Maintenance GM ENGINE REPAIR GM 2.4 LITER ENGINE GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) [A910]; GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875] PART NO. 524223755 600 YRM 1121
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 contained in the Service Manual could result in damage to the products, personal injury, property damage or death. When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load. Do not lift heavy parts by hand, use a lifting mechanism. Wear safety glasses. DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks. Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section. Keep the unit clean and the working area clean and orderly. Use the correct tools for the job. Keep the tools clean and in good condition. Always use 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 remove parts. Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs. Be sure to follow the WARNING and CAUTION notes in the instructions. Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems. Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated. NOTE: The following symbols and words indicate safety information in this manual: WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage. On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.
GM Engine Repair Table of Contents TABLE OF CONTENTS General... 1 Engine Serial Number... 1 Engine Removal and Installation... 3 Intake Manifold... 3 Remove... 3 Clean and Inspect... 4 Install... 4 Exhaust Manifold... 5 Remove... 5 Clean and Inspect... 5 Install... 5 Camshaft and Cylinder Head Repair... 6 Rocker Arm Cover... 6 Remove... 6 Install... 6 Camshaft Timing Pulley and/or Front Seal... 6 Remove... 6 Install... 7 Camshaft Carrier and Cylinder Head... 8 Remove... 8 Disassemble... 9 Camshaft Carrier... 9 Cylinder Head... 10 Clean and Inspect... 11 Camshaft Carrier... 11 Cylinder Head... 11 Valve and Valve Seat... 13 Assemble... 14 Cylinder Head... 14 Camshaft Carrier... 14 Install... 14 Timing Belt... 16 Timing Belt Front Cover... 16 Remove... 16 Install... 17 Timing Belt and Timing Belt Tensioner... 17 Remove... 17 Install... 18 Timing Belt Rear Cover... 19 Remove... 19 Install... 19 Lubrication System Repair... 20 Oil Pan... 20 Remove... 20 Install... 20 Oil Pump... 22 Remove... 22 Clean and Inspect... 23 Install... 24 Piston and Piston Rod Assemblies Repair... 24 Piston Rod Bearings, Replace... 24 2012 Yale Materials Handling Corp. i
Table of Contents GM Engine Repair TABLE OF CONTENTS (Continued) Piston and Piston Rod Assemblies... 26 Remove... 26 Disassemble... 27 Pistons, Clean and Inspect... 28 Cylinder Bores, Inspect and Repair... 28 Piston Rings, Inspect... 29 Assemble... 30 Install... 30 Crankshaft and Main Bearings... 31 Crankshaft Timing Pulley and/or Front Seal... 31 Remove... 31 Install... 32 Crankshaft Rear Main Oil Seal... 33 Remove... 33 Install... 33 Crankshaft/RPM Sensor... 33 Remove... 33 Install... 34 Crankshaft Reluctor Wheel... 34 Remove and Install... 34 Crankshaft and Main Bearings... 34 Remove... 34 Inspect and Repair... 35 Bearing Selection... 36 Main Bearings and Journal Clearance, Check... 37 Install... 38 Flywheel and Flywheel Housing... 39 Remove... 39 Install... 39 Cooling System Repair... 40 Serpentine Belt... 40 Remove... 40 Inspect... 40 Install... 40 Water Pump... 41 Remove... 41 Inspect... 41 Install... 43 Thermostat... 44 Remove... 44 Check... 44 Install... 45 Thermostat Housing... 46 Remove... 46 Clean and Inspect... 46 Install... 46 Sensors and Switches... 48 Crankshaft Position (CKP) Sensor... 48 Remove... 48 Install... 48 Camshaft Position (CMP) Sensor... 48 ii
GM Engine Repair Table of Contents TABLE OF CONTENTS (Continued) Remove for Lift Trucks Built Before January, 2010... 48 Assembly... 48 Sensor Only... 48 Install for Lift Trucks Built Before January, 2010... 49 Assembly... 49 Sensor Only... 49 Remove for Lift Trucks Built After January, 2010... 50 Install for Lift Trucks Built After January, 2010... 50 Oil Pressure Sensor... 50 Remove... 50 Install... 50 Ignition System... 51 Spark Plug Wire Inspection... 51 Spark Plug Wire Replacement... 51 Remove... 51 Install... 52 Spark Plug Replacement... 52 Remove... 52 Install... 53 Spark Plug Inspection... 53 Usage... 53 Inspect... 53 Visual Inspection... 55 Coil Pack... 55 Remove... 55 Install... 55 Alternator Repair... 56 Alternator... 56 Remove... 56 Install... 56 Alternator Fuse, Replace... 56 Starter Repair... 57 Remove... 57 Install... 57 Engine Specifications... 58 Engine Data... 58 Cylinder Bore... 58 Piston... 58 Piston Rings... 59 Wrist Pin... 59 Crankshaft... 59 Piston Rod... 60 Camshaft and Camshaft Carrier... 60 Valve System... 60 Cylinder Head Warpage... 61 Lubrication System... 61 Cooling System... 61 Torque Specifications... 62 Special Tools... 63 iii
Table of Contents GM Engine Repair TABLE OF CONTENTS (Continued) This section is for the following models: GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) [A910]; GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875] iv
600 YRM 1121 Engine Serial Number This section has the repair instructions for the GM 2.4 liter engine. General The location of the engine serial number is shown in Figure 1 and Figure 2. Engine Serial Number 1. ENGINE SERIAL NUMBER Figure 1. Engine Serial Number Prior to January, 2010 1
Engine Serial Number 600 YRM 1121 1. ENGINE SERIAL NUMBER Figure 2. Engine Serial Number After January, 2010 2
600 YRM 1121 Intake Manifold CAUTION Disconnect the battery cables before doing any disassembly and repair to the engine or parts of the electrical system. The diodes and resistors in the electrical 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 is made of the wire before it is connected. Make sure a battery is the correct voltage and polarity before it is connected. Engine Removal and Installation Intake Manifold Do not check for current flow by making a spark because the electronic components can be damaged. CAUTION Many parts of the engine assembly are made of aluminum. Use care not to damage mating surfaces or threads. To preventpossible damage to mating surfaces, do not clean with wire brushes, steel wool, or sharp objects. Do not overtighten parts that are aluminum or mount to an aluminum part, as this can cause damage to the threads or part. The procedures to remove and install the engine are not included in this section. See the section Frame 100 YRM 1120 for these procedures. REMOVE NOTE: Step 1 is for gasoline engines only. 1. Disconnect the electrical connector from the fuel pump. NOTE: Step 2 is for LPG fuel systems only. 2. Close the fuel valve on the propane tank. 3. Start the engine and let it idle until the engine shuts down from the lack of fuel. NOTE: Step 4 is for gasoline engines only. 4. Crank the engine for approximately five seconds for full pressure relief from the fuel system. 5. Disconnect the negative battery cable. 6. Remove the left rear side cover. Refer to the section Frame 100 YRM 1120. 7. Disconnect the air intake hoses from the air filter assembly. NOTE: The ECM assembly must be disconnected from the air filter assembly before removing the air filter assembly. For gasoline engines, refer to the section Gasoline Fuel System, GM 2.4L Engine 900 YRM 1126. For LPG fuel systems, refer to the section LPG Fuel System, GM 2.4L Engine 900 YRM 1124. 8. Remove the three bolts that attach the air filter assembly mounting bracket to the frame and remove air filter assembly with mounting bracket. 9. Disconnect the electrical connections to the throttle body. 10. Disconnect the fuel delivery hoses and return hoses, or LPG vapor hose. 11. Disconnect the vacuum hose from the intake manifold. 12. Disconnect the air intake hoses and positive crankcase ventilation (PCV) valve hoses from the intake manifold. 13. Disconnect the wiring harness connectors to the fuel injectors. 14. Disconnect the electrical connector to the MAP sensor. 15. Remove the nuts retaining the intake manifold to the cylinder head. See Figure 3. 3
Intake Manifold 600 YRM 1121 4. Place the intake manifold into position on the cylinder head. 5. Install the retaining nuts on the studs. Tighten the nutsto18to22n m(13to16lbfft). 6. Connect the electrical connector to the MAP sensor. 7. Connect the wiring harness connectors to the fuel injectors. 8. Connect the air intake hoses and PCV valve hoses to the intake manifold. 1. INTAKE MANIFOLD 2. NUT Figure 3. Intake Manifold 16. Remove the intake manifold. 3. CYLINDER HEAD 17. Remove the intake manifold gasket and discard. 18. Remove and replace fuel system components as needed. For gasoline engines, refer to the section Gasoline Fuel System, GM 2.4L Engine 900 YRM 1126. For LPG fuel systems, refer to the section LPG Fuel System, GM 2.4L Engine 900 YRM 1124. CLEAN AND INSPECT CAUTION Use caution not to scratch the gasket mating surfaces when cleaning the intake manifold and cylinder head. Carefully remove all gasket residue from the intake manifold and cylinder head. Inspect the intake manifold for scratches, cracks, or any other damage. Repair or replace as needed. INSTALL 1. Verify the mating surfaces are clean and not damaged. 2. If necessary, install fuel system components. For gasoline engines, refer to the section Gasoline Fuel System, GM 2.4L Engine 900 YRM 1126. For LPG fuel systems, refer to the section LPG Fuel System, GM 2.4L Engine 900 YRM 1124. 9. Connect the vacuum hose to the intake manifold. 10. Connect the fuel delivery hose to the intake manifold. 11. Connect the breather hose to the intake manifold. 12. Connect the fuel delivery hoses and return hoses, or LPG vapor hose. 13. Connect the electrical connections to the throttle body. NOTE: Step 14 is for gasoline engines only. 14. Connect the electrical connector to the fuel pump. NOTE: Step 15 is for LPG fuel systems only. 15. Slowly open the fuel valve on the propane tank. NOTE: The ECM assembly must be connected to the air filter assembly after installing the air filter assembly. For gasoline engines, refer to the section Gasoline Fuel System, GM 2.4L Engine 900 YRM 1126. For LPG fuel systems, refer to the section LPG Fuel System, GM 2.4L Engine 900 YRM 1124. 16. Place the air filter assembly with mounting bracket in position on the frame. Install bolts and tighten to 20 N m (15 lbf ft). 17. Connect the air intake hoses to the air filter assembly. 18. Install the left rear side cover. Refer to the section Frame 100 YRM 1120. 19. Connect the negative battery cable. 3. Place a new gasket in position between the intake manifold and the cylinder head. 4
600 YRM 1121 Exhaust Manifold WARNING During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury. WARNING The radiator or other parts of the cooling system may be hot or under pressure and can cause serious injury. 20. Start the engine and check for proper operation and leaks. Exhaust Manifold REMOVE 1. Remove the battery, battery tray, and power distribution module (PDM). Refer to the section Electrical System 2200 YRM 1142. 2. Tag and disconnect the spark plug wires. 3. Disconnect the electrical connection to the coil pack. 4. Remove the coil pack and coil pack mounting bracket. 5. Remove the capscrews retaining the exhaust manifold heat shield and remove the heat shield. 6. Disconnect the oxygen sensor electrical connection. 7. Remove and discard the locking nuts retaining the exhaust manifold adapter to the exhaust manifold. 8. Remove and discard the gasket between the exhaust manifold adapter and the exhaust manifold. 9. Remove and discard the locking nuts retaining the exhaust manifold to the cylinder head. See Figure 4. Legend for Figure 4 1. GASKET 2. EXHAUST MANIFOLD 3. NUT 10. Remove the exhaust manifold. 11. Remove the gasket and discard. CLEAN AND INSPECT CAUTION Use caution not to scratch the gasket mating surfaces when cleaning the exhaust manifold and cylinder head. Carefully remove all gasket residue from the exhaust manifold and cylinder head. Inspect the exhaust manifold for scratches, cracks, or any other damage. Repair or replace as needed. INSTALL 1. Verify the mating surfaces are clean and not damaged. 2. Place a new gasket in position between the exhaust manifold and the cylinder head. 3. Place the exhaust manifold into position on the cylinder head. 4. Install new locking nuts on the studs. Tighten the nuts to 18 to 22N m(13to16lbfft). 5. Place a new gasket in position between the exhaust manifold adapter and the exhaust manifold. 6. Connect the exhaust manifold adapter to the exhaust manifold and secure with new locking nuts. Tighten the nuts to 14 to 20 N m(10 to 15 lbf ft). 7. Connect the oxygen sensor electrical connection. Figure 4. Exhaust Manifold Removal/Installation 5
Camshaft and Cylinder Head Repair 600 YRM 1121 8. Place the exhaust manifold heat shield in position and secure with capscrews. Tighten the capscrews to6to8n m(53to71lbfin). 9. Install the coil pack mounting bracket and coil pack. 10. Connect the electrical connection to the coil pack. 11. Connect the spark plug wires and remove tags. 12. Install the battery, battery tray, and PDM. Refer to the section Electrical System 2200 YRM 1142. 13. Start the engine and check for proper operation and leaks. Camshaft and Cylinder Head Repair ROCKER ARM COVER Remove 1. Disconnect the two hoses from the PCV valve. 2. Disconnect the crankcase vent tube from the rocker arm cover. 3. Remove the capscrews retaining the rocker arm cover to the camshaft carrier assembly. See Figure 5. 4. Remove the rocker arm cover and gasket. Discard gasket. Install 1. Clean the mating surfaces of the rocker arm cover and the camshaft carrier assembly. 2. Place a new gasket in position in the rocker arm cover. 3. Place the rocker arm cover in position on the camshaft carrier assembly. 4. Install the capscrews to retain the rocker arm cover to the camshaft carrier assembly. Tighten the capscrewsto8n m(71lbfin). 5. Connect the crankcase vent tube to the rocker arm cover. 6. Connect the two hoses to the PCV valve. CAMSHAFT TIMING PULLEY AND/OR FRONT SEAL Remove NOTE: Before removing the timing belt, make sure the alignment mark on the crankshaft timing pulley is aligned with the alignment mark on the oil pump case flange, with the No. 1 cylinder in the combustion stroke; the camshaft timing pulley alignment mark is aligned with the timing mark on the rear timing belt cover; and the camshaft pin is in the top hole of the camshaft timing pulley. See Timing Belt and Timing Belt Tensioner, Remove. 1. CAPSCREW 2. OIL FILLER CAP 3. ROCKER ARM COVER 4. CAMSHAFT CARRIER ASSEMBLY Figure 5. Rocker Arm Cover 1. Remove the timing belt. See Timing Belt and Timing Belt Tensioner, Remove. 2. Remove the rocker arm cover. See Rocker Arm Cover, Remove. 3. Use a 22-mm, open-end wrench and lock the camshaft. Using a 17-mm wrench, remove the bolt retaining the camshaft timing pulley. See Figure 6. 6
600 YRM 1121 Camshaft and Cylinder Head Repair Install 1. Using a special tool, a camshaft seal installer, install new front seal. See Figure 8. 1. CAMSHAFT TIMING PULLEY 2. 22-MM, OPEN-END WRENCH 3. 17-MM WRENCH Figure 6. Camshaft Timing Pulley 4. Remove the camshaft timing pulley. 5. Drill a small hole into the front seal face. Install a fine thread screw. Using a pair of pliers, pull the seal outward, and remove the seal. See Figure 7. Figure 8. Camshaft Front Seal Installation 2. Use a 22-mm, open-end wrench and lock the camshaft. 3. Place the camshaft timing pulley in position. Install the retaining bolt and tighten bolt to 40 to 50 N m (30 to 37 lbf ft). See Figure 6. NOTE: Before installing the timing belt, verify the alignment mark on the crankshaft timing pulley is aligned with the alignment mark on the oil pump case flange, with the No. 1 cylinder in the combustion stroke; the camshaft timing pulley alignment mark is aligned with the timing mark on the rear timing belt cover; and the camshaft pin is in the top hole of the camshaft timing pulley. See Timing Belt and Timing Belt Tensioner, Install. 4. Install the timing belt. See Timing Belt and Timing Belt Tensioner, Install. 5. Install the rocker arm cover. See Rocker Arm Cover, Install. Figure 7. Camshaft Front Seal Removal 7
Camshaft and Cylinder Head Repair 600 YRM 1121 CAMSHAFT CARRIER AND CYLINDER HEAD Remove 1. Turn the ignition switch to the OFF position. 2. Disconnect the negative battery cable. WARNING DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator cap is removed, pressure will release from the coolant system. If the coolant system is hot, the steam and boiling coolant can cause severe burns. WARNING The radiator or other parts of the cooling system may be hot or under pressure and can cause serious injury. Wait 30 minutes for the radiator and engine to cool before performing maintenance to the cooling system. After 30 minutes, do a touch test by touching the radiator with your hand. If the radiator is still hot to the touch, wait another 30 minutes before attempting any maintenance to the cooling system. CAUTION Disposal of lubricants must meet local environmental regulations. 3. Remove the radiator cap. case flange, with the No. 1 cylinder in the combustion stroke; the camshaft timing pulley alignment mark is aligned with the timing mark on the rear timing belt cover; and the camshaft pin is in the top hole of the camshaft timing pulley. See Timing Belt and Timing Belt Tensioner, Remove. 9. Remove the timing belt. See Timing Belt and Timing Belt Tensioner, Remove. 10. Remove the timing belt rear cover. See Timing Belt Rear Cover, Remove. 11. Remove the thermostat housing. See Thermostat Housing, Remove. 12. Disconnect the electrical connector for the camshaft sensor. 13. Remove the rocker arm cover. See Rocker Arm Cover, Remove. CAUTION Since there is spring tension on the camshaft and carrier, use caution when removing camshaft carrier/cylinder head bolts. Remove the bolts in the sequence shown in Figure 9 in even increments to prevent possible damage to the camshaft and camshaft carrier. 14. Remove and discard the camshaft carrier/cylinder head bolts in sequence and in even increments. See Figure 9 and Figure 10. 4. Loosen the lower radiator hose and drain the coolant from the coolant system. 5. Remove the intake manifold. See Intake Manifold, Remove. 6. Remove the exhaust manifold. See Exhaust Manifold, Remove. 7. Remove the spark plugs. 8. Remove the fan belt. See Serpentine Belt, Remove. NOTE: Before removing the timing belt, make sure the alignment mark on the crankshaft timing pulley is aligned with the alignment mark on the oil pump Figure 9. Removal Sequence 8
600 YRM 1121 Camshaft and Cylinder Head Repair 1. WASHER 2. BOLT 3. CAMSHAFT CARRIER ASSEMBLY 4. CYLINDER HEAD Figure 10. Camshaft Carrier Assembly 15. Remove the camshaft carrier assembly from the cylinder head. 1. CAMSHAFT FOLLOWER 2. KEEPERS 3. LIFTERS 4. CYLINDER HEAD 5. CYLINDER HEAD GASKET 6. CYLINDER BLOCK Figure 11. Cylinder Head NOTE: Organize camshaft followers and keepers so they can be installed in their original positions. 16. Remove the camshaft followers and keepers from the cylinder head. See Figure 11. NOTE: Organize camshaft lifters so they can be installed in their original positions. 17. Remove the camshaft lifters from the cylinder head. 18. Remove the cylinder head from the engine block. 19. Remove the cylinder head gasket and discard. Disassemble Camshaft Carrier 1. Remove the camshaft sensor assembly. 2. Remove the capscrews from the camshaft retainer. See Figure 12. 1. RETAINER 2. CAPSCREW Figure 12. Camshaft Retainer 3. Carefully move the camshaft slightly out of the camshaft carrier and remove the camshaft retainer. 9
Camshaft and Cylinder Head Repair 600 YRM 1121 CAUTION All camshaft journals are the same diameter. Be careful when removing the camshaft to avoid damage to the camshaft carrier. 9. Remove the inlet valve. 10. Repeat Step 1 through Step 9 for remaining valves. 4. Carefully rotate and remove the camshaft out of the camshaft carrier. See Figure 13. 1. VALVE SPRING COMPRESSOR Figure 14. Valve Spring Compressor 1. CAMSHAFT CARRIER 2. CAMSHAFT Figure 13. Camshaft Removal/Installation 5. Remove the front camshaft seal. See Camshaft Timing Pulley and/or Front Seal, Remove. Cylinder Head NOTE: Keep cylinder head components in order so they will be installed in the same positions during assembly. 1. Using a valve spring compressor, compress the valve spring. See Figure 14. 2. Removethevalvestemkeys.SeeFigure15. 3. Remove the retainers from the valve spring. 4. Remove the valve springs. 5. Using a special tool, remove the valve stem oil seals. 6. Remove valve spring seat (Inlet). 7. Remove the valve spring rotator assembly. 8. Remove the exhaust valve. 1. VALVE STEM KEYS 2. RETAINER 3. VALVE SPRING 4. VALVE STEM OIL SEAL 5. VALVE SEAT (INLET) 6. VALVE INLET 7. VALVE EXHAUST 8. CYLINDER HEAD 9. VALVE SPRING ROTATOR ASSEMBLY (EXHAUST) Figure 15. Valve Removal/Installation 10
600 YRM 1121 Camshaft and Cylinder Head Repair Clean and Inspect Camshaft Carrier CAUTION Use care not to damage the mating surfaces when removing old gaskets and sealant residues. 1. Clean all debris, old gaskets, and sealants from the mating surfaces of the camshaft carrier. See Figure 16. Cylinder Head CAUTION Do not use a wire brush to clean the combustion chambers. This can damage the seats and possibly the sealing surface at the edge of the combustion chamber. Use a soft brush and cleaner to remove the carbon from the combustion chambers and the valve ports. Be careful not to scuff the chamber. 1. THREADED HOLE 2. MATING SURFACE 3. BOLT HOLE 1. Clean the following areas: a. Carbon and sludge from the lifters, followers, and keepers. b. Valvestemsandheads. c. Cylinder head and engine block gasket surfaces. d. Bolt holes and threads in the cylinder head and the engine block. 2. Inspect the following areas: a. Cylinder head for cracks in the exhaust ports and the combustion chambers. b. Cylinder head for external cracks in the water chamber. Figure 16. Camshaft Carrier 2. Clean the bolt holes and threads in the camshaft carrier. c. Valves for burned heads, cracked faces, or damaged stems. 3. Inspect the camshaft carrier mating surfaces for damage. Replace as needed. 4. Inspect the camshaft carrier for cracks or any other damage. Replace as needed. 5. Inspect the bottom mating surface of the camshaft carrier for warpage. Replace as needed. 6. Inspect the bores in the camshaft carrier for damage. Replace as needed. See Figure 17. 7. Using a dial indicator, measure the camshaft bore surfaces. See Engine Specifications for the correct measurements. If not within specifications, replace camshaft carrier. 1. CAMSHAFT BORE Figure 17. Camshaft Bores Inspection 11
Camshaft and Cylinder Head Repair 600 YRM 1121 3. Check the valve stem-to-bore clearance of each valve and valve guide. Use the following procedure: a. Install the dial indicator into the valve guide and measure the inner diameter of the valve guide. See Figure 18. Figure 19. Valve Guide Reaming 4. Inspect the valve springs for squareness. See Figure 20. Figure 18. Valve Guide Inner Diameter Measurement b. Measure the outside diameter of the valve stem withamicrometer. c. Determine the difference between the outer diameter of the valve stem and the inner diameter of the valve guide. d. The maximum clearance between the valve stems and their valve guides is shown in Engine Specifications. NOTE: If the valve stem to valve guide clearance cannot be obtained using an oversized valve stem, the cylinder head must be replaced. e. If the clearance between the valve stem and its valve guide is greater than the specification, a valvewithanoversizestemmustbeinstalled. Use a reamer to make the bore the correct diameter for the next oversize valve. See Figure 19. See the Parts Manual for oversize valves. Figure 20. Valve Springs Inspection 5. Measure the valve seat runout. The valve seats should be centered to within 0.05 mm (0.002 in.). See Figure 21. 12
600 YRM 1121 Camshaft and Cylinder Head Repair 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 seats within the specifications. Make sure all of the lapping compound is removed from the valve and valve seat when the process is completed. Damaged valve seats can be repaired with a 45 ±30 cutter tool. See Figure 23. If the valve seat cannot be repaired so that the valve depth is within specifications, the cylinder head must be replaced. The specifications forthevalveseatsarelistedinenginespecifications. Figure 21. Valve Seat Runout Measurement 6. Inspect the cylinder head and measure it for warpage. A cylinder head with excessive warpage must be repaired or replaced. Refer to Engine Specifications for cylinder head dimensions. Also, seefigure22. Figure 22. Cylinder Head Measurement Valve and Valve Seat The condition of the valves and alignment of the valves to their valve seats are important for the correct operation of the engine. Before any work is done on the valve Figure 23. Valve Seat Repair 13
Camshaft and Cylinder Head Repair 600 YRM 1121 Assemble Cylinder Head 1. Install the valves into the proper ports. See Figure 15. 2. Install the valve seat (inlet) on the inlet valve. 3. Install the valve seat (exhaust) on the exhaust valve. 4. Install the inlet valve and exhaust valve into the cylinder head. 5. Install the valve spring rotator assembly over the valve guide. 6. Lubricate the valve stem oil seal with clean engine oil. 7. Using a special tool, install the valve stem oil seal onto the exhaust valve. 8. Lubricate the valve stem oil seal with clean engine oil. 9. Using a special tool, install the valve stem oil seal onto the inlet valve. 10. Install the valve springs. 11. Install the retainers onto the valve spring. 12. Using a valve spring compressor, compress the valve spring. NOTE: Make sure the keys seat properly in the upper groove of the valve stem. If necessary, tap the end of the valve stem with a plastic-faced hammer, making sure the valves will not come into contact with the work bench, in order to seat the keys. 13. Install the valve stem keys. 14. Remove the valve spring compressor. 15. Repeat Step 1 through Step 14 for remaining valves. Camshaft Carrier 1. Using a special tool, a camshaft seal installer, install new front seal. See Figure 8. CAUTION All camshaft journals are the same diameter. Be careful when installing the camshaft to avoid damage to the camshaft carrier. 2. Carefully rotate and install the camshaft into the camshaft carrier. NOTE: The camshaft may need to be pulled slightly out of the camshaft carrier to place the camshaft retainer in position. 3. Install the camshaft retainer. 4. Install the capscrews to retain the camshaft retainer. Tighten capscrews to 8 N m (71 lbf in). 5. Install the camshaft sensor assembly. Install NOTE: Verify the cylinder head locators are installed in the engine block. 1. Install the new cylinder head gasket over the locators onto the engine block with the TOP mark facing upward and toward the front end of the engine block. See Figure 11. 2. Install the cylinder head over the locators onto the gasket. 3. Coat the bottom of the valve lifters with molybdenum lubricant. NOTE: If using the old valve lifters, install the lifters in original positions. 4. Install valve lifters. 5. Install the camshaft follower keepers and followers. 6. Apply RTV sealant (Yale part number 520039889) tothematingsurfaceofthecylinderheadforthe carrier assembly. 7. Place the camshaft carrier assembly in position on the cylinder head. 8. Install new camshaft carrier/cylinder head bolts and washers. Tighten bolts finger tight only. 9. Tighten the camshaft carrier/cylinder head bolts in sequence to 25 N m (18 lbf ft). See Figure 24. 14
600 YRM 1121 Camshaft and Cylinder Head Repair 17. Install the fan belt. See Serpentine Belt, Install. 18. Install the spark plugs. 19. Install the exhaust manifold. See Exhaust Manifold, Install. 20. Install the intake manifold. See Intake Manifold, Install. 21. Connect the lower radiator hose and tighten the clamp. Figure 24. Tightening Sequence 10. Tighten the cylinder head bolts in sequence an additional 180 degrees. 11. Tighten the cylinder head bolts in sequence an additional 10 degrees. 12. Install the rocker arm cover. See Rocker Arm Cover, Install. 13. Connect the electrical connector for the camshaft sensor. 14. Install the thermostat housing. See Thermostat Housing, Install. 15. Install the timing belt rear cover. See Timing Belt Rear Cover, Install. NOTE: Before installing the timing belt, verify the alignment mark on the crankshaft timing pulley is aligned with the alignment mark on the oil pump case flange, with the No. 1 cylinder in the combustion stroke; the camshaft timing pulley alignment mark is aligned with the timing mark on the rear timing belt cover; and the camshaft pin is in the top hole of the camshaft timing pulley. See Timing Belt and Timing Belt Tensioner, Install. CAUTION Additives may damage the cooling system. Before using additives, contact your local Yale dealer. 22. Connect the bottom radiator hose. Fill cooling system with coolant. Refer to the section Periodic Maintenance 8000 YRM 1150 for correct coolant amount and type. 23. Install radiator cap on radiator. WARNING During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury. WARNING The radiator or other parts of the cooling system may be hot or under pressure and can cause serious injury. 24. Start engine and check cooling system for leaks. 25. Bleed air from the cooling system by opening the bleed screw located on the left side behind the alternator. When the air has been bled from the system, close the bleed screw. 16. Install the timing belt. See Timing Belt and Timing Belt Tensioner, Install. 15
Timing Belt 600 YRM 1121 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 system. 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. 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. CAUTION Additives may damage the cooling system. Before using additives, contact your local Yale dealer. 26. Stop engine. If coolant is hot, give engine time to cool. Check coolant level and fill as required between the ADD and FULL marks on the coolant reservoir. Timing Belt TIMING BELT FRONT COVER Remove 1. Turn the ignition to the OFF position. 2. Remove the battery, battery tray, and PDM. Refer to the section Electrical System 2200 YRM 1142. 13. Remove the bolts retaining the crankshaft fan pulley and remove the crankshaft fan pulley and the crankshaft pulley spacer. See Figure 25. 14. Remove the front timing belt cover bolts and remove the front timing belt cover. 3. Remove the auxiliary coolant reservoir. 4. Remove the fan shroud. Refer to the section Cooling System 700 YRM 1123. 5. Place a piece of cardboard over the radiator surface to prevent damage to the radiator. 6. Remove the four bolts retaining the fan assembly. 7. Remove the fan assembly. 8. Remove the serpentine belt. See Serpentine Belt, Remove. 9. Remove the spacer and the pulley. 10. Disconnect the electrical connections to the alternator. 11. Remove the alternator mounting bolts and remove the alternator. 12. Remove the alternator bracket bolts, fan hub bracket bolts, and fan hub bracket. NOTE: Before removing the crankshaft pulley and the crankshaft pulley hub, make alignment marks on the crankshaft hub, crankshaft pulley, and crankshaft spacer. 1. CRANKSHAFT PULLEY HUB 2. CRANKSHAFT PULLEY SPACER 3. CRANKSHAFT PULLEY 4. SERPENTINE BELT 5. OIL PUMP HOUSING 6. ALIGNMENT MARK Figure 25. Crankshaft Pulley Arrangement 16
600 YRM 1121 Timing Belt Install 1. Place the timing belt cover over the timing belt and install bolts. Tighten bolts to 6 N m (53 lbf in). NOTE: Before installing the crankshaft pulley and crankshaft spacer, align these components with the alignment marks made when disassembled. 2. Install the crankshaft spacer and crankshaft pulley, ensuring that all alignment marks made during removal are lined up properly. Tighten crankshaft pulley bolts to 15 to 25 N m (11 to 18 lbf ft). 3. Install fan hub bracket and retaining bolts. Tighten boltsto52n m(38lbfft). 4. Install alternator bracket and retaining bolts. Tighten bolts to 38 N m (28 lbf ft). 5. Install the alternator. See the section Alternator Repair. 6. Install the fan spacer and the pulley. 7. Install the serpentine belt. See Serpentine Belt, Install. Figure 26. Crankshaft Timing Pulley Alignment Mark CAUTION The camshaft pin must be in the top hole of the camshaft timing pulley. 3. Position the camshaft timing pulley alignment mark with the timing mark on the rear timing belt cover. Verify that the camshaft pin is located in the 12 o clock position. See Figure 27. 8. Placethefaninpositiononthepulleyandinstall the four retaining bolts. Tighten the bolts to 26 N m (19 lbf ft). 9. Remove cardboard from the radiator surface. 10. Install the fan shroud. Refer to the section Cooling System 700 YRM 1123. 11. Install the auxiliary coolant reservoir. 12. Install the battery, battery tray, and PDM. Refer to the section Electrical System 2200 YRM 1142. TIMING BELT AND TIMING BELT TENSIONER Remove 1. Remove the timing belt front cover. See Timing Belt Front Cover, Remove. 2. Turn the crankshaft until the alignment mark on the crankshaft timing pulley is aligned with the alignment mark on the oil pump case flange, with the No. 1 cylinder in the combustion stroke. See Figure 26. 1. CAMSHAFT PIN Figure 27. Camshaft Timing Pulley and Crankshaft Timing Pulley Alignment Marks 17
Timing Belt 600 YRM 1121 4. Use chalk to mark direction of timing belt rotation. See Figure 28. Install 1. Align the camshaft timing pulley alignment mark with the timing mark on the rear timing belt cover. See Figure 27. CAUTION The camshaft pin must be in the top hole of the camshaft timing pulley. 2. Verify that the camshaft pin is located in the 12 o clock position. See Figure 27. 3. Verify the alignment mark on the crankshaft timing pulley is aligned with the alignment mark on the oil pump case flange, with the No. 1 cylinder in the combustion stroke. See Figure 27. Figure 28. Timing Belt NOTE: Before removing the timing belt tensioner, verify the tensioner tab is between the two locator tabs at the 7 o clock position. See Figure 29. 5. Remove the bolt retaining the timing belt tensioner. NOTE: The timing belt tensioner tab must be placed in the 7 o clock position between the locators. See Figure 29. 4. Install the timing belt tensioner, but do not tighten the bolt. 5. Place the timing belt over the pulleys and the timing belt tensioner. 6. Tighten the tensioner to the appropriate reference mark with the crankshaft timing pulley hub timing mark aligned with the oil pump housing timing mark and the camshaft timing belt pulley timing mark aligned with the timing mark located on the plastic timing belt housing. NOTE: The timing belt tensioner has two markings, NEW and USED, for the appropriate timing belt. The tensioner pointer will need to be aligned with the correct timing belt installed. See Figure 29. 1. WATER PUMP BOLT 2. WATER PUMP 3. WATER PUMP TAB (11 O CLOCK POSITION) 4. TIMING BELT TENSIONER POINTER 5. LOCATORS 6. TENSIONER TAB (7 O CLOCK POSITION) 7. USED TIMING BELT MARK 8. NEW TIMING BELT MARK 9. TENSIONER Figure 29. Tensioner Tab and Locators 6. Remove the timing belt and the timing belt tensioner. 7. If timing belt is too tight and cannot be adjusted with the tensioner, loosen water pump bolts (see Figure 29) and turn water pump counterclockwise until proper tension is achieved. Tighten water pump bolts to 20 to30n m(15to22lbfft). 8. If timing belt is too loose and cannot be adjusted with the tensioner, loosen water pump bolts and turn water pump clockwise until proper tension is reached. Tighten water pump bolts to 20 to 30 N m (15to22lbf ft). 9. Tighten the timing belt tensioner bolt to 20 N m (15 lbf ft). Verify the timing belt tensioner pointer is aligned with the appropriate mark after tightening. 18
600 YRM 1121 Timing Belt Recheck tensioner and timing belt marks to make sure they are still aligned correctly. 10. Install the timing belt front cover. See Timing Belt Front Cover, Install TIMING BELT REAR COVER Remove 1. Remove the timing belt front cover. See Timing Belt Front Cover, Remove. NOTE: Before removing the timing belt, verify the alignment mark on the crankshaft timing pulley is aligned with the alignment mark on the oil pump case flange, withtheno. 1cylinderinthecombustionstroke,the camshaft timing pulley alignment mark is aligned with the timing mark on the rear timing belt cover, and the camshaft pin is in the top hole of the camshaft timing pulley. See Timing Belt and Timing Belt Tensioner, Remove. 2. Remove the timing belt and timing belt tensioner. See Timing Belt and Timing Belt Tensioner, Remove. 3. Remove the rocker arm cover. 4. Remove the camshaft timing pulley. See Camshaft Timing Pulley and/or Front Seal, Remove. 5. Remove the crankshaft timing pulley. See Crankshaft Timing Pulley and/or Front Seal, Remove. 6. Remove the Torx head capscrews retaining front bracket and remove front bracket. 8. Remove timing belt rear cover. Install 1. Place timing belt rear cover in position on engine. 2. Install bolts to retain timing belt rear cover. Tighten capscrewsto6n m(53lbfin). 3. Place front bracket in position and install Torx head capscrews. Tighten Torx head capscrews to 25 N m (18 lbf ft). 4. Install the camshaft timing pulley. See Camshaft Timing Pulley and/or Front Seal, Install. 5. Install crankshaft timing pulley and retaining bolt. See Crankshaft Timing Pulley and/or Front Seal, Install. NOTE: Before installing the timing belt, verify the alignment mark on the crankshaft timing pulley is aligned with the alignment mark on the oil pump case flange, with the No. 1 cylinder in the combustion stroke; the camshaft timing pulley alignment mark is aligned with the timing mark on the rear timing belt cover; and the camshaft pin is in the top hole of the camshaft timing pulley. See Timing Belt and Timing Belt Tensioner, Install. 6. Install the timing belt and timing belt tensioner. See Timing Belt and Timing Belt Tensioner, Install. 7. Install the timing belt front cover. See Timing Belt Front Cover, Install. 7. Remove the capscrews retaining the timing belt rear cover. 19
Lubrication System Repair 600 YRM 1121 Lubrication System Repair OIL PAN Remove 1. Remove the engine from the lift truck. Refer to the section Frame 100 YRM 1120 for the procedures to remove the engine. 2. Remove the oil pan drain plug and drain the engine oil into a suitable container. Install 1. Apply a 3.175 mm (0.125 in.) continuous bead of sealant around the sealing surface of the oil pan. 2. Place the oil pan into position on the cylinder block using the locating pins. 3. Remove the right side bell housing alignment bushing. SeeFigure31. 3. If necessary, remove the oil filter. 4. Remove the capscrews retaining the oil pan to the engine block. See Figure 30. 5. Remove the oil pan. CAUTION Use care not to damage the mating surfaces when removing old gaskets and sealant residues. 6. Carefully remove old sealant residue from the mating surfaces of the oil pan and cylinder block. 7. Thoroughly clean the outside and inside surfaces of the oil pan. 1. BUSHING 2. BELL HOUSING 3. REMOVAL TOOL Figure 31. Bell Housing Alignment Bushing 4. Install special tool, rear flange alignment tool, to keep the alignment of the oil pan to the cylinder block. See Figure 32. 5. Install capscrews, except the two capscrews where the alignment tool is using the mounting holes. 6. Verify the alignment of the oil pan and cylinder block is correct. The edge of the oil pan should be a maximumdistanceof0.15mm(0.006in.)fromthe edge of the cylinder block. See Figure 33. Adjust the oil pan as needed. 1. OIL PAN 2. DRAIN PLUG Figure 30. Oil Pan 7. Tighten the capscrews to 18 to 22 N m (13 to 16 lbf ft). 8. Remove the special tool. 20
600 YRM 1121 Lubrication System Repair 1. OIL PAN 2. REAR FLANGE ALIGNMENT TOOL 3. BELL HOUSING Figure 32. Rear Flange Alignment Tool 9. Install the remaining two capscrews and tighten to 18 to 22 N m (13 to 16 lbf ft). 10. Install the right side bell housing alignment bushing. 11. Install the drain plug and tighten to 18 to 22 N m (13to16lbfft). 12. If removed, install new oil filter. 13. Install the engine into the lift truck. Refer to the section Frame 100 YRM 1120. 14. Fill the engine oil to the correct level. Refer to the section Periodic Maintenance 8000 YRM 1150 for correct oil amount and type. 1. CYLINDER BLOCK 2. OIL PAN Figure 33. Oil Pan Alignment 21
Lubrication System Repair 600 YRM 1121 OIL PUMP Remove 1. Remove the oil pan. See Oil Pan, Remove. 9. Remove the capscrew from the oil pump suction tube bracket. See Figure 36. 10. Remove the capscrews from the suction tube. 2. Remove the timing belt rear cover. See Timing Belt Rear Cover, Remove. 3. Disconnect the electrical connector for the crankshaft sensor. 4. Disconnect the electrical connector for the oil pressure sensor. See Figure 34 and Figure 35. 5. Remove the oil pressure sensor. 6. Remove the oil filter. NOTE: Step 7 and Step 8 are for engines with an oil filter adapter only. 7. Using vise grips, remove the banjo bolt retaining the oil filter adapter and remove oil filter adapter. 8. Discard the seal washer and the banjo bolt. 1. ELECTRICAL CONNECTOR 2. OIL PRESSURE SENSOR 3. OIL FILTER Figure 35. Oil Pressure Sensor and Oil Filter Without Adaptor 1. OIL FILTER 2. OIL PRESSURE SENSOR 3. BANJO BOLT 4. OIL FILTER ADAPTER 5. ELECTRICAL CONNECTOR Figure 34. Oil Pressure Sensor and Oil Filter With Adaptor 1. O-RING 2. BRACKET 3. SUCTION TUBE 4. CAPSCREWS Figure 36. Oil Suction Tube 22
600 YRM 1121 Lubrication System Repair NOTE: Theoilsuctiontubeandscreenaretobeserviced as an assembly. Do not attempt to repair the wire mesh portion of the tube and screen assembly. 11. Remove the suction tube and O-ring. Discard O-ring. 12. Remove the capscrews retaining the oil pump to the engine block. See Figure 37. WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield topreventinjurytotheeyes. NOTE: The internal parts of the oil pump are not serviced separately. If the oil pump components are worn or damaged, replace the oil pump as an assembly. If the drive gear and drive shaft are worn, replace the entire oil pump. The oil suctiontubeandscreenaretobeservicedas an assembly. Do not attempt to repair the wire mesh portion of the tube and screen assembly. 2. Clean all of the parts in cleaning solvent. Dry the parts with compressed air. 3. Inspect the gears and the pump body for wear and damage. If the parts are worn or damaged, replace the oil pump. 1. CAPSCREW 2. SAFETY VALVE 3. SPACER 4. GASKET 5. OIL PUMP Figure 37. Oil Pump NOTE: Be sure to retain the spacers for installation. 13. Remove the oil pump, gasket, and spacers. Discard gasket. 4. Check the gap of the gears with a feeler gauge and a straight edge. The dimension should be 0.03 to 0.10 mm (0.0011 to 0.004 in.). See Figure 39. 5. Attach the oil pump cover to the oil pump. Install the retaining screws. Tighten retaining screws to 6N m(53lbfin). 14. Remove the safety valve. Clean and Inspect NOTE: The internal components of the oil pump are not serviceable. If the oil pump components are damaged or worn, replace the oil pump as an assembly. 1. Remove the screws retaining the oil pump cover and remove oil pump cover. See Figure 38. WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer. 1. SCREW 2. OIL PUMP COVER Figure 38. Oil Pump Cover 23
Piston and Piston Rod Assemblies Repair 600 YRM 1121 7. Install the oil filter adapter, new seal washer, and new shear banjo bolt. Tighten banjo bolt with an open-end, 10-mm wrench until the head of the bolt completely shears off. See Figure 40. 8. Install new oil filter. 9. Install the oil pressure sensor. Tighten sensor to 20 N m (15 lbf ft). 10. Connect the electrical connector for the oil pressure sensor. 11. Install the timing belt rear cover. See Timing Belt Rear Cover, Install. 1. STRAIGHT EDGE 2. FEELER GAUGE Install Figure 39. Gear Inspection 12. Connect the electrical connector for the crankshaft sensor. 13. Install the oil pan. See Oil Pan, Install. 1. Install safety valve with a new O-ring. Tighten safety valve to 37 N m (27 lbf ft). 2. Install new oil pump gasket. 3. Install the oil pump and spacers. 4. Install the capscrews to retain the oil pump to engine block. Tighten capscrews to 6 to 10 N m (53 to 89 lbf in). 5. Install new O-ring on oil pump suction tube. Install the oil pump suction tube and capscrews. Tighten the capscrews to 8 N m(71 lbf in). 6. Install the oil pump suction tube bracket capscrew. Tighten capscrew to 18 to 22 N m (13 to 16 lbf ft). NOTE: Step 7 is for engines with an oil filter adapter only. 1. SEAL WASHER 2. BANJO BOLT 3. SHEAR HEAD 4. OIL FILTER ADAPTER Figure 40. Shear Banjo Bolt Installation Piston and Piston Rod Assemblies Repair PISTON ROD BEARINGS, REPLACE NOTE: Thepistonrodbearingsareavailableinastandard size and several undersizes. See the Parts Manual for bearing sizes. If a bearing on a journal is worn, both the upper and lower halves of the bearing must be replaced. 1. Remove the oil pan and oil pump. See Lubrication System Repair. 2. Remove the capscrews retaining the baffle plate and remove baffle plate. 3. Remove the remaining capscrews from the bearing bracket and remove the bearing bracket. 4. Before the cap for the piston rod is removed, mark the piston rod and cap with the cylinder number so that the parts will be installed in their original positions. 24
600 YRM 1121 Piston and Piston Rod Assemblies Repair 5. Remove the capscrews retaining the cap and removecapforthepistonrodbearingandthelower bearing half. See Figure 41. journal ground to an undersize. If the bearing journal cannot be repaired so that the bearing journal is a correct undersize, the crankshaft must be replaced. See Engine Specifications. 10. If the bearing journal is within specifications, measure the clearance between the new bearing and the crankshaft. Use Plastigage, or equivalent, to check the clearance as described below: a. Put a piece of Plastigage across the full width of the bearing journal as shown in Figure 42. Do not rotate the crankshaft when the Plastigage is between the bearing and its journal. b. Install the bearing and bearing cap. Tighten the capscrewsto30to40n m(22to29.5lbfft). Tighten the capscrews an additional 40 to 45 degrees. 1. BEARING CAP 2. BEARING 3. CRANKSHAFT Figure 41. Piston Rod Cap Removal c. Remove the bearing and bearing cap. The Plastigage will be compressed and wider and it will adhere to either the bearing or its journal. Use the scale on the envelope for the Plastigage to measure the width of the plastic at its widest point. The scale will indicate the clearance in millimeters or thousandths of an inch. See Figure 43. 6. Push the piston rod away from the crankshaft and remove the upper bearing half. Wipe the oil from the bearing halves and the bearing journal. 7. Inspect bearings for craters, pockets, excessive scoring, and dirt or debris imbedded into the bearing material. Replace as needed. Replace the upper and lower halves as a set. 8. Inspect the bearings for improper seating indicated by bright, polished sections of the bearing. Replace as needed. Replace the upper and lower halves as aset. 9. Use a micrometer to measure the bearing journal. The bearing journal must be within the following specification: Out-of-roundness less than 0.004 mm (0.00016 in.); taper less than 0.005 mm (0.0002 in.) If the bearing journals are not within specifications, the crankshaft must be removed and the bearing 1. BEARING CAP 2. PLASTIGAGE Figure 42. Bearing Journal Plastigage Placement 25
Piston and Piston Rod Assemblies Repair 600 YRM 1121 Figure 44. Piston Rods Side Clearance Measurement PISTON AND PISTON ROD ASSEMBLIES Remove Figure 43. Bearing Journal Plastigage Measurement d. If the clearance is greater than the specifications, select a new undersize bearing set and install it. Measure the clearance again. If the clearance cannot meet specifications with the available undersize bearings, the bearing journal must be ground to a new undersize. If the bearing journal is already at the maximum undersize, the crankshaft must be replaced. e. If the clearance is within specifications, lubricate the bearing with engine oil and install the bearing and bearing cap. Tighten the capscrews to 30 to 40 N m (22 to 29.5 lbf ft). Tighten the capscrews an additional 40 to 45 degrees. 11. When all of the connecting rod bearings have been replaced, use the following procedure to check the side clearances between the piston rods and the crankshaft (refer to Engine Specifications for clearance specifications): a. Use a hammer to lightly hit the piston rod parallel to the crankshaft journal to make sure there is a clearance. b. Measure the clearance between the caps for the piston rods and the crankshaft. See Figure 44. 1. Remove the oil pan and oil pump. See Lubrication System Repair. 2. Remove the capscrews retaining the baffle plate and remove baffle plate. 3. Remove the cylinder head. See Camshaft Carrier and Cylinder Head, Remove. 4. If the engine has been in service for many hours, a ridge can be worn in the top of the cylinder. This ridge can be removed with a ridge reamer tool (see Figure 45) using the procedures described below: a. Turnthecrankshafttolowerthepistontothe bottom of the stroke in its cylinder. b. Putaclothontopofthepistontocollectmetal particles. c. Remove the ridge at the top of the cylinder. d. Turn the crankshaft so the piston is at the top of the stroke. e. Remove the cloth. f. Remove the cutting debris. 5. Clean the carbon from the top of each cylinder. 6. Put an identification mark on the top of each piston. 26
600 YRM 1121 Piston and Piston Rod Assemblies Repair WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer. WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. 3. Use solvent to clean the pistons and piston rods. Use compressed air to dry the parts. Make sure that the holes for oil passages are clean. Figure 45. Ridge Reamer 7. Remove the caps and bearings from each piston rod. Keep the caps and bearings with their original piston assemblies. Mark the caps so that they will be installed again in their original positions. Do not mix the parts. 8. Push the piston rod and piston from the cylinder. Temporarily install the bearing cap on the piston rod to keep the 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 the piston rings from the pistons. See Figure 46. 1. UPPER COMPRESSION RING 2. LOWER COMPRESSION RING 3. OIL CONTROL RING 4. PISTON Figure 46. Piston Rings 2. Use a press to remove the wrist pins from the pistons. See Figure 47. 27
Piston and Piston Rod Assemblies Repair 600 YRM 1121 than 0.127 mm (0.005 in.) will require that the short block assembly be replaced as oversized pistons are not available. Figure 48. Cylinder Bore Measurement 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 47. Wrist Pin Removal Pistons, Clean and Inspect Inspect the pistons for wear, cracks, and damage. Replace a piston that is worn or damaged. NOTE: If the cylinder bore must be repaired, the piston must be changed to the correct oversize piston. Check the clearance of the piston in its cylinder after the surface of the cylinder bore has been finished with a hone. A cylinder bore that has been repaired with a hone or a boringmachinemustbefittedwithapistonthatisthe correct size. Use the following procedure to determine the clearance between the pistons and cylinders. 1. Measure the inner diameter of the cylinder bore as shown in Figure 48. 2. Using a micrometer, measure the bore gauge and record the reading. See Figure 49. Check the clearance of the wrist pin in the piston. The normal clearance is shown in Engine Specifications. The wrist pin will normally fall from the hole in the piston by its own weight. The wrist pin is a press fit in the piston rod. The piston and wrist pin are a matched set and must be replaced as a unit if the clearances are greater than the specifications. Cylinder Bores, Inspect and Repair Inspect the cylinder bores for wear and damage. Measure the cylinder bores with a bore gauge in several positions as shown in Figure 48. Measure the cylinder bore at right angles to the centerline to find any distortion from wear. A cylinder that is out of round greater Figure 49. Bore Gauge Measurement 28
600 YRM 1121 Piston and Piston Rod Assemblies Repair 3. Using a micrometer, measure the outer diameter of thepiston. SeeFigure50. 1. Measure the clearance between the piston ring and thegrooveinthepistonasshowninfigure51.the clearances are shown in Engine Specifications. Replace the piston if the clearances are greater than the specifications. Figure 50. Piston Measurement 4. Subtract the piston diameter from the bore diameter to determine the piston to bore clearance. Using an oversize piston in the engine does not affect the dynamic balance of the engine. Replacement pistons are available in standard size and 0.50 mm (0.020 in.) oversize. The clearance between a piston and its cylinder bore should be between 0.010 to 0.030 mm (0.00039 to 0.00118 in.). Piston Rings, Inspect NOTE: Check the clearance of the piston rings in the cylinder after the surface of the cylinder has been finished with a hone. New piston rings are available for the different piston sizes. See the Parts Manual for sizes. The piston rings must match the size of the piston on which they are installed. Check the side clearance and the end clearance of the piston rings as described in the following paragraphs. Figure 51. Piston Ring and Groove Clearance Check 2. Measuretheendclearanceofeachpistonringas shown in Figure 52. The end clearances are shown in Engine Specifications. Install the piston ring into the cylinder where it will be used. Use a thickness gauge to measure the amount of end clearance. Replace the piston ring if the clearances are greater than the specifications. Each compression ring has a dimple or orientation mark on one surface. This mark must be toward the top of the cylinder when the piston ring is installed. The lower compression ring also has a bevel edge that faces the bottom of the piston. The upper compression ring has amolybdenumfillingandnobevellededge. Theoilcontrolringhasthreepieces.Therearetwothin steel rings separated by a spacer. The oil control ring has no dimple or orientation mark and may be installed in either direction. Figure 52. Piston Ring End Clearance Check 29
Piston and Piston Rod Assemblies Repair 600 YRM 1121 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 Figure 56. The piston rods have a notch cast in the bearing journal as shown in Figure 53. This notch must be opposite the notch on the top of the piston when the piston and piston rod are assembled. B. POSITION OF GAP FOR OIL RING C. POSITION OF GAP FOR SPACER OF OIL RING D. POSITION OF GAP FOR OIL RING E. POSITION OF GAP FOR LOWER COMPRESSION RING F. POSITION OF GAP FOR UPPER COMPRESSION RING 1. NOTCHES ON ROD OPPOSITE NOTCH IN PISTON Figure 53. Piston Rod Identification 1. Assemble the piston rod to the piston. Make sure the orientation of the piston rod and piston are correct as described in the NOTE above. Use a press to install the wrist pin into the piston and piston rod. Lubricate the wrist pin with engine oil during installation. Install Figure 54. Piston Ring Arrangement 1. Lubricate the assembly with engine oil during installation. Arrange the piston rings on the piston as shown in Figure 54. Install a ring compressor on the piston as shown in Figure 55. NOTE: Each compression ring has a dimple or orientation mark on one surface. This mark must be toward the top of the cylinder when the piston ring is installed. Thelowercompressionringalsohasabeveledgethat faces the bottom of the piston. The upper compression ring has a molybdenum filling and no bevelled edge. The oil control rings do not have a dimple or orientation mark and may be installed in either direction. 2. Check the clearances of the piston rings as described in Piston Rings, Inspect. Install the piston rings on the piston as shown in Figure 54, considering that the vertical dash line corresponds to the wrist pin position. Figure 55. Ring Compressor Installation 2. Makesurethatthenotchinthepistonistowardthe fan end of the engine as shown in Figure 56. Install the piston and piston rod assemblies in the cylinder bores. 30
600 YRM 1121 Crankshaft and Main Bearings to 29.5 lbf ft). Tighten the capscrews an additional 40 to 45 degrees. Check the side clearance of each piston rod after the bearing cap is installed. See the paragraphs in the procedure Piston Rod Bearings, Replace. 4. Install the cylinder head. See Camshaft Carrier and Cylinder Head, Install. NOTE: CAST NOTCH MUST BE TOWARD FAN END OF ENGINE. A. FAN END OF ENGINE Figure 56. Piston Position Inside Cylinder 3. Install the bearings and the caps for the piston rods. Tightenthecapscrewsto30to40N m(22 5. Place the bearing bracket in position on the engine block. 6. Place the baffle plate in position on the bearing bracket and install capscrews. Tighten capscrews to 20 to 24 N m (15 to 17.7 lbf ft). 7. Install the oil pump and oil pan. See Lubrication System Repair. Crankshaft and Main Bearings CRANKSHAFT TIMING PULLEY AND/OR FRONT SEAL Remove 1. Remove the timing belt. See Timing Belt and Timing Belt Tensioner, Remove. 3. Using the special tool, piston flange universal puller, remove the crankshaft timing pulley. See Figure 58. 4. Remove the crankshaft keyway and the spacer. See Figure 59. 2. Using a special tool to hold the pulley, remove the crankshaft timing pulley retaining bolt. See Figure 57. Figure 58. Crankshaft Timing Pulley Removal Figure 57. Crankshaft Timing Pulley Retaining Bolt Removal/Installation 31