Motores GM

GM ENGINES
4.3 LITER V-6

S4.0, 5.0, 5.50FT ([S80, 100, 120FT]; S80, 100, 120FTBCS; S120FTPRS) [G004]; H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) [N005]
PART NO. 1627339
600 SRM 1251
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR

When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load. Do not lift heavy parts by hand, use a lifting mechanism. Wear safety glasses. DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks. Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic 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 condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
GM Engines
Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... Engine Removal and Installation ..................................................................................................................... Cylinder Head Repair ........................................................................................................................................ Remove and Disassemble .............................................................................................................................. Clean and Inspect .......................................................................................................................................... Valve Guides and Seats, Repairs .................................................................................................................. Valves, Repair ................................................................................................................................................ Valve Seats, Repair........................................................................................................................................ Valve Springs ................................................................................................................................................. Assemble and Install ..................................................................................................................................... Engine Block Cleaning and Inspection............................................................................................................. Piston Bore Preparation .................................................................................................................................... Engine Mounts Installation .............................................................................................................................. Remove ........................................................................................................................................................... Clean and Inspect .......................................................................................................................................... Installation..................................................................................................................................................... Lubrication System Repair................................................................................................................................ Oil Pump, Remove and Disassemble ............................................................................................................ Clean and Inspect .......................................................................................................................................... Oil Pump, Assemble and Install ................................................................................................................... Oil Pan, Install............................................................................................................................................... Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters ...................................................................... Timing Cover.................................................................................................................................................. Remove....................................................................................................................................................... Install ......................................................................................................................................................... Timing Sprockets ........................................................................................................................................... Remove....................................................................................................................................................... Install ......................................................................................................................................................... Camshaft ........................................................................................................................................................ Remove....................................................................................................................................................... Inspect........................................................................................................................................................ Install ......................................................................................................................................................... Balance Shaft................................................................................................................................................. Remove....................................................................................................................................................... Install ......................................................................................................................................................... Valve Lifters ................................................................................................................................................... Remove....................................................................................................................................................... Clean and Inspect...................................................................................................................................... Install ......................................................................................................................................................... Crankshaft Repair ............................................................................................................................................. Remove ........................................................................................................................................................... Inspect and Repair......................................................................................................................................... How to Check Clearance Between Main Bearings and Their Journals ..................................................... Install ............................................................................................................................................................. Piston and Connecting Rod Assemblies Repair ............................................................................................... Connecting Rod Bearings, Replace ............................................................................................................... Piston and Connecting Rod Assemblies, Remove ........................................................................................ Disassemble ................................................................................................................................................... Piston, Clean and Inspect ............................................................................................................................. Cylinder Bores, Inspect and Repair.............................................................................................................. Piston Rings ................................................................................................................................................... 1 1 1 1 3 4 5 6 7 7 11 12 13 13 13 13 13 13 14 16 17 18 18 18 19 19 19 20 20 20 20 20 21 21 22 23 23 23 24 24 24 25 26 26 28 28 29 29 30 30 31
2006 HYSTER COMPANY
Table of Contents
GM Engines
TABLE OF CONTENTS (Continued)

Assemble ........................................................................................................................................................ Piston and Connecting Rod Assemblies, Install .......................................................................................... Flywheel and Flywheel Housing Repair........................................................................................................... Flywheel, Remove .......................................................................................................................................... Clean .............................................................................................................................................................. Inspect ............................................................................................................................................................ Flywheel, Install ............................................................................................................................................ Coolant Pump Repair......................................................................................................................................... Remove ........................................................................................................................................................... Clean and Inspect .......................................................................................................................................... Install ............................................................................................................................................................. Thermostat Replacement .................................................................................................................................. Remove ........................................................................................................................................................... Thermostat Operation Check........................................................................................................................ Install ............................................................................................................................................................. Fan Assembly Replacement .............................................................................................................................. Remove ........................................................................................................................................................... Inspect ............................................................................................................................................................ Install ............................................................................................................................................................. Drive Belt Installation....................................................................................................................................... Remove ........................................................................................................................................................... Clean .............................................................................................................................................................. Inspect ............................................................................................................................................................ Installation..................................................................................................................................................... Compression Check............................................................................................................................................ Engine Specifications......................................................................................................................................... Engine Data ................................................................................................................................................... Cylinder Head ................................................................................................................................................ Hydraulic Valve Lifter ................................................................................................................................... Camshaft ........................................................................................................................................................ Pistons ............................................................................................................................................................ Crankshaft ..................................................................................................................................................... Connecting Rods ............................................................................................................................................ Balance Shaft................................................................................................................................................. Cooling System .............................................................................................................................................. Lubrication System ....................................................................................................................................... Torque Specifications ......................................................................................................................................... This section is for the following models: S4.0, 5.0, 5.50FT ([S80, 100, 120FT]; S80, 100, 120FTBCS; S120FTPRS) [G004]; H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) [N005] 32 32 33 33 33 33 34 34 34 34 34 36 36 36 36 37 37 37 37 39 39 39 39 39 40 41 41 41 41 41 42 42 43 43 43 43 44
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600 SRM 1251
Cylinder Head Repair
General
CAUTION
Disconnect the battery cables before doing any disassembly and repair of the engine or parts of the electrical system. The diodes and resistors in the electrical system can be damaged if the following cautions are not followed: Do not disconnect the battery when the engine is running. The voltage surge can damage the diodes and resistors. Do not disconnect an electric wire before the 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 of the wire is made before it is connected. Make sure a battery is the correct voltage and polarity before it is connected. Do not check for current flow by making a spark because the electronic components can be damaged. This SRM has the repair instructions for the GM 4.3 liter, V-6 engine. Checks and Adjustments and Specifications are also included.
Engine Removal and Installation

The Removal and Installation procedures for the engine are in the Frame section for each model of lift truck. If the engine and transmission were removed from the lift truck as a unit, see the Transmission sections to separate the transmission from the engine. The Removal and Installation procedures for the gasoline and LPG components of the engine are covered in the Gasoline Fuel System and LPG Fuel System sections for each model of lift truck.

REMOVE AND DISASSEMBLE WARNING
Disconnect the battery cables before making repairs to the engine. 1. Drain cooling system. 2. Disconnect and remove coolant hose from thermostat housing. NOTE: Prior to removing the distributor, mark the location of the distributor on the distributor and the engine to aid in proper installation. For more information regarding removal and installation of the distributor, see High Voltage Switch (HVS) Ignition, GM 4.3L EPA Compliant Engines 2200 SRM 1097. 3. Remove air cleaner, distributor, intake manifold, and exhaust manifolds. Remove drive belt(s) and remove brackets for drive belt tensioner and alternator. 4. Remove spark plugs and spark plug wire shields. 5. Remove the valve rocker arm cover bolts and grommets. Discard the grommets. 6. Remove rocker arm cover. See Figure 1. 7. Remove valve rocker arms. Organize rocker arms so they can be installed in their original positions. See Figure 2. 8. Remove valve rocker arm supports. 9. Remove the valve push rods. 10. Remove capscrews that hold cylinder head to block in the sequence shown in Figure 3. Remove cylinder head and gasket. Discard cylinder head gasket.
600 SRM 1251
A. FAN END Figure 3. Cylinder Head Capscrew Removal Sequence 11. Using a valve spring compressor, remove valve stem keys, caps, springs, and oil seals. Discard oil seals. Remove valves. Organize valves and springs so they can be installed in their original positions. See Figure 4. 1. ROCKER COVER BOLTS 2. ROCKER COVER 3. CYLINDER HEAD Figure 1. Rocker Cover Removal
1. VALVE STEM KEYS 2. VALVE SPRING CAP 3. VALVE SPRING 1. VALVE ROCKER ARM 2. VALVE ROCKER ARM SUPPORT 3. PUSH ROD Figure 2. Remove Valve Rocker Arm and Push Rod
4. VALVE 5. VALVE STEM OIL SEAL 6. CYLINDER HEAD
Figure 4. Valve Removal
600 SRM 1251
Cylinder Head Repair Cracks in the exhaust ports and combustion chambers External cracks in the water chamber Restrictions in the intake or exhaust passages Restrictions in the cooling system passages Rusted, damaged, or leaking core plugs
CLEAN AND INSPECT

1. Clean carbon from valve ports and combustion chambers in cylinder head. Use care not to scuff the combustion chambers.
WARNING
Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturers recommended safety procedures.
WARNING
Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. 2. Using cleaning solvent, clean the following items: valve stem keys valve spring cap valve spring valve cylinder head When cleaning is complete, dry components with compressed air. See Figure 5. 3. Clean valve guides.
1. VALVE STEM KEYS 2. VALVE SPRING CAP 3. VALVE SPRING
4. VALVE 5. VALVE STEM OIL SEAL 6. CYLINDER HEAD
Figure 5. Valve Component Cleaning 6. Measure cylinder head for warpage with a straight edge and feeler gauge. See Figure 6. A cylinder head block deck with warpage in excess of 0.10 mm (0.004 in.) within a 152.4 mm (6.0 in.) area must be repaired or replaced. A cylinder head exhaust manifold mounting surface with a warpage in excess of 0.05 mm (0.002 in.) within a 152.4 mm (6.0 in.) area must be repaired or replaced. A cylinder head intake manifold mounting surface with a warpage in excess of 0.10 mm (0.004 in.) within a 152.4 mm (6.0 in.) area must be repaired or replaced.
CAUTION
To prevent possible gouging of the cylinder head surfaces, use care when removing gasket material. 4. Remove all gasket material from the surfaces of cylinder head. 5. Inspect cylinder head for the following defects: Damage to the gasket surfaces Damage to threaded bolt holes Burnt or eroded areas in the combustion chamber
600 SRM 1251
VALVE GUIDES AND SEATS, REPAIRS

Measure the clearance between the valve stem and the guide as follows: 1. Clamp a dial indicator on the exhaust port side of the cylinder head. See Figure 9. 2. Position the dial indicator so that the movement of the valve stem from side to side, crosswise to the cylinder head, will cause a direct movement of the dial indicator stem. The dial indicator stem must contact the side of the valve stem just above the valve guide. 3. Lower the valve head about 1.6 mm (0.063 in.) below the valve seat. 4. Using light pressure, move the valve stem from side to side in order to obtain valve stem-to-guide clearance reading See Engine Specifications for maximum clearances. If the clearance is more than the maximum amount, oversize valves or new valve guides must be installed. Use a reamer of the correct size when installing new valve guides. Use normal service procedures when grinding the valve seats. See the Engine Specifications for dimensions.
Figure 6. Cylinder Head Warpage Inspection 7. Inspect valves for: Burnt or damaged areas undersized margin Bent stem Scoring or other damage to the stem Worn key groove worn stem tip See Figure 7. Valve stems with excessive guide clearance must be repaired or replaced. Refer to Engine Specifications. 8. Inspect the valve contact surface for the following: Undersized margin Pitted surface Burnt or eroded areas Acceptable edge margin See Figure 8. Valves with excessive damage must be replaced. Minor imperfections of the valve or valve seat may be repaired. Refer to Valve Guides and Seats, Repairs or Valves, Repair.
1. BURNT OR DAMAGED AREAS 2. UNDERSIZED MARGIN 3. BENT STEM
4. SCORING/DAMAGE TO THE STEM 5. WORN KEY GROOVE 6. WORN STEM TIP
Figure 7. Valve Inspection
600 SRM 1251
VALVES, REPAIR
NOTE: Before any work is performed on the valve faces and seats, make sure the clearance of the valve stems in their valve guides is within specifications. A correction for minimum wear and damage to the valve and seat can be done by a process called lapping. When the valve seats are lapped, keep the valve faces and seats within the specifications. Make sure all of the lapping compound is removed from the valve and valve seat when the process is completed. Valves with minor pits in the valve faces can be machined to the proper angle. There are many different types of equipment for repairing valve faces. Follow the instructions of the manufacturer of the equipment that you are using. Valves must be machined to the proper specifications. See Figure 10. 1. 2. 3. 4. UNDERSIZED MARGIN PITTED SURFACE BURNT OR ERODED AREAS ACCEPTABLE EDGE MARGIN Figure 8. Valve Contact Surface Inspection
NOTE: SEAT WIDTH DIMENSION APPLIES TO THE 46 FACE ONLY. 1. CYLINDER HEAD Figure 10. Valve Seat Specifications for Inlet and Exhaust Valves Replace a valve if any of the following conditions are present: Valve stem is worn below specifications. Valve stem is bent. Valve face is warped. Any part of the valve is cracked. Any wear or damage to the valve face that cannot be removed by resurfacing and still meet the specifications shown in Figure 11.
1. VALVE STEM 2. DIAL INDICATOR Figure 9. Valve Steam Clearance
600 SRM 1251 many different types of equipment for repairing valve seats. Follow the instructions of the manufacturer of the equipment that you are using. The valve seats are ground at three different angles: 30 , 46 , and 60 . This method makes a valve seat that is the proper width and produces the correct contact line between the valve and valve seat. The specifications for the valve seats are shown in the Engine Specifications section and in Figure 10. If the contact line is too high, it can be made lower by using a 30 stone. If the contact line is too low, it can be raised using the 46 stone. If the seat is too narrow, it can be made wider using a 46 stone. If the seat is too wide, it can be made narrower using a 60 stone. The correct dimensions for the valve seat widths and valve/valve seat overlap are shown in Figure 12. The valve seat widths are the dimensions of the 46 face only. The valve/valve seat overlap is the distance from the edge of the seat to the outside edge of the valve.
Figure 11. Valve Head Measurements
VALVE SEATS, REPAIR

NOTE: Before any work is done on the valve faces and seats, make sure the clearance of the valve stems in their valve guides is within specifications. Damaged valve seats can be resurfaced with a tool that is designed to repair valve seats. There are
A. EXHAUST VALVE 1. CYLINDER HEAD
B. INTAKE VALVE 2. VALVE Figure 12. Valve Seat Widths and Valve/Valve Seat Overlap
600 SRM 1251
VALVE SPRINGS
Measure the length of the valve springs. The correct length is 51.6 mm (2.03 in.).
WARNING
Be careful when testing the valve springs. These springs can come loose with enough force to cause an injury. Always use equipment that was designed to test springs. Always wear eye and face protection while testing valve springs. Use a special tool to check the tension of the valve springs. Compress the spring to the correct height and check the tension. For the correct specifications, see Figure 13. Replace valve springs that are not within specifications. NOTE: THIS LIST IS FOR 4.3L GASOLINE ENGINES.
ASSEMBLE AND INSTALL

1. Install each valve in correct port. Install oil seal in lower groove. Install shim, damper, spring, shield, and cap or rotator. Using a spring compressor, compress assembly and install retainers. Measure height of valve spring as shown in Figure 13. Measure from top of shim to top of retainer cap. Install shims to get correct height shown in Figure 13. The installed height of valve spring must not be less than minimum height. 2. Clean surface of cylinder head and top of cylinder block. Make sure threads in block are clean. If the threads are not clean, use a thread chaser to clean the threads. 3. Install cylinder head gasket and cylinder head. Make sure cylinder head is aligned with pins in block. 4. Use sealant Hyster P/N 1451215 on threads of capscrews for cylinder head. Install capscrews as follows: a. Tighten all capscrews to 30 Nm (22 lbf ft). Use sequence shown in Figure 14 b. Tighten capscrews 11, 7, 3, 2, 6, 10 an additional 55 degrees. Tighten capscrews 12 and 13 an additional 65 degrees. Tighten capscrews 1, 4, 8, 5, 9 an additional 75 degrees.
A. VARIATION FROM VERTICAL: LESS THAN 1.6 mm (0.063 in.) B. FREE LENGTH: 51.3 mm (2.02 in.) C. SPRING COMPRESSED TO 338 TO 374 N (76 TO 84 lbf) AT 43.2 mm (1.70 in.) CLOSED SPRING COMPRESSED TO 832 TO 903 N (187 TO 203 lbf) AT 32.3 mm (1.27 in.) OPEN D. INSTALLED HEIGHT INTAKE: 42.92 TO 43.43 mm (1.670 TO 1.700 in.) EXHAUST: 42.92 TO 43.43 mm (1.670 TO 1.700 in.) NOTE: THIS LIST IS FOR 4.3L LPG ENGINES. A. VARIATION FROM VERTICAL: LESS THAN 1.6 mm (0.063 in.) B. FREE LENGTH: 50 mm (2.0 in.) C. SPRING COMPRESSED TO 265 N (59.5 lbf) AT 43.2 mm (1.70 in.) CLOSED SPRING COMPRESSED TO 718 N (161.5 lbf) AT 32.3 mm (1.27 in.) OPEN D. INSTALLED HEIGHT INTAKE: 42.92 TO 43.43 mm (1.670 TO 1.700 in.) EXHAUST: 42.92 TO 43.43 mm (1.670 TO 1.700 in.) Figure 13. Valve Spring Specifications
600 SRM 1251
A. FAN END Figure 14. Cylinder Head Tightening Sequence 5. Apply RTV sealant (Hyster part number 280472) to front and rear surfaces between intake manifold and engine block. See Figure 15. The bead of sealant must be 5 mm (0.2 in.) thick and extend up sides of heads 13 mm (0.5 in.) to seal and retain gaskets. A. FAN END Figure 16. Intake Manifold Tightening Sequence 7. Install valve push rods. See Figure 17.
1. EXTEND BEAD 13 mm (0.5 in.) UP HEADS (FRONT AND REAR). 2. REAR 3. FRONT Figure 15. Intake Manifold Sealant Locations 6. Install gaskets and intake manifold. Tighten capscrews in sequence shown in Figure 16. Tighten capscrews on first pass to 3 Nm (27 lbf in). Tighten capscrews on second pass to 12 Nm (106 lbf in). Tighten capscrews on final pass to 15 Nm (133 lbf in). Figure 17. Install Valve Push Rod
CAUTION
Be sure that the arrow on the valve rocker arm support is in the up position. See Figure 18. 8. Install valve rocker arm supports.
600 SRM 1251
Figure 18. Install Valve Rocker Arm Supports 9. Apply a molybdenum grease or equivalent to the following valve rocker arm contact surfaces: See Figure 19. Valve push rod socket Roller pivot Valve stem tip 10. See Figure 20. Install the valve rocker arm assemblies as follows: a. Finger start the rocker arm bolt at location 1 in Figure 20. b. Finger start the rocker arm bolt at location 2 in Figure 20. c. Finger start the rocker arm bolt at location 3 in Figure 20. d. Finger start the remaining three valve rocker arm bolts. 11. Rotate the crankshaft balancer to position the crankshaft balancer alignment mark 57 to 63 degrees clockwise or counterclockwise from the engine front cover alignment tab. See Figure 21.
1. 2. 3. 4.
VALVE PUSH ROD SOCKET ROLLER PIVOT VALVE STEM TIP ROCKER ARM BOLT Figure 19. Lubricate Valve Rocker Arm Surfaces
1. BOLT AT LOCATION 1 2. BOLT AT LOCATION 2 3. BOLT AT LOCATION 3 Figure 20. Install Valve Rocker Arm Assemblies
600 SRM 1251 16. Install exhaust manifolds. Tighten capscrews in two steps; first to 15 Nm (133 lbf in), then to 31 Nm (274 lbf in). If used, bend lock tabs against heads of capscrews. 17. Install coolant hose to housing for thermostat. Fill coolant system with coolant. See the Periodic Maintenance section for your lift truck.
1. CRANKSHAFT BALANCER ALIGNMENT MARK 2. ENGINE FRONT COVER ALIGNMENT TAB Figure 21. Rotate Crankshaft Balancer NOTE: Once the valve rocker arm assemblies are installed and properly torqued, no additional valve lash adjustment is required. 12. Tighten the valve rocker arm bolts to 30 Nm (22 lbf ft). See Figure 19. 13. Use new gasket and install valve covers. Install new grommets on the capscrews and install the capscrews into the valve covers. Tighten capscrews to 12 Nm (107 lbf in). See Figure 22. 14. Install spark plugs. 15. Install throttle body, air cleaner, and distributor. Install brackets for drive belt tensioner and alternator. Install drive belt(s). 1. CAPSCREW 2. ROCKER COVER 3. CYLINDER HEAD Figure 22. Valve Cover Installation
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600 SRM 1251
Engine Block Cleaning and Inspection
Engine Block Cleaning and Inspection

CAUTION
To prevent possible gouging of the engine block surfaces, use care when removing gasket and sealing material. 1. Clean all remaining sealing or gasket material from the sealing surfaces. If a crankshaft bearing cap is damaged and requires replacement, replace the bearing cap first, then re-bore the engine block crankshaft bearing bores and check for proper alignment. Finally, check the crankshaft for the proper clearances. Engine block core hole plug for damage Engine block for cracks for damage Engine mount bosses for damage
WARNING
Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturers recommended safety procedures. 2. Clean the engine block with solvent. 3. Flush the engine block with water or steam. 4. Clean the following engine block components: Cylinder bores Oil galleries and oil passages Scale and deposits from the coolant passages
CAUTION
Clean all, debris and coolant from the engine block cylinder head bolt holes. failure to do so may result in damaged threads, improperly tightened fasteners or damage to components. Engine block cylinder head bolt holes. 5. After cleaning the engine block, spray or wipe the cylinder bores and the machined surfaces with clean engine oil. 6. Inspect the following areas, see Figure 23: Coolant jackets for cracks. Cylinder bores for scratches or gouging. Valve lifter bores for excessive scoring or wear. Threaded holes for damage Crankshaft bearing webs for cracks Crankshaft bearing caps and bores for damage Crankshaft bearing bores should be round and uniform when measuring the inside diameter (ID). The surface where the crankshaft bearings contact the crankshaft bearing bore should be smooth.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
COOLANT JACKET CYLINDER BORE VALVE LIFTER BORES THREADED HOLES CRANKSHAFT BEARING WEBS CRANKSHAFT BEARING CAPS CRANKSHAFT BEARING BORES ENGINE BLOCK HOLE PLUG BORE ENGINE BLOCK ENGINE MOUNT BOSSES Figure 23. Engine Block Inspection
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Piston Bore Preparation 7. Measure the cylinder bores for taper and out-ofround. See Figure 24
600 SRM 1251
1. PISTON CYLINDER BORE 2. BORE MEASURING DEVICE Figure 24. Cylinder Bore Taper and Out-of-Round Inspection
Piston Bore Preparation

NOTE: It is important that the piston bores are prepared correctly before new piston rings are installed. Incorrect preparation can cause the parts to wear quickly. Use a hone in the piston bores when installing new rings. Use the hone as follows: 1. Use a hone with a 280-grit stone. Make sure stone is clean and will not damage bore. 2. Move hone quickly (approximately 60 times per minute) up and down in bore. Make sure hone makes a cross pattern of 45 to 60 degrees. Use hone until entire length of bore has this pattern. See Figure 25 3. After using the hone, clean cylinder block with hot water and detergent. Make sure all metal particles are removed from block. Dry bores and lubricate them with engine oil.
1. CYLINDER BORE 2. HONING PATTERN Figure 25. Correct Honing Pattern
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600 SRM 1251
Lubrication System Repair
Engine Mounts Installation

REMOVE
1. Remove six capscrews and the support bracket from the motor mounts. See Figure 26. 2. Remove four capscrews and the motor mount from the engine. See Figure 26. 3. Repeat Step 2 to remove the motor mount on the opposite side of the engine.
INSTALLATION
1. Using four capscrews, install the motor mount on the engine. Tighten capscrews to 90 Nm (66 lbf ft). See Figure 26. 2. Repeat Step 1 to install the motor mount on the opposite side of the engine. 3. Using six capscrews, install the support bracket on the motor mount. Tighten capscrews to 90 Nm (66 lbf ft). See Figure 26.
CLEAN AND INSPECT WARNING

WARNING
Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. Clean all components with cleaning solvent and dry with compressed air. Inspect the support bracket and motor mounts for cracks or other damage. If damaged, replace.
NOTE: EXHAUST MANIFOLD NOT SHOWN FOR CLARITY. 1. MOTOR MOUNT 2. CAPSCREW 3. SUPPORT BRACKET Figure 26. Engine Mount Removal

OIL PUMP, REMOVE AND DISASSEMBLE
1. Remove oil pan capscrews, nuts and gasket from the engine. Discard gasket. See Figure 27. 2. Remove capscrew at mount for pump. Remove oil pump assembly from the engine. Remove drive shaft retainer, and drive shaft from the oil pump assembly. See Figure 28. 3. Remove cover for oil pump. Put marks on gear teeth to show their correct location during assembly. See Figure 29. 4. Do not remove tube and screen assembly unless it is damaged. The tube and screen must be replaced as an assembly. 5. Remove and discard retaining pin, pressure relief spring, and pressure relief valve from pump cover.
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600 SRM 1251
1. CAPSCREW 2. NUT 3. OIL PAN
4. GASKET 5. ENGINE 6. THREADED STUD
1. CAPSCREW 2. OIL PUMP ASSEMBLY 3. ENGINE
4. DRIVE SHAFT RETAINER 5. DRIVE SHAFT
Figure 28. Oil Pump Removal
Figure 27. Oil Pan Removal
WARNING
Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. Clean parts of oil pump and oil pan in solvent and dry with compressed air.
CLEAN AND INSPECT WARNING

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600 SRM 1251
Lubrication System Repair Minor imperfections or scratches may be removed with a fine oil stone.
1. 2. 3. 4. 5. 6. 7.
CAPSCREW SCREEN DRIVEN GEAR DRIVE GEAR RETAINER SHAFT HOUSING
8. PRESSURE VALVE RELIEF SPRING 9. PRESSURE RELIEF VALVE 10. COVER 11. RETAINING PIN 1. 2. 3. 4. 5. 6. SCORED GEAR DAMAGED GEAR OIL PUMP BODY GEAR SHAFT CAPSCREW HOLE DRIVESHAFT HOLE Figure 30. Oil Pump Inspection
Figure 29. Oil Pump Disassembly Inspect the oil pump for the following conditions, see Figure 30: Scoring on the top of the gears Damaged Gears for the following: Chipping Galling Wear Scoring or damage to the body Damaged or scored gear shaft(s) Damaged capscrew hole threads Worn oil pump driveshaft bore
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600 SRM 1251
OIL PUMP, ASSEMBLE AND INSTALL

1. Install NEW pressure relief valve and spring into pump cover. Install retaining pin. See Figure 31.
Figure 32. Oil Pump Tube and Screen Installation 4. Install oil pump shaft and NEW retainer. See Figure 33.
1. 2. 3. 4. 5. 6.
CAPSCREW SCREEN DRIVEN GEAR DRIVE GEAR RETAINER SHAFT
7. HOUSING 8. PRESSURE VALVE RELIEF SPRING 9. PRESSURE RELIEF VALVE 10. COVER 11. RETAINING PIN
Figure 31. Oil Pump Assembly 2. Install gears in body of pump. Make sure to align identification marks. Install cover for oil pump and tighten capscrews to 12 Nm (106 lbf in). Turn oil pump shaft to check for smooth operation. 3. Use a sealant when replacement of tube and screen assembly is necessary. The tube and screen assembly must have a good press fit into the oil pump body. Do not damage tube during installation. Make sure surface of screen assembly is parallel to bottom surface of cylinder block. See Figure 32.
1. CAPSCREW 2. OIL PUMP ASSEMBLY 3. ENGINE
4. DRIVE SHAFT RETAINER 5. DRIVE SHAFT
Figure 33. Oil Pump Installation
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600 SRM 1251 5. Install oil pump assembly to engine. Make sure shaft is aligned with slot in distributor shaft. Tighten capscrew to 90 Nm (66 lbf ft).
OIL PAN, INSTALL

1. Install oil pan as follows: a. Apply an RTV sealant to surfaces of engine block as shown in Figure 34. b. Install gasket and oil pan. Make sure vertical surfaces at back of engine block and oil pan are even. See Figure 35. c. Tighten capscrews and nuts for oil pan in sequence shown in Figure 36 to 25 Nm (221 lbf in).
1. CAPSCREW 2. NUT 3. OIL PAN
4. GASKET 5. ENGINE 6. THREADED STUD
Figure 35. Oil Pan Installation
A. FAN END Figure 34. Sealant Application
Figure 36. Oil Pan Tightening Sequence
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Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters
600 SRM 1251

TIMING COVER Remove
1. Remove fan assembly and belts. 2. Remove crankshaft pulley and vibration damper. See Figure 37. Use a tool that pulls on center of vibration damper. Do not pull on outside diameter of vibration damper.
1. CRANKSHAFT POSITION SENSOR BOLT 2. CRANKSHAFT POSITION SENSOR 3. TIMING COVER Figure 38. Crankshaft Position Sensor
1. TIMING COVER 2. VIBRATION DAMPER 3. TOOL FOR REMOVING VIBRATION DAMPER Figure 37. Timing Cover 3. Remove crankshaft position sensor from timing cover. See Figure 38. 4. Remove capscrews and stud for timing cover. Remove timing cover from engine. See Figure 39. 5. Remove crankshaft position sensor reluctor ring from crankshaft. See Figure 40. 1. TIMING COVER 2. ENGINE
Figure 39. Timing Cover
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600 SRM 1251
1. SPECIAL TOOL
2. VIBRATION DAMPER
Figure 41. Timing Cover 1. CRANKSHAFT POSITION SENSOR RELUCTOR RING 2. CRANKSHAFT Figure 40. Crankshaft Position Sensor Reluctor Ring
TIMING SPROCKETS Remove

1. Remove timing covers described in section Timing Cover, Remove. 2. Check timing chain for wear. See Figure 42. If timing chain can be moved back and forth more than 11 mm (0.43 in.), install a new chain.
Install
NOTE: The plastic timing cover can be used only once. When the engine has a plastic timing cover, always install a new one. 1. Install crankcase position sensor reluctor ring on crankshaft. See Figure 40. Make sure open side of seal is toward inside of cover. 2. During installation of the cover, use a special tool to align oil seal with crankshaft. The vibration damper will damage the oil seal if it is not installed correctly. Tighten capscrews for cover to 12 Nm (106 lbf in). See Figure 39. 3. Install crankshaft position sensor. Tighten crankshaft position sensor bolt to 8 Nm (71 lbf in). See Figure 38. 4. Lubricate lips of seal with clean engine oil before vibration dampener is installed. Use a special tool to push vibration damper onto crankshaft. See Figure 41. Tighten capscrew for damper to 95 Nm (70 lbf ft). 5. Install crankshaft pulley, belts, and fan assembly.
1. TIMING MARKS 2. TIMING CHAIN
3. CAMSHAFT SPROCKET
Figure 42. Timing Marks
19
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 3. Remove capscrews for camshaft sprocket. Use a puller to remove crankshaft sprocket. Make sure timing chain is removed with sprockets.
600 SRM 1251
4. If necessary, use a special tool as shown in Figure 44 to remove camshaft bearings. Remove front and rear bearings last.
Install
1. Install crankshaft sprocket. Install timing chain on camshaft sprocket. Install camshaft sprocket with chain. Make sure marks are aligned as shown in Figure 42. The number 4 cylinder will be at top dead center (TDC) on the compression stroke. Tighten capscrews to camshaft sprocket to 28 Nm (21 lbf ft). 2. Lubricate chain and sprockets with new engine oil. Install timing cover as described in section for Timing Cover, Install.
CAMSHAFT Remove
1. Remove intake manifold, push rods, lifter guides, and valve lifters. 2. Remove timing cover as described in section Timing Cover, Remove. Align timing marks. Remove timing chain, sprockets, and camshaft retainer. 3. Install two or three 5/16-18 capscrews that are 100 to 125 mm (4 to 5 in.) long into camshaft. See Figure 43. These capscrews will make the camshaft easier to control. Carefully rotate the camshaft and remove camshaft from cylinder block. All camshaft bearings are the same size. Do not damage bearings or camshaft during removal.
1. TOOL FOR CAMSHAFT BEARINGS Figure 44. Camshaft Bearings
Inspect
Inspect entire camshaft for any signs of wear or damage. Measure diameter of each bearing surface on camshaft. Do the measurement at different positions on the surface of the bearing to see if they are round. If the difference of the readings for each bearing is more than 0.025 mm (0.001 in.), replace camshaft. Check for a bent camshaft or excessive camshaft runout. If runout exceeds 0.065 mm (0.0026 in.), replace the camshaft.
Install
NOTE: Camshaft bearings are numbered 1-4 starting at the fan end of the engine. NOTE: Camshaft bearings 4 and 1 must be installed first. They will serve as a guide for the installation of bearings 2 and 3. 1. Use a special tool as shown in Figure 44 to install camshaft bearings. Use a sealant on rear camshaft plug and install plug in block. Make sure plug is even with or 0.80 mm (0.03 in.) below surface of block. a. Install the number 4 camshaft bearing on the installation tool. Orient the bearing so that the lubrication hole in the camshaft bearing bore at the rear of the engine block and the
Figure 43. Camshaft
20
600 SRM 1251
camshaft bearing are aligned. Install the camshaft bearing into engine block. Remove the installation tool from the bearing. b. Install the number 1 camshaft bearing on the installation tool. Orient the bearing so that the lubrication hole in the camshaft bearing bore at the front of the engine block and the camshaft bearing are aligned. Install the camshaft bearing into engine block. Remove the installation tool from the bearing. c. Slide the installation tool into the engine block until the installation tool is located between the number 2 and 3 camshaft bearing positions. Install the number 3 camshaft bearing on the installation tool. Orient the bearing so that the lubrication hole in the camshaft bearing bore at the front of the engine block and the camshaft bearing are aligned. Install the camshaft bearing into engine block. Remove the installation tool from the bearing. d. Slide the installation tool into the engine block until the installation tool is located between the number 2 and 1 camshaft bearing positions. Install the number 2 camshaft bearing on the installation tool. Orient the bearing so that the lubrication hole in the camshaft bearing bore at the front of the engine block and the camshaft bearing are aligned. Install the camshaft bearing into engine block. Remove the installation tool from the engine block. 2. Lubricate camshaft lobes with a molybdenum lubricant. Lubricate camshaft bearings with engine oil. Install two or three 5/16-18 capscrews that are 100 to 125 mm (4 to 5 in.) long into camshaft. See Figure 43. These capscrews will make camshaft easier to control. Carefully install camshaft in cylinder block. 3. Lubricate and install retainer for camshaft. Tighten capscrews to 12 Nm (106 lbf in). See Figure 45. 4. Install gear for the balance shaft as described in procedures for Balance Shaft.
1. RETAINER
2. CAMSHAFT
Figure 45. Camshaft and Retainer 5. Install timing sprockets, chain, and cover as described in procedures for Timing Cover. 6. Lubricate valve lifters with a molybdenum lubricant. Install lifters in block. Install push rods and adjust valve mechanism as described in Valve Clearance Adjustment (New Models).
BALANCE SHAFT Remove

1. Remove intake manifold. 2. Remove retainer for lifters. 3. Remove timing cover as described in section Timing Cover. 4. Remove timing chain, sprocket, and balance shaft drive gear from camshaft. See Figure 46. 5. Remove driven gear from balance shaft. Remove retainer. See Figure 46. 6. Use a soft-faced hammer to remove balance shaft. See Figure 47. NOTE: The balance shaft and front bearing are serviced as a unit. 7. Use a special tool to remove rear bearing.
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600 SRM 1251
Install
1. Lubricate rear bearing with new engine oil. Use a special tool to push rear bearing into block. See Figure 46 and Figure 48.
A. FRONT 1. HAMMER 2. BEARING DRIVER
Figure 48. Balance Shaft Installation 2. Lubricate front bearing with new engine oil. Use a driver to install balance shaft into engine block. 3. Install retainer for balance shaft. Tighten screws for retainer to 12 Nm (106 lbf in). 1. CAMSHAFT SPROCKET 2. BALANCE SHAFT DRIVE GEAR 3. BALANCE SHAFT DRIVEN GEAR 4. BALANCE SHAFT 5. RETAINER 4. Install balance shaft driven gear onto balance shaft. Tighten bolt to 20 Nm (177 lbf in), plus an additional 35 degrees of rotation. Rotate balance shaft by hand to make sure there is clearance between retainer and shaft. If the balance shaft does not rotate freely, check that retaining ring on the front bearing is in its seat. 5. Temporarily install balance shaft drive gear on camshaft. Turn camshaft until timing mark on balance shaft drive gear is in the straight up (12:00 Oclock) position. Remove balance shaft drive gear and rotate balance shaft until mark on balance shaft driven gear is in the straight down (6:00 Oclock) position. Install balance shaft drive gear on camshaft. Make sure timing marks are aligned in the position shown in Figure 49. 6. Install timing chain and sprocket on camshaft. Make sure timing marks are in the position shown in Figure 42. Tighten capscrews that attach sprocket to camshaft to 25 Nm (18 lbf ft).
Figure 46. Balance Shaft Components
A. FRONT Figure 47. Balance Shaft Removal
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600 SRM 1251
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 4. Remove the valve lifter pushrod guide. NOTE: Valve lifters must be placed in the rack in the upright position to maintain oil in the valve lifters. 5. Remove valve lifters. Put lifters in a rack so they can be installed in their original positions.
Clean and Inspect WARNING

1. ALIGNMENT OF TIMING MARKS 2. BALANCE SHAFT DRIVEN GEAR, 3. BALANCE SHAFT DRIVE GEAR Figure 49. Balance Shaft Timing Marks 7. Install timing cover as described in section Timing Cover. 8. Make sure all lifters and guides for lifters are properly installed. Install retainer for lifters. Tighten bolts for retainer to 16 Nm (142 lbf in). 9. Install intake manifold as described in the section Cylinder Head Repair, Assemble and Install.
WARNING
Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. 1. Clean all parts in a cleaning solvent and dry with compressed air. 2. Inspect the valve lifter for the following, see Figure 50: Broken or damaged clip Worn pushrod socket Scuffed or worn lifter body If the valve lifter shows scuffing or wear, inspect the engine block valve lifter bores for wear. Worn roller If the valve lifter roller is worn or damaged, inspect camshaft lobe for wear and damage. Loose or damaged pin Plugged oil hole 3. If any parts are damaged or worn, the complete hydraulic valve lifter must be replaced.
VALVE LIFTERS Remove

1. The valve lifters normally do not need repair unless they become dirty, causing them to malfunction or the roller does not operate properly. The valve lifters must be clean to operate correctly. If a valve lifter must be disassembled, make sure small parts are handled carefully to prevent loss or damage. 2. Remove air bonnet, distributor, and intake manifold. 3. The pushrods must be removed as described in Cylinder Head Repair, Remove and Disassemble.
23
Crankshaft Repair
600 SRM 1251
1. 2. 3. 4. 5. 6.
CLIP PUSHROD SOCKET VALVE LIFTER BODY ROLLER PIN OIL HOLE Figure 50. Valve Lifter Inspection
Install
1. Lubricate all roller and valve lifter surfaces with new engine oil. Install valve lifters in their original positions. Install the valve lifter pushrod guide. Tighten valve lifter pushrod guide bolts to 16 Nm (142 lbf in). See Figure 51. 2. Install push rods as described in Cylinder Head Repair, Assemble and Install. Adjust valves see Valve Clearance Adjustment (New Models). 1. CYLINDER BLOCK 2. VALVE LIFTER 3. VALVE LIFTER PUSHROD GUIDE Figure 51. Valve Lifter Installation
Crankshaft Repair
REMOVE
1. Remove oil pan, oil pump, and flywheel. 2. Remove timing cover as described in the procedure Timing Cover, Remove. 3. Mark caps for connecting rods so they can be installed in their correct locations. Remove caps and bearing inserts for connecting rods. Make sure all parts from each rod assembly remain together. 4. Mark caps for main bearings so they can be installed in their correct locations. Remove caps for main bearings. Make sure all parts from each bearing assembly remain together. 5. Remove crankshaft with extreme care to prevent damage to journals and thrust flanges of crankshaft.
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600 SRM 1251
Crankshaft Repair
INSPECT AND REPAIR WARNING

Commercial cleaning solvents can be flammable and toxic and can cause severe skin irritation. When using commercial cleaning solvents, always comply with the solvent manufacturers recommended safety precautions. Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. 1. Clean crankshaft with solvent and dry it with compressed air. Make sure oil passages are not plugged. 2. Inspect crankshaft for cracks or other damage. 3. Inspect bearing journals and thrust surfaces for scratches or damage caused by a lack of lubrication. 4. Inspect crankshaft for wear and damage. See Figure 52. Use a micrometer to measure journals for bearings of crankshaft. Do measurement at different positions to see if the surface of the bearing is round. The correct sizes are given in the Engine Specifications section. 5. If crankshaft journals must be repaired, they can be ground to the following diameters smaller (undersize) than the original size: 0.254 mm (0.010 in.) 0.508 mm (0.020 in.) NOTES ABOUT MAIN BEARINGS: Main bearings are an insert bearing that do not use shims for adjustment. Main bearings are available in a standard size and the following undersizes: 0.0254 mm (0.001 in.), 0.0508 mm (0.002 in.), 0.2286 mm (0.009 in.), 0.254 mm (0.010 in.), and 0.508 mm (0.020 in.). If a bearing on a journal is worn, both the upper and lower half of the bearing must be replaced.
Figure 52. Crankshaft Inspection When the crankshaft is assembled by the manufacturer, the main bearings are specially selected to obtain close tolerances. For this reason, you can find one-half of a standard size insert with one-half of a 0.0254 mm (0.001 in.) undersize insert. This combination will decrease the clearance 0.0127 mm (0.0005 in.) from using a full standard bearing. When a production crankshaft cannot be fitted with this method, the main journal is then ground 0.2286 mm (0.009 in.) undersize. Only those main bearing journals that cannot be fitted with standard, 0.0254 mm (0.001 in.), or 0.0508 mm (0.002 in.) undersize main bearing will be ground. A 0.2286 mm (0.009 in.) and a 0.254 mm (0.010 in.) undersize bearings will be selected as described to obtain close tolerances. A production crankshaft that has been ground will have the following identification: The crankshaft journal that has been ground will have a 9 marked in the metal of the crankshaft next to the journal. A spot of light green paint is also added to the crankshaft. The main bearing cap is also marked with green paint.
25
Crankshaft Repair
600 SRM 1251
HOW TO CHECK CLEARANCE BETWEEN MAIN BEARINGS AND THEIR JOURNALS

1. Use Plastigage or equivalent to check clearance. The procedure is similar for both connecting rod bearings and main bearings. If engine has been removed from lift truck, put engine so crankshaft is up. The weight of the crankshaft is against the upper bearing half and the total clearance can be measured correctly. If the engine is still in the lift truck, the crankshaft must have a support to remove any additional clearance between the upper bearing half and its journal. 2. All main bearing caps must be installed and their capscrews tightened to the specifications. 3. Check rear main bearing first. Remove cap for rear main bearing. The procedure for checking the clearance of the other bearings is similar. 4. Clean oil from bearing half and journal to be checked. Put a piece of Plastigage across full width of bearing journal as shown in Figure 53. Do not rotate crankshaft when Plastigage is between main bearing and its journal.
Figure 54. Measuring Plastigage on Bearing Journal 7. If the clearance is greater than the specifications, select a new undersize bearing set and install it. Measure clearance again. If clearance cannot meet specifications with the available undersize bearings, bearing journal must be ground to a new undersize. If bearing journal is already at maximum undersize, crankshaft must be replaced. 8. If clearance is within specifications, lubricate bearing with engine oil and install main bearing and bearing cap. Tighten capscrews on main bearing cap to correct specifications. 9. Turn crankshaft to make sure it rotates smoothly. 10. Check axial clearance between rear main bearing and thrust surface. Push crankshaft forward. See Figure 55. Measure clearance between crankshaft and thrust surface of rear bearing. See Engine Specifications for correct clearances.
Figure 53. Plastigage on Bearing Journal 5. Install main bearing cap and tighten capscrews. See Torque Specifications. The capscrews must be tightened to their final torque or there will be an error in the measurement. 6. Remove main bearing cap. The Plastigage will be compressed and wider and will adhere to either the bearing or its journal. Use scale on envelope for Plastigage to measure width of plastic at its widest point. The scale will indicate the clearance in millimeters or thousandths of an inch. See Figure 54.
INSTALL
1. On engines with a two-piece rear seal, install seal halves so lips are toward fan end of engine. Apply sealant to ends of seal halves. Apply engine oil to seal during installation. Do not get any oil on ends of seal. NOTE: With the use of special tools, the main bearings and the rear crankshaft seal (two-piece) can be replaced without removing the crankshaft. 2. Install main bearings in cylinder block and bearing caps. Lubricate bearings with engine oil and carefully install crankshaft in cylinder block.
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600 SRM 1251
Crankshaft Repair 3. Install bearing caps. Make sure arrows on bearing caps are toward front (fan end) of engine. Push crankshaft forward and measure clearance at front side of rear main bearing. The correct clearance is 0.050 to 0.20 mm (0.002 to 0.008 in.). See Figure 55. 4. Tighten capscrews for bearing caps to 70 Nm (52 lbf ft). Move crankshaft forward and backward to align rear main bearing. Tighten capscrews for all bearing caps to 106 Nm (78 lbf ft). On late model engines, tighten capscrews for bearing caps to 20 Nm (177 lbf in) on the first pass. Move crankshaft forward and backward to align rear main bearing. Tighten capscrews for all bearing caps an additional 73 degrees on the final pass.
A. FAN END 1. MEASURE CLEARANCE Figure 55. Measuring Crankshaft Axial Clearance 5. Install connecting rods, oil pump, and oil pan. Install flywheel and other parts. 6. Install seal in retainer. Use new gasket and install seal retainer. See Figure 56. Tighten screws and nut to 15 Nm (133 lbf in).
A. SEAL REMOVAL NOTCHES 1. 2. 3. 4. CRANKSHAFT OIL SEAL SEAL RETAINER ENGINE BLOCK 5. 6. 7. 8. GASKET STUD SCREW NUT
Figure 56. Rear Seal Installation
27
Piston and Connecting Rod Assemblies Repair
600 SRM 1251

CONNECTING ROD BEARINGS, REPLACE
NOTE: Connecting rod bearings are insert bearings that do not use shims for adjustment. These bearings are available in a standard size and the following undersizes: 0.025 mm (0.001 in.), 0.051 mm (0.002 in.), 0.254 mm (0.010 in.), and 0.508 mm (0.020 in.). If a bearing on a journal is worn, both the upper and lower half of the bearing must be replaced. 1. Remove oil pan and oil pump. 2. Mark caps for connecting rods so they can be installed in their correct locations and positions. 3. Push connecting rod away from crankshaft and remove upper bearing half. Wipe oil from bearing halves and bearing journal. Make sure all parts from each rod assembly remain together. 4. Use a micrometer to measure bearing journal. The bearing journal must be within the following specifications: Out-of-round less than 0.0254 mm (0.001 in.) Taper less than 0.0254 mm (0.001 in.) If bearing journals are not within specifications, crankshaft must be removed and bearing journal ground to an undersize. If bearing journal cannot be repaired so bearing journal is a correct undersize, crankshaft must be replaced. See Engine Specifications, Crankshaft. 5. If bearing journal is within specifications, measure clearance between new bearing and crankshaft. Use Plastigage or equivalent to check clearance: a. Put a piece of Plastigage across the full width of the bearing journal as shown in Figure 57. Do not rotate crankshaft when Plastigage is between bearing and its journal. b. Install bearing cap and tighten bearing cap nuts first to 27 Nm (240 lbf in) and then an additional 70 degrees. c. Remove bearing cap. The Plastigage will be compressed and wider and will adhere to either the bearing or its journal. Use scale on Figure 58. Measuring Plastigage on Bearing Journal d. If clearance is greater than specifications, select a new undersize bearing set and install it. Measure clearance again. If clearance cannot meet specifications with available undersize bearings, bearing journal must be ground to a new undersize. If bearing journal is already at maximum undersize, crankshaft must be replaced. e. If clearance is within specifications, lubricate bearing with engine oil and install bearing and bearing cap. First tighten nuts on bearing caps to 27 Nm (240 lbf in). After this step, tighten nuts an additional 70 degrees. envelope for Plastigage to measure width of plastic at its widest point. The scale will indicate the clearance in millimeters or thousandths of an inch. See Figure 58.
Figure 57. Plastigage on Bearing Journal
28
600 SRM 1251 6. When all rod bearings have been replaced, use the following procedure to check side clearances between connecting rods and crankshaft: a. Use a hammer to lightly hit connecting rod parallel to crankshaft journal to make sure there is clearance. b. Measure side clearance between caps for connecting rods and crankshaft. See Figure 59 and Engine Specifications.
Piston and Connecting Rod Assemblies Repair 7. Push connecting rod and piston from cylinder. Temporarily install bearing cap on connecting rod to keep parts together.
DISASSEMBLE 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 piston rings from pistons. 2. Use a press to remove piston pins from piston. See Figure 60.
Figure 59. Measuring Connecting Rods Side Clearance
PISTON AND CONNECTING ROD ASSEMBLIES, REMOVE

1. Remove oil sump and oil pump. 2. Remove cylinder head as described in , Remove and Disassemble. 3. If engine has been in service for many hours, a ridge can be worn in the top of the cylinder. This ridge can be removed with a ridge reamer tool. Turn crankshaft to lower piston to bottom of stroke in its cylinder. Put cloth on top of piston for a collector of metal particles. Use a ridge reamer to remove ridge at top of cylinder. 4. Clean carbon from top of each cylinder. 5. Put an identification mark on top of each piston. 6. Remove caps and bearings from each connecting rod. Keep caps and bearings with their original piston assemblies. Mark caps so they will be installed again in their original positions. Do not mix parts. Figure 60. Piston Pin Removal
29
600 SRM 1251
PISTON, CLEAN AND INSPECT WARNING

Commercial cleaning solvents can be flammable and toxic and can cause severe skin irritation. When using commercial cleaning solvents, always comply with the solvent manufacturers recommended safety precautions. Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. 1. Use solvent to clean pistons and connecting rods. Use compressed air to dry parts. 2. Clean piston ring grooves with a ring groove cleaning tool. 3. Clean piston oil lubrication holes and slots. 4. Inspect pistons for wear, cracks, and damage. Replace a piston that is worn or damaged. NOTE: If the cylinder bore must be repaired, the piston must be changed to the correct oversize. Check clearance of piston in its cylinder after surface of cylinder bore has been finished with a hone. 5. Check clearance of piston pin in piston. The normal clearance is shown in the Engine Specifications. The piston pin will normally fall from the hole in the piston by its own weight. The piston pin is a press fit in the connecting rod. The piston and piston pin are a matched set and must be replaced as a unit if the clearances are greater than the specifications.
Figure 61. Cylinder Bore Measurement Measure cylinder bore in positions from top to bottom to find any taper from wear. A normal wear pattern for a cylinder bore is shown in Figure 62. A cylinder that has a taper (measurement A that is 0.127 mm (0.005 in.) greater than measurement B) must have a new bore. A tool called a hone can be used to remove a small amount of taper from a cylinder bore. Use a boring machine to repair a badly worn cylinder. The boring machine will make a more accurate cylinder bore. The hone is then used to finish the surface of the cylinder bore.
Figure 62. Pattern for Normal Cylinder Wear A cylinder bore that has been repaired with a hone or a boring machine must be fitted with a piston that is the correct size. Measure outer diameter of piston and inner diameter of cylinder bore as shown in Figure 63. Using different oversize pistons in the engine does not affect the dynamic balance of the engine. Replacement pistons from standard size to 0.508 mm (0.020 in.) oversize normally have the same weight. The clearance specifications between a piston and its cylinder bore is shown in Engine Specifications.
CYLINDER BORES, INSPECT AND REPAIR

Inspect cylinder bores for wear and damage. Measure cylinder bores in several positions as shown in Figure 61. Measure cylinder bore at right angles to centerline to find any distortion from wear. A cylinder that is out-of-round greater than 0.05 mm (0.002 in.) must be repaired.
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600 SRM 1251
Piston and Connecting Rod Assemblies Repair clearances are shown in the Engine Specifications. Replace piston if clearances are greater than specifications. 2. Measure end clearance of each piston ring as shown in Figure 65. The end clearances are shown in the Engine Specifications. Install piston ring into cylinder where it will be used. Use a thickness gauge to measure the amount of end clearance. Replace piston if clearances are greater than the specifications.
PISTON RINGS
NOTE: Check clearance of piston rings in cylinder after surface of cylinder has been finished with a hone. New piston rings are available for the following piston sizes: standard size, and 0.127 mm (0.005 in.), 0.254 mm (0.010 in.), 0.508 mm (0.020 in.), and 0.762 mm (0.030 in.) oversize. The piston rings must match the size of the piston on which they are installed. Check side clearance and end clearance of piston rings as described in the following paragraphs. Each compression ring has a mark on one surface. This mark must be toward the top of the cylinder when the piston ring is installed. The No. 1 compression ring normally has a chrome or molybdenum surface.
Figure 64. Piston Ring and Groove Clearance Check
A. PISTON GAUGE POINT
B. BORE GAUGE POINT
Figure 63. Piston and Cylinder Bore Gauge Points The oil control ring has three pieces. There are two thin steel rings separated by a spacer. 1. Measure clearance between piston ring and groove in piston as shown in Figure 64. The Figure 65. Piston Rings End Clearance Check
31
600 SRM 1251 Table 1. Piston Rings Arrangement on Piston A Position of Gap for Spacer of Oil Ring B Position of Gap for Oil Ring C Position of Gap for Second Compression Ring D Position of Gap for First Compression Ring Fan End of Engine
ASSEMBLE
NOTE: There are notches cast in the top of all pistons to indicate the correct assembly and installation. The pistons must always be installed with this notch toward the fan end of the engine. See Table 1. The connecting rods have a notch cast in the bearing journal as shown in Figure 66. This notch must be opposite the notch on the top of the piston when the piston and connecting rod are assembled. On later engines the flanges on the connecting rods and caps should face to the front of the engine on the left bank and to the rear of the engine on the right bank.
PISTON AND CONNECTING ROD ASSEMBLIES, INSTALL

1. Lubricate assembly with engine oil during installation. Arrange piston rings on piston as shown in Table 1. Install ring compressor on piston. 2. Make sure notch in piston is toward fan end of engine. Install piston and connecting rod assemblies in cylinder bores. 3. Install bearings and caps for connecting rods. Tighten nuts. See the procedure in Connecting Rod Bearings, Replace. 4. Check side clearance of each connecting rod after bearing cap is installed. See the procedure in Connecting Rod Bearings, Replace. 5. Install cylinder head as described in Cylinder Head Repair, Assemble and Install. 6. Install oil pump and oil pan.
1. NOTCHES ON ROD OPPOSITE NOTCH IN PISTON Figure 66. Connecting Rod Identification 1. Assemble connecting rod to piston. Make sure the orientation of connecting rod and piston are correct as described in the NOTE above. Use a press to install piston pin into piston and connecting rod. Lubricate piston pin with engine oil during installation. 2. Check clearances of piston rings as described in Piston Rings. Install piston rings on piston as shown in Table 1.
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600 SRM 1251
Flywheel and Flywheel Housing Repair
Flywheel and Flywheel Housing Repair

FLYWHEEL, REMOVE
1. Remove six flywheel capscrews and the flywheel from the engine. 2. Remove the bearing from flywheel. 3. Remove nine flywheel housing capscrews and flywheel housing from the engine. See Figure 67.
INSPECT
NOTE: Do not attempt to repair the welded areas, if present, that retain the ring gear to the flywheel plate. If the welded area is damaged, replace the flywheel assembly. 1. Inspect the flywheel for the following, see Figure 68: Stress cracks around the flywheel-to-torque converter bolt hole locations Missing balance weights Stress cracks around the flywheel-to-crankshaft bolt hole locations Welded areas that retain the ring gear onto the flywheel for cracking, if present Damaged ring gear teeth Damaged bearing
1. 2. 3. 4. 5.
FLYWHEEL HOUSING CAPSCREW FLYWHEEL CAPSCREW FLYWHEEL FLYWHEEL HOUSING FLYWHEEL BEARING Figure 67. Flywheel Removal
CLEAN WARNING
WARNING
Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. Clean the flywheel, bearing, and flywheel housing with cleaning solvent and dry using compressed air.
1. STRESS CRACK FLYWHEEL-TO-TORQUE CONVERTER BOLT HOLE 2. STRESS CRACK FLYWHEEL-TO-CRANKSHAFT BOLT HOLE 3. STRESS CRACK FLYWHEEL-TO-CRANKSHAFT BOLT HOLE 4. RING GEAR TO FLYWHEEL WELD 5. RING GEAR TEETH Figure 68. Flywheel Inspection
33
Coolant Pump Repair
600 SRM 1251
FLYWHEEL, INSTALL
1. Using nine flywheel housing capscrews, install flywheel housing on the engine. Tighten capscrews to 38 Nm (28 lbf ft). See Figure 67. 2. Install the bearing in the flywheel. 3. Install the flywheel to the crankshaft, and align the locator hole to the alignment pin. See Figure 69. 4. Install six flywheel capscrews and tighten in sequence shown in Figure 69 to 100 Nm (74 lbf ft).
1. FLYWHEEL 2. ALIGNMENT HOLE Figure 69. Tightening Sequence
Coolant Pump Repair

REMOVE
1. Remove four flange head bolts and fan clutch from the water pump. See Figure 70. 2. Disconnect inlet hose from the water pump. 3. Remove four capscrews, water pump, and two gaskets from the engine. Discard the gaskets. See Figure 71. A stain around the vent hole is acceptable. If leakage occurred (dripping) with the engine operating and the cooling system pressurized, the replace the water pump. Damaged bolt hole threads Excessive side-to-side movement of the water pump shaft Leakage around the water inlet pipe Leakage around the heater hose pipe Restrictions within the internal coolant passages If any of the above items are apparent during the inspection, replace the water pump.
CLEAN AND INSPECT

1. Remove all old gasket material from the sealing surfaces using care not to damage the sealing surfaces. 2. Clean all dirt and debris from the water pump. 3. Inspect the water pump for the following, see Figure 72: Leakage or damage to the housing cover Excessive scratches or gouging to the gasket sealing surfaces Leakage from the water pump vent hole
INSTALL
1. Using four capscrews, install two new gaskets and the water pump on the engine. Tighten the capscrews to 45 Nm (33 lbf ft). See Figure 71. 2. Connect inlet hose to the water pump. 3. Using four flange head bolts, install the fan clutch on the water pump. Tighten the flange head bolts to 25 Nm (18 lbf ft). See Figure 70.
34
600 SRM 1251
Coolant Pump Repair Legend for Figure 71 1. 2. 3. 4. CAPSCREW WATER PUMP GASKET ENGINE
1. 2. 3. 4.
FLANGE HEAD BOLT FAN CLUTCH INLET HOSE WATER PUMP Figure 70. Fan Clutch Removal
1. HOUSING COVER 2. GASKET SURFACES 3. VENT HOLE 4. BOLT HOLE THREADS
5. PUMP SHAFT 6. INLET PIPE 7. HEATER HOSE PIPE
Figure 72. Water Pump Inspection
Figure 71. Water Pump Removal
35
Thermostat Replacement
600 SRM 1251
Thermostat Replacement
REMOVE CAUTION
DO NOT operate the engine without a thermostat. The engine and cooling system can be damaged. 1. Remove two flange head bolts and thermostat housing from the engine. See Figure 73. 2. Remove the thermostat from the engine. 2. Using two flange head bolts install thermostat housing on the engine. Tighten Flange bolts to 25 Nm (221 lbf in). See Figure 73.
THERMOSTAT OPERATION CHECK

1. Mix a solution (33% antifreeze and water). Heat the solution to 14 C (57 F) above the temperature indicated on top of thermostat. 2. Hold thermostat with a wire and put it in the solution. Stir solution. When operating correctly, the thermostat will open. 3. Remove thermostat and put in a solution (33% antifreeze and water) that is 12 C (10 F) below the temperature on indicated on top of the thermostat. When operating correctly, the thermostat will close. The valve must close completely.
INSTALL
1. Install the thermostat in the engine. 1. 2. 3. 4. FLANGE HEAD BOLTS THERMOSTAT HOUSING THERMOSTAT ENGINE Figure 73. Thermostat Removal
CAUTION
To prevent possible damage to the thermostat seal, make sure the seal is completely seated in the engine groove before installing the thermostat housing.
36
600 SRM 1251
Fan Assembly Replacement

REMOVE WARNING
During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury. 10. Remove the fan.
INSPECT WARNING
DO NOT try to repair a damaged fan. If a fan has a bent blade or is cracked, install a new fan. A damaged fan can break during use and cause damage or serious injury. 1. Inspect the fan for any damage. 2. If the fan is damaged, replace the entire fan.
WARNING
The radiator or other parts of the cooling system 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.
INSTALL WARNING
The radiator fins on the radiator are very sharp and can cause serious injury. Wear gloves while installing fan assembly. 1. Install the lower portion of the shroud in the retaining clips and lean the shroud toward the engine. See Figure 74. 2. Install the spacer, washers, and capscrews to the fan. Tighten the capscrews to 55 Nm (40.5 lbf). See Figure 74. 3. Lean the radiator shroud back toward the radiator. Install the radiator shroud cover. 4. Install the screws and washers and tighten. 5. Reconnect the negative battery cable to the negative terminal of the battery. 6. Pull engine cover down and re-latch with engine cover latch. 7. Move the seat back. 8. Release the steering wheel tilt latch and move the steering wheel back. 9. If equipped, swing the LPG tank bracket back toward the truck and re-latch. 10. If equipped, turn the LPG tank valve to the ON position.
WARNING
The radiator fins on the radiator are very sharp and can cause serious injury. Wear gloves while removing fan assembly. NOTE: The fan that is used is a puller type fan. Do not replace with a pusher type fan. 1. Turn OFF lift truck. 2. If equipped, turn the LPG tank valve to the OFF position. 3. If equipped, release the LPG tank bracket and swing tank away from the lift truck. 4. Release the steering tilt latch and move the steering wheel forward. 5. Release the seat latch and move the seat forward. 6. Release engine cover latch on engine cover and swing engine cover up. 7. Disconnect the negative battery cable from the negative battery terminal. 8. Remove screws and washers from the radiator shroud. See Figure 74. Lean radiator shroud toward the fan. 9. Remove capscrews, washers, and spacer from the fan pulley.
37
600 SRM 1251
1. 2. 3. 4.
FAN SPACER WASHER CAPSCREW
5. SCREW 6. RADIATOR SHROUD 7. RADIATOR Figure 74. GM 4.3L Fan Removal
38
600 SRM 1251
Drive Belt Installation
Drive Belt Installation

REMOVE
1. Remove the drive belt from the engine. See Figure 75. 2. Remove locknut, tensioner pulley, and tensioner from the bracket. NOTE: Remove the bracket only if it is damaged. 3. Remove three capscrews, bracket, and alternator from the engine. Metal components (except the alternator) may be wiped down using a cloth with cleaning solvent.
INSPECT
1. Inspect the drive belt for wear and damage. See Figure 76. A few small cracks that run across the belt are acceptable. A belt with cracks that run the length of the belt or a belt with pieces missing is not acceptable. Replace a drive belt that is damaged.
1. ACCEPTABLE CRACKS 2. NOT ACCEPTABLE CRACKS AND DAMAGE Figure 76. Drive Belt Inspection 1. DRIVE BELT 2. LOCKNUT 3. TENSIONER PULLEY 4. CAPSCREW 5. 6. 7. 8. TENSIONER BRACKET ALTERNATOR ENGINE 2. Inspect all other components for cracks or other damage that would render the part as non-usable. Replace damaged parts or assemblies
INSTALLATION
NOTE: Perform step 1 only if the bracket was removed. 1. Using three capscrews, install the alternator and bracket on the engine. Tighten the capscrews to 90 Nm (66 lbf ft). 2. Install tensioner, tensioner pulley, and locknut on the bracket. 3. Install the drive belt on the engine. See Figure 75. 4. Ensure that the drive belt is routed correctly. See Figure 77.
Figure 75. Drive Belt Tensioner
CLEAN WARNING
Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturers recommended safety procedures. Clean all components thoroughly Clean rubber components with warm soapy water.
39
Compression Check
600 SRM 1251 Legend for Figure 77 1. 2. 3. 4. 5. 6. FAN PULLEY WATER PUMP PULLEY CRANKSHAFT PULLEY DRIVE BELT TENSIONER CENTERING PULLEY ALTERNATOR PULLEY
Figure 77. Drive Belt Arrangement
Compression Check
Check the compression as follows: 1. Remove all spark plugs. 2. Make sure battery is fully charged. 3. Install a compression gauge. Hold throttle open and crank engine with starter. The minimum pressure is 690 kPa (100 psi). The lowest pressure in a cylinder must not be less than 70% of the highest pressure. 4. If the readings are lower than the minimum readings, there is a problem with the valves, piston rings, or cylinder head gasket. Do the following tests to find the problem: a. Add approximately 30 ml (1 oz) of engine oil to each cylinder at spark plug hole. b. Crank engine approximately ten revolutions to distribute oil. c. Install compression gauge and do the same tests as described in Step 3. d. If compression pressure increases to a normal reading, the low pressure was caused by worn or damaged piston rings. The cylinder bore can also be damaged. e. If compression pressure does not increase, the low pressure was caused by worn valves, valve seats, or valve guides. f. If low pressure readings are in two cylinders next to each other, the cylinder head gasket can be leaking.
40
600 SRM 1251
Engine Specifications
ENGINE DATA
Number of cylinders Firing order Bore Stroke Compression Ratio Displacement Governor speed 6 1 6 5 4 3 2 101.62 to 101.64 mm (4.0008 to 4.0016 in.) 88.39 mm (3.480 in.) 9.2:1 4.3 liter (262.4 in. 3 ) See Periodic Maintenance section for each model of lift truck.
CYLINDER HEAD
Valve seat specifications Valve seat width (inlet valves) Valve Seat Width (exhaust valves) Clearance between inlet valve and guide Clearance between exhaust valve and guide Valve spring, free length See Figure 10 and Figure 12. 0.89 to 1.52 mm (0.035 to 0.060 in.) 1.57 to 2.36 mm (0.062 to 0.093 in.) 0.0254 mm (0.001 in.) max 0.0508 mm (0.002 in.) max See Figure 13.
HYDRAULIC VALVE LIFTER

Leak rate Body diameter Plunger travel Clearance in bore Lifter bore diameter 12 to 90 seconds with 50-lb load 21.3868 to 21.4046 mm (0.8420 to 0.8427 in.) 3.175 mm (0.125 in.) 0.0635 mm (0.0025 in.) 21.425 to 21.450 mm (0.8435 to 0.8445 in.)
CAMSHAFT
Variation from front to rear of a cam lobe Bearing journals, diameter Bearing journals, clearance Variation of a bearing journal in either diameter or axial direction Axial clearance Taper with larger dimension away from No. 1 piston 47.45 to 47.48 mm (1.8681 to 1.8693 in.) 0.01778 to 0.9685 mm (0.0007 to 0.0381 in.) 0.03 mm (0.001 in.) 0.10 to 0.30 mm (0.004 to 0.012 in.)
41
600 SRM 1251
PISTONS
Piston diameter (see gauge points in Figure 63 Cylinder Bore Out-of-round (see Figure 61) Maximum cylinder taper Clearance at bottom of cylinder 0.0508 mm (0.002 in.) 0.025 mm (0.001 in.) 0.068 mm (0.0027 in.)
Piston ring to groove clearance for piston rings (see Figure 64) Compression rings Oil ring to groove clearance Piston ring end clearance (see Figure 65) Compression rings Oil ring Piston pin to piston clearance Piston pin to connecting rod clearance 1.524 to 0.88 mm (0.06 to 0.035 in.) 0.23 to 1.65 mm (0.009 to 0.065 in.) 0.025 mm (0.001 in.) 0.020 to 0.040 mm (0.0008 to 0.0016 in.) 0.107 mm (0.0042 in.) 0.508 to 2.032 mm (0.02 to 0.08 in.)
CRANKSHAFT
Diameter of main bearing journal Number 1 Number 2, 3 Number 4 Out-of-round of main bearing journal (maximum) Taper of main bearing journal (maximum) Clearance between journals and main bearings Number 1 Number 2, 3, 4 Available undersize main bearings 0.0254 to 0.05 mm (0.0010 to 0.0020 in.) 0.025 to 0.006 mm (0.0010 to 0.0002 in.) 0.0254 mm ( 0.001 in.) 0.0508 mm ( 0.002 in.) 0.2285 mm ( 0.009 in.) 0.25 mm ( 0.010 in.) 0.50 mm ( 0.020 in.) Axial Clearance (crankshaft to thrust surface main bearing) 0.050 to 0.20 mm (0.002 to 0.008 in.) 62.20 to 62.22 mm (2.4488 to 2.4496 in.) 62.20 to 62.21 mm (2.4488 to 2.4492 in.) 62.18 to 62.20 mm (2.4480 to 2.4488 in.) 0.0254 mm (0.001 in.) 0.0254 mm (0.001 in.)
42
600 SRM 1251
CONNECTING RODS
Diameter of connecting rod journals Out-of-round of bearing journal (maximum) Taper of bearing journal (maximum) Clearance between crankshaft journals and connecting rod bearings Available undersize connecting rod bearings 57.12 to 57.14 mm (2.2488 to 2.2496 in.) 0.0254 mm (0.001 in.) 0.0254 mm (0.001 in.) 0.076 mm (0.0030 in.) 0.0254 mm ( 0.001 in.) 0.0508 mm ( 0.002 in.) 0.254 mm ( 0.010 in.) 0.508 mm ( 0.020 in.) Side clearance of connecting rod to crankshaft 0.15 to 0.44 mm (0.006 to 0.017 in.)
BALANCE SHAFT
Front bearing journal diameter Rear Bearing Journal Diameter Rear Bearing Journal Clearance 54.99 to 55.00 mm (2.1650 to 2.1654 in.) 38.08 to 38.10 mm (1.4992 to 1.500 in.) 0.025 to 0.091 mm (0.001 to 0.0036 in.)
COOLING SYSTEM
Thermostat 92 C (198 F)
LUBRICATION SYSTEM
Oil pressure @ 2000 rpm Minimum oil pressure Oil pressure @ 1000 rpm Oil pressure switch ON 34 kPa (5 psi) 20 to 39 kPa (2.9 to 5.7 psi) 207 to 380 kPa (30 to 55 psi)
43
Torque Specifications
600 SRM 1251
Torque Specifications
Alternator Pulley 61 Nm (45 lbf ft) Balance Shaft Gear Capscrew 20 Nm (177 lbf in) Plus 35 Degrees Balance Shaft Retainer Capscrews 12 Nm (106 lbf in) Camshaft Retainer Screws 12 Nm (106 lbf in) Camshaft Sprocket Capscrews 28 Nm (21 lbf ft) Camshaft Sprocket Nut 25 Nm (18 lbf ft) Chain Control Block for Hydraulic Pump Drive 19 Nm (168 lbf in) with Adhesive Sealant Connecting Rod Cap See Text Coolant Pump to Engine Block 41 Nm (30 lbf ft) Cooling Fan to Pulley 24 Nm (212 lbf in) Cylinder Head See Text Distributor Mount Capscrew 25 Nm (18 lbf ft) Exhaust Manifold 15 Nm (133 lbf in) - first step 30 Nm (22 lbf ft) - second step Flywheel 100 Nm (74 lbf ft) Flywheel Housing 48 Nm (35 lbf ft) Inlet Manifold to Cylinder Head 3 Nm (27 lbf in) - first step 12 Nm (106 lbf ft) - second step 15 Nm (133 lbf in) - third step (final) Main Bearing Cap 105 Nm (77 lbf ft) Motor Mount to Engine 31 Nm (23 lbf ft) Oil Pump Cover 12 Nm (106 lbf in) Oil Pump to Crankcase 90 Nm (66 lbf ft) Oil Pressure Switch 27 Nm (20 lbf ft) Oil Screen Support to Crankcase 50 Nm (37 lbf ft) Oil Pan to Crankcase Capscrews 25 Nm (18 lbf ft) Nuts 25 Nm (18 lbf ft) Rear Oil Seal Retainer Screws and Nut 15 Nm (133 lbf in) Rocker Arm Cover 12 Nm (106 lbf in) Rocker Arm Nuts 25 Nm (18 lbf ft) Rocker Arm Studs 47 Nm (35 lbf ft) Rocker Arm Bolts 30 Nm (22 lbf ft) Thermostat Housing 25 Nm (18 lbf ft) Timing Cover 12 Nm (106 lbf in) Valve Lifter Retainer Capscrews 16 Nm (142 lbf in) Vibration Damper 95 Nm (70 lbf ft)
44
TECHNICAL PUBLICATIONS
600 SRM 1251 6/06 (3/06) Printed in United Kingdom

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GM ENGINES

4.3 LITER V-6

PART NO. 1627339

600 SRM 1251

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR

2006 HYSTER COMPANY

TABLE OF CONTENTS (Continued)

600 SRM 1251

Cylinder Head Repair

Engine Removal and Installation

Cylinder Head Repair

Cylinder Head Repair

600 SRM 1251

4. VALVE 5. VALVE STEM OIL SEAL 6. CYLINDER HEAD

Figure 4. Valve Removal

600 SRM 1251

CLEAN AND INSPECT

1. VALVE STEM KEYS 2. VALVE SPRING CAP 3. VALVE SPRING

4. VALVE 5. VALVE STEM OIL SEAL 6. CYLINDER HEAD

Cylinder Head Repair

600 SRM 1251

VALVE GUIDES AND SEATS, REPAIRS

1. BURNT OR DAMAGED AREAS 2. UNDERSIZED MARGIN 3. BENT STEM

4. SCORING/DAMAGE TO THE STEM 5. WORN KEY GROOVE 6. WORN STEM TIP

Figure 7. Valve Inspection

600 SRM 1251

Cylinder Head Repair

1. VALVE STEM 2. DIAL INDICATOR Figure 9. Valve Steam Clearance

Cylinder Head Repair

Figure 11. Valve Head Measurements

VALVE SEATS, REPAIR

A. EXHAUST VALVE 1. CYLINDER HEAD

600 SRM 1251

Cylinder Head Repair

ASSEMBLE AND INSTALL

Cylinder Head Repair

600 SRM 1251

600 SRM 1251

Cylinder Head Repair

Cylinder Head Repair

600 SRM 1251

Engine Block Cleaning and Inspection

Engine Block Cleaning and Inspection

600 SRM 1251

Piston Bore Preparation

1. CYLINDER BORE 2. HONING PATTERN Figure 25. Correct Honing Pattern

600 SRM 1251

Lubrication System Repair

Engine Mounts Installation

CLEAN AND INSPECT WARNING

Lubrication System Repair

Lubrication System Repair

600 SRM 1251

1. CAPSCREW 2. NUT 3. OIL PAN

4. GASKET 5. ENGINE 6. THREADED STUD

1. CAPSCREW 2. OIL PUMP ASSEMBLY 3. ENGINE

4. DRIVE SHAFT RETAINER 5. DRIVE SHAFT

Figure 28. Oil Pump Removal

Figure 27. Oil Pan Removal

CLEAN AND INSPECT WARNING

600 SRM 1251

CAPSCREW SCREEN DRIVEN GEAR DRIVE GEAR RETAINER SHAFT HOUSING

Lubrication System Repair