Maintenance

MAZDA 2.2L ENGINE

GLC20-35VX (GC/GLC040-070VX,
GC/GLC55SVX) [B910];
GLP20-35VX (GP/GLP040-070VX) [C875]

PART NO. 550096315 0600 YRM 1673

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Yale® dealer.
Service Manuals provide general guidelines for maintenance and service and are intended for use by
trained and experienced technicians. Failure to properly maintain equipment or to follow instructions con-
tained 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 YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the
specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to re-
move 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 man-
ual:

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.
 Table of Contents

TABLE OF CONTENTS

General ..................................................................................................................................................................... 1
Serial Number .......................................................................................................................................................1
Engine Removal and Installation .............................................................................................................................. 1
Cylinder Head, Camshaft, and Valve Mechanism Repair .........................................................................................2
Remove ................................................................................................................................................................ 2
Clean .................................................................................................................................................................... 4
Inspect and Repair ............................................................................................................................................... 4
Cylinder Head .................................................................................................................................................. 4
Rocker Shaft Assembly ....................................................................................................................................4
Camshaft ..........................................................................................................................................................5
Valve Guides ....................................................................................................................................................6
Valve Seats ...................................................................................................................................................... 6
Valves .............................................................................................................................................................. 6
Valve Springs ................................................................................................................................................... 7
Install .................................................................................................................................................................... 8
Crankshaft and Main Bearings Repair ....................................................................................................................12
Remove .............................................................................................................................................................. 12
Inspect and Repair ............................................................................................................................................. 12
Crankshaft ......................................................................................................................................................12
Main Bearings ................................................................................................................................................ 13
Install .................................................................................................................................................................. 14
Pistons and Connecting Rods Repair .....................................................................................................................14
Remove and Disassemble ..................................................................................................................................14
Clean .................................................................................................................................................................. 15
Inspect and Repair ............................................................................................................................................. 15
Pistons ........................................................................................................................................................... 15
Piston Rings ................................................................................................................................................... 15
Connecting Rods and Bearings ..................................................................................................................... 16
Assemble and Install .......................................................................................................................................... 16
Cylinder Block Repair ............................................................................................................................................. 18
Oil Pump Repair ..................................................................................................................................................... 18
Remove .............................................................................................................................................................. 18
Disassemble ....................................................................................................................................................... 19
Clean .................................................................................................................................................................. 20
Inspect ................................................................................................................................................................ 20
Assemble ............................................................................................................................................................20
Install .................................................................................................................................................................. 21
Cooling System Repair ........................................................................................................................................... 23
Thermostat ......................................................................................................................................................... 23
Replace .......................................................................................................................................................... 23
Fan Assembly .....................................................................................................................................................23
Remove and Disassemble ............................................................................................................................. 23
Assemble and Install ...................................................................................................................................... 23
Water Pump ........................................................................................................................................................24
Remove ..........................................................................................................................................................24
Install ..............................................................................................................................................................24
Flywheel and Ring Gear Repair ..............................................................................................................................26
Remove .............................................................................................................................................................. 26
Install .................................................................................................................................................................. 26
Valve Adjustment ....................................................................................................................................................27

©2014 Yale Materials Handling Corp. i

Table of Contents

TABLE OF CONTENTS (Continued)

Compression Pressure Check ................................................................................................................................ 28

Engine Timing Adjustment ......................................................................................................................................28
Engine Specifications ............................................................................................................................................. 29
Engine Data ........................................................................................................................................................29
Engine Speeds ................................................................................................................................................... 29
Thermostat ......................................................................................................................................................... 29
Cylinder Head .....................................................................................................................................................29
Valve Mechanism ............................................................................................................................................... 29
Camshaft ............................................................................................................................................................ 30
Crankshaft .......................................................................................................................................................... 30
Connecting Rods ................................................................................................................................................ 31
Cylinder Block .....................................................................................................................................................31
Pistons ................................................................................................................................................................31
Oil Pump .............................................................................................................................................................32
Torque Specifications ............................................................................................................................................. 32

This section is for the following models:

GLC20-35VX (GC/GLC040-070VX, GC/GLC55SVX) [B910];

GLP20-35VX (GP/GLP040-070VX) [C875]

ii
0600 YRM 1673 General

General
This section contains instructions for removal, SERIAL NUMBER
disassembly, repair, assembly, installation, checks,
and adjustments for the Mazda 2.2L engine. The The engine serial number is located on the top left
engine specifications are provided at the end of the hand side of the cylinder head cover. See Figure 1.
section.

Additional information on the Mazda 2.2L engine can

be found in the following:

See section Gasoline Fuel System, Mazda 2.2L

Engine 0900YRM1676 for lift truck models
• GC040-070VX, GC055SVX) (B910)
• GP040-070VX (C875)

See section LPG Fuel System, Mazda 2.2L Engine

0900YRM1675 for lift truck models
• GLC20-35VX (GLC040-070VX, GC/
GLC055SVX) (B910)
• GLP20-35VX (GLP040-070VX) (C875)

See section Electrical System, Mazda 2.2L Engine

2200YRM1686 for lift truck models
• GLC20-35VX (GC/GLC040-070VX, GC/
GLC055SVX) (B910)
• GLP20-35VX (GP/GLP040-070VX) (C875)
Figure 1. Engine Serial Number Location

Engine Removal and Installation

The removal and installation procedures for the engine are not included in this section. See section Frame
0100YRM1672 for procedures to remove and install the engine.

1
Cylinder Head, Camshaft, and Valve Mechanism Repair 0600 YRM 1673

Cylinder Head, Camshaft, and Valve Mechanism Repair

REMOVE
1. Disconnect connections at battery.

2. Drain cooling system.

3. Remove air cleaner, throttle cable (if equipped),

intake manifold, and exhaust manifold.

4. Remove coolant hoses.

5. Remove the V belt.

6. Remove the cooling fan.

7. Remove bracket for cooling fan.

8. Remove the six capscrews retaining the crank-

shaft pulley to the timing pulley and remove the
crankshaft pulley.

9. Remove the spark plugs from the cylinder head.

10. Remove upper and lower timing belt covers. See

Figure 2.

11. Loosen capscrews for timing belt tensioner and

remove spring. Remove capscrews and timing
belt tensioner.

12. Use chalk to mark direction of timing belt rotation.

See Figure 3. Remove timing belt. 1. LOWER TIMING BELT COVER
2. UPPER TIMING BELT COVER
3. TIMING BELT TENSIONER
13. Remove the CAM angle sensor. Refer to the sec-
tion Electrical System, Mazda 2.2L Engine Figure 2. Timing Belt Covers
2200YRM1686 for procedures.

NOTE: Keep pulley from rotating when loosening

capscrew.

14. Loosen and remove capscrew and camshaft pul-

ley. See Figure 4.

15. Remove nuts, capscrews, and front housing. See

Figure 5.

16. Remove valve cover.

17. Loosen capscrews for rocker shaft supports in

proper sequence as shown in Figure 6. Remove
rocker shaft assembly and camshaft.

18. Remove capscrews for cylinder head in proper

sequence. See Figure 7.

19. Lift cylinder head from the block. Figure 3. Timing Belt

2
0600 YRM 1673 Cylinder Head, Camshaft, and Valve Mechanism Repair

Figure 4. Camshaft Gear Removal

Figure 6. Rocker Assembly Removal Sequence

1. FRONT HOUSING
2. GASKET
3. OIL SEAL

Figure 5. Front Housing Figure 7. Cylinder Head Removal Sequence

3
Cylinder Head, Camshaft, and Valve Mechanism Repair 0600 YRM 1673

20. Use valve spring compressor to remove valve re- 2. For the intake and exhaust manifold mounting
tainers, springs, and valves from head. See Fig- surfaces, use the same inspection procedures
ure 8. and correct if there are any faults.

Maximum amount of distortion is

0.15 mm (0.0059 in.). If grinding of cylinder head is
necessary, maximum amount of correction is
0.2 mm (0.008 in.).

Figure 8. Valve Removal

CLEAN

WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufactur-
er's recommended safety procedures.
Figure 9. Cylinder Head Inspection

CAUTION
DO NOT damage machined surfaces when clean- Rocker Shaft Assembly
ing.
1. Disassemble rocker shaft assembly. Put marks on
Clean all parts in solvent. Make sure all oil passages rocker arms so they can be installed on correct
are clean and all machined surfaces are smooth. shafts.

2. Clean oil passages in rocker shafts and rocker

INSPECT AND REPAIR arms.
Cylinder Head 3. Check clearance between rocker arms and rocker
shafts. Maximum clearance is
1. Use straight edge and thickness gauge to check
0.10 mm (0.004 in.).
bottom surface of cylinder head for distortion. Do
the measurements at the positions shown in Fig- Correct dimension for inside diameter of rocker arm
ure 9. is 16.000 to 16.027 mm (0.6299 to 0.6311 in.). Cor-
rect dimension for outside diameter of rocker shaft
Maximum amount of distortion is
is 15.966 to 15.984 mm (0.6286 to 0.6293 in.). If
0.15 mm (0.0059 in.). If grinding of cylinder head is
components do not meet specifications, replace
necessary, maximum amount of correction is
rocker arm(s) or rocker shaft(s) as necessary.
0.2 mm (0.008 in.).

4
0600 YRM 1673 Cylinder Head, Camshaft, and Valve Mechanism Repair

Camshaft 6. Measure clearance between camshaft and bore in

cylinder head as follows:
1. Check camshaft for cracks or damage.
a. Install camshaft in cylinder head.
2. Use dial indicator on end of camshaft to check
movement of camshaft in cylinder head. See Fig- b. Put plastic gauge material between each cam-
ure 10. Maximum movement is shaft journal and cap. Do not allow camshaft to
0.20 mm (0.008 in.). rotate.

c. Tighten capscrews for caps to 18 to

27 N•m (13 to 20 lbf ft). See Figure 13.

Correct clearance for journals No. 1 and 5 is

0.035 to 0.085 mm (0.0014 to 0.0033 in.). Cor-
rect clearance for journals No. 2, 3, and 4 is
0.065 to 0.115 mm (0.0026 to 0.0045 in.). If any
clearances are greater than
0.15 mm (0.0059 in.), replace cylinder head as-
sembly.

7. Replace camshaft if there is any damage or if it

does not meet specifications.

Figure 10. Camshaft Check

3. Measure height of camshaft lobes. See Figure 11.

Minimum height of intake and exhaust lobes is
37.170 mm (1.4634 in.).

4. Measure camshaft journals at four points (A-D) as

shown in Figure 11. Minimum dimensions for the
journals are as follows:
Front and Rear Journals (Nos. 1 and 5) -
31.940 to 31.965 mm (1.2575 to
1.2585 in.)
Center Journals (Nos. 2, 3 and 4) - 31.910
to 31.935 mm (1.2563 to 1.2573 in.)
Front Oil Seal Surface - 33.961 to
34.000 mm (1.3371 to 1.3386 in.)
1. FRONT OIL SEAL SURFACE
5. Check camshaft for straightness. Put front and 2. FRONT JOURNAL (NO. 1)
3. CENTER JOURNALS (NOS. 2, 3, AND 4)
rear journals in V blocks and rotate camshaft one 4. REAR JOURNAL (NO. 5)
complete turn. See Figure 12. Maximum amount
that the dial indicator should indicate is Figure 11. Camshaft Inspection
0.03 mm (0.0012 in.).

5
Cylinder Head, Camshaft, and Valve Mechanism Repair 0600 YRM 1673

3. To install valve guide, install retaining ring on

valve guide. Use valve guide installation tool to in-
stall valve guide so that retaining ring contacts
cylinder head. See Figure 14.

Correct height of valve guide above valve spring

seat is 19.1 to 19.6 mm (0.75 to 0.77 in.).

Figure 12. Camshaft Check

1. CYLINDER HEAD
2. RETAINING RING
3. VALVE GUIDE

Figure 14. Valve Guide Inspection

Valve Seats
1. PLASTIC GAUGE
2. SCALE 1. Inspect condition of valve seats. If valve seats
have cracks, cylinder head must be replaced.
Figure 13. Camshaft Clearance Measurement
2. If valve seats are in good condition, check contact
pattern of valve and valve seat. Use valve seat
grinder to make sure valve seats are within speci-
Valve Guides
fications shown in Figure 15. Use valve com-
1. Measure clearance between valve stems and pound to make sure valves fit seats.
valve guides.
Valves
Normal clearance for intake valve guides is 0.025
to 0.060 mm (0.001 to 0.002 in.). 1. Measure length of each valve.

Normal clearance for exhaust valve guides is 0.030 Minimum length for intake valve is
to 0.065 mm (0.0012 to 0.0026 in.). 111.19 mm (4.378 in.).

If clearance is more than 0.10 mm (0.004 in.), re- Minimum length for exhaust valve is
place valve or valve guide. 110.99 mm (4.370 in.).

2. If replacement is necessary, remove seal from

valve guide(s). Then use tool to remove valve
guide(s) from the combustion chamber side.

6
0600 YRM 1673 Cylinder Head, Camshaft, and Valve Mechanism Repair

Correct squareness of outer valve spring is

1.82 mm (0.072 in.).

If measurement is more than specification, replace

valve spring(s).

A. EXHAUST B. INTAKE
1. VALVE SEAT WIDTH
2. EXHAUST VALVE SEAT
3. INTAKE VALVE SEAT
Figure 15. Valve Seat Specifications

2. Inspect stem of each valve for wear. Use micro-

meter to measure outside diameter of stem at dif-
ferent points (A - E). See Figure 16.

Minimum dimension for intake valve is

7.980 mm (0.3142 in.). Minimum dimension for ex-
haust valve is 7.975 mm (0.3140 in.).
1. VALVE STEM
3. Inspect valves for cracks, burned faces, and dis- 2. THICKNESS, VALVE HEAD
tortion. Inspect seat face of valves for wear and Figure 16. Valve Inspection
damage.

4. Measure thickness of valve head. Minimum thick-

ness for intake valve is 0.5 mm (0.020 in.). Mini-
mum thickness for exhaust valve is
1.0 mm (0.040 in.).

If valves need grinding, correct surface angle is 30

degrees for both intake and exhaust valves.

Valve Springs
1. Check valve springs for damage.

2. Measure free length of valve springs. See Fig-

ure 17.

Minimum length of inner valve spring is

46.3 mm (1.823 in.). Minimum length of outer valve
spring is 50.6 mm (1.992 in.).

3. Check valve springs for squareness. See Fig-

ure 17.
A. MEASURE HERE
Correct squareness of inner valve spring is Figure 17. Valve Springs Inspection
1.66 mm (0.065 in.).

7
Cylinder Head, Camshaft, and Valve Mechanism Repair 0600 YRM 1673

INSTALL 5. Install capscrews and washers for cylinder head.

Tighten capscrews to 82 to 88 N•m (60 to
1. Clean surface of cylinder head and surface of en- 65 lbf ft) in proper sequence. See Figure 20.
gine block.
6. Apply gasket sealer to areas shown by arrows.
2. Using the appropriate seal installer tool, insert Lubricate camshaft with clean engine oil. Then in-
valve seals into valve guides. See Figure 18. stall camshaft. Make sure dowel pin is at top of
camshaft. See Figure 21.

1. TOOL
2. CYLINDER HEAD
3. VALVE GUIDE
4. VALVE SEAL

Figure 18. Valve Seal Installation

Figure 20. Cylinder Head Installation
3. Use valve spring compressor to install valve re-
tainers, springs, and valves into head. See Fig- 7. Lubricate rocker arms and shafts with engine oil.
ure 19. Put capscrews in rocker shaft supports. Then in-
stall assembly on cylinder head. See Figure 22.

8. Tighten capscrews for rocker shaft supports to 18

to 27 N•m (13 to 20 lbf ft) in proper sequence as
shown in Figure 23.

9. If necessary, install oil seal in front housing. See

Figure 24. Use new gasket and install front hous-
ing on cylinder head. Tighten capscrews for front
housing to 19 to 26 N•m (168 to 230 lbf in).

10. With dowel pin at top of camshaft, install camshaft

pulley. Check that number 1 on pulley is posi-
tioned approximately 2.5 degrees in the retard di-
rection.

11. Install capscrew and washer for camshaft pulley.

Figure 19. Valve Installation Keep pulley from turning and tighten capscrew to
48 to 66 N•m (35 to 49 lbf ft). See Figure 25.

4. Install new gasket and cylinder head on engine

block.

8
0600 YRM 1673 Cylinder Head, Camshaft, and Valve Mechanism Repair

Figure 23. Rocker Shaft Assembly Installation

1. DOWEL PIN
2. APPLY SEALANT HERE

Figure 21. Camshaft Installation

1. FRONT HOUSING
2. GASKET
3. OIL SEAL

Figure 24. Front Housing

A. NO. 1 AND NO. 3 ARE THE SAME

B. NO. 2 AND NO. 4 ARE THE SAME

Figure 22. Rocker Shaft Assembly

9
Cylinder Head, Camshaft, and Valve Mechanism Repair 0600 YRM 1673

13. Install timing belt tensioner and spring. Move ten-

sioner fully toward intake side of engine and tem-
porarily tighten lock bolt.

14. Clean any oil or grease from pulleys. Install timing

belt so that it goes in same direction as mark
made during removal.

15. Loosen lock bolt and apply spring tension on belt.

Rotate crankshaft pulley clockwise two complete
turns and check timing marks.

If timing marks are correct, tighten lock bolt for ten-

sioner to 20 to 35 N•m (15 to 26 lbf ft). Be sure ten-
sioner does not move together with lock bolt rota-
tion. Check movement on tension side of timing
belt. See Figure 27.

If tension is correct, belt will move 9 to 10 mm (0.36

to 0.39 in.) with 10 kg (22 lb) of force.

1. TIMING MARKS
2. CAMSHAFT PULLEY

Figure 25. Camshaft Pulley Installation

12. Align timing marks for crankshaft timing pulley.

See Figure 26.

1. TENSIONER 3. LOCK BOLT

2. SPRING 4. TENSION SIDE

Figure 27. Timing Belt Installation

16. Install lower timing belt cover and new gasket.

Tighten capscrews to 7 to 8 N•m (5 to 6 lbf ft). In-
stall upper timing belt cover and new gasket.
Tighten capscrews to 8 to 12 N•m (6 to 9 lbf ft).
See Figure 28.
1. CRANKSHAFT TIMING PULLEY 17. Install crankshaft pulley and six capscrews to re-
2. TIMING MARK tain pulley. Tighten pulley to 12 to 17 N•m (9 to
Figure 26. Timing Belt Installation 13 lbf ft).

10
0600 YRM 1673 Cylinder Head, Camshaft, and Valve Mechanism Repair

18. Apply gasket sealer to the areas shown in Fig-

ure 29. Install new gasket and valve cover.

19. Install valve cover capscrews and tighten to 6 to

8 N•m (52 to 70 lbf in).

20. Install spark plugs in cylinder head. Tighten spark

plugs to 15 to 23 N•m (11 to 16 lbf ft).

21. Install the CAM angle sensor. Refer to the section

Electrical System, Mazda 2.2L Engine
2200YRM1686 for procedures.

22. Install bracket for cooling fan.

23. Install coolant hoses.

24. Install air cleaner, throttle linkage (if equipped), in-

take manifold, and exhaust manifold.

CAUTION
Additives may damage the cooling system. Before
using additives, contact your local Yale dealer.

25. Fill cooling system.

26. Connect connections at battery.

1. LOWER TIMING BELT COVER

2. UPPER TIMING BELT COVER
3. TIMING BELT TENSIONER

Figure 28. Timing Belt Covers

Figure 29. Valve Cover Installation

11
Crankshaft and Main Bearings Repair 0600 YRM 1673

Crankshaft and Main Bearings Repair

REMOVE Maximum clearance is 0.30 mm (0.012 in.). If clear-
ance is greater than specification, replace center
1. Remove V belt. main bearing or grind crankshaft and install new
main bearing.
2. Remove cooling fan.

3. Remove bracket for cooling fan.

4. Remove six capscrews holding crankshaft pulley

to timing pulley.

5. Remove capscrew from crankshaft timing pulley.

Install special tool with spacer on crankshaft to re-
move timing pulley. Rotate tool until it touches
front of crankshaft. Hit tool with hammer to loosen
timing pulley. Remove pulley, dowel pin, tapered
ring, and spacer. Remove tool. See Figure 30.

6. Remove oil pan and oil strainer.

1. CENTER MAIN BEARING

Figure 31. Crankshaft Clearance Measurement

10. Put identification marks on bearing caps. Loosen

capscrews for main bearing caps in steps. Then
remove capscrews, caps, and crankshaft.

1. SPACER INSPECT AND REPAIR

2. TOOL
Crankshaft
Figure 30. Crankshaft Timing Pulley Removal
1. Inspect crankshaft for wear, cracks, or other dam-
age. Replace crankshaft if it has cracks.
7. Remove rear cover. Remove front cover with oil
pump. 2. Use micrometer to measure diameter of journals
for crankshaft. See Figure 32.
8. Remove caps for connecting rods. Put identifica-
tion mark on each cap so they will be installed in Take measurements at several locations for each
correct location. journal. Correct dimensions for journals are as fol-
lows:
9. Before removing crankshaft, measure clearance
between crankshaft and flange of center main Main Journal Diameter - 59.937 to
bearing. See Figure 31. Push crankshaft fully for- 59.995 mm (2.3597 to 2.3620 in.)
ward before making measurement.

12
0600 YRM 1673 Crankshaft and Main Bearings Repair

Connecting Rod Journals - 50.940 to Correct clearance for journal No. 3 is 0.031 to
50.955 mm (2.0055 to 2.0061 in.) 0.049 mm (0.00123 to 0.00192 in.).
Rear Oil Seal Surface - 89.946 to If any clearance is greater than specification, re-
90.000 mm (3.5412 to 3.5433 in.) place all main bearings.
Front Oil Seal Surface - 33.961 to
34.000 mm (1.3371 to 1.3386 in.)

If measurements are less than specifications, grind

crankshaft and install oversize bearings. Refer to
Parts Manual for different bearing sizes.

3. Check crankshaft for straightness. Put front and

rear journals in V blocks and rotate crankshaft
one complete turn. Maximum amount that dial in-
dicator should indicate is 0.03 mm (0.0012 in.).
See Figure 32

4. Check oil passages crankshaft. Make sure pas-

sages are clean and have no restrictions.

Main Bearings
NOTE: Inspect main bearings for damage. If any
main bearing is damaged, all main bearings must be
replaced.

1. To inspect main bearings for wear, measure

clearance between main bearings and crankshaft
using plastic gauge. See Figure 33.

a. Reinstall crankshaft in cylinder block.

b. Put plastic gauge material on journals and in-

stall main bearing caps. Tighten capscrews for
bearing caps to 84 to 90 N•m (62 to 66 lbf ft).

c. Remove bearing caps. Plastic gauge material

will adhere to journals or bearing caps.
1. REAR OIL SEAL SURFACE
d. Use graduations on scale to measure width of 2. CONNECTING ROD JOURNALS
plastic gauge material at its widest point. 3. MAIN BEARING JOURNALS
4. FRONT OIL SEAL SURFACE
Correct clearance for journals No. 1, 2, 4, and 5 Figure 32. Crankshaft Inspection
is 0.025 to 0.043 mm (0.00099 to 0.00169 in.).

13
Pistons and Connecting Rods Repair 0600 YRM 1673

Tighten M10 capscrews to 38 to 53 N•m (28 to

39 lbf ft). Tighten M8 capscrews to 19 to
26 N•m (14 to 19 lbf ft).

6. Lubricate surfaces of oil seal with engine oil. Use

press to install oil seal in rear cover. Install align-
ment pin in cylinder block.

7. Install new gasket and rear cover. See Figure 34.

Make sure dowel pin is installed. Tighten cap-
screws to 8 to 12 N•m (70 to 106 lbf in). Cut off
part of gasket that extends past bottom of cylinder
block.

8. Install oil strainer. Tighten capscrews to 8 to

12 N•m (70 to 106 lbf in).
1. PLASTIC GAUGE MATERIAL
2. SCALE 9. Apply adhesive sealant to a new oil pan gasket
and install new gasket and oil pan. Tighten cap-
Figure 33. Main Bearings Clearance Check screws to 8 to 12 N•m (71 to 106 lbf in).

INSTALL
1. Clean area of cylinder block around main bear-
ings. Carefully install bottom half of new main
bearings if necessary. Lubricate bearings with
clean engine oil.

2. Install crankshaft.

3. Install top half of main bearings in caps and lubri-

cate with oil. Use identification marks to install
main bearing caps in correct locations. Tighten
capscrews for main bearing caps to 84 to
90 N•m (62 to 66 lbf ft).

4. Install pistons and connecting rods as described

in Pistons and Connecting Rods Repair. 1. REAR COVER
2. OIL SEAL
5. Make sure O-ring is in oil pump housing. Lubri- 3. CRANKSHAFT
cate oil seal with engine oil. Use adhesive sealant
to install housing to cylinder block. Make sure Figure 34. Rear Cover
there is no sealant in oil port.

Pistons and Connecting Rods Repair

REMOVE AND DISASSEMBLE
CAUTION
1. Remove cylinder head as described in Cylinder DO NOT damage top of piston when placing iden-
Head, Camshaft, and Valve Mechanism Repair. tification mark. DO NOT make a deep identifica-
2. Remove oil pan and oil strainer. tion mark on top of piston.

3. Put identification mark on top of each piston.

14
0600 YRM 1673 Pistons and Connecting Rods Repair

4. Clean carbon from top of each cylinder bore. Piston Rings

5. Remove caps and bearings from each connecting 1. Install piston ring into cylinder bore where it will
rod. Keep caps and bearings with correct piston be used. Use thickness gauge to measure
assemblies. amount of end clearance of each piston ring. See
Figure 36. Correct dimensions are as follows:
NOTE: Measure and record the pin depth in the pis-
Top Piston Ring - 0.20 to 0.35 mm (0.008
ton for correct reassembly.
to 0.014 in.)
6. Push connecting rod and piston from cylinder 2nd Piston Ring - 0.15 to 0.30 mm (0.006
block. to 0.012 in.)
7. Carefully remove piston rings from pistons. Use Oil Ring - 0.20 to 0.70 mm (0.008 to
tool to push piston pin from connecting rod. 0.027 in.)
Maximum clearance is 1.0 mm (0.039 in.)
CLEAN
2. Measure clearance between piston ring and
groove in piston. See Figure 36. Correct dimen-
WARNING sions are as follows:
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning Top Piston Ring - 0.03 to 0.07 mm (0.0012
solvents, always follow solvent manufacturer's to 0.0028 in.)
recommended safety procedures. 2nd Piston Ring - 0.03 to 0.07 mm (0.0012
to 0.0028 in.)
Clean all parts in solvent. Make sure all oil passages Maximum clearance is
and grooves are clean. Make sure all machined surfa- 0.15 mm (0.0059 in.)
ces are smooth.

INSPECT AND REPAIR

Pistons
1. Inspect pistons for wear and cracks. Replace any
piston that is damaged.

2. Measure outside diameter of piston. Correct di-

mension is 85.943 to 85.965 mm (3.3836 to
3.3844 in.). Maximum clearance between piston
and cylinder bore is 0.15 mm (0.0059 in.). See
Figure 35.

1. PISTON RING END CLEARANCE

2. PISTON RING GROOVE CLEARANCE

Figure 36. Piston Rings Measurement

Figure 35. Piston Measurement

15
Pistons and Connecting Rods Repair 0600 YRM 1673

Connecting Rods and Bearings ASSEMBLE AND INSTALL

1. Use alignment tool to check connecting rods for 1. Align oil port on large end of connecting rod with
straightness. Contact your local machine shop. F mark on piston. See Figure 38.

Maximum amount of distortion per 50 mm (1.97 in.) 2. Lubricate piston pin and bore in piston with en-
is 0.18 mm (0.007 in.). gine oil.

Maximum amount of bending per 50 mm (1.97 in.) 3. Use press to install piston pin. Amount of force re-
is 0.075 mm (0.003 in.). quired to push pin into piston must be 500 to
1500 kg (1102 to 3306 lb).
If amount of distortion is greater than specification,
install new connecting rod. Make sure piston pin is installed to correct depth,
as recorded earlier. After installation, check that
2. Clean rod bearings and crankshaft journals. To piston moves freely on piston pin.
check bearings for wear, measure clearance be-
tween rod bearings and journals. See Figure 37.

a. Put plastic gauge material on crankshaft jour-

nals and install rod caps. Tighten capscrews
for rod caps to 51 to 56 N•m (48 to 51 lbf ft).
Do not rotate connecting rod.

b. Remove rod caps. Plastic gauge material will

adhere to journals or rod caps.

c. Use graduations on scale to measure width of

plastic gauge material at its widest point.

Correct clearance is 0.027 to 0.067 mm (0.0011

to 0.0026 in.). If any clearance is greater than
specification, replace all rod bearings.

1. F MARK 2. OIL PORT

Figure 38. Connecting Rod and Piston

4. Install piston rings on pistons. During installation,

the writing on each piston ring must be toward top
of piston. Check that rings rotate freely. Then put
ends of rings in positions shown in Figure 39.
Make sure ends of upper and lower oil control
rings are each 30 degrees from piston pin. Also
make sure that top and second rings are each 30
degrees from piston pin. Lubricate rings with en-
gine oil.
1. PLASTIC GAUGE
2. SCALE 5. Apply clean engine oil to piston assembly. Install
bearings for connecting rods. Install piston into
Figure 37. Connecting Rod Bearings Clearance
correct cylinder, making sure F is toward front
Check
(timing belt end) of engine. See Figure 40.

16
0600 YRM 1673 Pistons and Connecting Rods Repair

6. Apply clean engine oil to bearing. Then install

each cap to the correct connecting rod. During in-
stallation of caps, make sure to align identification
marks that were made during disassembly.
Tighten nuts for caps to 51 to 56 N•m (38 to
41 lbf ft).

1. F MARK
Figure 40. Piston Installation

A. OIL CONTROL RING

B. TOP AND SECOND RINGS
1. EXPANDER RING
2. OIL RING (UPPER)
3. OIL RING (LOWER)
4. TOP RING
5. SECOND RING
Figure 39. Piston Rings

17
Cylinder Block Repair 0600 YRM 1673

Cylinder Block Repair

1. After cylinder block is cleaned, check surface for
distortion. See Figure 41.

If amount of distortion is greater than

0.15 mm (0.0059 in.), grind surface of cylinder
block. Maximum amount of correction permitted is
0.20 mm (0.008 in.).

2. Check cylinder bores for wear and damage.

Measure each bore. Correct dimension is 86.00 to
86.019 mm (3.3858 to 3.3866 in.). Wear limit
above this dimension is .

Repair cylinder block or use bigger pistons as nec-

essary.

Refer to Parts Manual for available sizes.

Figure 41. Cylinder Block Inspection

Oil Pump Repair

Before removing oil pump, replace sending unit with 6. Align engine timing marks.
pressure gauge and check oil pressure. Minimum oil
pressure at governed rpm is approximately 7. Loosen capscrews for timing belt tensioner and
275 kPa (40 psi). If pressure is less than specification, remove spring. Remove capscrews and timing
oil pump or engine bearings need repair. belt tensioner.

8. Use chalk to mark direction of rotation of timing

REMOVE belt. Remove timing belt. See Figure 43.
1. Remove the V belt.
9. Remove capscrew from crankshaft timing pulley.
2. Remove the cooling fan. See Cooling System Re- Install special tool with spacer on crankshaft to re-
pair. move timing pulley. Rotate tool until it touches
front of crankshaft. Hit tool with hammer to loosen
3. Remove bracket for cooling fan. See Cooling Sys- timing pulley. Remove pulley, dowel pin, tapered
tem Repair. ring, and spacer. Remove tool. See Figure 44.

4. Remove six capscrews that hold crankshaft shaft 10. Remove capscrews and oil pan from cylinder
pulley to timing pulley. block.

5. Remove upper and lower timing belt covers. See 11. Remove capscrew and oil strainer assembly.
Figure 42.

18
0600 YRM 1673 Oil Pump Repair

12. Remove capscrews, front cover (pump housing)

and oil pump assembly.

1. SPACER 2. TOOL

Figure 44. Crankshaft Timing Pulley Removal

DISASSEMBLE
1. Remove screws and pump cover. See Figure 45.

2. Remove outer gear and inner gear from pump

body.

3. Remove snap ring and plunger assembly from

housing.

1. LOWER TIMING BELT COVER

2. UPPER TIMING BELT COVER
3. TIMING BELT TENSIONER
Figure 42. Timing Belt Covers

1. SCREW
2. COVER
3. OUTER GEAR
4. INNER GEAR
5. FRONT COVER (HOUSING)
6. OIL SEAL
7. PLUNGER
8. SNAP RING

Figure 45. Oil Pump

Figure 43. Timing Belt

19
Oil Pump Repair 0600 YRM 1673

CLEAN b. Measure clearance between housing and outer

rotor. Correct clearance is 0.090 to
0.176 mm (0.0035 to 0.0069 in.). If clearance is
WARNING more than 0.20 mm (0.008 in.), repair as nec-
Cleaning solvents can be flammable and toxic and essary.
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufactur- c. Use straight edge to measure side clearance of
er's recommended safety procedures. rotors. Correct clearance is 0.03 to
0.09 mm (0.0012 to 0.0035 in.). If clearance is
more than 0.10 mm (0.004 in.), repair as nec-
CAUTION essary.
DO NOT damage machined surface when clean-
ing. ASSEMBLE

Clean all parts in solvent. Make sure all machined 1. Install oil seal in oil pump housing. Make sure
surfaces are smooth. front edge of oil seal is even with outer edge of
housing. See Figure 45.
INSPECT 2. Lubricate gears with clean engine oil. Install gears
1. Check front cover (pump housing) and pump in housing.
cover for wear or damage. Check plunger spring 3. Install pump cover. Apply thread-locking com-
for damage. pound on screws for pump cover. Then install
2. Measure parts of oil pump. See Figure 46. screws.

a. Measure clearance between inner rotor tip and 4. Install plunger assembly and snap ring.
outer rotor. Maximum clearance is
0.18 mm (0.007 in.). If clearance is more than
0.18 mm (0.007 in.), repair as necessary.

1. CLEARANCE BETWEEN INNER ROTOR TOOTH TIP AND OUTER ROTOR

2. CLEARANCE BETWEEN HOUSING AND OUTER ROTOR
3. SIDE CLEARANCE OF ROTORS IN HOUSING

Figure 46. Oil Pump Measurement

20
0600 YRM 1673 Oil Pump Repair

INSTALL
1. Install O-ring on oil pump housing. Use grease to
hold O-ring in position. Lubricate oil seal with en-
gine oil. See Figure 47.

2. Use adhesive sealant to install oil pump housing

on cylinder block. Make sure there is no sealant in
oil port. Tighten M10 capscrews to 38 to
53 N•m (28 to 39 lbf ft). Tighten M8 capscrews to
19 to 26 N•m (14 to 19 lbf ft).

3. Install new gasket for strainer and install strainer

assembly. Tighten capscrews to 8 to 12 N•m (70
to 106 lbf in). See Figure 48.
1. O-RING
4. Apply adhesive sealant to a new oil pan gasket
and install new gasket and oil pan. Tighten cap- Figure 47. Oil Pump
screws to 8 to 12 N•m (70 to 106 lbf in). See Fig-
ure 48.

21
Cooling System Repair 0600 YRM 1673

1. CAPSCREW 5. GASKET
2. OIL STRAINER 6. CAPSCREW
3. CAPSCREW 7. GASKET
4. OIL PAN 8. OIL PUMP

Figure 48. Oil Strainer and Oil Pan

22
0600 YRM 1673 Cooling System Repair

Cooling System Repair

THERMOSTAT FAN ASSEMBLY
Replace Remove and Disassemble
1. Drain cooling system to level of thermostat. 1. Loosen alternator and remove fan belt.

2. Disconnect hose and remove thermostat housing. 2. Remove capscrews, fan, and pulley from hub.
Remove thermostat. See Figure 49.
3. Remove capscrews and fan bracket from engine.

4. Use press to remove fan hub from shaft. Remove

snap ring, push bearing, and shaft from bracket.
See Figure 50.

Assemble and Install

1. Use press to install shaft and bearing in bracket.
See Figure 50. Push bearing in until it touches
bracket. Install snap ring. Install hub on shaft.

2. Install bracket assembly on cylinder block.

Tighten M10 and M12 capscrews to 38 to
64 N•m (28 to 47 lbf ft).

3. Install pulley and fan on hub. Tighten capscrews

to 27 N•m (20 lbf ft).

1. CYLINDER BLOCK
2. GASKET
3. THERMOSTAT
4. HOUSING
Figure 49. Thermostat

3. Test operation of thermostat. See the section

Cooling System 0700YRM1674.

Thermostat must begin to open at 82 ±1.5°C (180

±3°F). Thermostat must be completely open at
95°C (203°F).

4. Install thermostat and new gasket. Make sure

print side of gasket is toward thermostat. See Fig-
ure 49.

5. Install thermostat housing and tighten capscrews

to 19 to 26 N•m (14 to 19 lbf ft).
1. FAN 4. SNAP RING
2. PULLEY 5. SHAFT
CAUTION 3. HUB 6. BRACKET
Additives may damage the cooling system. Before Figure 50. Fan Assembly
using additives, contact your local Yale dealer.

6. Connect hose and fill cooling system. Start engine

and check for leaks.

23
Cooling System Repair 0600 YRM 1673

NOTE: Tension for belt is correct when it moves 17 2. Clean any oil or grease from pulleys. Install timing
to 19 mm (0.67 to 0.75 in.) with 10 kg (22 lb) of force. belt so that it goes in same direction as mark
Tighten alternator when tension is correct. made during removal.

4. Install fan belt. Adjust tension of the fan belt. 3. Loosen lock bolt and apply spring tension on belt.
Check movement of fan belt between fan and al- Rotate crankshaft pulley clockwise two complete
ternator. turns and check timing marks.

WATER PUMP If timing marks are correct, tighten lock bolt for ten-
sioner to 38 to 53 N•m (28 to 39 lbf ft). Check
Remove movement on tension side of timing belt. See Fig-
ure 53.
1. Drain cooling system.
If tension is correct, belt will move 9 to 10 mm (0.36
2. Loosen alternator and remove fan belt. to 0.39 in.) with 10 kg (22 lb) of force.
3. Remove capscrews, fan, and pulley from hub.

4. Remove capscrews and fan bracket from engine.

5. Remove six capscrews that hold crankshaft shaft

pulley to timing pulley.

6. Remove upper and lower timing belt covers. See

Figure 51.

7. Align engine timing marks.

8. Loosen capscrews for timing belt tensioner and

remove spring. Remove capscrews and timing
belt tensioner.

CAUTION
DO NOT rotate the camshaft gear or the crank-
shaft gear while the timing belt is removed. If ei-
ther of the gears is moved, it will be necessary to
align the timing marks.

9. Use chalk to mark direction of rotation of timing

belt (see Figure 52). Then remove timing belt.

10. Disconnect hose at water pump. Remove cap-

screws and water pump from cylinder block.

Install
1. LOWER TIMING BELT COVER
1. Install water pump with a new gasket. Tighten 2. UPPER TIMING BELT COVER
capscrews to 19 to 26 N•m (14 to 19 lbf ft). 3. TIMING BELT TENSIONER

Figure 51. Timing Belt Covers

24
0600 YRM 1673 Cooling System Repair

4. Install lower timing belt cover and gasket. Tighten

capscrews to 7 to 10 N•m (62 to 89 lbf in). Install
upper timing belt cover and gasket. Tighten cap-
screws to 7 to 10 N•m (62 to 89 lbf in). See Fig-
ure 51.

5. Install fan assembly as described in the proce-

dure for Fan Assembly, Assemble and Install.

CAUTION
Additives may damage the cooling system. Before
using additives, contact your local Yale dealer.

6. Install coolant hoses. Fill cooling system with

coolant. See the Operating Manual or service
manual Periodic Maintenance 8000YRM1687
Figure 52. Timing Belt for the correct quantity and type of coolant to use.

7. Start engine and check cooling system for leaks.

WARNING
DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator cap is
removed, the pressure is released from the sys-
tem. If the system is hot, the steam and boiling
coolant can cause burns. DO NOT remove the
cover for the radiator when the engine is running.

8. After engine has been operated, stop engine. If

coolant is hot, give engine time to cool. Check
coolant level and add coolant if necessary.

1. TENSIONER
2. SPRING
3. LOCK BOLT
4. TENSION SIDE
Figure 53. Timing Belt Installation

25
Flywheel and Ring Gear Repair 0600 YRM 1673

Flywheel and Ring Gear Repair

REMOVE
1. Remove capscrews, flywheel, and adapter plate.
See Figure 54.

2. If necessary, remove flywheel housing.

INSTALL
1. If flywheel housing was removed, install it on en-
gine. Tighten M14 capscrews to 114 to
136 N•m (84 to 100 lbf ft). Tighten M10 cap-
screws to 38 N•m (28 lbf ft).

2. Install adapter plate on crankshaft. Install the fly-

wheel.

3. Apply Loctite® 222 or equivalent on threads of

capscrews. Then install capscrews for flywheel.
Tighten capscrews to 96 to 103 N•m (71 to
A. TIGHTENING SEQUENCE
76 lbf ft) in proper sequence. See Figure 54.
1. FLYWHEEL HOUSING
2. WASHER
3. CAPSCREW (M14)
4. ADAPTER PLATE
5. CAPSCREW
6. WASHER
7. FLYWHEEL
8. PIN
9. CAPSCREW (M10)
10. CAPSCREW (M10)

Figure 54. Flywheel Arrangement

26
0600 YRM 1673 Valve Adjustment

Valve Adjustment
1. Rotate crankshaft until No. 1 piston is at TDC on
compression stroke (intake and exhaust valves
closed).

NOTE: Correct clearance for intake valves when en-

gine is cold is 0.15 ±0.05 mm (0.0059 ±0.002 in.).
Correct clearance for exhaust valves when engine is
cold is 0.35 ±0.05 mm (0.0138 ±0.002 in.). See Fig-
ure 55.

2. Adjust clearance of intake valves for No. 1 and

No. 2 cylinders and exhaust valves for the No. 1
and No. 3 cylinders, by loosening lock nut and
turning adjustment screw. Tighten lock nut to 16
to 21 N•m (12 to 15 lbf ft).

NOTE: During adjustment of valves, check position

of balls in ends of rocker arms. Flat surface of ball
must be in contact with stem of valve.

3. Rotate crankshaft clockwise one complete turn.

Adjust remaining valves.

A. INTAKE VALVES
B. EXHAUST VALVES
C. INTAKE (ENGINE COLD): 0.15 mm (0.0059 in.),
EXHAUST (ENGINE COLD):
0.35 mm (0.0138 in.)
1. CAMSHAFT
2. ROCKER ARM
3. BALL
4. VALVE STEM

Figure 55. Valve Adjustment

27
Compression Pressure Check 0600 YRM 1673

Compression Pressure Check

CAUTION
When removing or installing the spark plugs from
the aluminum cylinder head, it is important that
you use care because of the dissimilar metals.
Penetrating oil may need to be used when remov-
ing the spark plugs. Apply a couple of drops of
engine oil to the spark plugs before installation.

1. Remove spark plugs from cylinder head. Discon-

nect high tension wire at ignition coil.

2. Install compression gauge in No. 1 cylinder. Make

sure gauge has minimum range of
1. ADAPTER
1725 kPa (250 psi). See Figure 56.
Figure 56. Compression Pressure Check
3. Use starter to crank engine at least six revolu-
tions. Check pressure reading and release pres-
sure. Repeat test again and make note of highest
4. If the readings are lower than minimum reading,
pressure. Do this test for each cylinder.
there is a problem with the valves, piston rings, or
The standard and minimum pressure specifications cylinder head gasket. Do the following tests to
are shown in Table 1. find the problem:

a. Add approximately 30 ml (1.0 oz) of engine oil

Table 1. Pressure Specifications to each cylinder at spark plug hole.

Pressure Gasoline LPG b. Crank engine approximately 10 revolutions to

distribute oil.
Standard Pres- 1130 kPa 1130 kPa
sure (164 psi) @ 270 (164 psi) @ 270 c. Install compression gauge and do same tests
rpm rpm as described in Step 3.
Minimum Pres- 793 kPa 793 kPa • If pressure reading increases to normal
sure (115 psi) @ 270 (115 psi) @ 270 reading, low pressure was caused by
rpm rpm worn or damaged piston rings. Cylinder
Maximum Differ- bore may also be damaged.
ence Between 196 kPa (28 psi) • If pressure reading does not increase,
Cylinders low pressure was caused by worn
valves, valve seats, or valve guides.
• If low pressure readings are in two cylin-
ders next to each other, cylinder head
may be leaking.

Engine Timing Adjustment

For Mazda 2.2L gas and LPG engines, see service The correct timing is as follows:
manual Electrical System, Mazda 2.2L Engine • Gasoline Engine = 6° ±1° BTDC @ 800 ±25
2200YRM1686 for the adjustment procedure for en- rpm (orange mark)
gine timing.
• LPG Engine = 6° ±1° BTDC @ 800 ±25 rpm
(orange mark)

28
0600 YRM 1673 Engine Specifications

Engine Specifications
ENGINE DATA THERMOSTAT
Starts to Open ..................... 82 ±1.5°C (180 ±35°F)
Engine Type ........................ In-line, Four Cylinders Fully Open ........................... 95 ±1.5°C (203 ±35°F)
Bore × Stroke ..................... 86 mm (3.39 in.) ×
94 mm (3.70 in.) CYLINDER HEAD
Displacement ..................... 2184 cm3 (133.2 in.3)
Firing Order ......................... 1 - 3 - 4 - 2 Height ................................. 91.95 to 92.05 mm
Valve Clearance (Exhaust, 0.35 ±0.05 mm (0.0138 (3.620 to 3.624 in.)
Engine Cold) ....................... ±0.002 in.) Distortion Limit .................... 0.15 mm (0.006 in.)
Valve Clearance (Intake, 0.15 ±0.05 mm (0.0059 Grinding Limit ......................0.20 mm (0.008 in.)
Engine Cold) ....................... ±0.002 in.)
Compression Ratio VALVE MECHANISM
– Gasoline 8.6:1
Compression Ratio Inside Diameter of Valve
– LPG 9.9:1 Guide ................................... 8.07 to 8.09 mm (0.3177
to 0.3185 in.)
Compression Pressure 1130 kPa (164 psi) @
Clearance in Guide (Ex-
– Gasoline 270 rpm
haust) .................................. 0.030 to
Compression Pressure 1130 kPa (164 psi) @ 0.065 mm (0.0012 to
– LPG 270 rpm 0.0026 in.)
Maximum Difference Be- 196 kPa (28 psi) Clearance in Guide (Intake)
tween Cylinders ................... 0.025 to
0.060 mm (0.001 to
Engine Timing (No. 1 Cylinder):
0.0024 in.)
– Gasoline 6° BTDC (Orange Mark)
– Service Limit 0.10 mm (0.004 in.)
– LPG 6° BTDC (Orange Mark) (Intake and Exhaust)
Oil Pressure @ 2400 rpm ....226 to 362 kPa (33 to Valve Length (Intake) .......... 111.49 to
53 psi) 112.29 mm (4.390 to
4.420 in.)
ENGINE SPEEDS
– Service Limit 111.19 mm (4.378 in.)
Idle and Governed Speed Valve Length (Exhaust) ....... 111.29 to
112.09 mm (4.382 to
– Idle Speed 800 ±25 rpm
4.412 in.)
– Governed Speed 2700 ±25 rpm
– Service Limit 110.99 mm (4.370 in.)
Stall Speed (New Engine):
– Gasoline 2073 ±100 rpm
– LPG 1995 ±100 rpm
Stall Speed (Engine With 30 Hours or More):
– Gasoline 2183 ±100 rpm
– LPG 2100 ±100 rpm

29
Engine Specifications 0600 YRM 1673

Diameter of Valve Stem (In- CAMSHAFT

take) .................................... 8.03 to
8.045 mm (0.3161 to
0.3167 in.) Runout .................................Less than
– Service Limit 7.980 mm (0.3142 in.) 0.03 mm (0.0012 in.)

Diameter of Valve Stem (Ex- Cam Lobes to Production

haust) .................................. 8.025 to Limit .....................................37.370 mm (1.4713 in.)
8.045 mm (0.3159 to Cam Lobes to Service Limit
0.3167 in.) 37.170 mm (1.4634 in.)
– Service Limit 7.975 mm (0.3140 in.) Bearing Journals (Nos. 1 31.940 to 31.965 mm
Valve Head Thickness (In- and 5) .................................. (1.2575 to 1.2585 in.)
take) .................................... 0.5 mm (0.020 in.) Bearing Journals (Nos. 2, 3, 31.910 to 31.935 mm
Valve Head Thickness (Ex- and 4) .................................. (1.2563 to 1.2573 in.)
haust) .................................. 1.0 mm (0.040 in.) Bearing Journal Wear Limit . 0.03 mm (0.0012 in.)
Valve Face Angle (Intake Clearance Between Jour-
and Exhaust) ....................... 30° nals and Bore (Nos. 1 and 0.035 to 0.085 mm
Spring Free Length - Outer 5) ......................................... (0.0014 to 0.0033 in.)
52.2 mm (2.055 in.) Clearance Between Jour-
– Service Limit 50.6 mm (1.992 in.) nals and Bore (Nos. 2, 3, 0.065 to 0.115 mm
and 4) .................................. (0.0026 to 0.0045 in.)
Spring Free Length - Inner . 47.7 mm (1.878 in.)
– Service Limit 0.15 mm (0.006 in.)
– Service Limit 46.3 mm (1.823 in.)
End Clearance .................... 0.08 to 0.16 mm (0.003
Spring Out of Square - to 0.006 in.)
Outer .................................. More than
1.82 mm (0.072 in.) – Service Limit 0.20 mm (0.008 in.)

Spring Out of Square - Inner CRANKSHAFT

............................................ More than
1.66 mm (0.065 in.)
Rocker Arm Shaft Diameter Runout ................................ less than
15.966 to 0.03 mm (0.0012 in.)
15.984 mm (0.6286 to Main Bearing Journal Diam-
0.6293 in.) eter, Standard ..................... 59.937 to 59.955 mm
Rocker Arm Bore Diameter . (2.3597 to 2.3604 in.)
16.000 to – Service Limit 0.05 mm (0.002 in.)
16.027 mm (0.6299 to
0.6311 in.) 0.25 mm (0.01 in.) Under-
size (Nos. 1, 2, 4, and 5) ..... 59.679 to 59.736 mm
Clearance Between Rocker (2.3496 to 2.3518 in.)
Arm and Shaft ..................... 0.016 to 0.061 mm
(0.0006 to 0.0024 in.) 0.25 mm (0.01 in.) Under- 59.673 to 59.730 mm
size (No. 3) ......................... (2.3494 to 2.3515 in.)
– Service Limit 0.10 mm (0.004 in.)
0.50 mm (0.02 in.) Under-
size (Nos. 1, 2, 4, and 5) ..... 59.429 to 59.486 mm
(2.3398 to 2.3419 in.)
0.50 mm (0.02 in.) Under- 59.423 to 59.480 mm
size (No. 3) ......................... (2.3395 to 2.3417 in.)
0.75 mm (0.03 in.) Under-
size (Nos. 1, 2, 4, and 5) ..... 59.179 to 59.236 mm
(2.3299 to 2.3321 in.)

30
0600 YRM 1673 Engine Specifications

0.75 mm (0.03 in.) Under- 59.173 to 59.230 mm CONNECTING RODS

size (No. 3) ......................... (2.3297 to 2.3318 in.)
– Grinding Limit 0.75 mm (0.030 in.)
Distortion Limit .................... 0.18 mm (0.007 in.) per
Clearance Between Jour- 50 mm (1.97 in.)
nals and Main Bearings
(Nos. 1, 2, 4, and 5) ............ 0.025 to 0.043 mm Bending Limit ...................... 0.075 mm (0.003 in.) per
(0.000099 to 50 mm (1.97 in.)
0.00169 in.) Small End Bore ...................21.943 to 21.961 mm
Clearance Between Jour- (0.8639 to 0.8646 in.)
nals and Main Bearings Interference Between Piston
(No. 3) ................................. 0.031 to 0.049 mm Pin and Bore ....................... 0.037 to
(0.0012 to 0.0019 in.) 0.013 mm (0.0014 to
– Service Limit 0.08 mm (0.003 in.) 0.0006 in.)

Connecting Rod Journal Di- Clearance Between Crank-

ameter, Standard ................ 50.940 to 50.955 mm shaft Journals and Rod 0.027 to
(2.0055 to 2.0061 in.) Bearings .............................. 0.067 mm (0.0011 to
0.0026 in.)
0.25 mm (0.01 in.) Under- 50.690 to 50.705 mm
size ..................................... (1.9957 to 1.9962 in.) – Service Limit 0.10 mm (0.004 in.)

0.50 mm (0.02 in.) Under- 50.440 to 50.455 mm CYLINDER BLOCK

size ..................................... (1.9859 to 1.9864 in.)
0.75 mm (0.03 in.) Under- 50.190 to 50.205 mm
size ..................................... (1.9760 to 1.9765 in.) Distortion at Top Surface .... 0.15 mm (0.0059 in.)
– Service Limit 0.05 mm (0.002 in.) Grinding Limit ...................... 0.20 mm (0.008 in.)
– Grinding Limit 0.75 mm (0.030 in.) Bore Diameter ..................... 86.00 to 86.019 mm
Thrust Bearing Thickness, (3.3858 to 3.3866 in.)
Standard ............................. 27.94 to 27.99 mm – Wear Limit 0.15 mm (0.0059 in.)
(1.1000 to 1.1019 in.)
0.25 mm (0.01 in.) Under- 28.04 to 28.09 mm PISTONS
size ..................................... (1.1040 to 1.1060 in.)
0.50 mm (0.02 in.) Under- 28.12 to 28.17 mm
Diameter, Standard ............. 85.945 to 85.965 mm
size ..................................... (1.1071 to 1.1090 in.)
(3.3836 to 3.3844 in.)
0.75 mm (0.03 in.) Under- 28.20 to 28.25 mm
0.25 mm (0.01 in.) Over- 86.193 to 86.215 mm
size ..................................... (1.1103 to 1.1122 in.)
size ...................................... (3.394 to 3.3943 in.)
Thrust Bearing Clearance ...
0.50 mm (0.02 in.) Over- 86.443 to 86.465 mm
0.08 to 0.18 mm (0.003
size ...................................... (3.4033 to 3.4041 in.)
to 0.007 in.)
Clearance Between Piston
– Service Limit 0.30 mm (0.012 in.)
and Bore .............................. 0.035 to 0.076 mm
(0.0014 to 0.0030 in.)

31
Torque Specifications 0600 YRM 1673

– Service Limit 0.15 mm (0.0059 in.) OIL PUMP

Piston Pin Diameter ............ 21.988 to 21.998 mm
(0.8657 to 0.8660 in.)
Clearance Between Inner Rotor Tip and Outer Rotor
Groove Width for Piston
Rings Nos. 1 and 2 .............. 1.520 to 1.540 mm – Service Limit 0.18 mm (0.007 in.)
(0.0598 to 0.0606 in.) Clearance Between Hous-
Groove Width for Oil Ring ... ing and Outer Rotor ............ 0.090 to 0.176 mm
4.020 to 4.040 mm (0.0036 to 0.0069 in.)
(0.1583 to 0.1591 in.) – Service Limit 0.20 mm (0.008 in.)
Piston Ring Clearance in Side Clearance Between
Groove (Nos. 1 and 2) ......... 0.03 to 0.07 mm (0.0012 Rotors and Housing ............ 0.03 to 0.09 mm (0.0012
to 0.0028 in.) to 0.0035 in.)
– Service Limit 0.15 mm (0.0059 in.) – Service Limit 0.10 mm (0.004 in.)
Piston Ring End Clearance:
– Top Ring 0.20 to 0.35 mm (0.008
to 0.014 in.)
– Second Ring 0.15 to 0.30 mm (0.006
to 0.012 in.)
– Oil Control Ring 0.20 to 0.70 mm (0.008
to 0.027 in.)
– Service Limit
(All Rings) 1.0 mm (0.039 in.)

Torque Specifications
Camshaft Pulley Lock Bolt Exhaust Manifold
48 to 66 N•m (35 to 49 lbf ft) 22 to 29 N•m (16 to 21 lbf ft)

Camshaft Cap Flywheel

18 to 27 N•m (13 to 20 lbf ft) 96 to 103 N•m (71 to 76 lbf ft)

Cooling Fan Flywheel Housing

27 N•m (20 lbf ft) M10 Capscrews 38 N•m (28 lbf ft)
M14 Capscrews 114 to 136 N•m (84 to 100 lbf ft)
Connecting Rod Cap
66 to 70 N•m (49 to 52 lbf ft) Front Housing
19 to 26 N•m (14 to 19 lbf ft)
Crankshaft Pulley
12 to 17 N•m (9 to 13 lbf ft) Heat Gauge Unit
11.8 to 17.6 N•m (105 to 156 lbf in)
Cylinder Head
81 to 88 N•m (60 to 65 lbf ft) Intake Manifold
19 to 31 N•m (14 to 23 lbf ft)
Engine Mount to Engine
55 N•m (41 lbf ft) Main Bearing Cap
84 to 90 N•m (62 to 66 lbf ft)
Engine Mount Capscrew
150 N•m (111 lbf ft) Oil Pan
8 to 12 N•m (71 to 106 lbf in)

32
0600 YRM 1673 Torque Specifications

Oil Pressure Switch Spark Plugs

12 to 17 N•m (9 to 13 lbf ft) 15 to 23 N•m (11 to 16 lbf ft)

Oil Pan Drain Plug Starter

30 to 41 N•m (22 to 30 lbf ft) 38 N•m (28 lbf ft)

Oil Pump Thermostat Housing Capscrews

M8 Capscrews 19 to 26 N•m (14 to 19 lbf ft) 19 to 26 N•m (14 to 19 lbf ft)
M10 Capscrews 38 to 53 N•m (28 to 39 lbf ft)
Timing Belt Cover Capscrews
Oil Strainer 7 to 10 N•m (62 to 89 lbf in)
8 to 12 N•m (71 to 106 lbf in)
Timing Belt Tension Lock Bolt
Rocker Cover 38 to 53 N•m (28 to 39 lbf ft)
6 to 8 N•m (52 to 70 lbf in)
Timing Pulley Lock Bolt
Rear Cover 157 to 167 N•m (116 to 123 lbf ft)
8 to 12 N•m (70 to 106 lbf in)
Water Pump
Rocker Shaft Assembly 19 to 26 N•m (14 to 19 lbf in)
18 to 27 N•m (13 to 20 lbf ft)

33
 NOTES

34
0600 YRM 1673 4/14