GM 3.0 Mexicano

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GM ENGINES

4-153, 4-181, 3.0L, 6-250


S30E; S40/50E; S60/70/80/100/120E; S40/50F;
S2.00/3.00XL (S40/50/60XL);
H2.00/3.00XL (H40/50/60XL);
S2.00/2.50/3.00/3.20XM
(S40/45/50/55/60/65XM) [D187];
H2.00/2.50/3.00/3.20XM (H40/45/50/55/60/65XM);
H45-65XM [H177]; H30-60H; H40/50J; H60J; H60JS;
H60/70/80/100/110E; H110/130/150F; P40-50A

PART NO. 899766 600 SRM 3


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

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

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair


on electric lift trucks.

• Disconnect the battery ground cable on internal combustion lift trucks.

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

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

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

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

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

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

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

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

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

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

WARNING
Indicates a condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
GM Engines Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Engine Removal and Installation ..................................................................................................................... 3
Cylinder Head and Valve Mechanism Repair .................................................................................................. 3
Cylinder Head, Remove................................................................................................................................. 3
Cylinder Head, Disassemble ......................................................................................................................... 3
Clean and Inspect .......................................................................................................................................... 3
Valves and Valve Seats .................................................................................................................................. 6
Studs for Rocker Arms .................................................................................................................................. 6
Hydraulic Valve Lifters, Replace .................................................................................................................. 7
Hydraulic Valve Lifters, Clean and Inspect ................................................................................................. 7
Cylinder Head, Assemble .............................................................................................................................. 7
Cylinder Head, Install ................................................................................................................................... 7
Valve Clearance, Adjust ................................................................................................................................ 8
Rocker Arm Cover, Install............................................................................................................................. 9
Timing Gear Cover Repair ................................................................................................................................ 9
Remove ........................................................................................................................................................... 9
Install ............................................................................................................................................................. 10
Camshaft Repair ................................................................................................................................................ 11
Remove ........................................................................................................................................................... 11
Inspect ............................................................................................................................................................ 11
Camshaft Bearing.......................................................................................................................................... 12
Remove....................................................................................................................................................... 12
Install ......................................................................................................................................................... 12
Distributor Repair.............................................................................................................................................. 13
Remove ........................................................................................................................................................... 13
Install ............................................................................................................................................................. 13
Lubrication System Repair................................................................................................................................ 14
Oil Sump ........................................................................................................................................................ 14
Remove....................................................................................................................................................... 14
Install ......................................................................................................................................................... 14
Oil Pump ........................................................................................................................................................ 14
Remove....................................................................................................................................................... 14
Disassemble and Repair............................................................................................................................ 14
Assemble .................................................................................................................................................... 15
Install ......................................................................................................................................................... 15
Piston and Connecting Rod Assemblies Repair ............................................................................................... 15
Connecting Rod Bearings, Replace ............................................................................................................... 15
Piston and Connecting Rod Assemblies, Remove ........................................................................................ 16
Piston and Connecting Rod Assemblies, Disassemble................................................................................. 17
Piston, Clean and Inspect ............................................................................................................................. 17
Cylinder Bores, Inspect and Repair.............................................................................................................. 17
Piston Rings, Inspect ..................................................................................................................................... 18
Piston and Connecting Rod Assemblies, Assemble...................................................................................... 18
Piston and Connecting Rod Assemblies, Install .......................................................................................... 20
Crankshaft Repair ............................................................................................................................................. 20
Main Bearings, Replace................................................................................................................................. 20
Oil Seal for Rear Main Bearing, Replace (GM 4-181 and 3.0L Only) ......................................................... 21
Oil Seal for Rear Main Bearing, Replace (Engines That Have Two-Piece Oil Seal).................................. 21
Remove ........................................................................................................................................................... 23
Inspect and Repair......................................................................................................................................... 23

©2003 HYSTER COMPANY i


Table of Contents GM Engines

TABLE OF CONTENTS (Continued)


Main Bearing and Journal Clearance, Check .............................................................................................. 24
Install ............................................................................................................................................................. 24
Flywheel and Flywheel Housing Repair........................................................................................................... 25
Remove ........................................................................................................................................................... 26
Ring Gear, Replace ........................................................................................................................................ 27
Install ............................................................................................................................................................. 27
Cooling System Repair ...................................................................................................................................... 27
Coolant Pump ................................................................................................................................................ 27
Fan Drive ....................................................................................................................................................... 27
Viscous Fan Drive .......................................................................................................................................... 27
Engine Specifications......................................................................................................................................... 29
Engine Data ................................................................................................................................................... 29
Cylinder Head ................................................................................................................................................ 30
Hydraulic Valve Lifter ................................................................................................................................... 30
Camshaft ........................................................................................................................................................ 31
Pistons ............................................................................................................................................................ 32
Cylinder Bore ................................................................................................................................................. 32
Crankshaft ..................................................................................................................................................... 33
Connecting Rods ............................................................................................................................................ 33
Cooling System .............................................................................................................................................. 34
Lubrication System ....................................................................................................................................... 34
Torque Specifications ......................................................................................................................................... 34
Troubleshooting.................................................................................................................................................. 35

This section is for the following models:

S30E; S40/50E; S60/70/80/100/120E; S40/50F; S2.00/3.00XL


(S40/50/60XL); H2.00/3.00XL (H40/50/60XL); S2.00/2.50/3.00/3.20XM
(S40/45/50/55/60/65XM) [D187];
H2.00/2.50/3.00/3.20XM (H40/45/50/55/60/65XM); H45-65XM [H177];
H30-60H; H40/50J; H60J; H60JS; H60/70/80/100/110E;
H110/130/150F; P40-50A

ii
600 SRM 3 Description

General
The diodes and resistors in the electrical sys-
WARNING tem can be damaged if the following cautions
Some gaskets used in this engine can contain are not followed:
dangerous fibers. Breathing dust from these • Do not disconnect the battery when the en-
fibers is a cancer or lung disease hazard. Do gine is running. The voltage surge can dam-
not create dust! Use vacuum equipment for age the diodes and resistors.
asbestos or follow the cleaning procedure de- • Do not disconnect an electric wire before the
scribed below. engine is stopped and the switches are OFF.
• Make sure the gasket material is wet with wa- • Do not cause a short circuit by connection
ter or oil to prevent particles in the air. of the electric wires to the wrong terminals.
• Use a hand scraper to remove old gasket ma- Make sure a correct identification is made of
terial. Do not use a power tool or compressed the wire before it is connected.
air. • Make sure a battery is the correct voltage and
• Discard all asbestos material in a closed con- polarity before it is connected.
tainer while it is still wet. • Do not check for current flow by making a
spark because the electronic components can
Put a DANGEROUS FIBERS warning label on
be damaged.
the container. Discard dangerous fiber mate-
rial safely. This section has the description and the repair in-
structions for the engine. Disassembly, cleaning, as-
CAUTION sembly, specifications, and troubleshooting are in-
cluded.
Disconnect the battery cables before doing any
disassembly and repair to the engine or parts
of the electrical system.

Description
The GM engines described in this section are the and serial codes B177 and C177 [H2.00-3.00XL
four-cylinder and six-cylinder models that have the (H40-60XL)] are the same engine.
arrangement of the cylinders in a straight line.
These engines have a similar design. The number The GM 3.0L engine is a later model of the 4-181 en-
one cylinder for these engines is toward the cooling gine. It is used in the S/H2.00-3.20XM (S/H40-65XM)
fan. These engines can have either a gasoline or an lift trucks.
LPG fuel system. See Figure 1.
The GM 6-250 engine is used in some models of 3.00
The GM 4-153 engine is used in some models of 2.00 to 7.50 ton (6000 to 15,000 lb) capacity lift trucks
to 3.00 ton (4000 to 6000 lb) capacity lift trucks from from 1975 until 1988.
June 1975 until June 1990. During 1990, production
A camshaft in the engine block operates the overhead
of the GM 4-153 engine was stopped and it was re-
valves with push rods. A cast iron crankshaft gear
placed with variations of the GM 4-181 engine. The
drives a camshaft gear. The cam lobes are hardened
GM 4-181 engine is also used in some models of 2.00
and have a taper with the high side toward the rear of
to 3.00 ton (4000 to 6000 lb) capacity lift trucks begin-
the engine. The valve lifters have a rounded surface
ning in 1978. The two engines are the same design
where they contact the cam lobes. This combination
except for different displacements. The GM 4-181 en-
of surfaces causes the valve lifters to rotate during
gines installed in the lift trucks with serial code B187
engine operation. All of the engines have hydraulic
[S2.00-3.00XL (S40-60XL)] beginning in 1990 have a
valve lifters.
different camshaft than the GM 4-181 engines used
in the lift trucks with other serial codes. Each rocker arm rotates on a pivot ball stud fastened
to the cylinder head. The valve guides and valve
The GM 4-181 engines installed in the lift trucks
seats are part of the cylinder head. The exhaust
with serial codes C187 [S2.00-3.00XL (S40-60XL)]
valve seats are induction hardened.

1
Description 600 SRM 3

A. 4-153, 4-181, AND 3.0L ENGINES B. 6-250 ENGINE


1. ROCKER ARM COVER 5. OIL SUMP
2. FILL CAP FOR ENGINE OIL 6. ENGINE BLOCK
3. WATER PUMP 7. CYLINDER HEAD ASSEMBLY
4. VIBRATION DAMPENER

Figure 1. GM Engines

2
600 SRM 3 Cylinder Head and Valve Mechanism Repair

The crankshaft in the four-cylinder engines has five different design. Some oil control rings have three
main bearings. The crankshaft in the six-cylinder parts that must be assembled when the oil control
engine has seven main bearings. The rear main bear- ring is installed on the piston.
ing in all engines is the thrust bearing.
The specifications for engine repair are shown in En-
The pistons are aluminum alloy and have three pis- gine Specifications at the end of this section.
ton rings. The two compression rings each have a

Engine Removal and Installation


NOTE: The removal and installation procedures for section. See the Frame section for the model of lift
the engine and transmission are not included in this truck for these procedures.

Cylinder Head and Valve Mechanism Repair


CYLINDER HEAD, REMOVE 14. Loosen the cylinder head bolts in two or three
steps. Do not completely loosen the cylinder
1. Disconnect the battery cables at the battery. head bolts during the first sequence. Remove
the cylinder head bolts. Remove the cylinder
2. Drain the cooling system.
head and the gasket.
3. Disconnect and remove the coolant hose from the
housing for the thermostat. CYLINDER HEAD, DISASSEMBLE

4. Remove or disconnect the air filter. 1. Use a compressor tool to compress the valve
springs and remove the retainers. See Figure 2
5. Disconnect the PCV valve. and Figure 3. Release the compressor tool and
remove the spring cap, (rotators when used), oil
6. Disconnect the wires and hoses fastened to shield, and valve springs. Remove the oil seal
brackets on the rocker arm cover. and any shims from the springs.
7. Disconnect the spark plug wires. 2. Remove the valves from the cylinder head and
put them in a rack so that the valves can be in-
8. Disconnect the linkages, fuel lines, and hoses for
stalled again in their same positions in the cylin-
the fuel system.
der head.
9. Disconnect the exhaust pipe at the exhaust man-
ifold and remove the intake and exhaust mani- CLEAN AND INSPECT
folds. 1. Clean the carbon from the combustion chambers
10. If necessary, remove the alternator and bracket. and the valve ports.

11. Remove the dipstick tube for engine oil. 2. Clean the valve guides. Use a tool as shown in
the example in Figure 4.
12. Remove the rocker arm cover.
3. Clean the push rods and rocker arms.
NOTE: Keep the rocker arm assemblies and the push
rods in order so that they will be installed in the same 4. Clean the surfaces of the cylinder head where the
position. gaskets fit.

13. Remove the rocker arms and the push rods. 5. Inspect the cylinder head for cracks in the ex-
haust ports, combustion chambers, and external
surfaces.

3
Cylinder Head and Valve Mechanism Repair 600 SRM 3

Figure 2. Cylinder Head

4
600 SRM 3 Cylinder Head and Valve Mechanism Repair

Legend for Figure 2

NOTE: GM 6-250 SHOWN.


1. PCV VALVE 10. VALVE SPRING
2. ROCKER ARM COVER 11. EXHAUST MANIFOLD
3. INTAKE MANIFOLD 12. SHIELD
4. OUTLET 13. SPRING CAP
5. THERMOSTAT 14. ROCKER ARM
6. CYLINDER HEAD 15. BALL
7. INTAKE VALVE 16. NUT
8. PUSH ROD 17. RETAINER
9. EXHAUST VALVE
a. Use a micrometer to measure the diameter
of the valve stem in three places: top, cen-
ter, and bottom. The stems of exhaust valves
have a small taper. The end of the valve stem
near the spring is approximately 0.025 mm
(0.001 in.) larger than the diameter near the
valve head. Use a hole gauge to measure the
bore in the valve guide.

b. Another method of measuring the clearance


of the valve stem in its valve guide is to use a
dial indicator as shown in Figure 5. Put the
dial indicator so that it can measure the side-
to-side movement of the valve stem. Lower
the valve away from its valve seat approxi-
Figure 3. Valve Spring Compression mately 3 mm (0.1 in.). Move the valve stem
from side to side and check the measurement
on the dial indicator.

Figure 4. Valve Guide Cleaning Tool

6. Inspect the valves for burned or damaged areas Figure 5. Valve Guide and Valve Clearance
in the seat surfaces. Inspect for cracks and dam- Check
aged or worn valve stems.

7. Check the clearance of each valve stem in its


valve guide. Use the following procedure:

5
Cylinder Head and Valve Mechanism Repair 600 SRM 3

c. The maximum clearance between the valve wrench to remove the damaged stud. See Fig-
stems and their valve guides is shown in the ure 7.
Engine Specifications.

d. If the clearance between the valve stem and


its valve guide is greater than the specifica-
tion, a valve with an oversize stem must be
installed. Use a reamer to make the bore the
correct diameter for the next oversize valve.
See the Parts Manual for oversize valves.

8. Use a valve spring tester to check the valve


springs. A typical tester is shown in Figure 48.
The specifications for the valve springs are
shown in the Engine Specifications.

9. Inspect the rocker arm bolts for wear and dam- 1. VALVE SEAT
age. 2. MINIMUM THICKNESS OF VALVE HEAD IS
0.80 mm (0.031 in.)
VALVES AND VALVE SEATS
Figure 6. Intake and Exhaust Valve Seat
The condition and alignment of the valves to their Specifications
valve seats are important so that the engine will op-
erate correctly. Before any work is done on the valve
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 lap-
ping. 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.

NOTE: Some engines have valve seats that can be


replaced. If the valve seats cannot be repaired or
replaced, install a new cylinder head.
Figure 7. Rocker Arm Stud Removal
Damaged valve seats can be repaired with a cutter
tool. If the valve seat cannot be repaired so that
the valve depth is within specifications, the cylin- CAUTION
der head must be replaced. The specifications for the Do not try to install an oversize stud without
valve seats are shown in Figure 6. reaming the stud hole to the new size. Instal-
lation of an oversize stud without reaming the
STUDS FOR ROCKER ARMS stud hole can cause cracks in the cylinder head.

Replace a stud that has damaged threads or is loose 2. Use a reamer of the correct size for the new over-
in the cylinder head. See the Parts Manual for over- size stud. Apply SAE 90 lubricant to the new
size studs. stud during installation. Install the new stud as
shown in Figure 8.
1. Remove the old stud. Install a spacer, flat
washer, and nut to the damaged stud. Use a

6
600 SRM 3 Cylinder Head and Valve Mechanism Repair

CYLINDER HEAD, ASSEMBLE


1. Install the valves in their correct ports. See Fig-
ure 2. If a spring shim is used, install it on the
valve stem. Install the valve spring, oil shield,
and valve cap or rotator (exhaust valves) in posi-
tion on each valve.

2. Use a valve spring compressor to compress the


valve spring. Install a new oil seal on each valve
stem. Make sure the oil seal is not twisted on the
valve stem.

3. Install the retainers for the valve spring assem-


bly. Make sure the retainers fit correctly in the
upper groove of the valve stem. Release the
spring compressor tool.
Figure 8. Rocker Arm Stud Installation
CYLINDER HEAD, INSTALL
HYDRAULIC VALVE LIFTERS, REPLACE
1. Clean the surface of the cylinder head and the top
The hydraulic valve lifters normally do not need ser- of the engine block. The surfaces for the gaskets
vice unless they are dirty or damaged. The hydraulic must be clean. The threads for the head bolts
valve lifters must be clean to operate correctly. If the must be clean so that the correct torque is applied
lifters make noise or do not operate correctly, replace during installation.
them. The lifters can be removed with a flexible mag-
net after the push rods are removed. 2. Install a new gasket for the cylinder head to the
engine block. Do not use a sealant on the gasket.
HYDRAULIC VALVE LIFTERS, CLEAN AND 3. Carefully install the cylinder head to the engine
INSPECT block. Use a sealant on the capscrews during
installation. Tighten the head bolts evenly in a
WARNING minimum of three steps. Tighten the head bolts
Cleaning solvents can be flammable and toxic evenly to a final torque of 122 N•m (90 lbf ft) in
and can cause skin irritation. When using the sequence shown in Figure 9.
cleaning solvents, always follow the solvent
manufacturer’s recommended safety precau-
tions.

Clean all parts in a cleaning solvent and inspect them


carefully. If any parts are damaged or worn, the com-
plete hydraulic valve lifter must be replaced. If the
body of the hydraulic valve lifter is worn, also inspect
the bore in the engine block. If the bottom of the hy-
draulic valve lifter is worn or damaged, inspect the
camshaft lobe for wear and damage. The bottom of
the lifter must be convex for correct rotation during
engine operation.

Figure 9. Cylinder Head Tightening Sequence

7
Cylinder Head and Valve Mechanism Repair 600 SRM 3

4. If the hydraulic valve lifters (cam followers) were 19. Connect the battery cables at the battery.
removed, install them in their positions in the en-
gine block. Install the side cover for the hydraulic 20. When the engine can be operated, adjust the igni-
valve lifters. tion timing and carburetor as necessary. See the
Periodic Maintenance section for additional
5. Install the push rods in their positions in the en- information.
gine. Make sure each push rod fits in its socket
in its hydraulic valve lifter. VALVE CLEARANCE, ADJUST
6. Lubricate the rocker arms and rocker arm balls 1. Remove the cover for the rocker arm assembly.
with engine oil during installation. Install the
rocker arms, rocker arm balls, and rocker arm 2. Adjust the valves for each cylinder when the
nuts. Tighten the rocker arm nuts until there is piston is at top dead center on the compression
zero clearance. stroke. Use the rotor in the distributor to find
top dead center for each piston. Make an identi-
7. Install the intake manifold and exhaust mani- fication mark for each cylinder on the distributor
fold. Connect the exhaust pipe at the exhaust housing. Make the marks directly under the
manifold. connections of the spark plug wires.

8. Install the carburetor. Connect the carburetor 3. Remove the distributor cap. Turn the crankshaft
linkage, fuel line, and hoses. until the rotor is aligned over the mark for the
number one cylinder. Now adjust both valves for
9. Install the alternator and bracket. the number one cylinder. Tighten the nut for the
rocker arm while turning the push rod with your
10. Install the dipstick tube for engine oil.
fingers as shown in Figure 10. Tighten the nut
11. Connect the coolant hose to the housing for the just until the movement of the push rod stops.
thermostat. This condition is zero clearance. Now tighten the
nut one more turn.
12. Adjust the clearance of the rocker arm assem-
blies as described in Valve Clearance, Adjust.

NOTE: If performing repair on the GM 3.0 liter en-


gine, go to Step 14.

13. When the valve clearances are adjusted correctly,


install the rocker arm cover. Use a new gas-
ket between the cylinder head and the rocker
arm cover. Install the retaining bolts and tighten
them to 6 N•m (50 lbf in).

14. Install the rocker arm cover as described in


Rocker Arm Cover, Install.

15. Install and connect the PCV valve.

16. If the distributor cap was removed, install it.


Connect the spark plug wires. Connect the wires
and hoses fastened to brackets on the rocker arm
cover.

17. Install the air cleaner and component parts.

18. Fill the cooling system with the correct coolant. Figure 10. Valve Clearance Adjustment
See the Periodic Maintenance section for your
unit.

8
600 SRM 3 Timing Gear Cover Repair

4. Turn the crankshaft in the normal direction of ro- 3. Install a new gasket onto the cylinder head rail.
tation until the rotor aligns over the next mark.
(For the six-cylinder engine, the valves for the 4. Apply Loctite Flange Sealant around the bolt
number five cylinder can now be adjusted. For holes of the gasket, and install the rocker arm
the four-cylinder engine, the valves for the num- cover.
ber three cylinder can now be adjusted.) Adjust
5. Tighten the rocker arm cover bolts to 6 N•m
the valves as described in Step 3.
(50 lbf in) in the sequence shown in Figure 11.
5. Follow the same procedure as described in Step 4
until all the valves are adjusted.

6. Install the distributor cap and the cover for the


rocker arms.

ROCKER ARM COVER, INSTALL


1. Remove all gasket material from the cylinder
head and the rocker arm cover.

2. Coat the cylinder head rail with Loctite Flange Figure 11. Rocker Arm Cover Tightening
Sealant. Sequence

Timing Gear Cover Repair


REMOVE
NOTE: The oil seal can be replaced without removing
the timing gear cover. The crankshaft pulley and vi-
bration dampener must be removed. The oil seal can
be removed with a pry bar. Work carefully so that
the sheet metal of the timing gear cover is not bent
or damaged during removal or installation of the oil
seal. The replacement of the oil seal is easier if the
timing gear cover is removed from the engine.

1. Drain the coolant system. Remove the radiator.

2. Remove the drive belts. Remove the pulley from


the vibration dampener. See Figure 12.

NOTE: The vibration dampener on the 3.0L engine


is pressed onto the crankshaft. It must be pulled off
with a puller.

3. Remove the vibration dampener. Use a tool that


pulls on the center of the vibration dampener. (A
special tool, GM Part No. J-23523, is available.)
See Figure 13. Do not use a puller that pulls on 1. WOODRUFF KEY 4. VIBRATION
the outside diameter of the vibration dampener. 2. ENGINE BLOCK DAMPENER
3. HUB 5. PULLEY
6. TIMING COVER

Figure 12. Timing Gear Cover and Pulleys

9
Timing Gear Cover Repair 600 SRM 3

is available for GM 4-153, 4-181, and 3.0L, and


GM Part No. 23042 is available for GM 6-250.)
The oil seal must be aligned so that it is evenly in
position around the hub. An oil seal that is not
correctly aligned with the hub will be damaged
and will leak oil.

1. VIBRATION DAMPENER
2. TOOL FOR REMOVAL AND INSTALLATION OF
VIBRATION DAMPENER

Figure 13. Vibration Dampener


1. CENTERING TOOL
4. Remove the screws that hold the oil sump to the
timing gear cover. Remove the screws that hold Figure 14. Timing Gear Cover Centering Tool
the timing gear cover to the engine block.
5. GM 4-153, 4-181, and 3.0L. Install the timing
GM 4-153, 4-181 and 3.0L. Remove the timing gear cover. Install the two screws for the oil
gear cover. sump and the screws for the timing gear cover
and tighten the screws with your fingers. Make
GM 6-250. Pull the timing gear away from the sure the oil seal is correctly aligned. Tighten the
engine block only enough to cut the front gasket screws to 10 N•m (90 lbf in).
of the oil sump. Use a sharp knife and cut the
gasket even with the edge of the engine block. GM 6-250. Cut the tabs from the oil seal for the
Remove the timing gear cover. front of the oil sump as shown in Figure 15. Ap-
ply a thin coat of sealant to both sides of the gas-
5. Remove the oil seal from the timing gear cover. ket and put it in position. Apply a 3 mm (1/8 in.)
Do not bend or damage the sheet metal of the bead of RTV sealant at the joint between the gas-
timing gear cover when removing the oil seal. kets at the edge of the engine block. Install the
timing gear cover. Install the screws for the oil
INSTALL sump and the screws for the timing gear cover
and tighten the screws with your fingers. Make
1. Make sure the gasket surfaces on the engine sure the oil seal is correctly aligned. Tighten the
block, timing gear cover, and oil sump are clean. screws to 9 N•m (80 lbf in).
2. Install a new oil seal. Carefully press the oil seal
into the timing gear cover. Make sure the lip of
the oil seal is toward the engine.

3. Install a new gasket if your engine uses a gasket


between the timing gear cover and engine block.
Apply a thin coat of sealant to both sides of the
gasket. Figure 15. Front Oil Sump Seal Modification,
GM 6–250
4. Install a centering tool in the oil seal. See Fig-
ure 14. (A special tool, GM Part No. J-34995,

10
600 SRM 3 Camshaft Repair

6. Remove the centering tool. vibration dampener is against the crankshaft


gear. Tighten the capscrew for the vibration
NOTE: The vibration dampener on the 3.0L engine dampener. See Torque Specifications.
is pressed on to the crankshaft and does not use a
capscrew. 8. When used, install the pulley on the vibration
dampener. Tighten the capscrews to 44 N•m
7. Install the vibration dampener. Use a tool that (32 lbf ft). Install the drive belts.
presses on the center of the vibration damp-
ener. (A special tool, GM Part No. J-23523, is 9. If the coolant system is complete, fill the system
available.) See Figure 13. Do not use a tool with coolant and check for leaks.
that pushes on the outside diameter of the vi-
bration dampener. Make sure the hub of the

Camshaft Repair
REMOVE INSPECT
NOTE: The engine is removed from the lift truck for Measure the amount of clearance between the thrust
this procedure. plate and the camshaft as shown in Figure 17. If
the clearance is greater than 0.203 mm (0.008 in.),
1. Remove the drive belts, fan, and pulley. replace the thrust plate.
2. Remove the timing gear cover. See the procedure
under Timing Gear Cover Repair, Remove.

3. Remove the rocker arms and push rods as de-


scribed in Cylinder Head, Disassemble. Put the
parts in a rack so that they will be installed again
in the same position.

4. Remove the side cover for access to the hydraulic


valve lifters. Remove the hydraulic valve lifters
and put them in a rack so that they will be in-
stalled again in the same position in the engine
block.

5. Remove the fuel pump.

6. Align the timing marks on the timing gears as


shown in Figure 16. On engines with holes in
the timing gear, remove the two capscrews that
hold the thrust plate to the engine block. On en-
gines with a capscrew for the timing gear, remove
the capscrew and the gear. Remove the two cap-
screws for the thrust plate. 1. TIMING MARKS
2. CAPSCREWS FOR THRUST PLATE
7. Carefully pull the camshaft from the engine
Figure 16. Timing Gears
block. Give enough support to the camshaft so
that the bearings are not damaged.

11
Camshaft Repair 600 SRM 3

Figure 17. Thrust Plate and Camshaft Figure 18. Camshaft Bearings Replacement
Clearance Check

If the camshaft gear or the thrust plate must be re-


placed, the camshaft gear must be removed. A press
must be used to remove and install the camshaft gear
on the camshaft.

CAUTION
Make sure the force is applied to the hub of
the camshaft gear or the camshaft gear will be
damaged. Make sure the Woodruff key does not
damage the thrust plate during removal or in-
stallation.

Check the surfaces of the camshaft for wear and dam-


age. See the Engine Specifications, Camshaft.

CAMSHAFT BEARING Figure 19. Camshaft Bearings Replacement

Remove Install
Special tools are required to remove and install the CAUTION
camshaft bearings. See Figure 18. Remove the front
The holes for the oil passages in the camshaft
and rear bearings last.
bearings must be aligned with the oil passages
1. Remove the plug in the bore for the camshaft at in the bore of the engine block. If the oil pas-
the rear of the engine block. sages are not aligned correctly, the loss of lu-
brication will cause a failure of the camshaft
2. Install the removal and installation tool as bearings or other parts of the engine.
shown in Figure 18. Remove the intermediate
bearings. 1. Install the front and rear camshaft bearings
first. These bearings will be guides for installa-
3. Install the head of the special tool on the end tion of the intermediate bearings. See Figure 19.
of a driver. Remove the front and rear bearings Use the special tool to install the front and rear
by pushing them toward the center of the engine camshaft bearings.
block. See Figure 19.

12
600 SRM 3 Distributor Repair

GM 4-153, 4-181 and 3.0L. The front camshaft 3. Install a new plug in the bore in the rear end of
bearing must be 3.0 mm (0.12 in.) below the sur- the engine block. The surface of the plug must
face of the engine block so that the oil passage to be even with the surface of the engine block or
the nozzle for the timing gears is open. not greater than 0.80 mm (0.03 in.) below the
surface.
2. Install the intermediate camshaft bearings. Use
the special tool as shown in Figure 18.

Distributor Repair
REMOVE a. Remove the No. 1 spark plug.

NOTE: This section has only removal and installa- b. Put a finger over the No. 1 spark plug hole
tion procedures for the distributor. The service pro- and slowly rotate the engine until pressure is
cedures for the ignition system are found in the fol- felt on the compression stroke.
lowing sections:
• High Energy Ignition System 2200 SRM 107 c. Align the timing mark on the crankshaft pul-
• Microprocessor Spark Timing System ley to 0 (TDC) on the engine timing indica-
(MSTS) 2200 SRM 463 tor.

d. Turn the distributor rotor to point between


CAUTION the positions on the distributor cap for No.
Carefully lift and release the lock tabs on the 1 and No. 4 (or No. 1 and No. 6 for six
connectors to the distributor. The lock tabs can cylinders) spark plug wires.
be easily broken if too much force is applied
with a screwdriver or other tool. e. Install the distributor in the engine. The ro-
tor and shaft will rotate a few degrees when
Never let the TACH CONN. terminal touch a the gear on the distributor shaft engages the
ground. The HEI module or the ignition coil drive gear on the engine cam. The timing is
will be damaged. correct if the rotor points at the position on
the distributor cap for the No. 1 spark plug
1. Disconnect the battery negative (ground) cable. wire.
2. If removal of the spark plug wires are not re- f. Continue with the installation of the distrib-
quired for the repairs, leave them connected to utor as described in Install.
the distributor cap. Remove the two capscrews
that fasten the distributor cap to the distribu- INSTALL
tor. Move the distributor cap away from the work
area. 1. Put the rotor and distributor in the same position
as it was removed from the engine.
3. Disconnect the distributor 4-terminal connector.
2. Install the clamp and bolt. Tighten the bolt with
4. Disconnect the ignition coil connector. your hand.
5. Remove the bolt and clamp that hold the distrib- 3. Install the distributor connector(s) at the distrib-
utor in the engine. Make a note of the positions of utor.
the rotor to distributor housing and the distrib-
utor to the engine. Slowly pull the distributor 4. Install the ignition coil connector.
from the engine until the rotor just stops turning
counterclockwise and make a note of the position 5. Install the distributor cap and the two capscrews.
of the rotor. This position must be used when the If the spark plug wires were removed, install
distributor is installed again. them in the correct sequence.

If the engine has been rotated after the distrib- 6. Connect the battery negative cable.
utor was removed, the following procedure must
be used before the distributor is installed again:

13
Lubrication System Repair 600 SRM 3

7. Start the engine and check the engine timing. 8. Tighten the bolt for the distributor clamp. See
See the section for Periodic Maintenance for Torque Specifications.
your lift truck for procedures on Ignition Timing.

Lubrication System Repair


OIL SUMP Disassemble and Repair
Remove 1. Disassemble the oil pump as necessary for clean-
ing and inspection. Remove the four screws that
1. Disconnect the battery negative (ground) cable. fasten the cover to the pump body. Remove the
cover and gasket. See Figure 20.
2. Remove the dipstick. Drain the engine oil.

3. Remove the starter.

4. Remove the bolts that fasten the oil sump to the


engine block. Remove the oil sump.

Install
1. Clean the sealing surfaces on the oil sump and
the engine block. Remove old gasket material or
sealant.

NOTE: Some engines use a gasket to seal the joint


between the oil sump and the engine block. Earlier
production engines use a two-piece gasket and sepa-
rate rear oil seal for the crankshaft. Some later pro-
duction engines use a one-piece gasket. If a gasket
is used in your engine, apply a thin coat of liquid
sealant to the gasket surfaces to hold it in position
on the oil sump during installation. Other later pro-
duction engines use an RTV sealant between the oil
sump and the engine block. If your engine uses only
an RTV sealant, apply a 3.0 mm (0.12 in.) bead of
sealant around the sealing surfaces of the oil sump.

2. Apply RTV sealant or install the gasket on the oil


sump.

3. Install the capscrews that fasten the oil sump to


the engine block. Tighten the 1/4 - 20 capscrews
to 10 N•m (7 lbf ft). Tighten the 5/16 - 18 cap-
screws to 19 N•m (14 lbf ft).
1. RELIEF VALVE 6. DRIVE
OIL PUMP 2. SPRING 7. IDLER GEAR
3. PIN 8. PUMP BODY
Remove 4. COVER 9. SCREEN AND
5. GASKET TUBE ASSEMBLY
1. Remove the oil sump.
Figure 20. Oil Pump
2. Remove the mount bolts and remove the oil pump
and screen assembly.

14
600 SRM 3 Piston and Connecting Rod Assemblies Repair

2. Make an index mark on the gears so that they of the screen assembly is parallel to the bottom sur-
can be installed again in the same position to face of the engine block.
each other. Remove the gears. Do not remove the
screen and tube assembly unless it is damaged. 1. If the relief valve was disassembled, install the
relief valve, spring, and pin. See Figure 20.

WARNING 2. Install the gears in the pump body. Align the


The relief valve has a compressed spring. When identification marks. Make sure that the smooth
the pin is removed, do not permit a sudden re- side of the idler gear is toward the cover.
lease of the spring and cause an injury.
3. Use a new gasket and install the cover. Tighten
3. Remove the pin, spring, and the relief valve. the screws to 8 N•m (71 lbf in). Turn the drive
shaft with your hand to check for a smooth oper-
4. Inspect the gears and the pump body for wear ation.
and damage. If the parts are worn or damaged,
replace the oil pump. Parts are not available for Install
repairs.
1. Install the oil pump and screen assembly. Make
Assemble sure the screen is parallel to the bottom of the oil
sump when the oil pump is installed.
NOTE: Use a sealant when replacement of the screen
and tube assembly is necessary. Do not damage the 2. Install the oil sump.
tube during installation. Make sure that the surface

Piston and Connecting Rod Assemblies Repair


CONNECTING ROD BEARINGS, REPLACE Out-of-round less than 0.0127 mm
(0.0005 in.)
NOTE: The connecting rod bearings are available in a Taper less than 0.0127 mm (0.0005 in.)
standard size and several undersizes. See the Parts Six-cylinder engines
Manual for bearing sizes. If a bearing on a journal Out-of-round less than 0.0254 mm
is worn, both the upper and lower half of the bearing (0.001 in.)
must be replaced. Taper less than 0.0254 mm (0.001 in.)
1. Remove the oil sump and the oil pump. If the bearing journals are not within specifica-
tions, the crankshaft must be removed and the
2. Before the cap for the connecting rod is removed,
bearing journal ground to an undersize. If the
mark the connecting rod and cap with the cylin-
bearing journal cannot be repaired so that the
der number so that the parts will be installed
bearing journal is a correct undersize, the crank-
again in their original positions. Remove the
shaft must be replaced. See Engine Specifica-
cap for the connecting rod bearing and the lower
tions, Crankshaft.
bearing half.
5. If the bearing journal is within specifications,
3. Push the connecting rod away from the crank-
measure the clearance between the new bearing
shaft and remove the upper bearing half. Wipe
and the crankshaft. Use Plastigage® or equiva-
the oil from the bearing halves and the bearing
lent to check the clearance.
journal.
a. Put a piece of Plastigage across the full width
4. Use a micrometer to measure the bearing jour-
of the bearing journal as shown in Figure 21.
nal. The bearing journal must be within the fol-
Do not rotate the crankshaft when the Plas-
lowing specifications:
tigage is between the bearing and its journal.
Four-cylinder engines:

15
Piston and Connecting Rod Assemblies Repair 600 SRM 3

6. When all of the rod bearings have been replaced,


use the following procedure to check the side
clearances between the connecting rods and the
crankshaft:

a. Use a hammer to lightly hit the connecting


rod parallel to the crankshaft journal to
make sure there is a clearance.

b. Measure the clearance between the caps for


the connecting rods and the crankshaft. See
Figure 23.

Figure 21. Bearing Journal Plastigage®


Placement

b. Remove the bearing cap. The Plastigage will


be compressed and wider and 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 22.

Figure 23. Connecting Rods Side Clearance


Measurement

PISTON AND CONNECTING ROD


ASSEMBLIES, REMOVE
1. Remove the oil sump and the oil pump.

2. Remove the cylinder head as described in Cylin-


der Head, Remove.

3. If the engine has been in service for many hours,


Figure 22. Bearing Journal Plastigage® a ridge can be worn in the top of the cylinder.
Measurement This ridge can be removed with a ridge reamer
tool. Turn the crankshaft to lower the piston to
c. If the clearance is greater than the specifica-
the bottom of the stroke in its cylinder. Put a
tions, select a new undersize bearing set and
cloth on top of the piston for a collector of metal
install it. Measure the clearance again. If
particles. Remove the ridge at the top of the
the clearance cannot meet specifications with
cylinder.
the available undersize bearings, the bearing
journal must be ground to a new undersize. 4. Clean the carbon from the top of each cylinder.
If the bearing journal is already at the max-
imum undersize, the crankshaft must be re- 5. Put an identification mark on the top of each pis-
placed. ton.

d. If the clearance is within specifications, lu- 6. Remove the caps and bearings from each connect-
bricate the bearing with engine oil and in- ing rod. Keep the caps and bearings with their
stall the bearing and bearing cap. Tighten original piston assemblies. Mark the caps so that
the nuts on the bearing cap. See Torque Spec- they will be installed again in their original posi-
ifications. tions. Do not mix the parts.

16
600 SRM 3 Piston and Connecting Rod Assemblies Repair

7. Push the connecting rod and piston from the PISTON, CLEAN AND INSPECT
cylinder. Temporarily install the bearing cap on
the connecting rod to keep the parts together. Inspect the pistons for wear, cracks, and damage. Re-
place a piston that is worn or damaged.
PISTON AND CONNECTING ROD
NOTE: If the cylinder bore must be repaired, the pis-
ASSEMBLIES, DISASSEMBLE ton must be changed to the correct oversize. Check
the clearance of the piston in its cylinder after the
CAUTION surface of the cylinder bore has been finished with a
The pistons are aluminum alloy and can be hone.
damaged if they are hit with a hard object. The
Check the clearance of the piston pin in the piston.
grooves for the piston rings are machined to
The normal clearance is shown in Engine Specifica-
close tolerances. Use a tool made to clean the
tions. The piston pin will normally fall from the hole
grooves of the piston rings. Do not use a wire
in the piston by its own weight. The piston pin is a
brush to clean a piston.
press fit in the connecting rod. The piston and piston
1. Remove the piston rings from the pistons. Use a pin are a matched set and must be replaced as a unit
press to remove the piston pins from the piston. if the clearances are greater than the specifications.
See Figure 24.
CYLINDER BORES, INSPECT AND REPAIR
2. Use solvent to clean the pistons and connecting
rods. Use compressed air to dry the parts. Make Inspect the cylinder bores for wear and damage.
sure that the holes for oil passages are clean. Measure the cylinder bores in several positions as
shown in Figure 25. Measure the cylinder bore at
right angles to the centerline to find any distortion
from wear. A cylinder that is out-of-round greater
than 0.05 mm (0.002 in.) must be repaired.

Figure 25. Cylinder Bore Measurement

Measure the cylinder bore in positions from top to


bottom to find any taper from wear. A normal wear
pattern for a cylinder bore is shown in Figure 26.
A cylinder that has a taper [measurement A that is
0.127 mm (0.005 in.) greater than measurement B]
must have a new bore. A tool called a hone can be
used to remove a small amount of taper from a cylin-
der bore. Use a boring machine to repair a badly
worn cylinder. The boring machine will make a more
Figure 24. Piston Pin Removal accurate cylinder bore. The hone is then used to fin-
ish the surface of the cylinder bore.

17
Piston and Connecting Rod Assemblies Repair 600 SRM 3

Legend for Figure 27


A. PISTON GAUGE POINT
B. BORE GAUGE POINT

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 several piston size. See the Parts Manual for
sizes. The piston rings must match the size of the
piston on which they are installed. Check the side
Figure 26. Normal Cylinder Wear Pattern clearance and the end clearance of the piston rings
as described in the following paragraphs.
A cylinder bore that has been repaired with a hone
or a boring machine must be fitted with a piston that Each compression ring has a mark on one surface.
is the correct size. Measure the outer diameter of the This mark must be toward the top of the cylinder
piston and the inner diameter of the cylinder bore as when the piston ring is installed. The No. 1 com-
shown in Figure 27. Using different oversize pistons pression ring normally has a chrome or molybdenum
in the engine does not affect the dynamic balance of surface.
the engine. Replacement pistons from standard size
The oil control ring has three pieces. There are two
to 0.762 mm (0.030 in.) oversize normally have the
thin steel rings separated by a spacer.
same weight. The clearance specifications between a
piston and its cylinder bore is shown in the Engine 1. Measure the clearance between the piston ring
Specifications. and the groove in the piston as shown in Fig-
ure 28. The clearances are shown in the Engine
Specifications. Replace the piston if the clear-
ances are greater than the specifications.

2. Measure the end clearance of each piston ring


as shown in Figure 29. The end clearances are
shown in the 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 if the clear-
ances are greater than the specifications.

PISTON AND CONNECTING ROD


ASSEMBLIES, ASSEMBLE
NOTE: There are notches cast in the top of all pis-
tons to indicate the correct assembly and installa-
tion. The pistons must always be installed with this
notch toward the fan end of the engine. See Fig-
ure 33.

The connecting rods have a notch cast in the bearing


journal as shown in Figure 30. This notch must be
opposite the notch on the top of the piston when the
piston and connecting rod are assembled.

Figure 27. Piston and Cylinder Bore Gauge


Points

18
600 SRM 3 Piston and Connecting Rod Assemblies Repair

above. Use a press to install the piston pin into


the piston and connecting rod. Lubricate the
piston pin with engine oil during installation.

2. Check the clearances of the piston rings as de-


scribed in Piston Rings, Inspect. Install the pis-
ton rings on the piston as shown in Figure 31.

1. NOTCHES ON ROD OPPOSITE NOTCH IN


PISTON

Figure 30. Connecting Rod Identification


Figure 28. Piston Ring and Groove Clearance
Check

A. POSITION OF GAP FOR SPACER OF OIL RING


B. POSITION OF GAP FOR OIL RING
C. POSITION OF GAP FOR SECOND
COMPRESSION RING
D. POSITION OF GAP FOR FIRST COMPRESSION
Figure 29. Piston Ring End Clearance Check RING
1. Assemble the connecting rod to the piston. Make 1. FAN END OF ENGINE
sure the orientation of the connecting rod and
piston are correct as described in the NOTE Figure 31. Piston Ring Arrangement

19
Crankshaft Repair 600 SRM 3

PISTON AND CONNECTING ROD


ASSEMBLIES, INSTALL
1. Lubricate the assembly with engine oil during in-
stallation. Arrange the piston rings on the piston
as shown in Figure 31. Install a ring compressor
on the piston as shown in Figure 32.

2. Make sure that the notch in the piston is toward


the fan end of the engine as shown in Figure 33.
Install the piston and connecting rod assemblies NOTE: NOTCH IN PISTON MUST BE TOWARD FAN
in the cylinder bores. END OF ENGINE.
A. FAN END OF ENGINE

Figure 33. Piston Position Inside Cylinder

3. Install the bearings and the caps for the connect-


ing rods. Tighten the nuts. See Torque Specifica-
tions. Check the side clearance of each connect-
ing rod after the bearing cap is installed. See the
procedure in the paragraphs under Connecting
Rod Bearings, Replace.

4. Install the cylinder head as described in Cylinder


Head, Install.
Figure 32. Ring Compressor Installation 5. Install the oil sump and the oil pump.

Crankshaft Repair
MAIN BEARINGS, REPLACE of the crankshaft. See Figure 34. Turn the
crankshaft to remove the upper bearing half.
NOTE: The following procedure is for replacement of
the main bearings without removing the crankshaft c. Lubricate a new bearing half of the cor-
from the engine. rect size with engine oil. Insert the end of
the bearing without the notch between the
1. Remove the oil sump and the oil pump as de- crankshaft and the side of the engine block
scribed in the procedures under Lubrication Sys- with the notch.
tem Repair.
d. Use the pliers described in Step b to rotate
2. Remove the cap on the main bearing that needs the bearing half into position.
replacement. Remove the bearing half from the
cap. 4. The other crankshaft journals have oil holes. Use
the following procedure to replace the upper half
3. The rear main bearing does not have an oil hole. of the main bearing:
Use the following procedure to replace the upper
half of the rear main bearing: a. Put a thin rod or a bent cotter pin through
the oil hole in the crankshaft to contact the
a. Use a small drift punch and a hammer to main bearing half.
start the bearing half from the engine block.
b. Rotate the crankshaft clockwise as seen from
b. Put some tape on a pair of pliers to make the fan end of the engine. This movement
soft jaws. Use the pliers to hold the thrust will rotate the main bearing half from the
surface of the bearing to the oil control ring engine block.

20
600 SRM 3 Crankshaft Repair

c. Lubricate a new bearing half of the cor-


rect size with engine oil. Insert the end of
the bearing without the notch between the
crankshaft and the side of the engine block
with the notch.

d. Rotate the main bearing half into position in


the engine block.

1. ENGINE BLOCK 4. MAIN BEARING


2. MAIN BEARINGS CAPS
3. CRANKSHAFT 5. REAR OIL SEAL

Figure 34. Rear Main Bearing Replacement Figure 35. GM 3.0L Crankshaft, Main Bearings,
and Oil Seal
OIL SEAL FOR REAR MAIN BEARING,
REPLACE (GM 4-181 AND 3.0L ONLY) OIL SEAL FOR REAR MAIN BEARING,
REPLACE (ENGINES THAT HAVE
The oil seal is a one-piece unit that can be replaced TWO-PIECE OIL SEAL)
without removal of the oil sump or the crankshaft.
See Figure 35. The transmission must be discon- NOTE: The following procedure is for replacement of
nected from the engine. the oil seal for the rear main bearing without remov-
ing the crankshaft from the engine. Always replace
1. Remove the flywheel. both halves of the oil seal as a unit.
2. Use a screwdriver or small pry bar to carefully This procedure requires careful work so that the oil
remove the oil seal from the engine. seal is not damaged during installation. The seal
3. Clean the surface of the engine block area for the bead in the channel on the outside diameter of the
oil seal. oil seal must be protected during installation. An
oil seal installation tool can be made from a piece of
4. Lubricate the oil seal with engine oil and care- 0.10 mm (0.004 in.) shim stock. See Figure 36.
fully install it.
1. The oil sump and the oil pump must be removed.
5. Install the flywheel and tighten the bolts. See Remove the cap for the rear main bearing.
Torque Specifications.
2. Use a small screwdriver to remove the lower half
of the oil seal from the main bearing cap. See
Figure 37.

21
Crankshaft Repair 600 SRM 3

the oil seal in the engine block. Put the oil seal
between the engine block and the tip of the tool
so that the bead on the oil seal is against the tip
of the tool. Make sure the lip of the oil seal is to-
ward the fan end of the engine. See Figure 39.

Figure 36. Rear Oil Seal Installation Tool

Figure 39. Rear Main Bearing Oil Seal Half

7. Carefully rotate the oil seal around the crank-


shaft until both ends are even with the surface
of the engine block. Use the tool to protect the
bead on the oil seal from the sharp edge of the
engine block.

Figure 37. Oil Seal Lower Half Removal 8. Carefully remove the tool. Make sure the bead is
not damaged.
3. Use a hammer and a small punch. Lightly hit
one end of the upper oil seal half to rotate it until 9. Install the lower half of the oil seal in the cap
it can be removed with a pair of pliers. See Fig- for the main bearing. Make sure the ends of the
ure 38. oil seal are even with the surfaces of the main
bearing cap.

10. Remove any engine oil from the ends of the oil
seal, both upper and lower halves. Apply a thin
coat of sealant ONLY to the ends of the oil seal.
Do not permit any sealant on the surfaces where
the main bearing cap joins the engine block. See
Figure 40.

Figure 38. Oil Seal Upper Half Removal

4. Clean the area for the oil seal in the engine block
and main bearing cap.

5. Lubricate the lips and bead of the oil seal with


engine oil. Keep oil from the end surfaces of the
oil seal.
Figure 40. Oil Seal Sealant Application
6. Put the tip of the tool shown in Figure 36 in po-
sition between the crankshaft and the cavity for

22
600 SRM 3 Crankshaft Repair

11. Install the cap for the rear main bearing and surface of the bearing is round. The correct sizes
tighten the capscrews to an initial torque of are given in the Engine Specifications.
14 N•m (10 lbf ft). Use a hammer to lightly hit
the crankshaft and move it forward against the
rear main bearing. Then use the hammer to
lightly hit the crankshaft and move it backward
against the rear main bearing. This procedure
is to align the thrust surfaces on the rear main
bearing. Tighten the capscrews for the main
bearing cap. See Torque Specifications.

REMOVE
1. Remove the flywheel housing and the flywheel.

2. Remove the oil sump and the oil pump as de-


scribed in the procedures under Lubrication Sys-
tem Repair.

3. Remove the crankshaft pulley or vibration damp-


ener and timing gear cover as described in the
procedures under Timing Gear Cover Repair.

4. Remove the bearing caps for the connecting rods


as described in the procedures under Piston and
Connecting Rod Assemblies Repair. If the pis-
ton and connecting rod assemblies will not be re-
moved for repair, push them to the top of their
bores so that they are away from the crankshaft. Figure 41. Crankshaft Inspection

5. Remove the caps for the main bearings. Make 4. If the crankshaft journals must be repaired, they
sure that there are identification marks on the can be ground to a smaller (undersize) than the
caps so that they can be installed again in the original size. See the Parts Manual for available
same position. bearing sizes.

6. Carefully remove the crankshaft from the engine When the crankshaft is assembled by the manufac-
block. turer, the main bearings are specially selected to ob-
tain close tolerances. For this reason, you can find
7. Remove the oil seal for the rear main bearing. one-half of a standard size insert with one-half of a
Remove the main bearings from the crank case 0.025 mm (0.001 in.) undersize insert. This combina-
and the main bearing caps. tion will decrease the clearance 0.013 mm (0.0005 in.)
from using a full standard bearing.
INSPECT AND REPAIR
When a production crankshaft cannot be fitted
1. Clean the crankshaft with solvent and dry it with with this method, the main journal is then ground
compressed air. 0.229 mm (0.009 in.) undersize. Only those main
bearing journals that cannot be fitted with stan-
2. Inspect the crankshaft for cracks or other dam-
dard, 0.025 mm (0.001 in.) or 0.051 mm (0.002 in.)
age.
undersize main bearing will be ground. A 0.229 mm
3. Inspect the crankshaft for wear and damage. See (0.009 in.) and a 0.25 mm (0.010 in.) undersize
Figure 41. Use a micrometer to measure the jour- bearings will be selected as described to obtain close
nals for the bearings of the crankshaft. Do the tolerances.
measurement at different positions to see if the

23
Crankshaft Repair 600 SRM 3

A production crankshaft that has been ground will 7. If the clearance is greater than the specifications,
have the following identification: select a new undersize bearing set and install it.
• The crankshaft journal that has been ground will Measure the clearance again. If the clearance
have a 9 marked in the metal of the crankshaft next cannot meet specifications with the available un-
to the journal. A spot of light green paint is also dersize bearings, the bearing journal must be
added to the crankshaft. ground to a new undersize. If the bearing journal
• The main bearing cap is also marked with green is already at the maximum undersize, the crank-
paint. shaft must be replaced.

MAIN BEARING AND JOURNAL 8. If the clearance is within specifications, lubricate


CLEARANCE, CHECK the bearing with engine oil and install the main
bearing and bearing cap. Tighten the capscrews
1. Use Plastigage® or equivalent to check the clear- on the main bearing cap to the correct specifica-
ance. The procedure is similar for both connect- tions.
ing rod bearings and main bearings. If the en-
gine has been removed from the lift truck put the 9. Turn the crankshaft to make sure it rotates
engine so that the crankshaft is up. The weight smoothly.
of the crankshaft is against the upper bearing 10. Check the axial clearance between the rear main
half and the total clearance can be measured cor- bearing and the thrust surface. Push the crank-
rectly. If the engine is still in the lift truck, the shaft forward. See Figure 42. Measure the clear-
crankshaft must have a support to remove any ance between the crankshaft and the thrust sur-
additional clearance between the upper bearing face of the rear bearing. The correct clearance is
half and its journal. 0.05 to 0.15 mm (0.002 to 0.006 in.).
2. All main bearing caps must be installed and their
capscrews tightened to the specifications.
INSTALL
1. If the engine has a two-piece oil seal, install a
3. Check the rear main bearing first. Remove the
new oil seal for the crankshaft. Apply engine oil
cap for the rear main bearing. The procedure for
to the oil seal during installation. Do not per-
checking the clearance of the other bearings is
mit any oil on the ends of the oil seal. See Fig-
similar.
ure 40. Install the oil seal so that the lip is to-
4. Clean the oil from the bearing half and journal ward the fan end of the engine. See Oil Seal
to be checked. Put a piece of Plastigage across for Rear Main Bearing, Replace (Engines That
the full width of the bearing journal as shown Have Two-Piece Oil Seal) for additional informa-
in Bearing Journal Plastigage® Placement. Do tion about the rear oil seal.
not rotate the crankshaft when the Plastigage is
2. Lubricate new main bearing halves with engine
between the main bearing and its journal.
oil and install them in the bearing housing of the
5. Install the main bearing cap and tighten the engine block.
capscrews. See Torque Specifications. The cap-
3. Carefully install the crankshaft in the engine
screws must be tightened to their final torque or
block.
there will be an error in the measurement.
4. Lubricate the lower halves of the main bearings
6. Remove the main bearing cap. The Plastigage
and install them in their caps. Install each main
will be compressed and wider and will adhere to
bearing cap in its position on the engine block.
either the bearing or its journal. Use the scale
Make sure each main bearing cap is installed in
on the envelope for the Plastigage to measure the
its original position. If a main bearing cap is
width of the plastic at its widest point. The scale
not installed correctly, there can be an alignment
will indicate the clearance in millimeters or thou-
problem which will cause rapid wear and possi-
sandths of an inch. See Bearing Journal Plasti-
ble damage to the engine.
gage® Measurement.

24
600 SRM 3 Flywheel and Flywheel Housing Repair

of 14 N•m (10 lbf ft). Use a hammer to


lightly hit the crankshaft and move it for-
ward against the rear main bearing. Then
use the hammer to lightly hit the crankshaft
and move it backward against the rear main
bearing. This procedure is to align the thrust
surfaces on the rear main bearing. Tighten
the capscrews for the main bearing cap. See
Torque Specifications.

b. Check the clearance between the rear main


bearing and the thrust surface. Push the
crankshaft forward. Measure the axial clear-
ance between the crankshaft and the thrust
surface of the rear bearing. See Figure 42.

6. Check the clearance between the main bearing


and its crankshaft journal. See Main Bearing
and Journal Clearance, Check.

7. Install the piston assemblies as described in Pis-


Figure 42. Crankshaft Axial Clearance ton and Connecting Rod Assemblies, Install.
Measurement
8. Install the oil pump and the oil sump as described
5. Use the following procedure to install the cap for in the Lubrication System Repair.
the rear main bearing:

a. Install the cap for the rear main bearing and


tighten the capscrews to an initial torque

Flywheel and Flywheel Housing Repair


Some models of lift trucks have an oil clutch. Before
the flywheel is removed, check for an even surface on
the face of the flywheel. Fasten a dial indicator to the
engine as shown in Figure 43. Turn the flywheel and
check the variations indicated by the dial indicator.
Make a note of the high indication and the low indi-
cation. If the difference between the indications are
more than 0.20 mm (0.008 in.), replace the flywheel.

Some lift trucks have a hydraulic pump drive assem-


bly (Figure 44) that is part of the flywheel and fly-
wheel housing. See Hydraulic Pump Drive As-
sembly 1900 SRM 64 for additional information on
the S30-120E, S40-50F, H30-60H, H40-60J, H60JS,
and H60-110E lift trucks. See Hydraulic Pump
Drive Assembly 1900 SRM 339 for additional in-
formation on the S/H2.00-3.00XL (S/H40-60XL) lift
trucks.
Figure 43. Flywheel Surface Check

25
Flywheel and Flywheel Housing Repair 600 SRM 3

REMOVE
Remove the engine from the lift truck and separate
the engine from the transmission.

1. Make alignment marks between the flywheel


and the crankshaft so the parts will be assem-
bled again in their original positions.

2. Remove the oil sump and the rear main bearing


cap from the engine. See Figure 45.

Model Dimension X
S/H2.00-3.00XL 28.4 to 28.6 mm (1.118
(S/H40-60XL) to 1.125 in.)

A. DIMENSION X 1. GASKET 5. SEAL


1. FLYWHEEL 2. FLYWHEEL 6. O-RING
2. SHIMS 3. PILOT BEARING 7. CRANKSHAFT
3. CRANKSHAFT 4. RING GEAR 8. ADAPTER PLATE
4. DRIVE GEAR
5. DRIVEN GEAR ARRANGEMENT (OIL CLUTCH) Figure 45. Typical Oil Clutch Flywheel
6. DRIVEN GEAR ARRANGEMENT (POWERSHIFT Arrangement
TRANSMISSION)

Figure 44. Hydraulic Pump Drive Assembly


Flywheel Arrangement

26
600 SRM 3 Cooling System Repair

3. Remove the capscrews that fasten the flywheel to b. Heat the new ring gear to 200 C (392 F) in
the crankshaft. If there are dowel pins installed, an oven and install the ring gear on the fly-
use a hammer and driver to remove the dowel wheel. Push the ring gear fully against the
pins from the flywheel and crankshaft. Rotate shoulder of the flywheel.
the crankshaft as necessary so that the dowel
pins will not hit the engine block as they are re- c. The pilot bearing in the flywheel can be re-
moved. placed. Push the old bearing from the fly-
wheel and push in a new bearing.
4. Remove the flywheel. Discard the dowel pins on
the GM 6-250. INSTALL

RING GEAR, REPLACE 1. Install a new oil seal in the adapter plate on lift
trucks that have an oil clutch. Use a sealant on
the outside of the seal during installation.
WARNING
Wear eye protection for this operation to pre- 2. Apply a sealant to the flange of the adapter plate.
vent eye injury from metal chips. You will be Install the adapter plate to the engine.
using a hammer and driver to remove the ring
gear. 3. Install a new O-ring to the flywheel for lift trucks
that have an oil clutch transmission.
1. Use the following procedure to remove the ring
gear on the flywheel: 4. Install the flywheel to the crankshaft. Apply a
sealant to the capscrews that hold the flywheel
a. During removal or installation, do not heat to the crankshaft.
the ring gear greater than 230 C (446 F).
Heat the circumference of the ring gear 5. Tighten the capscrews. See Torque Specifica-
evenly and carefully remove it from the fly- tions.
wheel with a hammer and driver.

WARNING
Hot parts. Wear protective clothing and gloves
to prevent burns.

Cooling System Repair


COOLANT PUMP fan and a pulley on the engine. The fluid coupling
permits the cooling fan to rotate at a different speed
If any parts of the coolant pump are worn, replace than the engine speed. The fluid coupling also con-
the coolant pump. Parts for the coolant pump are trols the maximum speed of the cooling fan. The cool-
not available separately. During installation, apply ing fan can be rotated by hand when the engine is not
a sealant to the gasket for the coolant pump. Adjust running. If the engine temperature is above normal,
the tension of the drive belt as described in the Pe- check the following parts of the cooling system:
riodic Maintenance section for your lift truck. • Coolant level
• Damaged hose or restrictions to coolant flow
FAN DRIVE • Operation of the thermostat
• Restriction to the rotation of the cooling fan
See Figure 46 and Figure 47 for the correct assembly
• Restrictions that stop the air from flowing freely
procedures for the fan drive.
through the radiator
VISCOUS FAN DRIVE If these parts of the cooling system are normal when
Some lift trucks have a viscous fan drive. The vis- the engine temperature is above normal, check the
cous fan drive is a fluid coupling between the cooling viscous fan drive.

27
Cooling System Repair 600 SRM 3

A. S2.00-3.00XL (S40-60XL)
B. S40-50F, H40-50J-60JS, H30-60H (E3), H30-60H (D3)
1. FAN BRACKET
2. SHAFT AND BEARING
3. PULLEY
4. PLUG
5. HOLD BRACKET ON THIS SURFACE WHEN BEARING IS PRESSED INTO BRACKET
6. PRESS BEARING INTO BRACKET UNTIL BEARING AND BRACKET ARE EVEN
7. USE A SUPPORT ON SHAFT WHEN PRESSING PULLEY ONTO SHAFT

Figure 46. Fan Drive Assembly


Do the following procedure to check the viscous fan
drive:
Stop the engine. Rotate the cooling fan and fan
drive by hand. The rotation must be smooth with
some resistance. A small amount of movement
side to side will occur at the tips of the fan blades
because of bearing clearance. Approximately
5 mm (0.2 in.) maximum of side-to-side move-
ment at the tips of the fan blades is permitted. If
the cooling fan cannot be rotated by hand or has
a rough rotation, the fan drive must be replaced.
A very small leakage of oil around the bearing
is normal. If oil has leaked from the fan drive,
the cooling fan will turn too easily. If the cooling
fan will turn more than three revolutions when
pushed by the hand and released, the viscous fan
drive must be replaced.
1. HOUSING 3. HUB
2. SHAFT AND
BEARING

Figure 47. 3.0L Engine Fan Drive

28
600 SRM 3 Engine Specifications

Engine Specifications
ENGINE DATA
GM 4–153
Number of cylinders 4
Firing order 1–3–4–2
Bore and stroke 98.45 × 82.5 mm (3.876 × 3.25 in.)
Displacement 2512 cm 3 (153 in. 3 )
Compression Ratio 8.25:1
Governor speed See the Periodic Maintenance section for each
model of lift truck
GM 4–181
Number of cylinders 4
Firing order 1–3–4–2
Bore and stroke 101.6 × 91.44 mm (4.00 × 3.60 in.)
Displacement 2965 cm 3 (181 in. 3 )
Compression Ratio 8.25:1
Governor speed See the Periodic Maintenance section for each
model of lift truck
GM 3.0L
Number of cylinders 4
Firing order 1–3–4–2
Bore and stroke 101.6 × 91.44 mm (4.00 × 3.60 in.)
Displacement 2965 cm 3 (181 in. 3 )
Compression Ratio 8.25:1
Governor speed See the Periodic Maintenance section for each
model of lift truck
GM 6–260
Number of cylinders 6
Firing order 1–5–3–6–2–4
Bore and stroke 98.45 × 89.66 mm (3.88 × 3.53 in.)
Displacement 4095 cm 3 (250 in. 3 )
Compression Ratio 8.25:1
Governor speed See the Periodic Maintenance section for each
model of lift truck

29
Engine Specifications 600 SRM 3

CYLINDER HEAD
Valve seat specifications See Figure 6.
Valve seat width, intake valves 0.896 to 1.897 mm (0.035 to 0.074 in.)
Valve seat width, exhaust valves 1.468 to 2.468 mm (0.058 to 0.0971 in.)
Clearance between intake valve and guide
– Production Limit 0.0254 to 0.0686 mm (0.0010 to 0.0027 in.)
– Service Limit 0.094 mm (0.0037 in.)
Clearance between exhaust valve and guide

NOTE: The valve stems for the exhaust valves have a taper of 0.0025 mm (0.001 in.)
– Production Limit (top of taper) 0.0254 to 0.0686 mm (0.0010 to 0.0027 in.)
– Service Limit 0.119 mm (0.0047 in.)
– Production Limit (bottom of taper) 0.0508 to 0.0939 mm (0.0020 to 0.0037 in.)
– Service Limit 0.145 mm (0.0057 in.)
Diameter of exhaust valve stem 8.6817 to 8.6995 mm (0.3418 to 0.3425 in.)
Diameter of intake valve stem 8.6817 to 8.6995 mm (0.3418 to 0.3425 in.)
Valve head diameter (all) 8.6817 to 8.6995 mm (0.3418 to 0.3425 in.)
Valve installed height (all) 42.926 mm (1.69 in.)
Valve spring, free length (see Figure 48) 52.8 mm (2.08 in.)
Valve spring force (installed and valve is closed) 347 to 383 N @ 43 mm (78 to 86 lbs @ 1.69 in.)
Valve spring force (installed and valve is open) 756 to 800 N @ 32 mm (170 to 180 lbs @ 1.26 in.)

HYDRAULIC VALVE LIFTER


Leak rate 12 to 90 seconds with 50 lb load
Body diameter 21.3868 to 21.4046 mm (0.8420 to 0.8427 in.)
Plunger travel 3.175 mm (0.125 in.)
Clearance in bore 0.0635 mm (0.0025 in.)
Lifter bore diameter 21.425 to 21.450 mm (0.8435 to 0.8445 in.)

30
600 SRM 3 Engine Specifications

Legend for Figure 48


A. VARIATION FROM VERTICAL: PRODUCTION -
LESS THAN 1.5 mm (0.06 in.), SERVICE LIMIT -
2.5 mm (0.984 in.)
B. FREE LENGTH: STANDARD - 49.7 mm (1.96 in.),
SERVICE LIMIT - 48.2 mm (1.90 in.)
C. INSTALLATION HEIGHT: VALVE SPRINGS NEED
A MINIMUM FORCE OF 347 to 383 N (76 to
86 lbf) TO COMPRESS THEM TO A HEIGHT OF
43 mm (1.69 in.)

Figure 48. Valve Spring Specifications

CAMSHAFT
Variation from front to rear of a cam lobe
– Taper with larger dimension away from No. 1 piston
Bearing journals, diameter 47.44 to 47.49 mm (1.8677 to 1.8697 in.)
Bearing journals, clearance 0.01778 to 0.09685 mm (0.0007 to 0.0038 in.)
Variation of a bearing journal in either diameter or 0.03 mm (0.001 in.)
axial direction
Axial Clearance (see Figure 17)
– Production Limit 0.020 to 0.120 mm (0.001 to 0.005 in.)
– Service Limit 0.2 mm (0.008 in.)

31
Engine Specifications 600 SRM 3

PISTONS
Piston diameter (see gauge points in Figure 27)
Clearance at top of cylinder
– Production Limit 0.0635 to 0.0838 mm (0.0025 to 0.0033 in.)
Clearance at bottom of cylinder
– Production Limit 0.043 to 0.104 mm (0.0017 to 0.0041 in.)
Clearance in cylinder (service limit for top and bottom
of cylinder) 0.76 mm (0.030 in.)
Piston ring to groove clearance for piston rings (see Figure 28)
Compression rings No. 1 and No. 2
– Production Limit 0.0381 to 0.0889 mm (0.0015 to 0.0035 in.)
– Service Limit 0.1143 mm (0.0045 in.)
Oil ring to groove clearance

– Production Limit 0.127 to 0.1397 mm (0.005 to 0.0055 in.)


– Service Limit 0.1651 mm (0.0065 in.)
Piston ring end clearance (see Figure 29)
Piston ring No. 1 and No. 2
– Production Limit 0.254 to 0.559 mm (0.010 to 0.022 in.)
– Service Limit 0.813 mm (0.032 in.)
– Oil control ring 0.381 to 1.397 mm (0.015 to 0.055 in.)
– Service Limit 1.65 mm (0.065 in.)
Piston pin to piston clearance
– Production Limit 0.0076 to 0.0127 mm (0.0003 to 0.0005 in.)
– Service Limit 0.0254 mm (0.001 in.)
Piston pin to connecting rod clearance Press fit

CYLINDER BORE
Out-of-round (see Figure 25)
– Production Limit 0.254 mm (0.001 in.)
– Service Limit 0.0508 mm (0.002 in.)
Taper (see Figure 26)
– Production Limit 0.0127 mm (0.0005 in.)
– Service Limit 0.127 mm (0.005 in.)

32
600 SRM 3 Engine Specifications

CRANKSHAFT
Diameter of main bearing journal
– Production Limit 58.367 to 58.405 mm (2.2979 to 2.2994 in.)
– Grinding Limit 57.859 mm (2.278 in.)
Out-of-round of main bearing journal (maximum)
– Production Limit 0.0127 mm (0.0005 in.)
– Service Limit 0.0254 mm (0.001 in.)
Taper of main bearing journal (maximum)
– Production Limit 0.0127 mm (0.0005 in.)
– Service Limit 0.0254 mm (0.001 in.)
Clearance between journals and main bearings (except for rear main bearing of GM 6-250)
– Production Limit 0.0127 to 0.061 mm (0.0005 to 0.0024 in.)
– Service Limit 0.064 mm (0.0025 in.)
Clearance between journal and rear main bearing for GM 6-250
– Production Limit 0.0127 to 0.061 mm (0.0005 to 0.0024 in.)
– Service Limit 0.089 mm (0.0035 in.)
Available undersize main bearings (see Parts Manual)
Axial Clearance (crankshaft to thrust surface of rear main bearing)
– Production Limit 0.0508 to 0.1524 mm (0.002 to 0.006 in.)
– Service Limit 0.1524 mm (0.006 in.)

CONNECTING RODS
Diameter of connecting rod journals for earlier production engines
– Production Limit 50.775 to 50.800 mm (1.999 to 2.000 in.)
– Grinding Limit 50.27 mm (1.979 in.)
Diameter of connecting rod journals for later production engines
– Production Limit 58.369 to 58.420 mm (2.298 to 2.300 in.)
– Grinding Limit 57.86 mm (2.278 in.)
Out-of-round of bearing journal (maximum)
– Production Limit 0.0127 mm (0.0005 in.)
– Service Limit 0.0254 mm (0.001 in.)
Taper of bearing journal (maximum)
– Production Limit 0.0127 mm (0.0005 in.)
– Service Limit 0.0254 mm (0.001 in.)

33
Torque Specifications 600 SRM 3

Clearance between crankshaft journals and connecting rod bearings


– Production Limit 0.0127 to 0.066 mm (0.0005 to 0.0026 in.)
– Service Limit 0.0762 mm (0.003 in.)
Available undersize connecting rod bearings (see Parts Manual)
Side clearance of connecting rod to crankshaft
– Production Limit 0.1524 to 0.4318 mm (0.006 to 0.017 in.)
– Service Limit 0.5588 mm (0.022 in.)

COOLING SYSTEM
Thermostat 82 C (180 F)

LUBRICATION SYSTEM
Oil pressure @ 2500 rpm 170 to 241 kPa (25 to 35 psi)
Minimum oil pressure @ idle rpm 48 kPa (7 psi)
Oil pressure switch ON 20 to 39 kPa (2.9 to 5.7 psi)

Torque Specifications
Adapter Plate for Torque Converter Housing Exhaust Manifold to Intake Manifold
3.0L 44 N•m (32 lbf ft) 61 N•m (45 lbf ft)

Alternator Pulley Fan Belt Pulley to Vibration Dampener


61 N•m (45 lbf ft) 44 N•m (32 lbf ft)

Camshaft Thrust Plate Flywheel Capscrews


10 N•m (7 lbf ft) 4-153, 4-181 80 N•m (60 lbf ft) with
adhesive sealant
Chain Block for Hydraulic Pump Drive 3.0l 107 N•m (79 lbf ft) with adhesive sealant
19 N•m (14 lbf ft) with adhesive sealant 6-250 100 N•m (75 lbf ft) with adhesive sealant
Connecting Rod Cap Nuts Flywheel Housing
44 N•m (32 lbf ft) 44 N•m (32 lbf ft)
Coolant Pump to Block Inspection Cover (Lifters)
10 N•m (7 lbf ft) 10 N•m (7 lbf ft)
Cooling Fan to Hub Intake Manifold to Cylinder Head
19 N•m (14 lbf ft) 54 N•m (40 lbf ft)
Cylinder Head Main Bearing Cap
122 N•m (90 lbf ft) 95 N•m (70 lbf ft)
Engine Mount to Block Oil Sump
44 N•m (32 lbf ft) 1/4-20 Capscrews 10 N•m (7 lbf ft)
5/15-18 Capscrews 19 N•m (14 lbf ft)
Exhaust Manifold
41 N•m (30 lbf in)

34
600 SRM 3 Troubleshooting

Oil Sump to Timing Cover Starter


8 N•m (6 lbf ft) 44 N•m (32 lbf in)

Oil Pump to Engine Block Timing Cover


30 N•m (22 lbf ft) 11 N•m (97 lbf in)

Oil Pump Cover Vibration Dampener


14 N•m (10 lbf ft) 80 N•m (60 lbf ft)

Rocker Cover
8 N•m (6 lbf ft)

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

When the ignition switch is The battery has a problem. Install a new battery.
in the START position, the
starter does not operate.

The battery is not fully charged. Charge the battery.

The connections at the battery are Clean and tighten the battery con-
loose, or they have corrosion. nections.

The ignition switch has a problem. Repair or install an ignition switch.

The starter system has a problem. Check and repair the starter circuit.

There are damaged parts in the en- Repair the engine.


gine.

The engine will not start. The fuel tank is empty. Fill the fuel tank.

The battery is not fully charged. Charge the battery.

The valves are worn or damaged. Repair the valves.

The piston rings are worn or have Install new piston rings.
damage.

The ignition system has a problem. Check and repair the ignition system.

The fuel system has a problem. Check and repair the fuel system.

35
Troubleshooting 600 SRM 3

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

The engine does not run The valve mechanism does not oper- Repair the valve mechanism.
smoothly. ate correctly.

The head gasket has a leak. Install a new head gasket.

The cylinder head has cracks. Install a new cylinder head.

There is a leak in the intake system. Install new gaskets at the intake
manifold.

The spark plugs have a problem. Install new spark plugs.

The ignition system has problems. Repair the ignition system.


(See the sections for the electrical
components in the Service Manual
for more information.)

The engine does not have The air filter is dirty. Clean or install a new air cleaner.
enough power.

The fuel is the wrong type. Drain and fill fuel tank.

The ignition timing is not correct. Check timing.

The valve mechanism does not oper- Repair parts of valve mechanism.
ate correctly.

The piston assemblies are worn or Install new pistons.


damaged.

The spark plugs are the wrong type Install new spark plugs.
or they are not installed correctly.

The valve timing is not correct. Check valve mechanism.

The exhaust system has restrictions. Clean or repair exhaust system.

There is noise inside the en- The main bearings are worn or dam- Install new bearings.
gine. aged.

The bearings for the connecting rods Install new bearings.


are worn or damaged.

The pistons are worn or damaged. Install new pistons.

The engine is too hot. Check the cooling system.

There is not enough oil in the engine. Fill the engine to the correct level.

The flywheel is loose. Tighten the capscrews for the fly-


wheel.

36
600 SRM 3 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

There is noise inside the en- A connecting rod is bent. Repair the engine.
gine. (Cont.)

There is a leak in the exhaust sys- Repair the exhaust system.


tem.

A valve lifter has a problem. Check the valve lifters.

The valve mechanism does not oper- Repair the valve mechanism.
ate correctly.

There is noise in the engine The spark plugs are dirty. Install new spark plugs.
during acceleration.

The spark plugs are the wrong type. Install the correct spark plugs.

The ignition timing is not correct. Check the timing.

The fuel is the wrong type. Fill the tank with the correct fuel.

There is too much carbon in the com- Clean the cylinder head and pistons.
bustion chamber.

The engine is too hot. Check the cooling system.

The engine gets too hot. There is not enough coolant in the Fill cooling system with coolant.
cooling system.

The belt for the water pump is worn Adjust drive belts.
or not adjusted correctly.

The thermostat has damage. Install a new thermostat.

The cooling system has restrictions. Clean the cooling system parts.

The water pump has damage. Install a new water pump.

The radiator is dirty. Clean the radiator.

The exhaust system has restrictions. Clean or replace the parts of the ex-
haust system.

The bearings in the engine There is not enough oil in the engine. Fill engine with correct oil.
are damaged.

The oil in the engine is the wrong Fill engine with correct oil.
type.

The oil pump has damage. Install a new oil pump.

37
Troubleshooting 600 SRM 3

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

The bearings in the engine The connecting rods have damage. Install new connecting rods.
are damaged. (Cont.)

The camshaft is worn or damaged. Install a new camshaft.

The passages for oil have restric- Clean oil passages.


tions.

The bearings are not installed cor- Install new bearings.


rectly.

The oil in the engine is dirty. Install a new oil filter and oil.

38
TECHNICAL PUBLICATIONS

600 SRM 3 8/03 (1/03)(4/98)(9/95)(6/92)(9/90)(7/89)(8/83)(6/81)(11/80)(7/80) Printed in U.S.A.

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