
Intake Manifold
• Do not check for current flow by making a
spark because the electronic components can
be damaged.
CAUTION
Many parts of the engine assembly are made
of aluminum. Use care not to damage mating
surfaces or threads. To prevent possible dam-
age to mating surfaces, do not clean with wire
brushes, steel wool, or sharp objects. Do not
overtighten parts that are aluminum or mount
to an aluminum part, as this can cause damage
to the threads or part.
The procedures to remove and install the engine are
not included in this section. See the section Frame
100 SRM 1120 for these procedures.
900 SRM 1126. For LPG fuel systems, refer to the
section LPG Fuel System, GM 2.4L Engine 900
SRM 1124.
8. Remove the three bolts that attach the air filter
assembly mounting bracket to the frame and re-
move air filter assembly with mounting bracket.
9. Disconnect the electrical connections to the
throttle body.
10. Disconnect the fuel delivery hoses and return
hoses, or LPG vapor hose.
11. Disconnect the vacuum hose from the intake
manifold.
12. Disconnect the air intake hoses and positive
crankcase ventilation (PCV) valve hoses from
the intake manifold.
13. Disconnect the wiring harness connectors to the
fuel injectors.
14. Disconnect the electrical connector to the MAP
sensor.
15. Remove the nuts retaining the intake manifold
to the cylinder head. See Figure 3.
3
Intake Manifold
1. INTAKE MANIFOLD 3. CYLINDER HEAD
2. NUT
Figure 3. Intake Manifold
16. Remove the intake manifold.
17. Remove the intake manifold gasket and discard.
18. Remove and replace fuel system components as
needed. For gasoline engines, refer to the section
Gasoline Fuel System, GM 2.4L Engine 900
SRM 1126. For LPG fuel systems, refer to the
section LPG Fuel System, GM 2.4L Engine
900 SRM 1124.
CLEAN AND INSPECT
CAUTION
Use caution not to scratch the gasket mating
surfaces when cleaning the intake manifold
and cylinder head.
Carefully remove all gasket residue from the intake
manifold and cylinder head. Inspect the intake man-
ifold for scratches, cracks, or any other damage. Re-
pair or replace as needed.
INSTALL
1. Verify the mating surfaces are clean and not
damaged.
2. If necessary, install fuel system components. For
gasoline engines, refer to the section Gasoline
Fuel System, GM 2.4L Engine 900 SRM 1126.
For LPG fuel systems, refer to the section LPG
Fuel System, GM 2.4L Engine 900 SRM 1124.
3. Place a new gasket in position between the in-
take manifold and the cylinder head.
4
600 SRM 1121
4. Place the intake manifold into position on the
cylinder head.
5. Install the retaining nuts on the studs. Tighten
the nuts to 18 to 22 N•m (13 to 16 lbf ft).
6. Connect the electrical connector to the MAP sen-
sor.
7. Connect the wiring harness connectors to the fuel
injectors.
8. Connect the air intake hoses and PCV valve
hoses to the intake manifold.
9. Connect the vacuum hose to the intake manifold.
10. Connect the fuel delivery hose to the intake man-
ifold.
11. Connect the breather hose to the intake mani-
fold.
12. Connect the fuel delivery hoses and return hoses,
or LPG vapor hose.
13. Connect the electrical connections to the throttle
body.
NOTE: Step 14 is for gasoline engines only.
14. Connect the electrical connector to the fuel pump.
NOTE: Step 15 is for LPG fuel systems only.
15. Slowly open the fuel valve on the propane tank.
NOTE: The ECM assembly must be connected to the
air filter assembly after installing the air filter as-
sembly. For gasoline engines, refer to the section
Gasoline Fuel System, GM 2.4L Engine 900 SRM
1126. For LPG fuel systems, refer to the section LPG
Fuel System, GM 2.4L Engine 900 SRM 1124.
16. Place the air filter assembly with mounting
bracket in position on the frame. Install bolts
and tighten to 20 N•m (15 lbf ft).
17. Connect the air intake hoses to the air filter as-
sembly.
18. Install the left rear side cover. Refer to the sec-
tion Frame 100 SRM 1120.
19. Connect the negative battery cable.
600 SRM 1121
WARNING
During engine operation, be careful not to
touch the fan, pulleys, or drive belts. Contact
with these parts can cause serious injury.
Exhaust Manifold
REMOVE
1. Remove the battery, battery tray, and power
distribution module (PDM). Refer to the section
Electrical System 2200 SRM 1142.
2. Tag and disconnect the spark plug wires.
3. Disconnect the electrical connection to the coil
pack.
4. Remove the coil pack and coil pack mounting
bracket.
5. Remove the capscrews retaining the exhaust
manifold heat shield and remove the heat shield.
6. Disconnect the oxygen sensor electrical connec-
tion.
7. Remove and discard the locking nuts retaining
the exhaust manifold adapter to the exhaust
manifold.
8. Remove and discard the gasket between the ex-
haust manifold adapter and the exhaust mani-
fold.
9. Remove and discard the locking nuts retaining
the exhaust manifold to the cylinder head. See
Figure 4.
10. Remove the exhaust manifold.
11. Remove the gasket and discard.
CLEAN AND INSPECT
CAUTION
Use caution not to scratch the gasket mating
surfaces when cleaning the exhaust manifold
and cylinder head.
Carefully remove all gasket residue from the exhaust
manifold and cylinder head. Inspect the exhaust
Exhaust Manifold
WARNING
The radiator or other parts of the cooling sys-
tem may be hot or under pressure and can
cause serious injury.
20. Start the engine and check for proper operation
and leaks.
manifold for scratches, cracks, or any other damage.
Repair or replace as needed.
INSTALL
1. Verify the mating surfaces are clean and not
damaged.
2. Place a new gasket in position between the ex-
haust manifold and the cylinder head.
3. Place the exhaust manifold into position on the
cylinder head.
4. Install new locking nuts on the studs. Tighten
the nuts to 18 to 22 N•m (13 to 16 lbf ft).
5. Place a new gasket in position between the ex-
haust manifold adapter and the exhaust mani-
fold.
1. GASKET
2. EXHAUST MANIFOLD
3. NUT
Figure 4. Exhaust Manifold Removal/
Installation
5
Camshaft and Cylinder Head Repair 600 SRM 1121

6. Connect the exhaust manifold adapter to the
exhaust manifold and secure with new locking
nuts. Tighten the nuts to 14 to 20 N•m (10 to
15 lbf ft).
7. Connect the oxygen sensor electrical connection.
8. Place the exhaust manifold heat shield in posi-
tion and secure with capscrews. Tighten the cap-
screws to 6 to 8 N•m (53 to 71 lbf in).
10. Connect the electrical connection to the coil pack.
11. Connect the spark plug wires and remove tags.
12. Install the battery, battery tray, and PDM. Re-
fer to the section Electrical System 2200 SRM
1142.
13. Start the engine and check for proper operation
and leaks.

9. Install the coil pack mounting bracket and coil

pack.

Camshaft and Cylinder Head Repair

ROCKER ARM COVER 5. Connect the crankcase vent tube to the rocker
arm cover.
Remove
6. Connect the two hoses to the PCV valve.
1. Disconnect the two hoses from the PCV valve.

2. Disconnect the crankcase vent tube from the

rocker arm cover.

3. Remove the capscrews retaining the rocker arm

cover to the camshaft carrier assembly. See Fig-
ure 5.

4. Remove the rocker arm cover and gasket. Dis-

card gasket.

Install
1. Clean the mating surfaces of the rocker arm
cover and the camshaft carrier assembly.

2. Place a new gasket in position in the rocker arm

cover.

3. Place the rocker arm cover in position on the

camshaft carrier assembly.
1. CAPSCREW
4. Install the capscrews to retain the rocker arm 2. OIL FILLER CAP
3. ROCKER ARM COVER
cover to the camshaft carrier assembly. Tighten 4. CAMSHAFT CARRIER ASSEMBLY
the capscrews to 8 N•m (71 lbf in).
Figure 5. Rocker Arm Cover

6
600 SRM 1121 Camshaft and Cylinder Head Repair

CAMSHAFT TIMING PULLEY AND/OR Legend for Figure 6

FRONT SEAL 1. CAMSHAFT TIMING PULLEY
2. 22-MM, OPEN-END WRENCH
Remove 3. 17-MM WRENCH
NOTE: Before removing the timing belt, make sure
the alignment mark on the crankshaft timing pulley
is aligned with the alignment mark on the oil pump
case flange, with the No. 1 cylinder in the combustion
stroke; the camshaft timing pulley alignment mark
is aligned with the timing mark on the rear timing
belt cover; and the camshaft pin is in the top hole
of the camshaft timing pulley. See Timing Belt and
Timing Belt Tensioner, Remove.

1. Remove the timing belt. See Timing Belt and

Timing Belt Tensioner, Remove.

2. Remove the rocker arm cover. See Rocker Arm

Cover, Remove.

3. Use a 22-mm, open-end wrench and lock the

camshaft. Using a 17-mm wrench, remove the
bolt retaining the camshaft timing pulley. See
Figure 6.
4. Remove the camshaft timing pulley.
5. Drill a small hole into the front seal face. Install
a fine thread screw. Using a pair of pliers, pull
the seal outward, and remove the seal. See Fig-
ure 7.
Figure 7. Camshaft Front Seal Removal
Install
1. Using a special tool, a camshaft seal installer,
install new front seal. See Figure 8.
2. Use a 22-mm, open-end wrench and lock the
camshaft.
3. Place the camshaft timing pulley in position. In-
stall the retaining bolt and tighten bolt to 40 to
50 N•m (30 to 37 lbf ft). See Figure 6.

Figure 6. Camshaft Timing Pulley

Figure 8. Camshaft Front Seal Installation

7
Camshaft and Cylinder Head Repair
NOTE: Before installing the timing belt, verify the
alignment mark on the crankshaft timing pulley is
aligned with the alignment mark on the oil pump
case flange, with the No. 1 cylinder in the combustion
stroke; the camshaft timing pulley alignment mark
is aligned with the timing mark on the rear timing
belt cover; and the camshaft pin is in the top hole
of the camshaft timing pulley. See Timing Belt and
Timing Belt Tensioner, Install.
4. Install the timing belt. See Timing Belt and Tim-
ing Belt Tensioner, Install.
5. Install the rocker arm cover. See Rocker Arm
Cover, Install.
CAMSHAFT CARRIER AND CYLINDER
HEAD
Remove
1. Turn the ignition switch to the OFF position.
2. Disconnect the negative battery cable.
WARNING
DO NOT remove the radiator cap from the ra-
diator when the engine is hot. When the radia-
tor cap is removed, pressure will release from
the coolant system. If the coolant system is hot,
the steam and boiling coolant can cause severe
burns.
WARNING
The radiator or other parts of the cooling sys-
tem may be hot or under pressure and can
cause serious injury. Wait 30 minutes for the
radiator and engine to cool before performing
maintenance to the cooling system. After 30
minutes, do a touch test by touching the radi-
ator with your hand. If the radiator is still hot
to the touch, wait another 30 minutes before
attempting any maintenance to the cooling
system.
CAUTION
Disposal of lubricants must meet local environ-
mental regulations.
3. Remove the radiator cap.
8
600 SRM 1121
4. Loosen the lower radiator hose and drain the
coolant from the coolant system.
5. Remove the intake manifold. See Intake Mani-
fold, Remove.
6. Remove the exhaust manifold. See Exhaust
Manifold, Remove.
7. Remove the spark plugs.
8. Remove the fan belt. See Serpentine Belt, Re-
move.
NOTE: Before removing the timing belt, make sure
the alignment mark on the crankshaft timing pulley
is aligned with the alignment mark on the oil pump
case flange, with the No. 1 cylinder in the combustion
stroke; the camshaft timing pulley alignment mark
is aligned with the timing mark on the rear timing
belt cover; and the camshaft pin is in the top hole
of the camshaft timing pulley. See Timing Belt and
Timing Belt Tensioner, Remove.
9. Remove the timing belt. See Timing Belt and
Timing Belt Tensioner, Remove.
10. Remove the timing belt rear cover. See Timing
Belt Rear Cover, Remove.
11. Remove the thermostat housing. See Thermostat
Housing, Remove.
12. Disconnect the electrical connector for the
camshaft sensor.
13. Remove the rocker arm cover. See Rocker Arm
Cover, Remove.
CAUTION
Since there is spring tension on the camshaft
and carrier, use caution when removing
camshaft carrier/cylinder head bolts. Remove
the bolts in the sequence shown in Figure 9 in
even increments to prevent possible damage
to the camshaft and camshaft carrier.
14. Remove and discard the camshaft carrier/cylin-
der head bolts in sequence and in even incre-
ments. See Figure 9 and Figure 10.
15. Remove the camshaft carrier assembly from the
cylinder head.
600 SRM 1121 Camshaft and Cylinder Head Repair

NOTE: Organize camshaft followers and keepers so

they can be installed in their original positions.

16. Remove the camshaft followers and keepers from

the cylinder head. See Figure 11.

1. CAMSHAFT FOLLOWER
Figure 9. Removal Sequence 2. KEEPERS
3. LIFTERS
4. CYLINDER HEAD
5. CYLINDER HEAD GASKET
6. CYLINDER BLOCK

Figure 11. Cylinder Head

NOTE: Organize camshaft lifters so they can be in-

stalled in their original positions.

17. Remove the camshaft lifters from the cylinder

head.

18. Remove the cylinder head from the engine block.

19. Remove the cylinder head gasket and discard.

Disassemble
Camshaft Carrier

1. Remove the camshaft sensor assembly.

2. Remove the capscrews from the camshaft re-

1. WASHER
2. BOLT tainer. See Figure 12.
3. CAMSHAFT CARRIER ASSEMBLY
4. CYLINDER HEAD 3. Carefully move the camshaft slightly out of the
camshaft carrier and remove the camshaft re-
Figure 10. Camshaft Carrier Assembly tainer.

9
Camshaft and Cylinder Head Repair 600 SRM 1121

5. Remove the front camshaft seal. See Camshaft

Timing Pulley and/or Front Seal, Remove.

Cylinder Head

NOTE: Keep cylinder head components in order so

they will be installed in the same positions during
assembly.

1. Using a valve spring compressor, compress the

valve spring. See Figure 14.

1. RETAINER 2. CAPSCREW

Figure 12. Camshaft Retainer

CAUTION
All camshaft journals are the same diameter.
Be careful when removing the camshaft to
avoid damage to the camshaft carrier.
1. VALVE SPRING COMPRESSOR
4. Carefully rotate and remove the camshaft out of
the camshaft carrier. See Figure 13. Figure 14. Valve Spring Compressor

2. Remove the valve stem keys. See Figure 15.

3. Remove the retainers from the valve spring.

4. Remove the valve springs.

5. Using a special tool, remove the valve stem oil

seals.

6. Remove valve spring seat (Inlet).

7. Remove the valve spring rotator assembly.

8. Remove the exhaust valve.

9. Remove the inlet valve.

10. Repeat Step 1 through Step 9 for remaining

valves.

1. CAMSHAFT 2. CAMSHAFT
CARRIER

Figure 13. Camshaft Removal/Installation

10
600 SRM 1121 Camshaft and Cylinder Head Repair

1. THREADED HOLE 3. BOLT HOLE

2. MATING SURFACE

Figure 16. Camshaft Carrier

5. Inspect the bottom mating surface of the

1. VALVE STEM KEYS camshaft carrier for warpage. Replace as needed.
2. RETAINER
3. VALVE SPRING
4. VALVE STEM OIL SEAL 6. Inspect the bores in the camshaft carrier for dam-
5. VALVE SEAT (INLET) age. Replace as needed. See Figure 17.
6. VALVE INLET
7. VALVE EXHAUST 7. Using a dial indicator, measure the camshaft
8. CYLINDER HEAD bore surfaces. See Engine Specifications for the
9. VALVE SPRING ROTATOR ASSEMBLY correct measurements. If not within specifica-
(EXHAUST) tions, replace camshaft carrier.
Figure 15. Valve Removal/Installation

Clean and Inspect

Camshaft Carrier

CAUTION
Use care not to damage the mating sur-
faces when removing old gaskets and sealant
residues.

1. Clean all debris, old gaskets, and sealants from

the mating surfaces of the camshaft carrier. See
Figure 16.

2. Clean the bolt holes and threads in the camshaft 1. CAMSHAFT BORE
carrier.
Figure 17. Camshaft Bores Inspection
3. Inspect the camshaft carrier mating surfaces for
damage. Replace as needed.

4. Inspect the camshaft carrier for cracks or any

other damage. Replace as needed.

11
Camshaft and Cylinder Head Repair 600 SRM 1121

Cylinder Head d. The maximum clearance between the valve

CAUTION
Do not use a wire brush to clean the combus-
tion chambers. This can damage the seats and
possibly the sealing surface at the edge of the
combustion chamber.
Use a soft brush and cleaner to remove the carbon
from the combustion chambers and the valve ports.
Be careful not to scuff the chamber.
1. Clean the following areas:
a. Carbon and sludge from the lifters, followers,
and keepers.
b. Valve stems and heads.
c. Cylinder head and engine block gasket sur-
faces.
d. Bolt holes and threads in the cylinder head
and the engine block.
2. Inspect the following areas:
a. Cylinder head for cracks in the exhaust ports
and the combustion chambers.
stems and their valve guides is shown in En-
gine Specifications.
NOTE: If the valve stem to valve guide clearance can-
not be obtained using an oversized valve stem, the
cylinder head must be replaced.
e. If the clearance between the valve stem and
its valve guide is greater than the specifica-
tion, a valve with an oversize stem must be
installed. Use a reamer to make the bore the
correct diameter for the next oversize valve.
See Figure 19. See the Parts Manual for
oversize valves.
4. Inspect the valve springs for squareness. See
Figure 20.
5. Measure the valve seat runout. The valve seats
should be centered to within 0.05 mm (0.002 in.).
See Figure 21.
6. Inspect the cylinder head and measure it for
warpage. A cylinder head with excessive
warpage must be repaired or replaced. Refer
to Engine Specifications for cylinder head di-
mensions. Also, see Figure 22.

b. Cylinder head for external cracks in the wa-

ter chamber.

c. Valves for burned heads, cracked faces, or

damaged stems.

3. Check the valve stem-to-bore clearance of each

valve and valve guide. Use the following proce-
dure:

a. Install the dial indicator into the valve guide

and measure the inner diameter of the valve
guide. See Figure 18.

b. Measure the outside diameter of the valve

stem with a micrometer.

c. Determine the difference between the outer

diameter of the valve stem and the inner di- Figure 18. Valve Guide Inner Diameter
ameter of the valve guide. Measurement

12
600 SRM 1121 Camshaft and Cylinder Head Repair

Figure 19. Valve Guide Reaming

Figure 21. Valve Seat Runout Measurement

Figure 20. Valve Springs Inspection Figure 22. Cylinder Head Measurement

13
Camshaft and Cylinder Head Repair 600 SRM 1121

Valve and Valve Seat
The condition of the valves and alignment of the
valves to their valve seats are important for the
correct operation of the engine. Before any work is
done on the valve seats, make sure the clearance
of the valve stems in their valve guides is within
specifications.
12. Using a valve spring compressor, compress the
valve spring.
NOTE: Make sure the keys seat properly in the upper
groove of the valve stem. If necessary, tap the end of
the valve stem with a plastic-faced hammer, making
sure the valves will not come into contact with the
work bench, in order to seat the keys.

A correction for minimum wear and damage to the 13. Install the valve stem keys.
valve and seat can be done by a process called lap-
ping. When the valve seats are lapped, keep the 14. Remove the valve spring compressor.
valve seats within the specifications. Make sure all
15. Repeat Step 1 through Step 14 for remaining
of the lapping compound is removed from the valve
valves.
and valve seat when the process is completed.

Damaged valve seats can be repaired with a 45° ±30’

cutter tool. See Figure 23. If the valve seat cannot
be repaired so that the valve depth is within speci-
fications, the cylinder head must be replaced. The
specifications for the valve seats are listed in Engine
Specifications.

Assemble
Cylinder Head

1. Install the valves into the proper ports. See Fig-

ure 15.

2. Install the valve seat (inlet) on the inlet valve.

3. Install the valve seat (exhaust) on the exhaust

valve.

4. Install the inlet valve and exhaust valve into the

cylinder head.

5. Install the valve spring rotator assembly over the

valve guide.

6. Lubricate the valve stem oil seal with clean en-

gine oil.

7. Using a special tool, install the valve stem oil seal

onto the exhaust valve.

8. Lubricate the valve stem oil seal with clean en-

gine oil.

9. Using a special tool, install the valve stem oil seal

onto the inlet valve.
Figure 23. Valve Seat Repair
10. Install the valve springs.

11. Install the retainers onto the valve spring.

14
600 SRM 1121 Camshaft and Cylinder Head Repair

Camshaft Carrier 9. Tighten the camshaft carrier/cylinder head bolts

in sequence to 25 N•m (18 lbf ft). See Figure 24.
1. Using a special tool, a camshaft seal installer,
install new front seal. See Figure 8.

CAUTION
All camshaft journals are the same diameter.
Be careful when installing the camshaft to
avoid damage to the camshaft carrier.

2. Carefully rotate and install the camshaft into the

camshaft carrier.

NOTE: The camshaft may need to be pulled slightly

out of the camshaft carrier to place the camshaft re-
tainer in position.

3. Install the camshaft retainer.

4. Install the capscrews to retain the camshaft re-
tainer. Tighten capscrews to 8 N•m (71 lbf in).
5. Install the camshaft sensor assembly.
Install
Figure 24. Tightening Sequence
10. Tighten the cylinder head bolts in sequence an
additional 180 degrees.
11. Tighten the cylinder head bolts in sequence an
additional 10 degrees.

NOTE: Verify the cylinder head locators are installed 12. Install the rocker arm cover. See Rocker Arm
in the engine block. Cover, Install.

1. Install the new cylinder head gasket over the lo-
cators onto the engine block with the TOP mark
facing upward and toward the front end of the
engine block. See Figure 11.
2. Install the cylinder head over the locators onto
the gasket.
3. Coat the bottom of the valve lifters with molyb-
denum lubricant.
NOTE: If using the old valve lifters, install the lifters
in original positions.
4. Install valve lifters.
5. Install the camshaft follower keepers and follow-
ers.
6. Apply RTV sealant (Hyster part number 280472)
to the mating surface of the cylinder head for the
carrier assembly.
7. Place the camshaft carrier assembly in position
on the cylinder head.
13. Connect the electrical connector for the camshaft
sensor.
14. Install the thermostat housing. See Thermostat
Housing, Install.
15. Install the timing belt rear cover. See Timing
Belt Rear Cover, Install.
NOTE: Before installing the timing belt, verify the
alignment mark on the crankshaft timing pulley is
aligned with the alignment mark on the oil pump
case flange, with the No. 1 cylinder in the combustion
stroke; the camshaft timing pulley alignment mark
is aligned with the timing mark on the rear timing
belt cover; and the camshaft pin is in the top hole
of the camshaft timing pulley. See Timing Belt and
Timing Belt Tensioner, Install.
16. Install the timing belt. See Timing Belt and Tim-
ing Belt Tensioner, Install.
17. Install the fan belt. See Serpentine Belt, Install.
18. Install the spark plugs.

8. Install new camshaft carrier/cylinder head bolts 19. Install the exhaust manifold. See Exhaust Man-
and washers. Tighten bolts finger tight only. ifold, Install.

15
Timing Belt
20. Install the intake manifold. See Intake Manifold,
Install.
21. Connect the lower radiator hose and tighten the
clamp.
CAUTION
Additives may damage the cooling system. Be-
fore using additives, contact your local Hyster
dealer.
22. Connect the bottom radiator hose. Fill cooling
system with coolant. Refer to the section Peri-
odic Maintenance 8000 SRM 1150 for correct
coolant amount and type.
23. Install radiator cap on radiator.
WARNING
During engine operation, be careful not to
touch the fan, pulleys, or drive belts. Contact
with these parts can cause serious injury.
WARNING
The radiator or other parts of the cooling sys-
tem may be hot or under pressure and can
cause serious injury.
24. Start engine and check cooling system for leaks.
25. Bleed air from the cooling system by opening the
bleed screw located on the left side behind the
Timing Belt
TIMING BELT FRONT COVER
Remove
1. Turn the ignition to the OFF position.
2. Remove the battery, battery tray, and PDM. Re-
fer to the section Electrical System 2200 SRM
1142.
3. Remove the auxiliary coolant reservoir.
4. Remove the fan shroud. Refer to the section
Cooling System 700 SRM 1123.
5. Place a piece of cardboard over the radiator sur-
face to prevent damage to the radiator.
16
600 SRM 1121
alternator. When the air has been bled from the
system, close the bleed screw.
WARNING
DO NOT remove the radiator cap from the ra-
diator when the engine is hot. When the radi-
ator cap is removed, the pressure is released
from the system. If the system is hot, the steam
and boiling coolant can cause burns. DO NOT
remove the cover for the radiator when the en-
gine is running.
WARNING
The radiator or other parts of the cooling sys-
tem may be hot or under pressure and can
cause serious injury. Wait 30 minutes for the
radiator to cool. Do a touch test by touching
the radiator with your hand. If the radiator is
still hot to the touch, wait another 30 minutes
before attempting to check or fix any part of
the cooling system.
CAUTION
Additives may damage the cooling system. Be-
fore using additives, contact your local Hyster
dealer.
26. Stop engine. If coolant is hot, give engine time to
cool. Check coolant level and fill as required be-
tween the ADD and FULL marks on the coolant
reservoir.
6. Remove the four bolts retaining the fan assembly.
7. Remove the fan assembly.
8. Remove the serpentine belt. See Serpentine Belt,
Remove.
9. Remove the spacer and the pulley.
10. Disconnect the electrical connections to the alter-
nator.
11. Remove the alternator mounting bolts and re-
move the alternator.
12. Remove the alternator bracket bolts, fan hub
bracket bolts, and fan hub bracket.
600 SRM 1121
NOTE: Before removing the crankshaft pulley and
the crankshaft pulley hub, make alignment marks
on the crankshaft hub, crankshaft pulley, and crank-
shaft spacer.
13. Remove the bolts retaining the crankshaft fan
pulley and remove the crankshaft fan pulley and
the crankshaft pulley spacer. See Figure 25.
1. CRANKSHAFT PULLEY HUB
2. CRANKSHAFT PULLEY SPACER
3. CRANKSHAFT PULLEY
4. SERPENTINE BELT
5. OIL PUMP HOUSING
6. ALIGNMENT MARK
Figure 25. Crankshaft Pulley Arrangement
14. Remove the front timing belt cover bolts and re-
move the front timing belt cover.
Install
1. Place the timing belt cover over the timing
belt and install bolts. Tighten bolts to 6 N•m
(53 lbf in).
NOTE: Before installing the crankshaft pulley and
crankshaft spacer, align these components with the
alignment marks made when disassembled.
2. Install the crankshaft spacer and crankshaft pul-
ley, ensuring that all alignment marks made dur-
ing removal are lined up properly. Tighten crank-
shaft pulley bolts to 15 to 25 N•m (11 to 18 lbf ft).
3. Install fan hub bracket and retaining bolts.
Tighten bolts to 52 N•m (38 lbf ft).
Timing Belt
4. Install alternator bracket and retaining bolts.
Tighten bolts to 38 N•m (28 lbf ft).
5. Install the alternator. See the section Alternator
Repair.
6. Install the fan spacer and the pulley.
7. Install the serpentine belt. See Serpentine Belt,
Install.
8. Place the fan in position on the pulley and in-
stall the four retaining bolts. Tighten the bolts
to 26 N•m (19 lbf ft).
9. Remove cardboard from the radiator surface.
10. Install the fan shroud. Refer to the section Cool-
ing System 700 SRM 1123.
11. Install the auxiliary coolant reservoir.
12. Install the battery, battery tray, and PDM. Re-
fer to the section Electrical System 2200 SRM
1142.
TIMING BELT AND TIMING BELT
TENSIONER
Remove
1. Remove the timing belt front cover. See Timing
Belt Front Cover, Remove.
2. Turn the crankshaft until the alignment mark on
the crankshaft timing pulley is aligned with the
alignment mark on the oil pump case flange, with
the No. 1 cylinder in the combustion stroke. See
Figure 26.
Figure 26. Crankshaft Timing Pulley
Alignment Mark
17
Timing Belt 600 SRM 1121

CAUTION
The camshaft pin must be in the top hole of the
camshaft timing pulley.

3. Position the camshaft timing pulley alignment

mark with the timing mark on the rear timing
belt cover. Verify that the camshaft pin is located
in the 12 o’clock position. See Figure 27.

Figure 28. Timing Belt

1. CAMSHAFT PIN

Figure 27. Camshaft Timing Pulley and

Crankshaft Timing Pulley Alignment Marks 1. WATER PUMP BOLT
2. WATER PUMP
3. WATER PUMP TAB (11 O’CLOCK POSITION)
4. Use chalk to mark direction of timing belt rota- 4. TIMING BELT TENSIONER POINTER
tion. See Figure 28. 5. LOCATORS
6. TENSIONER TAB (7 O’CLOCK POSITION)
NOTE: Before removing the timing belt tensioner, 7. USED TIMING BELT MARK
verify the tensioner tab is between the two locator 8. NEW TIMING BELT MARK
tabs at the 7 o’clock position. See Figure 29. 9. TENSIONER

5. Remove the bolt retaining the timing belt ten- Figure 29. Tensioner Tab and Locators
sioner.

6. Remove the timing belt and the timing belt ten-

sioner.

18
600 SRM 1121
Install
1. Align the camshaft timing pulley alignment
mark with the timing mark on the rear timing
belt cover. See Figure 27.
CAUTION
The camshaft pin must be in the top hole of the
camshaft timing pulley.
2. Verify that the camshaft pin is located in the 12
o’clock position. See Figure 27.
3. Verify the alignment mark on the crankshaft
timing pulley is aligned with the alignment
mark on the oil pump case flange, with the No. 1
cylinder in the combustion stroke. See Figure 27.
NOTE: The timing belt tensioner tab must be placed
in the 7 o’clock position between the locators. See
Figure 29.
4. Install the timing belt tensioner, but do not
tighten the bolt.
5. Place the timing belt over the pulleys and the
timing belt tensioner.
6. Tighten the tensioner to the appropriate refer-
ence mark with the crankshaft timing pulley hub
timing mark aligned with the oil pump housing
timing mark and the camshaft timing belt pul-
ley timing mark aligned with the timing mark
located on the plastic timing belt housing.
NOTE: The timing belt tensioner has two markings,
NEW and USED, for the appropriate timing belt.
The tensioner pointer will need to be aligned with
the correct timing belt installed. See Figure 29.
7. If timing belt is too tight and cannot be adjusted
with the tensioner, loosen water pump bolts (see
Figure 29) and turn water pump counterclock-
wise until proper tension is achieved. Tighten
water pump bolts to 20 to 30 N•m (15 to 22 lbf ft).
8. If timing belt is too loose and cannot be adjusted
with the tensioner, loosen water pump bolts and
turn water pump clockwise until proper tension
is reached. Tighten water pump bolts to 20 to
30 N•m (15 to 22 lbf ft).
9. Tighten the timing belt tensioner bolt to 20 N•m
(15 lbf ft). Verify the timing belt tensioner
pointer is aligned with the appropriate mark
after tightening. Recheck tensioner and timing
Timing Belt
belt marks to make sure they are still aligned
correctly.
10. Install the timing belt front cover. See Timing
Belt Front Cover, Install
TIMING BELT REAR COVER
Remove
1. Remove the timing belt front cover. See Timing
Belt Front Cover, Remove.
NOTE: Before removing the timing belt, verify the
alignment mark on the crankshaft timing pulley is
aligned with the alignment mark on the oil pump
case flange, with the No. 1 cylinder in the combustion
stroke, the camshaft timing pulley alignment mark is
aligned with the timing mark on the rear timing belt
cover, and the camshaft pin is in the top hole of the
camshaft timing pulley. See Timing Belt and Timing
Belt Tensioner, Remove.
2. Remove the timing belt and timing belt ten-
sioner. See Timing Belt and Timing Belt Ten-
sioner, Remove.
3. Remove the rocker arm cover.
4. Remove the camshaft timing pulley. See
Camshaft Timing Pulley and/or Front Seal,
Remove.
5. Remove the crankshaft timing pulley. See
Crankshaft Timing Pulley and/or Front Seal,
Remove.
6. Remove the Torx head capscrews retaining front
bracket and remove front bracket.
7. Remove the capscrews retaining the timing belt
rear cover.
8. Remove timing belt rear cover.
Install
1. Place timing belt rear cover in position on engine.
2. Install bolts to retain timing belt rear cover.
Tighten capscrews to 6 N•m (53 lbf in).
3. Place front bracket in position and install Torx
head capscrews. Tighten Torx head capscrews to
25 N•m (18 lbf ft).
4. Install the camshaft timing pulley. See Camshaft
Timing Pulley and/or Front Seal, Install.
19
Lubrication System Repair
5. Install crankshaft timing pulley and retaining
bolt. See Crankshaft Timing Pulley and/or Front
Seal, Install.
NOTE: Before installing the timing belt, verify the
alignment mark on the crankshaft timing pulley is
aligned with the alignment mark on the oil pump
case flange, with the No. 1 cylinder in the combustion
stroke; the camshaft timing pulley alignment mark
is aligned with the timing mark on the rear timing
Lubrication System Repair
OIL PAN
Remove
1. Remove the engine from the lift truck. Refer to
the section Frame 100 SRM 1120 for the proce-
dures to remove the engine.
2. Remove the oil pan drain plug and drain the en-
gine oil into a suitable container.
3. If necessary, remove the oil filter.
4. Remove the capscrews retaining the oil pan to
the engine block. See Figure 30.
5. Remove the oil pan.
1. OIL PAN 2. DRAIN PLUG
Figure 30. Oil Pan
20
600 SRM 1121
belt cover; and the camshaft pin is in the top hole
of the camshaft timing pulley. See Timing Belt and
Timing Belt Tensioner, Install.
6. Install the timing belt and timing belt tensioner.
See Timing Belt and Timing Belt Tensioner, In-
stall.
7. Install the timing belt front cover. See Timing
Belt Front Cover, Install.
CAUTION
Use care not to damage the mating sur-
faces when removing old gaskets and sealant
residues.
6. Carefully remove old sealant residue from the
mating surfaces of the oil pan and cylinder block.
7. Thoroughly clean the outside and inside surfaces
of the oil pan.
Install
1. Apply a 3.175 mm (0.125 in.) continuous bead of
sealant around the sealing surface of the oil pan.
2. Place the oil pan into position on the cylinder
block using the locating pins.
3. Remove the right side bell housing alignment
bushing. See Figure 31.
4. Install special tool, rear flange alignment tool, to
keep the alignment of the oil pan to the cylinder
block. See Figure 32.
5. Install capscrews, except the two capscrews
where the alignment tool is using the mounting
holes.
6. Verify the alignment of the oil pan and cylinder
block is correct. The edge of the oil pan should be
a maximum distance of 0.15 mm (0.006 in.) from
the edge of the cylinder block. See Figure 33.
Adjust the oil pan as needed.
7. Tighten the capscrews to 18 to 22 N•m (13 to
16 lbf ft).
600 SRM 1121 Lubrication System Repair

Legend for Figure 31

1. BUSHING
2. BELL HOUSING
3. REMOVAL TOOL

Figure 31. Bell Housing Alignment Bushing

1. OIL PAN 3. BELL HOUSING

2. REAR FLANGE ALIGNMENT TOOL

Figure 32. Rear Flange Alignment Tool

21
Lubrication System Repair 600 SRM 1121

5. Remove the oil pressure sensor.

6. Remove the oil filter.

1. CYLINDER BLOCK 2. OIL PAN

Figure 33. Oil Pan Alignment

8. Remove the special tool.

9. Install the remaining two capscrews and tighten

to 18 to 22 N•m (13 to 16 lbf ft). 1. OIL FILTER
2. OIL PRESSURE SENSOR
10. Install the right side bell housing alignment 3. BANJO BOLT
bushing. 4. OIL FILTER ADAPTER
5. ELECTRICAL CONNECTOR
11. Install the drain plug and tighten to 18 to
Figure 34. Oil Pressure Sensor and Oil Filter
22 N•m (13 to 16 lbf ft).
With Adaptor
12. If removed, install new oil filter.

13. Install the engine into the lift truck. Refer to the
section Frame 100 SRM 1120.

14. Fill the engine oil to the correct level. Refer to

the section Periodic Maintenance 8000 SRM
1150 for correct oil amount and type.

OIL PUMP
Remove
1. Remove the oil pan. See Oil Pan, Remove.

2. Remove the timing belt rear cover. See Timing

Belt Rear Cover, Remove.

3. Disconnect the electrical connector for the crank-

shaft sensor. 1. ELECTRICAL CONNECTOR
2. OIL PRESSURE SENSOR
4. Disconnect the electrical connector for the oil 3. OIL FILTER
pressure sensor. See Figure 34 and Figure 35.
Figure 35. Oil Pressure Sensor and Oil Filter
Without Adaptor

22
600 SRM 1121 Lubrication System Repair

NOTE: Step 7 and Step 8 are for engines with an oil

filter adapter only.

7. Using vise grips, remove the banjo bolt retaining

the oil filter adapter and remove oil filter adapter.

8. Discard the seal washer and the banjo bolt.

9. Remove the capscrew from the oil pump suction

tube bracket. See Figure 36.

10. Remove the capscrews from the suction tube.

NOTE: The oil suction tube and screen are to be ser-

viced as an assembly. Do not attempt to repair the
wire mesh portion of the tube and screen assembly.
1. CAPSCREW 4. GASKET
11. Remove the suction tube and O-ring. Discard 2. SAFETY VALVE 5. OIL PUMP
O-ring. 3. SPACER

12. Remove the capscrews retaining the oil pump to
the engine block. See Figure 37.
NOTE: Be sure to retain the spacers for installation.
13. Remove the oil pump, gasket, and spacers. Dis-
card gasket.
Figure 37. Oil Pump
Clean and Inspect
NOTE: The internal components of the oil pump are
not serviceable. If the oil pump components are dam-
aged or worn, replace the oil pump as an assembly.

14. Remove the safety valve. 1. Remove the screws retaining the oil pump cover
and remove oil pump cover. See Figure 38.

1. SCREW 2. OIL PUMP COVER

1. O-RING 3. SUCTION TUBE
2. BRACKET 4. CAPSCREWS Figure 38. Oil Pump Cover

Figure 36. Oil Suction Tube

23
Lubrication System Repair
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the recom-
mendations of the manufacturer.
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air
is away from all personnel. Wear protective
goggles or a face shield to prevent injury to the
eyes.
NOTE: The internal parts of the oil pump are not
serviced separately. If the oil pump components are
worn or damaged, replace the oil pump as an assem-
bly. If the drive gear and drive shaft are worn, re-
place the entire oil pump.
The oil suction tube and screen are to be serviced as
an assembly. Do not attempt to repair the wire mesh
portion of the tube and screen assembly.
2. Clean all of the parts in cleaning solvent. Dry the
parts with compressed air.
3. Inspect the gears and the pump body for wear
and damage. If the parts are worn or damaged,
replace the oil pump.
4. Check the gap of the gears with a feeler gauge
and a straight edge. The dimension should be
0.03 to 0.10 mm (0.0011 to 0.004 in.). See Fig-
ure 39.
1. STRAIGHT EDGE 2. FEELER GAUGE
Figure 39. Gear Inspection
24
600 SRM 1121
5. Attach the oil pump cover to the oil pump. Install
the retaining screws. Tighten retaining screws to
6 N•m (53 lbf in).
Install
1. Install safety valve with a new O-ring. Tighten
safety valve to 37 N•m (27 lbf ft).
2. Install new oil pump gasket.
3. Install the oil pump and spacers.
4. Install the capscrews to retain the oil pump to
engine block. Tighten capscrews to 6 to 10 N•m
(53 to 89 lbf in).
5. Install new O-ring on oil pump suction tube. In-
stall the oil pump suction tube and capscrews.
Tighten the capscrews to 8 N•m (71 lbf in).
6. Install the oil pump suction tube bracket cap-
screw. Tighten capscrew to 18 to 22 N•m (13 to
16 lbf ft).
NOTE: Step 7 is for engines with an oil filter adapter
only.
7. Install the oil filter adapter, new seal washer, and
new shear banjo bolt. Tighten banjo bolt with an
open-end, 10-mm wrench until the head of the
bolt completely shears off. See Figure 40.
8. Install new oil filter.
1. SEAL WASHER 4. OIL FILTER
2. BANJO BOLT ADAPTER
3. SHEAR HEAD
Figure 40. Shear Banjo Bolt Installation
600 SRM 1121 Piston and Piston Rod Assemblies Repair

9. Install the oil pressure sensor. Tighten sensor to 12. Connect the electrical connector for the crank-
20 N•m (15 lbf ft). shaft sensor.

10. Connect the electrical connector for the oil pres- 13. Install the oil pan. See Oil Pan, Install.
sure sensor.

11. Install the timing belt rear cover. See Timing

Belt Rear Cover, Install.

Piston and Piston Rod Assemblies Repair

PISTON ROD BEARINGS, REPLACE
NOTE: The piston rod bearings are available in a
standard size and several undersizes. See the Parts
Manual for bearing sizes. If a bearing on a journal is
worn, both the upper and lower halves of the bearing
must be replaced.
1. Remove the oil pan and oil pump. See Lubrica-
tion System Repair.
2. Remove the capscrews retaining the baffle plate
and remove baffle plate.
3. Remove the remaining capscrews from the bear-
ing bracket and remove the bearing bracket.
9. Use a micrometer to measure the bearing jour-
nal. The bearing journal must be within the fol-
lowing specification:
• Out-of-roundness less than 0.004 mm
(0.00016 in.); taper less than 0.005 mm
(0.0002 in.)
If the bearing journals are not within specifica-
tions, the crankshaft must be removed and the
bearing journal ground to an undersize. If the
bearing journal cannot be repaired so that the
bearing journal is a correct undersize, the crank-
shaft must be replaced. See Engine Specifica-
tions.

4. Before the cap for the piston rod is removed,

mark the piston rod and cap with the cylinder
number so that the parts will be installed in
their original positions.

5. Remove the capscrews retaining the cap and re-

move cap for the piston rod bearing and the lower
bearing half. See Figure 41.

6. Push the piston rod away from the crankshaft

and remove the upper bearing half. Wipe the oil
from the bearing halves and the bearing journal.

7. Inspect bearings for craters, pockets, excessive

scoring, and dirt or debris imbedded into the
bearing material. Replace as needed. Replace
the upper and lower halves as a set.

8. Inspect the bearings for improper seating indi-

cated by bright, polished sections of the bearing.
Replace as needed. Replace the upper and lower 1. BEARING CAP 3. CRANKSHAFT
halves as a set. 2. BEARING

Figure 41. Piston Rod Cap Removal

25
Piston and Piston Rod Assemblies Repair 600 SRM 1121

10. If the bearing journal is within specifications, b. Measure the clearance between the caps for
measure the clearance between the new bearing the piston rods and the crankshaft. See Fig-
and the crankshaft. Use Plastigage®, or equiva- ure 44.
lent, to check the clearance as described below:

a. Put a piece of Plastigage® across the full

width of the bearing journal as shown in Fig-
ure 42. Do not rotate the crankshaft when
the Plastigage® is between the bearing and
its journal.

b. Install the bearing and bearing cap. Tighten

the capscrews to 30 to 40 N•m (22 to
29.5 lbf ft). Tighten the capscrews an addi-
tional 40 to 45 degrees.

c. Remove the bearing and bearing cap. The

Plastigage® will be compressed and wider
and it will adhere to either the bearing or its
journal. Use the scale on the envelope for the
Plastigage® to measure the width of the plas-
tic at its widest point. The scale will indicate
the clearance in millimeters or thousandths
of an inch. See Figure 43.
1. BEARING CAP 2. PLASTIGAGE®
d. If the clearance is greater than the specifica-
tions, select a new undersize bearing set and Figure 42. Bearing Journal Plastigage®
install it. Measure the clearance again. If Placement
the clearance cannot 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 max-
imum undersize, the crankshaft must be re-
placed.

e. If the clearance is within specifications,

lubricate the bearing with engine oil and
install the bearing and bearing cap. Tighten
the capscrews to 30 to 40 N•m (22 to
29.5 lbf ft). Tighten the capscrews an addi-
tional 40 to 45 degrees.

11. When all of the connecting rod bearings have

been replaced, use the following procedure to
check the side clearances between the piston
rods and the crankshaft (refer to Engine Specifi-
cations for clearance specifications):

a. Use a hammer to lightly hit the piston rod

parallel to the crankshaft journal to make Figure 43. Bearing Journal Plastigage®
sure there is a clearance. Measurement

26
600 SRM 1121 Piston and Piston Rod Assemblies Repair

e. Remove the cloth.

f. Remove the cutting debris.

5. Clean the carbon from the top of each cylinder.

6. Put an identification mark on the top of each pis-

ton.

7. Remove the caps and bearings from each piston

Figure 44. Piston Rods Side Clearance
Measurement
PISTON AND PISTON ROD ASSEMBLIES
rod. Keep the caps and bearings with their origi-
nal piston assemblies. Mark the caps so that they
will be installed again in their original positions.
Do not mix the parts.
8. Push the piston rod and piston from the cylinder.
Temporarily install the bearing cap on the piston
rod to keep the parts together.

Remove
1. Remove the oil pan and oil pump. See Lubrica-
tion System Repair.

2. Remove the capscrews retaining the baffle plate

and remove baffle plate.

3. Remove the cylinder head. See Camshaft Carrier

and Cylinder Head, Remove.

4. 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 (see Figure 45) using the procedures de-
scribed below:

a. Turn the crankshaft to lower the piston to the

bottom of the stroke in its cylinder.

b. Put a cloth on top of the piston to collect

metal particles. Figure 45. Ridge Reamer
c. Remove the ridge at the top of the cylinder.

d. Turn the crankshaft so the piston is at the

top of the stroke.

27
Piston and Piston Rod Assemblies Repair 600 SRM 1121

Disassemble goggles or a face shield to prevent injury to the

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. See
Figure 46.
eyes.
3. Use solvent to clean the pistons and piston rods.
Use compressed air to dry the parts. Make sure
that the holes for oil passages are clean.
Pistons, Clean and Inspect
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 pis-
ton must be changed to the correct oversize piston.
Check the clearance of the piston in its cylinder af-
ter the surface of the cylinder bore has been finished
with a hone.

Check the clearance of the wrist pin in the piston.

The normal clearance is shown in Engine Specifica-
tions. The wrist pin will normally fall from the hole
in the piston by its own weight.

The wrist pin is a press fit in the piston rod. The

piston and wrist pin are a matched set and must be
replaced as a unit if the clearances are greater than
the specifications.

1. UPPER COMPRESSION RING

2. LOWER COMPRESSION RING
3. OIL CONTROL RING
4. PISTON

Figure 46. Piston Rings

2. Use a press to remove the wrist pins from the

pistons. See Figure 47.

WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the recom-
mendations of the manufacturer.

WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air
is away from all personnel. Wear protective
Figure 47. Wrist Pin Removal

28
600 SRM 1121 Piston and Piston Rod Assemblies Repair

Cylinder Bores, Inspect and Repair
Inspect the cylinder bores for wear and damage.
Measure the cylinder bores with a bore gauge in
several positions as shown in Figure 48. Measure
the cylinder bore at right angles to the centerline
to find any distortion from wear. A cylinder that is
out of round greater than 0.127 mm (0.005 in.) will
require that the short block assembly be replaced as
oversized pistons are not available.
Using an oversize piston in the engine does not af-
fect the dynamic balance of the engine. Replacement
pistons are available in standard size and 0.50 mm
(0.020 in.) oversize. The clearance between a pis-
ton and its cylinder bore should be between 0.010 to
0.030 mm (0.00039 to 0.00118 in.).

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 bor-
ing machine will make a more accurate cylinder bore.
The hone is then used to finish the surface of the
cylinder bore.

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.

Use the following procedure to determine the clear-

ance between the pistons and cylinders.

1. Measure the inner diameter of the cylinder bore Figure 49. Bore Gauge Measurement
as shown in Figure 48.

2. Using a micrometer, measure the bore gauge and

record the reading. See Figure 49.

3. Using a micrometer, measure the outer diameter

of the piston. See Figure 50.

4. Subtract the piston diameter from the bore diam-

eter to determine the piston to bore clearance.

Figure 50. Piston Measurement

Figure 48. Cylinder Bore Measurement

29
Piston and Piston Rod Assemblies Repair 600 SRM 1121

Piston Rings, Inspect

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 different piston sizes. See the Parts Manual
for sizes.

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 dimple or orientation

mark on one surface. This mark must be toward the
top of the cylinder when the piston ring is installed.
The lower compression ring also has a bevel edge that
faces the bottom of the piston. The upper compres-
sion ring has a molybdenum filling and no bevelled
edge.

The oil control ring has three pieces. There are two
thin steel rings separated by a spacer. The oil control
ring has no dimple or orientation mark and may be
installed in either direction.

1. Measure the clearance between the piston ring Figure 51. Piston Ring and Groove Clearance
and the groove in the piston as shown in Fig- Check
ure 51. The clearances are shown in Engine
Specifications. Replace the piston if the clear-
ances are greater than the specifications.

2. Measure the end clearance of each piston ring

as shown in Figure 52. The end clearances are
shown in Engine Specifications. Install the pis-
ton ring into the cylinder where it will be used.
Use a thickness gauge to measure the amount
of end clearance. Replace the piston ring if the
clearances are greater than the specifications.

Figure 52. Piston Ring End Clearance Check

30
600 SRM 1121 Piston and Piston Rod Assemblies Repair

Assemble
NOTE: There are notches cast in the top of all pis-
tons to indicate the correct assembly and installa-
tion. The pistons must always be installed with this
notch toward the fan end of the engine. See Fig-
ure 56.

The piston rods have a notch cast in the bearing jour-

nal as shown in Figure 53. This notch must be oppo-
site the notch on the top of the piston when the piston
and piston rod are assembled.

B. POSITION OF GAP FOR OIL RING

C. POSITION OF GAP FOR SPACER OF OIL RING
D. POSITION OF GAP FOR OIL RING
E. POSITION OF GAP FOR LOWER
COMPRESSION RING
F. POSITION OF GAP FOR UPPER COMPRESSION
RING

Figure 54. Piston Ring Arrangement

1. NOTCHES ON ROD OPPOSITE NOTCH IN
PISTON Install
Figure 53. Piston Rod Identification 1. Lubricate the assembly with engine oil during in-
stallation. Arrange the piston rings on the piston
1. Assemble the piston rod to the piston. Make sure as shown in Figure 54. Install a ring compressor
the orientation of the piston rod and piston are on the piston as shown in Figure 55.
correct as described in the NOTE above. Use a
press to install the wrist pin into the piston and
piston rod. Lubricate the wrist pin with engine
oil during installation.

NOTE: Each compression ring has a dimple or ori-

entation mark on one surface. This mark must be
toward the top of the cylinder when the piston ring
is installed. The lower compression ring also has a
bevel edge that faces the bottom of the piston. The
upper compression ring has a molybdenum filling
and no bevelled edge.

The oil control rings do not have a dimple or orienta-

tion mark and may be installed in either direction. Figure 55. Ring Compressor Installation

2. Check the clearances of the piston rings as de-
scribed in Piston Rings, Inspect. Install the
piston rings on the piston as shown in Figure 54,
considering that the vertical dash line corre-
sponds to the wrist pin position.
2. Make sure that the notch in the piston is toward
the fan end of the engine as shown in Figure 56.
Install the piston and piston rod assemblies in
the cylinder bores.

31
Crankshaft and Main Bearings
NOTE: CAST NOTCH MUST BE TOWARD FAN END
OF ENGINE.
A. FAN END OF ENGINE
Figure 56. Piston Position Inside Cylinder
3. Install the bearings and the caps for the piston
rods. Tighten the capscrews to 30 to 40 N•m (22
Crankshaft and Main Bearings
CRANKSHAFT TIMING PULLEY AND/OR
FRONT SEAL
Remove
1. Remove the timing belt. See Timing Belt and
Timing Belt Tensioner, Remove.
2. Using a special tool to hold the pulley, remove
the crankshaft timing pulley retaining bolt. See
Figure 57.
Figure 57. Crankshaft Timing Pulley Retaining
Bolt Removal/Installation
32
600 SRM 1121
to 29.5 lbf ft). Tighten the capscrews an addi-
tional 40 to 45 degrees. Check the side clear-
ance of each piston rod after the bearing cap is
installed. See the paragraphs in the procedure
Piston Rod Bearings, Replace.
4. Install the cylinder head. See Camshaft Carrier
and Cylinder Head, Install.
5. Place the bearing bracket in position on the en-
gine block.
6. Place the baffle plate in position on the bear-
ing bracket and install capscrews. Tighten cap-
screws to 20 to 24 N•m (15 to 17.7 lbf ft).
7. Install the oil pump and oil pan. See Lubrication
System Repair.
3. Using the special tool, piston flange universal
puller, remove the crankshaft timing pulley. See
Figure 58.
4. Remove the crankshaft keyway and the spacer.
See Figure 59.
5. With an electric drill and a 2-mm drill bit, drill a
hole in the front face of the seal.
Figure 58. Crankshaft Timing Pulley Removal
600 SRM 1121
1. KEYWAY 2. SPACER
Figure 59. Crankshaft Keyway and Spacer
6. Install a special tool, crankshaft front seal puller,
on a universal sliding mallet. Thread the end of
the special tool into the hole previously drilled in
the seal. Remove the seal. See Figure 60.
1. SEAL PULLER
2. END OF SLIDING MALLET
Figure 60. Crankshaft Front Seal Removal
Crankshaft and Main Bearings
Install
1. Install a special tool, protective sleeve, onto the
crankshaft end with the outer surface lubricated
with clean engine oil and the chamfered end of
the sleeve facing away from the engine. See Fig-
ure 61.
2. Install the front seal onto the protective sleeve.
3. Using a special tool, crankshaft front seal in-
staller, install the front seal into its lodging.
4. Remove the special tools.
5. Install the spacer and the keyway.
6. Install the crankshaft timing pulley onto the
crankshaft end.
7. Using the special tool to hold the crankshaft
timing pulley, install the retaining bolt. See
Figure 57. Initially tighten bolt to 130 N•m
(96 lbf ft). Tighten the bolt an additional 45
degrees.
8. Install the timing belt. See Timing Belt and Tim-
ing Belt Tensioner, Install.
1. CRANKSHAFT FRONT SEAL INSTALLER
2. SEAL
3. PROTECTIVE SLEEVE
4. CRANKSHAFT END
Figure 61. Crankshaft Front Seal Installation
33
Crankshaft and Main Bearings 600 SRM 1121

CRANKSHAFT REAR MAIN OIL SEAL

Remove
1. Remove the engine. Refer to the section Frame
100 SRM 1120.

2. Remove the flywheel. See Flywheel and Fly-

wheel Housing.

3. With an electric drill and a 2-mm drill bit, drill a

hole in the front face of the seal.

4. Install a special tool, crankshaft rear main oil

seal puller, on a sliding mallet. Tighten the nut
on the sliding mallet against the special tool.
Thread the end of the special tool into the previ-
ously-drilled hole in the seal. Remove the seal. Figure 63. Crankshaft Rear Main Oil Seal
See Figure 62. Installation

Install 3. Install the flywheel. See Flywheel and Flywheel

Housing.
1. Remove the excess sealer from the oil seal recess.
4. Install the engine. Refer to the section Frame
2. Using a special tool, crankshaft rear main oil seal 100 SRM 1120.
installer, press the new oil seal into the housing.
See Figure 63. CRANKSHAFT/RPM SENSOR
Remove
1. Remove the timing belt front cover. See Timing
Belt Front Cover, Remove.

2. Disconnect the crankshaft/rpm sensor electrical

harness. See Figure 64.

1. SEAL PULLER
2. NUT
3. END OF SLIDING MALLET

Figure 62. Crankshaft Rear Main Oil Seal

Removal
1. CRANKSHAFT/RPM SENSOR
2. ELECTRICAL HARNESS

Figure 64. Crankshaft Sensor

34
600 SRM 1121 Crankshaft and Main Bearings

3. Remove the capscrew retaining the crankshaft/ 4. Remove the reluctor wheel.
rpm sensor.
5. Inspect the reluctor wheel for wear and damage.
4. Remove the crankshaft/rpm sensor. Replace as needed.

Install 6. Place the reluctor wheel in position on the crank-

1. Install the crankshaft/rpm sensor into the engine
block.
2. Install the capscrew to retain the crankshaft/rpm
sensor. Tighten capscrew to 8 N•m (71 lbf in).
3. Connect the crankshaft/rpm sensor electrical
harness.
shaft.
7. Verify the alignment mark on the reluctor wheel
is aligned with the alignment mark on the crank-
shaft.
8. Install capscrews to retain reluctor wheel to
the crankshaft. Tighten capscrews to 10 N•m
(88.5 lbf in).

4. Install the timing belt front cover. See Timing 9. Install the crankshaft. See Crankshaft and Main
Belt Front Cover, Install Bearings, Install.

CRANKSHAFT RELUCTOR WHEEL CRANKSHAFT AND MAIN BEARINGS

Remove and Install Remove
1. Remove the crankshaft. See Crankshaft and 1. Remove the engine. Refer to the section Frame
Main Bearings, Remove. 100 SRM 1120.

2. Make an alignment mark on the crankshaft and
the reluctor wheel to properly align the reluctor
wheel in the original position during installation.
3. Remove the capscrews retaining the reluctor
wheel to the crankshaft. See Figure 65.
2. Remove the flywheel and flywheel housing. See
Flywheel and Flywheel Housing.
3. Remove the oil pan and oil pump. See Lubrica-
tion System Repair.
4. Remove the capscrews retaining the baffle plate
and remove baffle plate.

5. Remove the remaining capscrews from the bear-

ing bracket and remove the bearing bracket.

6. Remove caps for connecting rods. Put identifi-

cation marks on bearing caps so they can be in-
stalled in the original locations during assembly.
See Piston and Piston Rod Assemblies Repair.

7. Remove the capscrews for bearing caps and re-

move caps. See Figure 66.

1. CAPSCREW
2. RELUCTOR WHEEL
3. CRANKSHAFT

Figure 65. Reluctor Wheel

35
Crankshaft and Main Bearings 600 SRM 1121

9. Remove the bearings from the bearing caps and

from the engine block.

10. If necessary, remove the reluctor wheel. See

Crankshaft Reluctor Wheel, Remove and Install.

Inspect and Repair

WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air
is away from all personnel. Wear protective
goggles or a face shield to prevent injury to the
eyes.

WARNING
Cleaning solvents can be flammable and toxic
1. MAIN BEARING 3. CAP CAPSCREWS and can cause skin irritation. When using
2. BEARING CAPS 4. BEARINGS (HALF) cleaning solvents, always follow the recom-
mendations of the manufacturer.
Figure 66. Crankshaft Bearings
1. Clean the crankshaft with solvent and dry it with
8. Remove the crankshaft and rear main oil seal.
compressed air.
Remove and discard rear main oil seal. See Fig-
ure 67. 2. Inspect the crankshaft for cracks, wear, and dam-
age.

3. Inspect bearings for craters, pockets, excessive

scoring, and dirt or debris imbedded into the
bearing material. Replace as needed. Replace
the upper and lower halves as a set.

4. Inspect the bearings for improper seating indi-

cated by bright, polished sections of the bearing.
Replace as needed. Replace the upper and lower
halves as a set.

5. Use a micrometer to measure the journals for the

bearings of the crankshaft. See Figure 68. Take
the measurement at different positions to see if
the surface of the bearing is round. The correct
sizes are given in Engine Specifications.

6. If the crankshaft journals must be repaired, they

can be ground to a smaller (undersize) than the
original size. See the Parts Manual for avail-
1. CRANKSHAFT able bearing sizes.
2. REAR MAIN OIL SEAL

Figure 67. Crankshaft Removal

36
600 SRM 1121 Crankshaft and Main Bearings

1. MAIN BEARING JOURNAL

2. CONNECTING ROD BEARING JOURNAL
3. CENTER BEARING
4. CRANKSHAFT COLOR CODE
5. BEARING COLOR CODE
6. BEARING IDENTIFICATION
Figure 68. Crankshaft Journal Measurement
Figure 69. Crankshaft and Bearing
Bearing Selection Identification
NOTE: The dimensions of a new crankshaft main
bearing journal, or one that was not subjected to
recondition procedures, can be identified by means
of the crankshaft color code.

The shell selection is performed by matching the

block main bearing diameter, identified by digits 0
and 1, and the crankshaft color code. See Figure 69.

At one end of the main bearing the color code (5)

and standard or oversize [0.25 to 0.50 mm (0.0098
to 0.0197 in.)] identification (6) is located. The iden-
tification code (365N - 366N) is located at the other
end of the bearing.

The diameter of the block main bearings is identified

by means of digits 0 and 1. See Figure 70. The diam-
eter identification numbers engraved on the engine
Figure 70. Engine Block Main Bearing
block main bearing direction are 01001.
Identification

37
Crankshaft and Main Bearings 600 SRM 1121

The standard crankshaft has a brown color code.
For a main bearing having an identification number
0 on the engine block, and a crankshaft with a brown
color code, you should install to the engine block main
bearing (with an identification number 0) a brown
color upper bearing half, and to the main bearing cap
a brown color lower bearing half.
For a main bearing having an identification number
1 on the engine block, and a crankshaft with a brown
color code, you should install to the engine block main
bearing (with an identification number 0) a green
color upper bearing half, and to the main bearing cap
a brown color lower bearing half.
For a main bearing having an identification number
0 on the engine block, and a crankshaft with a green
color code, you should install to the engine block main
bearing (with an identification number 0) a brown
color upper bearing half, and to the main bearing cap
a green color lower bearing half.
For a main bearing having an identification number
1 on the engine block, and a crankshaft with a green
color code, you should install to the engine block main
bearing (with an identification number 0) a green
color upper bearing half, and to the main bearing cap
a green color lower bearing half.
2. Install all the main bearings and caps. Initially
tighten the capscrews to 50 N•m (37 lbf ft). Sec-
ond, tighten the capscrews an additional 45 de-
grees. Finally, tighten the capscrews an addi-
tional 15 degrees.
3. Check the rear main bearing first. Remove the
cap for the rear main bearing. See Figure 66. 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 71. Do not rotate the crankshaft when the
Plastigage® is between the main bearing and its
journal.
5. Install the main bearing and main bearing
cap. Initially tighten the capscrews to 50 N•m
(37 lbf ft). Second, tighten the capscrews an
additional 45 degrees. Finally, tighten the cap-
screws an additional 15 degrees. The capscrews
must be tightened to their final torque or there
will be an error in the measurement.

Example: For a brown color crankshaft (standard

size) and a block having an identification number
01001 on the main bearings, use:
• For the bearing having identification 0, a brown
upper bearing half and a brown lower bearing half.
• For the bearing having identification 1, a green up-
per bearing half and a brown lower bearing half.

See the Parts Manual for available bearing sizes.

Main Bearings and Journal Clearance,

Check
NOTE: Crankshaft main bearings are a precision-in-
sert type. Main bearing caps are machined with
the engine block for proper clearance and cannot
be shimmed or filed for bearing fit. If crankshaft Figure 71. Bearing Journal Plastigage®
bearing clearances are not within specifications, new Placement
bearings and/or engine block and cap repair may be
required.

1. Place the upper bearing halves in position in the

cylinder block.

38
600 SRM 1121
6. Remove the main bearing cap. The Plastigage®
will be compressed and wider and it 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 millimeters or
thousandths of an inch. See Figure 72.
Figure 72. Plastigage® Measurement
7. Refer to Engine Specifications for clearances. If
the clearance is greater than the specifications,
select a new undersize bearing set and install it.
Measure the clearance again. If the clearance
cannot 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. Check the crankshaft end clearance. Install
a dial indicator so that the probe touches the
crankshaft end. See Figure 73. Using a flat blade
screwdriver, push forward and backward and
read the dial gauge. The correct end play clear-
ance is 0.050 to 0.152 mm (0.002 to 0.006 in.). If
clearance is greater than specification, replace
main bearings or crankshaft.
Crankshaft and Main Bearings
Figure 73. Crankshaft End Clearance
Measurement
Install
1. If removed, install the reluctor wheel. See
Crankshaft Reluctor Wheel, Remove and Install.
2. Lubricate new main bearing halves with engine
oil and install them in the bearing housing of the
engine block.
3. Carefully install the crankshaft in the engine
block. See Figure 61.
4. Lubricate the lower halves of the main bear-
ings and install them in their caps. Fill the
side grooves of the rear main bearing cap with
sealant. See Figure 74. Install each main bear-
ing cap in its position on the engine block. Make
sure each main bearing cap is installed in its
original position. If a main bearing cap is not
installed correctly, there can be an alignment
problem, which can cause rapid wear and dam-
age to the engine.
39
Crankshaft and Main Bearings
1. SIDE GROOVE
Figure 74. Rear Main Bearing Cap Side
Grooves
5. Install the capscrew for the main bearing caps
and tighten the capscrews handtight. Use a soft
hammer or plastic mallet to hit the crankshaft
lightly and move it forward against the rear main
bearing. Then, use the hammer to hit the crank-
shaft lightly and move it backward against the
rear main bearing. This procedure is to align
40
600 SRM 1121
the thrust surfaces on the rear main bearing.
Initially tighten the main bearing capscrews to
50 N•m (37 lbf ft). Second, tighten the capscrews
an additional 45 degrees. Finally, tighten the
capscrews an additional 15 degrees.
6. Check the crankshaft end clearance. See Fig-
ure 73.
7. Check the clearance between the main bearing
and its crankshaft journal. See Main Bearings
and Journal Clearance, Check.
8. Install the piston assemblies. See Piston and Pis-
ton Rod Assemblies Repair.
9. Place the bearing bracket in position on the en-
gine block. Install the three central capscrews
and hand tighten only.
10. Place the baffle plate in position on the bearing
bracket and install remaining capscrews. Ini-
tially tighten capscrews to 20 N•m (15 lbf ft).
Then tighten the capscrews an additional 45 de-
grees. This includes the three central capscrews
previously hand tightened.
11. Install the oil pump and oil pan. See Lubrication
System Repair.
12. Install the flywheel and flywheel housing. See
Flywheel and Flywheel Housing.
13. Install the engine. Refer to the section Frame
100 SRM 1120.
600 SRM 1121 Flywheel and Flywheel Housing

Flywheel and Flywheel Housing

REMOVE
1. Remove the engine. See Engine Removal and
Installation.
2. Remove capscrews for flywheel. Then remove fly-
wheel and adapter plate. See Figure 75.
3. If necessary, remove flywheel housing.
INSTALL
1. If flywheel housing was removed, install it on
engine. Tighten M10 capscrews to 38 N•m
(28 lbf ft). Tighten M12 capscrews to 66 N•m
(48.7 lbf ft). See Figure 75.
2. Install adapter plate on crankshaft. Install the
flywheel.
3. Apply Loctite® 222 or equivalent on threads of
capscrews. Then install capscrews for flywheel.
Tighten capscrews to 52 N•m (38.35 lbf ft) in
proper sequence. See Figure 75.
4. Install the engine. See Engine Removal and In-
stallation.

A. TIGHTENING SEQUENCE
1. ENGINE BLOCK 6. CAPSCREW
2. M10 CAPSCREWS 7. FLYWHEEL
3. LOCKWASHERS 8. M12 CAPSCREW
4. FLYWHEEL HOUSING 9. LOCKWASHER
5. ADAPTER PLATE

Figure 75. Flywheel Arrangement

41
Cooling System Repair 600 SRM 1121

Cooling System Repair

SERPENTINE BELT
Remove
WARNING
During engine operation, be careful not to
touch the fan, pulleys, or drive belts. Contact
with these parts can cause serious injury.
WARNING
The radiator or other parts of the cooling sys-
tem may be hot or under pressure and can
cause serious injury. Wait 30 minutes for the
radiator to cool. Do a touch test by touching
the radiator with your hand. If the radiator is
still hot to the touch, wait another 30 minutes
before attempting to check or fix any part of
the cooling system.
1. Turn the ignition switch to the OFF position.
Install
NOTE: The belt tensioner is a nonadjustable, self-
tensioning device with two positions, tension applied
and tension relieved.
NOTE: The drive tool slot will accommodate the drive
end of either a 3/8-in. ratchet or breaker bar.
1. Using a drive tool, placed in the drive tool slot
located on the self-tensioning device, move the
self-tensioning device in a downward motion to
relieve tension on the self-tensioning device. See
Figure 76.
2. Place the serpentine belt over the pulleys, and
release the self-tensioning device.
3. Remove truck from the blocks. Refer to How to
Put a Truck on Blocks in the Operating Man-
ual or to the section Periodic Maintenance
8000 SRM 1150.

2. Remove the four bolts retaining the fan assembly. 4. Replace the fan assembly.

3. Remove the fan assembly.

4. Place the truck up on blocks. Refer to How to

Put a Truck on Blocks in the Operating Man-
ual or to the section Periodic Maintenance
8000 SRM 1150.

NOTE: The belt tensioner is a nonadjustable, self-

tensioning device with two positions, tension applied
and tension relieved.

NOTE: The drive tool slot will accommodate the drive

end of either a 3/8-in. ratchet or breaker bar.

5. Using a drive tool, placed in the drive tool slot

located on the self-tensioning device, move the
self-tensioning device in a downward motion to
relieve tension on the serpentine belt. See Fig-
ure 76.

6. Remove the serpentine belt from the pulleys.

Inspect 1. CHECK TENSION HERE

2. DRIVE TOOL SLOT
Inspect the serpentine belt. If there are any cracks or 3. SELF-TENSIONING DEVICE
damage to the serpentine belt, replace the serpentine
belt. Figure 76. Serpentine Belt Check

42
600 SRM 1121
WARNING
During engine operation, be careful not to
touch the fan, pulleys, or drive belts. Contact
with these parts can cause serious injury.
5. Start the engine to make sure the serpentine belt
is operating correctly.
WATER PUMP
Remove
1. Turn the ignition switch to the OFF position.
2. Disconnect the negative battery cable at the bat-
tery.
3. Disconnect the air intake hoses from the air filter
assembly.
NOTE: The ECM assembly must be disconnected
from the air filter assembly before removing the air
filter assembly. For gasoline engines, refer to the
section Gasoline Fuel System, GM 2.4L Engine
900 SRM 1126. For LPG fuel systems, refer to the
section LPG Fuel System, GM 2.4L Engine 900
SRM 1124.
4. Remove the three bolts that attach the air filter
assembly mounting bracket to the frame and re-
move air filter assembly with mounting bracket.
WARNING
DO NOT remove the radiator cap from the ra-
diator when the engine is hot. When the radia-
tor cap is removed, pressure will release from
the coolant system. If the coolant system is hot,
the steam and boiling coolant can cause severe
burns.
WARNING
The radiator or other parts of the cooling sys-
tem may be hot or under pressure and can
cause serious injury. Wait 30 minutes for the
radiator and engine to cool before performing
maintenance to the cooling system. After 30
Cooling System Repair
minutes, do a touch test by touching the radi-
ator with your hand. If the radiator is still hot
to the touch, wait another 30 minutes before
attempting any maintenance to the cooling
system.
CAUTION
Disposal of lubricants must meet local environ-
mental regulations.
5. Remove the radiator cap.
6. Loosen the lower radiator hose and drain the
coolant from the coolant system.
7. Remove the fan shroud. Refer to the section
Cooling System 700 SRM 1123.
8. Place a piece of cardboard over the radiator sur-
face to prevent damage to the radiator.
9. Remove the four bolts retaining the fan assembly.
10. Remove the fan assembly.
11. Remove the serpentine belt. See Serpentine Belt,
Remove.
12. Remove the spacer and the pulley.
13. Disconnect the electrical connections to the alter-
nator.
14. Remove the alternator mounting bolts and re-
move the alternator.
15. Remove the alternator bracket bolts, fan hub
bracket bolts, and fan hub bracket.
16. Remove the timing belt and timing belt ten-
sioner. See Timing Belt and Timing Belt Ten-
sioner, Remove.
NOTE: Before loosening the water pump bolts, make
alignment marks on the water pump and cylinder
block to identify the correct alignment position of the
water pump. See Figure 77.
17. Remove the water pump bolts.
43
Cooling System Repair 600 SRM 1121

Figure 77. Water Pump Alignment

44
600 SRM 1121 Cooling System Repair

Legend for Figure 77

1. WATER PUMP 9. CRANKSHAFT TIMING BELT PULLEY
2. WATER PUMP TAB (11 O’CLOCK POSITION) 10. CRANKSHAFT TIMING PULLEY BOLT
3. WATER PUMP BOLT 11. CRANKSHAFT PULLEY HUB MARK
4. TENSIONER 12. OIL PUMP HOUSING TIMING MARK
5. TENSIONER BOLT 13. TIMING MARK (LOCATED ON PLASTIC TIMING
6. TENSIONER TAB (7 O’CLOCK POSITION) BELT HOUSING)
7. TIMING BELT TENSIONER POINTER 14. CAMSHAFT TIMING BELT MARK
8. USED AND NEW TIMING BELT MARKS

18. Remove the water pump O-ring. Discard O-ring. 2. Place the water pump into position and verify
See Figure 78. that the alignment marks are properly aligned.
Install the water pump bolts and tighten to 20 to
30 N•m (15 to 22 lbf ft).

3. Install the timing belt and timing belt tensioner.

See Timing Belt and Timing Belt Tensioner, In-
stall.

4. Install the timing belt front cover. See Timing

Belt Front Cover, Install.

NOTE: Before installing the crankshaft pulley and

crankshaft spacer, align these components with the
alignment marks made when disassembled.

5. Install the crankshaft spacer and crankshaft pul-

ley, ensuring that all alignment marks made dur-
ing removal are lined up properly. Tighten crank-
1. WATER PUMP BOLT shaft pulley bolts to 135 N•m (99 lbf ft).
2. WATER PUMP
3. O-RING 6. Install fan hub bracket and retaining bolts.
Figure 78. Water Pump Tighten bolts to 52 N•m (38 lbf ft).

7. Install alternator bracket and retaining bolts.

Inspect
Inspect the water pump for the following:
• Inspect the pulley for wear and damage.
• Worn or damaged gasket sealing surfaces.
• Side-to-side play in the pulley shaft.
• Leakage at the water inlet housing or rear cover
gasket areas.
• Leakage at the water pump vent hole. A stain
around the vent hole is acceptable. If leakage oc-
curs at the vent hole with the engine running and
the cooling system pressurized, replace the water
pump.
Tighten bolts to 38 N•m (28 lbf ft).
8. Install the alternator. See the section Alternator
Repair.
9. Install the fan spacer and the pulley.
10. Install the serpentine belt. See Serpentine Belt,
Install.
11. Place the fan in position on the pulley and in-
stall the four retaining bolts. Tighten the bolts
to 26 N•m (19 lbf ft).

12. Remove cardboard from the radiator surface.

Install
13. Install the fan shroud. Refer to the section Cool-
1. Install a new O-ring onto the water pump.
ing System 700 SRM 1123.
NOTE: Before installing a new water pump and tight-
ening the water pump bolts, make sure the water
pump tab is in the 11 o’clock position for proper align-
ment of the timing belt tensioner.

45
Cooling System Repair
CAUTION
Additives may damage the cooling system. Be-
fore using additives, contact your local Hyster
dealer.
14. Connect the bottom radiator hose. Fill cooling
system with coolant. Refer to the section Peri-
odic Maintenance 8000 SRM 1150 for correct
coolant amount and type.
15. Install radiator cap on radiator.
NOTE: The ECM assembly must be connected to the
air filter assembly after installing the air filter as-
sembly. For gasoline engines, refer to the section
Gasoline Fuel System, GM 2.4L Engine 900 SRM
1126. For LPG fuel systems, refer to the section LPG
Fuel System, GM 2.4L Engine 900 SRM 1124.
16. Place the air filter assembly with mounting
bracket in position on the frame. Install bolts
and tighten to 20 N•m (15 lbf ft).
17. Connect the air intake hoses to the air filter as-
sembly.
18. Connect the negative battery cable.
WARNING
During engine operation, be careful not to
touch the fan, pulleys, or drive belts. Contact
with these parts can cause serious injury.
WARNING
The radiator or other parts of the cooling sys-
tem may be hot or under pressure and can
cause serious injury.
19. Start engine and check cooling system for leaks.
20. Bleed air from the cooling system by opening the
bleed screw located on the left side behind the
alternator. When the air has been bled from the
system, close the bleed screw.
WARNING
DO NOT remove the radiator cap from the ra-
diator when the engine is hot. When the radi-
ator cap is removed, the pressure is released
from the system. If the system is hot, the steam
and boiling coolant can cause burns. DO NOT
remove the cover for the radiator when the en-
gine is running.
46
600 SRM 1121
WARNING
The radiator or other parts of the cooling sys-
tem may be hot or under pressure and can
cause serious injury. Wait 30 minutes for the
radiator to cool. Do a touch test by touching
the radiator with your hand. If the radiator is
still hot to the touch, wait another 30 minutes
before attempting to check or fix any part of
the cooling system.
CAUTION
Additives may damage the cooling system. Be-
fore using additives, contact your local Hyster
dealer.
21. Stop engine. If coolant is hot, give engine time to
cool. Check coolant level and fill as required be-
tween the ADD and FULL marks on the coolant
reservoir.
THERMOSTAT
Remove
WARNING
The radiator or other parts of the cooling sys-
tem may be hot or under pressure and can
cause serious injury. Wait 30 minutes for the
radiator to cool. Do a touch test by touching
the radiator with your hand. If the radiator is
still hot to the touch, wait another 30 minutes
before attempting to check or fix any part of
the cooling system.
CAUTION
DO NOT operate the engine without a ther-
mostat. The engine and cooling system can be
damaged.
CAUTION
Disposal of lubricants and fluids must meet lo-
cal environmental regulations.
1. Loosen the lower radiator hose and drain the
coolant from the coolant system.
2. Remove the capscrew that holds the oxygen sen-
sor wire clamp to thermostat cover. See Fig-
ure 79.
600 SRM 1121 Cooling System Repair

3. Remove the capscrews retaining the thermostat 4. Remove the thermostat and O-ring. See Fig-
cover to the thermostat housing. ure 79.

Check

WARNING
The radiator or other parts of the cooling sys-
tem may be hot or under pressure and can
cause serious injury.

CAUTION
DO NOT operate the engine without a ther-
mostat. The engine and cooling system can be
damaged.

1. Inspect the thermostat and O-ring that connects

to the thermostat housing. If the O-ring is dam-
aged, replace the O-ring.

2. Inspect the two inner discs on the thermostat

that seal the water flow. Verify that they are
clean and in good condition. If damaged, replace
thermostat.

NOTE: While performing the test of the thermostat

in Step 3, make sure that the thermostat and ther-
mometer do not touch the sides or the bottom of the
container used for heating the water.

3. Hold thermostat with a wire and place in the

water. Slowly heat the water to 82°C (180°F).
At this temperature, the thermostat should be
starting to open. Continue to heat the water to
97°C (207°F). At this temperature, the thermo-
stat should be fully open. If not, replace the ther-
mostat.

4. Cool the water to 70°C (158°F). The thermostat

must close completely. If it does not, replace the
thermostat.

Install
1. Install a new O-ring and install the thermostat
into the thermostat housing.
1. CAPSCREW
2. OXYGEN SENSOR WIRE CLAMP
3. THERMOSTAT COVER 2. Install the thermostat cover and tighten the cap-
4. THERMOSTAT screws to 20 N•m (15 lbf ft).
5. THERMOSTAT AND THERMOSTAT COVER
(ONE-PIECE) 3. Connect the capscrew that holds the oxygen sen-
6. O-RING sor wire clamp to thermostat cover.
7. THERMOSTAT HOUSING

Figure 79. Thermostat Replacement

47
Cooling System Repair
CAUTION
Additives may damage the cooling system. Be-
fore using additives, contact your local Hyster
dealer.
4. Connect the bottom radiator hose. Fill cooling
system with coolant. Refer to the section Peri-
odic Maintenance 8000 SRM 1150 for correct
coolant amount and type.
5. Install radiator cap on radiator.
WARNING
During engine operation, be careful not to
touch the fan, pulleys, or drive belts. Contact
with these parts can cause serious injury.
WARNING
The radiator or other parts of the cooling sys-
tem may be hot or under pressure and can
cause serious injury.
6. Start the engine and check cooling system for
leaks.
7. Bleed air from the cooling system by opening the
bleed screw located on the left side behind the
alternator. When the air has been bled from the
system, close the bleed screw.
WARNING
DO NOT remove the radiator cap from the ra-
diator when the engine is hot. When the radi-
ator cap is removed, the pressure is released
from the system. If the system is hot, the steam
and boiling coolant can cause burns. DO NOT
remove the cover for the radiator when the en-
gine is running.
WARNING
The radiator or other parts of the cooling sys-
tem may be hot or under pressure and can
cause serious injury. Wait 30 minutes for the
radiator to cool. Do a touch test by touching
the radiator with your hand. If the radiator is
still hot to the touch, wait another 30 minutes
before attempting to check or fix any part of
the cooling system.
48
600 SRM 1121
CAUTION
Additives may damage the cooling system. Be-
fore using additives, contact your local Hyster
dealer.
8. Stop engine. If coolant is hot, give engine time to
cool. Check coolant level and fill as required be-
tween the ADD and FULL marks on the coolant
reservoir.
THERMOSTAT HOUSING
Remove
1. Disconnect the negative battery cable at the bat-
tery.
2. Loosen the lower radiator hose and drain the
coolant.
3. Disconnect the electrical connector from the en-
gine coolant temperature sensor.
4. Disconnect the upper radiator hose to the ther-
mostat cover.
5. Remove the timing belt rear cover. See Timing
Belt Rear Cover, Remove.
6. Disconnect the coolant hoses, below the intake
manifold, from the thermostat housing to the
coolant manifold.
7. Remove the bolts retaining the thermostat hous-
ing to the cylinder head. See Figure 80.
8. Remove the thermostat housing.
9. Remove and discard the O-ring from the thermo-
stat housing.
Clean and Inspect
Remove all debris and residue from the thermostat
housing. Inspect the thermostat housing for cracks
and other damage. Inspect the coolant hoses for wear
and damage. Repair or replace as needed.
Install
1. Install a new O-ring in the thermostat housing.
2. Place the thermostat housing in position.
600 SRM 1121
1. BOLT
2. ENGINE COOLANT TEMPERATURE SENSOR
(ECT)
3. THERMOSTAT HOUSING
Figure 80. Thermostat Housing
3. Install the bolts to retain the thermostat housing
and tighten to 11 N•m (97 lbf in).
4. Connect the coolant hoses, below the intake man-
ifold, to the thermostat housing. Tighten the
clamps to 4 to 5 N•m (35 to 44 lbf in).
5. Install the timing belt rear cover. See Timing
Belt Rear Cover, Install.
6. Install the timing belt and timing belt tensioner.
See Timing Belt and Timing Belt Tensioner, In-
stall.
7. Install timing belt front cover. See Timing Belt
Front Cover, Install.
8. Install fan hub bracket and retaining bolts.
Tighten bolts to 52 N•m (38 lbf ft).
9. Install alternator bracket and retaining bolts.
Tighten bolts to 38 N•m (28 lbf ft).
Cooling System Repair
10. Install the alternator. See the section Alternator
Repair.
11. Install the fan spacer and pulley.
12. Install the serpentine belt. See Serpentine Belt,
Install.
13. Connect the upper radiator hose to the thermo-
stat housing. Tighten the clamp to 4 to 5 N•m
(35 to 44 lbf in).
14. Connect the electrical connection to the engine
coolant temperature sensor.
15. Connect the negative battery cable to the battery.
CAUTION
Additives may damage the cooling system. Be-
fore using additives, contact your local Hyster
dealer.
16. Connect the lower radiator hose. Fill cooling
system with coolant. Refer to the section Peri-
odic Maintenance 8000 SRM 1150 for correct
coolant amount and type.
17. Install radiator cap on radiator.
WARNING
During engine operation, be careful not to
touch the fan, pulleys, or drive belts. Contact
with these parts can cause serious injury.
WARNING
The radiator or other parts of the cooling sys-
tem may be hot or under pressure and can
cause serious injury.
18. Start engine and check cooling system for leaks.
19. Bleed air from the cooling system by opening the
bleed screw located on the left side behind the
alternator. When the air has been bled from the
system, close the bleed screw.
49
Sensors and Switches
WARNING
DO NOT remove the radiator cap from the ra-
diator when the engine is hot. When the radi-
ator cap is removed, the pressure is released
from the system. If the system is hot, the steam
and boiling coolant can cause burns. DO NOT
remove the cover for the radiator when the en-
gine is running.
WARNING
The radiator or other parts of the cooling sys-
tem may be hot or under pressure and can
cause serious injury. Wait 30 minutes for the
radiator to cool. Do a touch test by touching
Sensors and Switches
CRANKSHAFT POSITION (CKP) SENSOR
Remove
1. Raise the hood and disconnect the battery.
2. Disconnect the crankshaft sensor electrical har-
ness. See Figure 81.
3. Remove the capscrew retaining the crankshaft
sensor.
4. Remove the crankshaft sensor.
1. CRANKSHAFT SENSOR
2. ELECTRICAL HARNESS
Figure 81. Crankshaft Sensor, GM 2.4L Engine
50
600 SRM 1121
the radiator with your hand. If the radiator is
still hot to the touch, wait another 30 minutes
before attempting to check or fix any part of
the cooling system.
CAUTION
Additives may damage the cooling system. Be-
fore using additives, contact your local Hyster
dealer.
20. Stop engine. If coolant is hot, give engine time to
cool. Check coolant level and fill as required be-
tween the ADD and FULL marks on the coolant
reservoir.
Install
1. Install new crankshaft sensor into the engine
block.
2. Install the capscrew to secure the crankshaft sen-
sor. Tighten capscrew to 8 N•m (71 lbf in).
3. Connect the crankshaft sensor electrical harness.
See Figure 81.
4. Connect the battery and lower the hood.
CAMSHAFT POSITION (CMP) SENSOR
Remove for Lift Trucks Built Before
January, 2010
Assembly
1. Open the hood. Disconnect the negative battery
cable.
2. Disconnect the CMP sensor electrical connector.
See Figure 82.
3. Remove harness clamp from CMP sensor support
plate.
4. Remove retaining screws, CMP sensor assembly,
and O-ring from engine block. See Figure 83.
600 SRM 1121 Sensors and Switches

4. Remove screw, lockwasher, and CMP sensor from

CMP sensor plate. Remove and discard O-ring
from CMP sensor. See Figure 84.

1. CMP SENSOR
2. WIRE HARNESS CLAMP
3. ELECTRICAL CONNECTOR

Figure 82. CMP Sensor Electrical Connector

for Lift Trucks Built Before January, 2010

1. SCREW 4. O-RING
2. LOCKWASHER 5. CMP SENSOR
3. CMP SENSOR PLATE

Figure 84. CMP Sensor for Lift Trucks Built

Before January, 2010

Install for Lift Trucks Built Before January,

2010
Assembly

1. Lubricate new O-ring with clean engine oil. In-

stall O-ring into groove in CMP sensor plate. See
Figure 83.
1. RETAINING SCREW
2. CMP SENSOR ASSEMBLY 2. Install CMP sensor assembly onto engine block.
3. O-RING See Figure 83.
Figure 83. CMP Sensor Assembly for Lift NOTE: Before installing lockwasher and screw, verify
Trucks Built Before January, 2010 CMP sensor is fully seated.
Sensor Only 3. Install lockwasher and screw onto CMP sensor.
See Figure 83. Tighten to 10 N•m (88.5 lbf in).
1. Open the hood. Disconnect the negative battery
cable. 4. Connect the electrical connectors. Verify that the
connectors click/lock into place. See Figure 82.
2. Disconnect the CMP sensor electrical connector.
See Figure 82. 5. Install harness clamp onto CMP sensor plate.
See Figure 82.
3. Remove harness clamp from CMP sensor support
plate. 6. Connect the negative battery cable. Close the
hood.

51
Sensors and Switches
Sensor Only
1. Lubricate new O-ring with clean engine oil. In-
stall O-ring onto sensor. See Figure 84.
2. Install CMP sensor, lockwasher, and screws onto
CMP sensor plate. See Figure 84. Tighten screw
to 6 N•m (53 lbf in).
3. Connect the electrical connectors. Verify that the
connectors click/lock into place. See Figure 82.
4. Install harness clamp onto CMP sensor plate.
See Figure 82.
5. Connect the negative battery cable. Close the
hood.
Remove for Lift Trucks Built After January,
2010
1. Open the hood. Disconnect the negative battery
cable.
2. Disconnect the CMP sensor electrical connector.
See Figure 85.
1. CMP SENSOR ELECTRICAL CONNECTOR
2. SCREW
Figure 85. CMP Sensor Assembly for Lift Trucks Built After January, 2010
52
600 SRM 1121
3. Remove screw and CMP sensor assembly from
engine. See Figure 85.
Install for Lift Trucks Built After January,
2010
1. Install CMP sensor assembly and screw onto en-
gine. See Figure 85.
2. Connect CMP sensor electrical connector. See
Figure 85.
3. Connect negative battery cable. Close the hood.
OIL PRESSURE SENSOR
Remove
1. Raise hood and disconnect the battery.
2. Disconnect the electrical connector for the oil
pressure sensor. See Figure 86.
3. Remove the oil pressure sensor.
3. CMP SENSOR ASSEMBLY
600 SRM 1121 Ignition System

Install
1. Install new oil pressure sensor onto engine.
Tighten sensor to 20 N•m (177 lbf in).

2. Connect the electrical connector for the oil pres-

sure sensor. See Figure 86.

3. Connect battery and lower the hood.

1. ELECTRICAL CONNECTOR
2. OIL PRESSURE SENSOR
3. OIL FILTER
4. ADAPTER, O-RING, AND RETAINING RING

Figure 86. Oil Pressure Sensor, GM 2.4L Engine

Ignition System
SPARK PLUG WIRE INSPECTION
Spark plug wire integrity is vital for proper engine
operation. A thorough inspection will be necessary to
accurately identify conditions that may affect engine
operation. Inspect for the following conditions:
1. Correct routing of the spark plug wires. Incorrect
routing may cause cross-firing.
2. Any signs of cracks or splits in the wires.
3. Inspect each boot for the following conditions:
• Tearing
• Piercing
• Arcing
• Carbon tracking
• Corroded terminal
If corrosion, carbon tracking, or arcing is indicated
on a spark plug wire boot or on a terminal, replace
the wire and the component connected to the wire.
SPARK PLUG WIRE REPLACEMENT
Remove
1. Disconnect the spark plug wire at each spark
plug. See Figure 87.
a. Twist the boots 1/2 turn before removing the
boots.
b. Pull only on the boot or use a tool designed
for this purpose in order to remove the wire
from each spark plug.

53
Ignition System
1. ELECTRICAL CONNECTOR
2. COIL PACK
3. NO. 1 CYLINDER SPARK PLUG WIRE
4. NO. 2 CYLINDER SPARK PLUG WIRE
5. NO. 3 CYLINDER SPARK PLUG WIRE
6. NO. 4 CYLINDER SPARK PLUG WIRE
Figure 87. Spark Plug Wire Removal/
Installation
2. Disconnect the spark plug wire from the coil
pack.
a. Twist each spark plug boot 1/2 turn.
b. Pull only on the boot or use a tool designed
for this purpose in order to remove the wires
from the coil pack.
Install
NOTE: If the boot-to-wire movement has occurred,
the boot will give a false visual impression of being
fully seated. Ensure that the boots have been prop-
erly assembled by pushing sideways on the installed
boots. Failure to properly seat the terminal onto the
spark plug will lead to wire core erosion and result in
an engine misfire or crossfire condition and possible
internal damage to the engine.
1. Install the spark plug wires at the coil pack. You
should feel the terminal snap onto the coil.
2. Install the spark plug wire to each spark plug.
You should feel the terminal snap onto the spark
plug. See Figure 87.
3. Inspect the wires for proper installation:
54
600 SRM 1121
a. Push sideways on each boot in order to in-
spect the seating.
b. Reinstall any loose boot. You should feel the
terminal snap onto the spark plug or coil
when installing the spark plug wire. Inspect
and replace component that is damaged.
c. Wire routings must be kept intact during ser-
vice and followed exactly when wires have
been disconnected or when replacement of
the wires is necessary. Failure to route the
wires properly can lead to radio ignition noise
and cross firing of the plugs or shorting of the
leads to the ground.
d. Any time the spark plug wires or boots are
installed on the spark plugs, new dielectric
grease needs to be applied inside the boot.
SPARK PLUG REPLACEMENT
Remove
1. Remove the spark plug wires. Refer to Spark
Plug Wire Replacement.
2. Loosen each spark plug 1 or 2 turns.
3. Brush or air blast away any dirt from around the
spark plugs.
4. Remove the spark plugs 1 at a time. Place each
plug in a tray marked with the corresponding
cylinder number. See Figure 88.
5. Inspect each spark plug. See Spark Plug Inspec-
tion.
Install
1. Properly position each spark plug washer.
2. Inspect each spark plug gap. Adjust each plug as
needed.
Specification
Spark plug gap: 0.8 to 0.9 mm (0.031 to
0.035 in.)
3. Hand start the spark plugs in the corresponding
cylinders. See Figure 88.
600 SRM 1121 Ignition System

Inspect
1. Inspect the terminal post for damage. See Fig-
ure 89.

a. Inspect for a bent or broken terminal post.

1. NO. 1 CYLINDER SPARK PLUG

2. NO. 2 CYLINDER SPARK PLUG
3. NO. 3 CYLINDER SPARK PLUG
4. NO. 4 CYLINDER SPARK PLUG

Figure 88. Spark Plug Removal/Installation

CAUTION
Only use a spark plug socket or wrench to
tighten the spark plugs. Do not force the spark
plug into the cylinder head. Any misalignment
can damage the aluminum threads in the cylin-
der head and may require the replacement of
the cylinder head.
4. Tighten the spark plugs to 20 N•m (15 lbf ft).
SPARK PLUG INSPECTION
Usage
1. Ensure that the correct spark plug is installed.
An incorrect spark plug causes driveability con-
ditions. The correct spark plug type is NGK
BPR5EY.
2. Ensure that the spark plug has the correct heat
range. An incorrect heat range causes the follow-
ing conditions:
• Spark plug fouling - Colder plug
• Pre-ignition causing spark plug and/or engine
damage - Hotter plug
1. TERMINAL POST 3. ELECTRODE
2. INSULATOR 4. ELECTRODE
Figure 89. Spark Plug
b. Test for a loose terminal post by twisting and
pulling the post. The terminal post should
NOT move.
2. Inspect the insulator for flashover or carbon
tracking soot. See Figure 90. This is caused
by the electrical charge traveling across the in-
sulator between the terminal post and ground.
Inspect for the following conditions:
a. Inspect the spark plug boot for damage.
b. Inspect the spark plug recess area of the
cylinder head for moisture, such as oil,
coolant, or water. A spark plug boot that is
saturated causes arcing to ground.

55
Ignition System 600 SRM 1121

1. TERMINAL POST 3. ELECTRODE 1. TERMINAL POST 3. ELECTRODE

2. INSULATOR 4. ELECTRODE 2. INSULATOR 4. ELECTRODE

Figure 90. Spark Plug With Flashover or Figure 91. Spark Plug Arcing Through a Crack
Carbon Tracking

3. Inspect the insulator for cracks. All or part of

the electrical charge may arc through the crack
instead of the electrodes. See Figure 91.

4. Inspect for evidence of improper arcing. See Fig-

ure 92.

a. Measure the gap between the center elec-

trode (4) and the side electrode (3) terminals.
An excessively wide electrode gap can pre-
vent correct spark plug operation. Refer to
Engine Specifications for the proper gap. Ad-
just as necessary.

b. Inspect for the correct spark plug torque.

The correct torque is 20 N•m (15 lbf ft).
Insufficient torque can prevent correct spark
plug operation. An over-torqued spark plug
causes the insulator to crack.
1. TERMINAL POST 3. ELECTRODE
c. Inspect for signs of tracking that occurred 2. INSULATOR 4. ELECTRODE
near the insulator tip instead of the center
electrode (4). Figure 92. Spark Plug Arcing Improperly

d. Inspect for a broken or worn side electrode

(3).

56
600 SRM 1121 Ignition System

e. Inspect for a broken, worn, or loose center COIL PACK

electrode (4) by shaking the spark plug.
Remove
(1) A rattling sound indicates internal
damage. 1. Tag and disconnect the spark plug wires.

(2) A loose center electrode (4) reduces the 2. Disconnect the electrical connection to the coil
spark intensity. pack.

f. Inspect for bridged electrodes (3, 4). Deposits 3. Remove the capscrews retaining the coil pack to
on the electrodes (3, 4) reduce or eliminate the mounting bracket and remove coil pack. See
the gap. Figure 93.

g. Inspect for worn or missing platinum pads on
the electrodes (3, 4), if equipped.
h. Inspect for excessive fouling.
5. Inspect the spark plug recess area of the cylinder
head for debris. Dirty or damaged threads can
cause the spark plug not to seat correctly during
installation.
Visual Inspection
1. Normal operation - Brown to grayish-tan with
small amounts of white powdery deposits are
normal combustion by-products from fuels with
additives.
4. Remove the nuts retaining the mounting bracket
to the camshaft carrier assembly and remove
mounting bracket.
Install
1. Place the coil pack mounting bracket in position
on the camshaft carrier assembly. Install the two
nuts to retain the mounting bracket. Tighten
nuts to 38 N•m (28 lbf ft).
2. Place the coil pack in position on the mounting
bracket and install capscrews. Tighten cap-
screws to 10 N•m (88.5 lbf in).
3. Connect the electrical connector to the coil pack.

2. Carbon fouled - Dry, fluffy, black carbon or soot 4. Connect the spark plug wires.
caused by the following conditions:
• Rich fuel mixtures.
– Leaking fuel injectors
– Excessive fuel pressure
– Restricted air filter element
– Incorrect combustion
• Reduced ignition system voltage output.
– Weak coil pack
– Worn ignition wires
– Incorrect spark plug gap
• Excessive idling or slow speeds under light
loads can keep spark plug temperatures so low
that normal combustion deposits may not burn
off.

3. Deposit fouling - Oil, coolant, or additives that

include substances such as silicone, very white 1. SPARK PLUG WIRES
coating, reduce the spark intensity. Most pow- 2. COIL PACK
3. CAPSCREW
dery deposits will not effect spark intensity un- 4. MOUNTING BRACKET
less they form into a glazing over the electrode. 5. NUTS

Figure 93. Coil Pack Removal/Installation

57
Alternator Repair 600 SRM 1121

Alternator Repair
ALTERNATOR 4. Tighten lower bolt to 20 N•m (15 lbf ft).

Remove 5. Tighten the bolts retaining the alternator mount-

ing bracket to the cylinder block to 38 N•m
(28 lbf ft).
WARNING
Always disconnect the battery ground cable be- 6. Connect electrical connectors to alternator.
fore making repairs to prevent possible dam-
age and injury. Install a tag on the battery ter- 7. Install the serpentine belt. See Serpentine Belt,
minal so that no one connects the cable on the Install.
terminal.
8. Connect battery cable at negative terminal.
1. Disconnect battery cable at negative terminal.
Install a tag on battery terminal to warn against ALTERNATOR FUSE, REPLACE
connecting cable.
1. Remove the cover from the fuse holder. See Fig-
2. Remove the serpentine belt. See Serpentine Belt, ure 95.
Remove.
2. Remove fuse from the fuse holder and discard the
3. Put labels on electrical connectors and wires fuse.
prior to disconnecting to aid in correct installa-
3. Install new fuse into fuse holder.
tion.
4. Install cover onto fuse holder.
4. Disconnect electrical connectors and wires from
alternator.

5. Remove the lower bolt and spacer from the alter-

nator. See Figure 94.

6. Remove the upper bolt from the alternator and

remove alternator.

Install

CAUTION
The bolts retaining the alternator mounting
bracket to the cylinder block must be loosened
to achieve proper alignment when the alterna-
tor is installed or damage may occur.

1. Loosen the bolts retaining the alternator mount-

ing bracket to the cylinder block.

2. Place alternator in position on the mounting

bracket and install the lower bolt and spacer
finger tight only. 1. UPPER BOLT 3. LOWER BOLT
2. ALTERNATOR 4. SPACER
3. Attach the upper alternator boss to the strap on
the fan mount bracket and tighten the upper bolt Figure 94. Alternator
to 20 N•m (15 lbf ft).

58
600 SRM 1121 Starter Repair

Legend for Figure 95

1. FUSE HOLDER
2. FUSE
3. COVER

Figure 95. Alternator Fuse

Starter Repair
REMOVE
WARNING
Always disconnect the cables at the battery be-
fore you make repairs to the engine. Discon-
nect the cable at the negative terminal first. In-
stall a tag on the battery terminals so that no
one connects the cables on the terminals.
1. Disconnect battery negative cable at negative
terminal.
2. Disconnect the battery positive cable at positive
terminal.
3. Put labels on wires and cables prior to discon-
necting to aid in correct installation.
4. Disconnect wires and cables from starter.
5. Hold starter so it won’t fall. Remove capscrews
that fasten the starter to the flywheel housing.
Remove starter from flywheel housing.
INSTALL
1. Place starter in position in flywheel housing. In-
stall capscrews to fasten the starter to the fly-
wheel housing. Tighten capscrews to 38 N•m
(28 lbf ft).
2. Connect wires and cables as labeled in removal.
3. Connect the battery positive cable at positive ter-
minal.
4. Connect battery negative cable at negative ter-
minal.

59
Engine Specifications 600 SRM 1121

Engine Specifications
ENGINE DATA
Number of Cylinders 4
Displacement 2405 cm 3 (146.46 in. 3 )
Bore 87.5 mm (3.445 in.)
Stroke 100 mm (3.937 in.)
Compression Ratio 9.53:1
Firing Order 1-3-4-2
Idle Speed 800 ±25
Governor Speed (No Load) 2700 ±25
Converter Stall Speed - LPG
New Engine 1950 ±100 rpm
Broken-in Engine 2053 ±100 rpm
Converter Stall Speed - Gasoline
New Engine 1914 ±100 rpm
Broken-in Engine 2015 ±100 rpm
Spark Plug Gap 0.8 to 0.9 mm (0.031 to 0.035 in.)

CYLINDER BORE
Bore Diameter
Bore Out-of-Round Service Limit
Bore Taper Thrust Side Service Limit
Bore Taper Relief Side Service Limit
87.5 mm (3.44 in.)
0.127 mm (0.005 in.) Maximum
0.076 mm (0.003 in.) Maximum
0.076 mm (0.003 in.) Maximum

PISTON
Piston-to-Bore Clearance
Production 0.010 to 0.030 mm (0.00040 to 0.0012 in.)
Service Limit 0.060 mm (0.0024 in.)

PISTON RINGS
Piston Compression Ring Groove
Clearance Production Top 0.030 to 0.050 mm (0.0012 to 0.0020 in.)
Clearance Production 2nd 0.020 to 0.040 mm (0.0008 to 0.0016 in.)
Piston Compression Ring Gap Top
*Measured in Cylinder Bore

60
600 SRM 1121 Engine Specifications

Production* 0.25 to 0.45 mm (0.010 to 0.018 in.)

Service Limit* 0.55 mm (0.022 in.) Maximum
Piston Compression Ring Gap 2nd
Production* 0.30 to 0.50 mm (0.012 to 0.020 in.)
Service Limit* 0.60 mm (0.024 in.) Maximum
Piston Oil Ring Gap
Production* 0.40 to 0.56 mm (0.016 to 0.022 in.)
Service Limit* 0.64 mm (0.025 in.) Maximum
*Measured in Cylinder Bore

WRIST PIN
Diameter 20.995 to 21.00 mm (0.8266 to 0.8268 in.)
Clearance in Piston
Production 0.011 to 0.014 mm (0.0004 to 0.0006 in.)
Service Limit 0.023 mm (0.0009 in.) Maximum
Fit in Piston Rod (Interference) 0.024 to 0.041 mm (0.00095 to 0.0016 in.)
Interference

CRANKSHAFT
Crankshaft Maximum Warping
Crankshaft Main Journal Diameter (All)
Crankshaft Main Journal Taper
Crankshaft Main Journal Out-of-Round
Crankshaft Main Bearing Clearance
Production
Service Limit
Crankshaft Rod Journal Diameter
Crankshaft Rod Journal Taper
Crankshaft End Play - Production
0.03 mm (0.00118 in.)
57.981 to 57.988 mm (2.2827 to 2.2830 in.)
0.005 mm (0.00020 in.) Maximum
0.004 mm (0.00016 in.) Maximum
0.015 to 0.041 mm (0.0006 to 0.0016 in.)
0.018 to 0.046 mm (0.0007 to 0.0018 in.)
48.971 to 48.987 mm (1.9280 to 1.9286 in.)
0.020 mm (0.0008 in.)
0.050 to 0.152 mm (0.002 to 0.006 in.)

PISTON ROD
Rod Bearing Clearance
Production 0.019 to 0.063 mm (0.0007 to 0.0025 in.)
Service 0.020 to 0.074 mm (0.0008 to 0.0029 in.)
Rod Side Clearance 0.070 to 0.242 mm (0.0028 to 0.010 in.)

61
Engine Specifications
CAMSHAFT AND CAMSHAFT CARRIER
Camshaft Carrier Bores
Number 1 Bore
Number 2 Bore
Number 3 Bore
Number 4 Bore
Number 5 Bore
Camshaft Journal Diameter
Number 1 Journal
Number 2 Journal
Number 3 Journal
Number 4 Journal
Number 5 Journal
Maximum Camshaft Warpage
Camshaft End Play
Lobe Lift Intake
Lobe Lift Exhaust
VALVE SYSTEM
Valve Lash Intake
Valve Lash Exhaust
Face Angle
Seat Angle
Seat Runout
Seat Width Intake
Seat Width Exhaust
Stem Clearance Intake
Production
Service Limit
Stem Clearance Exhaust
Production
Service Limit
Valve Spring Free Length
Valve Spring Load - Closed
Valve Spring Load - Open
62
600 SRM 1121
42.500 to 42.525 mm (1.6732 to 1.6742 in.)
42.750 to 42.775 mm (1.6831 to 1.6841 in.)
43.000 to 43.025 mm (1.6929 to 1.6939 in.)
43.250 to 43.275 mm (1.7028 to 1.7037 in.)
43.500 to 43.525 mm (1.7126 to 1.7136 in.)
42.455 to 42.470 mm (1.6715 to 1.6720 in.)
42.705 to 42.720 mm (1.6813 to 1.6819 in.)
42.955 to 42.970 mm (1.6911 to 1.6917 in.)
43.205 to 43.220 mm (1.7010 to 1.7016 in.)
43.455 to 43.470 mm (1.7108 to 1.7114 in.)
0.04 mm (0.0016 in.)
0.79 to 0.91 mm (0.031 to 0.036 in.)
6.67 mm (0.263 in.)
6.67 mm (0.263 in.)
Not applicable - engine utilizes hydraulic lash
adjusters to maintain zero lash.
46 degrees from vertical (stem centerline)
45 degrees
0.05 mm (0.002 in.) Maximum
1.3 to 1.4 mm (0.051 to 0.055 in.)
1.6 to 1.8 mm (0.063 to 0.070 in.)
0.018 to 0.052 mm (0.0007 to 0.0020 in.)
0.052 mm (0.0020 in.)
0.038 to 0.072 mm (0.0015 to 0.0028 in.)
0.072 mm (0.0028 in.)
Approximately 48 mm (1.89 in.)
241 ±18 N (54 ±4 lbf) at 37.5 mm (1.48 in.)
615 ±29 N (138 ±7 lbf) at 26.5 mm (1.04 in.)
600 SRM 1121 Torque Specifications

Valve Spring Installed Height

Intake 37.5 mm (1.48 in.)
Exhaust 37.5 mm (1.48 in.)
Valve Lift
Intake 11.0 mm (0.433 in.)
Exhaust 11.0 mm (0.433 in.)

CYLINDER HEAD WARPAGE

Maximum Cylinder Head Warpage 0.015 mm (0.0006 in.) in 150 mm (5.9 in.) distance

LUBRICATION SYSTEM
Oil Pressure @ 80°C (176°F) 800 rpm: 186 ±34.5 kPa (27 ±5 psi) [oil temperature
approximately 60°C (140°F)]
NOTE: As engine oil temperature increases, oil pres- 2700 rpm: 345 ±69 kPa (50 ±10 psi) [oil temperature
sure will decrease. approximately 76.7 to 104.4°C (170 to 220°F)]
Oil Capacity (With Oil Filter Change) 5.0 liter (5.3 qt)
Oil Pump Type Internal Crescent Gear Pump

COOLING SYSTEM
Thermostat
Start to Open 82 ±1.5°C (179.6 ±34.7°F)
Fully Open 97 ±1.5°C (206.6 ±34.7°F)

Torque Specifications
Camshaft Carrier/Cylinder Head Bolts Crankshaft Timing Pulley Retaining Bolt
First Pass 25 N•m (18 lbf ft) First Pass 130 N•m (96 lbf ft)
Second Pass - Additional 180 degrees Final Final Pass - Additional 45 degrees
Pass - Additional 10 degrees
Crankshaft Pulley Bolts
Camshaft Timing Pulley Bolt 15 to 25 N•m (11 to 18 lbf ft)
40 to 50 N•m (30 to 37 lbf ft)
Crankshaft/RPM Sensor Capscrew
Camshaft Sensor Retaining Screws 8 N•m (71 lbf in)
10 N•m (88.5 lbf in)
Coil Mounting Capscrews
Camshaft Retainer Capscrews 10 N•m (88.5 lbf in)
8 N•m (71 lbf in)
Flywheel Capscrews
Crankshaft Main Bearing Cap Capscrews 52 N•m (38.35 lbf ft)
First Pass 50 N•m (37 lbf ft)
Second Pass - Additional 45 degrees Final Flywheel Housing Capscrews
Pass - Additional 15 degrees M10 Capscrews 38 N•m (28 lbf ft)
M12 Capscrews 66 N•m (48.7 lbf ft)

63
Torque Specifications 600 SRM 1121

Coil Mounting Bracket Attaching Nuts Reluctor Wheel Capscrews

38 N•m (28 lbf ft) First Pass 10 N•m (88.5 lbf in)
Final Pass - Additional 40 to 45 degrees
Exhaust Manifold to Head Nuts
18 to 22 N•m (13 to 16 lbf ft) Rocker Arm Cover Bolts
8 N•m (71 lbf in)
Exhaust Manifold Adapter to Exhaust Manifold
14 to 20 N•m (10 to 15 lbf ft) Spark Plugs
20 N•m (15 lbf ft)
Intake Manifold to Head Nuts
18 to 22 N•m (13 to 16 lbf ft) Starter mounting Bolts
38 N•m (28 lbf ft)
Lift Bracket Bolt
20 N•m (15 lbf ft) Timing Belt Front Cover Bolts
6 N•m (53 lbf in)
Lift Bracket Nut
20 N•m (15 lbf ft) Timing Belt Front Bracket Capscrews
25 N•m (18 lbf ft)
Oil Pump Safety Valve
37 N•m (27 lbf ft) Timing Belt Rear Cover Bolts
6 N•m (53 lbf in)
Oil Pan Capscrews
18 to 22 N•m (13 to 16 lbf ft) Timing Belt Tensioner Bolt
20 N•m (15 lbf ft)
Oil Pan Drain Plug
18 to 22 N•m (13 to 16 lbf ft) Thermostat Cover Capscrews
20 N•m (15 lbf ft)
Oil Pump Cover
6 N•m (53 lbf in) Thermostat Housing Capscrews
11 N•m (97 lbf in)
Oil Pump to Engine Block
8 N•m (71 lbf in) Water Pump Bolts
20 to 30 N•m (15 to 22 lbf ft)
Oil Pump Suction Tube Capscrews
6 to 10 N•m (53 to 89 lbf in) Cooling System Hose Clamps
4 to 5 N•m (35 to 44 lbf in)
Oil Pump Suction Tube Bracket Capscrew
18 to 22 N•m (13 to 16 lbf ft) Fan Hub Bracket Bolts
52 N•m (38 lbf ft)
Oil Pressure Sensor
20 N•m (15 lbf ft) Fan Retaining Bolts
26 N•m (19 lbf ft)
Baffle Plate Capscrews
First Pass 20 to 24 N•m (15 to 17.6 lbf ft) Alternator Bracket Bolts
Final Pass - Additional 45 degrees 38 N•m (28 lbf ft)

Bearing Bracket Capscrews Alternator Mounting Bolts

20 to 24 N•m (15 to 17.6 lbf ft) 20 N•m (15 lbf ft)

Piston Rod Bearing Cap Capscrews

First Pass 30 to 40 N•m (22 to 29.5 lbf ft)
Final Pass - Additional 40 to 45 degrees

64
600 SRM 1121 Special Tools

Special Tools
Valve Spring Compressor
Used to remove and install valve springs.

Valve Stem Oil Seal Tool

Used to remove and install valve stem oil seals.

Camshaft Seal Installer

Used to install the camshaft seal.

Wrench
Used to lock the crankshaft timing pulley.

65
Special Tools 600 SRM 1121

Piston Flange Universal Puller

Used to remove the crankshaft timing pulley.

Crankshaft Front and Rear Oil Seal Puller

Used with sliding mallet to remove oil seals.

Universal Sliding Mallet

Used with crankshaft front and rear oil seal puller
to remove oil seals.

66
600 SRM 1121 Special Tools

Crankshaft Front Seal Installer

Used to install crankshaft front oil seal.

Crankshaft Rear Main Oil Seal Installer

Used to install the crankshaft rear main oil seal.

Rear Flange Alignment Tool

Used to align the oil pan with the cylinder block.

67
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68
 TECHNICAL PUBLICATIONS

600 SRM 1121 12/12 (2/10)(11/08)(6/07)(1/07)(5/06) Printed in United Kingdom