HMM060001

Mazda Engine
M4-2.0G and M4-2.2G
H1.5-1.8TX, H2.0TXS [B475];
H2.0-3.5TX [B466]

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 ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK
ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed
the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), 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!

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 Disclaimer
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
Hyster® 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.
 INTRODUCTION

[1] General

This section has the repair instructions for the engine. Removal, disassembly, repair, assembly,
installation, checks and adjustments and troubleshooting are included. The specifications are
given at the end of the section.
Additional information on engine components are in the sections for THE GASOLINE FUEL
SYSTEM, THE LPG FUEL SYSTEM and THE ELECTRICAL SYSTEM.

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 key switch is “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.
• Do not check for current flow by making a spark because the transistors can be damaged.

[2] Description

The M4-2.0G and M4-2.2G engines are four cylinder engines that have a displacement of 1998
cm3 for M4-2.0G and 2184 cm3 for M4-2.2G. They are available with either a gasoline or an LPG
fuel system. The firing order is 1-3-4-2. The number one cylinder is toward the end of the engine
with the cooling fan.
The overhead camshaft is driven by a cog belt. The camshaft operates the rocker arms that
actuate the valves. The rocker arms are offset against the exhaust valve stem to rotate the
exhaust valve to prevent carbon damage and irregular wear.
The crankshaft has five main bearings. The main bearing in the center of the crankshaft is also
the thrust bearing.
The pistons are aluminum alloy and have three piston rings. Each of the two compression rings
have a special shape designed for its position on the piston. The third piston ring is the oil control
ring.

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 REPAIRS

[1] Removal and Installation of the Engine

NOTE: The removal and installation procedures for the engine are not included in this section. See the
section for THE FRAME for more information.

[2] Cylinder Head, Camshaft and Valve Mechanism

(1) Removal

1. Disconnect the connections at the battery.

2. Drain the cooling system.
3. Remove the air cleaner, the carburetor
linkage, the inlet and exhaust manifolds.
4. Remove the coolant hoses.
5. Remove the cooling fan, belt, alternator
and the alternator bracket.
6. Remove the bracket for the cooling fan.
7. Remove the upper and lower timing belt
covers. See Figure 26.
8. Loosen the capscrews for the timing Figure 1. Timing Belt
belt tensioner and remove the spring.
Remove the capscrews and the timing belt
tensioner.
9. Use chalk to mark the direction of rotation
of the timing belt. Remove the timing belt.
See Figure 1.
10. Disconnect the wires at the distributor.
Remove the capscrew for the distributor
mount and pull the distributor from the
front housing.
11. See Figure 2. Remove the camshaft pulley.
Prevent rotation of the pulley and loosen
the capscrew. Remove the capscrew and
the pulley.
12. Remove the nuts and capscrews for the Figure 2. Remove the Camshaft Gear
front housing, then remove the housing.
See Figure 22.
13. Remove the cylinder head cover.
14. Loosen the capscrews for the rocker
shaft supports in steps. See Figure 3.
Remove the rocker shaft assembly and
the camshaft.
15. Remove the capscrews for the cylinder
head in steps. Remove the capscrews in
the sequence shown in Figure 4.
16. Lift the cylinder head from the block.
17. Use a valve spring compressor and
remove the valve retainers, springs and
valves from the head. See Figure 5.
Figure 3. Sequence for Removal
of the Rocker Assembly

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 Figure 4. Sequence for Removal Figure 5. Remove the Valves
of the Cylinder Head

(2) Cleaning

WARNING
Cleaning solvents can be flammable and toxic and can cause skin irritation. When
using cleaning solvents, always follow the solvent manufacturer’s recommended safety
procedures.

Clean all of the parts in solvent. Make sure that all oil passages are clean. Make sure all
machined surfaces are smooth.

(3) Inspection and Repairs

Cylinder Head
Check the bottom surface of the cylinder head for distortion. Use a straight edge and a thickness
gauge. Do the measurements at the positions shown in Figure 6. The maximum amount of
distortion is 0.15 mm. When grinding the
cylinder head, the maximum amount of
correction is 0.2 mm.

Rocker Shaft Assembly

Disassemble the rocker shaft assembly. Put
marks on the rocker arms so that they can
be installed on the same shafts. Clean the
oil passages in the rocker shafts and rocker
arms. Check the clearance between the rocker
arms and the rocker shafts. The maximum
clearance is 0.10 mm. The correct dimension
for the inside diameter of a rocker arm is
16.000 to 16.027 mm. The correct dimension
for the outside diameter of a rocker shaft is
15.966 to 15.984 mm. If the parts do not meet
specification, replace the rocker arm(s) or the
rocker shaft(s).
Figure 6. Cylinder Head Inspection

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Camshaft
Check the camshaft for cracks or damage.
Check the movement of the camshaft in the
cylinder head. Use a dial indicator on the end
of the camshaft as shown in Figure 7. The
maximum movement is 0.20 mm.
Measure the height of the camshaft lobes.
See Figure 8. The minimum height of the
intake and exhaust lobes are 36.902 mm.
Measure the camshaft journals at four points
A-D as shown in Figure 8. The minimum
dimensions for the journals are as follows:

Front and Rear Journals (Nos. 1 and 5) -

31.940 to 31.965 mm
Center Journals (Nos. 2, 3 and 4) - 31.910 Figure 7. Check the Camshaft
to 31.935 mm
Front Oil Seal Surface - 33.961 to 34.000
mm
Fuel Pump Lobe - 37.1 mm

1. FRONT OIL SEAL

SURFACE
2. FRONT JOURNAL (NO. 1)
3. CENTER JOURNALS
(NOS. 2, 3 AND 4)
4. REAR JOURNAL (NO. 5)
5. FUEL PUMP LOBE

Figure 8. Camshaft Inspection

Check the camshaft for being straight. Put the

front and rear journals in V blocks and rotate
the camshaft one complete turn. See Figure 9.
The maximum amount that the dial indicator
can indicate is 0.03 mm.

Figure 9. Check the Camshaft

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Measure the clearance between the camshaft
and the bore in the cylinder head. Install the
camshaft in the cylinder head. Put a plastic
gauge material between the camshaft and the
cap. Tighten the capscrews for the caps to 18
to 27 N·m (180 to 270 kgf·cm). See Figure 10.
The correct clearance for journals Nos. 1 and
5 is 0.035 to 0.085 mm. The correct clearance
for journals Nos. 2, 3 and 4 is 0.065 to 0.115
mm. If any of the clearances are greater than
0.15 mm, replace the cylinder head assembly.
Replace the camshaft if there is any damage
or it does not meet specifications.
1. PLASTIC GAUGE
2. SCALE

Figure 10. Measure the Clearance for the Camshaft

Valve Guides
Measure the clearance between the valve
stems and the valve guides. Normal clearance
is 0.025 to 0.060 mm. Replace the valve or
valve guide when the clearance is more than
0.20 mm.
If replacement is necessary, use a tool to
remove the valve guide(s). Remove the seal
from the valve guide, then remove the valve
guide.
To install a valve guide, install the retaining
ring on the valve guide. Use the tool and
1. CYLINDER HEAD
install the valve guide until the retaining ring 2. RETAINING RING
contacts the cylinder head. See Figure 11. 3. VALVE GUIDE
The correct height of the valve guide above
the valve spring seat is 19.1 to 19.6 mm.
Figure 11. Valve Guide

Valve Seats
Inspect the condition of the valve seats. If the
valve seats have cracks, the cylinder head
must be replaced. If the condition of the valve
seats is good, check the contact pattern of
the valve and the valve seat. Use a valve seat
grinder to make sure the valve seats are with
the specifications shown in Figure 12. Use a
valve compound to make sure the valves fit
the seats.
1. VALVE SEAT WIDTH
2. EXHAUST VALVE SEAT
3. INTAKE VALVE SEAT

Figure 12. Valve Seat Specifications

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Check the depth of the valve seat. Insert the
valve(s) from the combustion chamber and
measure the height from the cylinder head by
using a caliper shown in Figure 13. Replace
the cylinder head assembly when the height is
more than 48.0 mm.

Valves
1. See Figure 14. Inspect the stem of
each valve for wear. Use a micrometer
to measure the outside diameter of the
stem. The minimum dimension for an
intake valve is 7.980 mm. The minimum
Figure 13. Measure the Valve Seat Depth
dimension for an exhaust valve is 7.975
mm.
2. Inspect the valves for cracks, burned faces
and distortion. Inspect the seat face of the
1. DIAMETER
valves for wear and damage. Measure the 2. THICKNESS,
thickness of the valve head. See Figure VALVE HEAD
14. The minimum thickness for an intake
valve is 0.5 mm. The minimum thickness
for an exhaust valve is 1.0 mm.
3. If the valves need grinding the correct
surface angle is 45° for both intake and
exhaust valves.

Valve Springs
Check the valve springs for damage. See
Figure 15. Measure the free length of both
inner and outer valve springs. The minimum
length of the inner spring is 46.3 mm. The
minimum length of the outer spring is 50.6
mm. Check the valve springs for being square.
See Figure 15. If the measurement is more
tham 1.81 mm, replace the valve spring(s). Figure 14. Inspect the Valves

Figure 15. Inspect the Valve Springs

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 Timing Belt

CAUTION
Do not allow any oil or water to contaminate
the timing belt. Do not twist, turn inside out
or bend the timing belt.

Check the timing belt for damage, wear,

peeling, or hardening. See Figure 16. If there
is any oil, water or there is even a slight fault
on the timing belt, replace the timing belt.

(4) Cylinder Head, Installation

1. Use a valve spring compressor and install

the valves retainers, springs and valves
on the head. Tap the valve end so that the
valves and springs are settled down. Figure 16. Inspect the Timing Belt

CAUTION
Make sure the shape of the valve cotters
of the intake and exhaust valves to avoid
wrong usage. See Figure 17.

2. Clean the surface of the cylinder head and

the surface of the block.
3. Install a new cylinder head gasket to the Figure 17. Valve Cotters
block. Install the cylinder head.
4. Install the capscrews and washers for
the cylinder head. Tighten the capscrews
to 80 to 86 N·m (820 to 880 kgf·cm) as
shown in Figure 18.
5. See Figure 19. Apply a gasket sealer to
the areas shown by the arrows. Lubricate
the camshaft with clean engine oil, then

1. DOWEL PIN
2. APPLY SEALANT
HERE

Figure 18. Installation of the Cylinder Head Figure 19. Install the Camshaft

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 install the camshaft. Make sure the dowel pin is at the top of the camshaft.
6. Assemble the rocker shaft assembly. See Figure 20. Lubricate the rocker arms and shafts
with engine oil. Rocker arms Nos. 1 and 3 are the same and Nos. 2 and 4 are the same. Put
the capscrews in the rocker shaft supports, then install the assembly on the cylinder head.
7. Tighten the capscrews for the rocker shaft supports to 18 to 26 N·m (180 to 270 kgf·cm) in
the sequence shown in Figure 21.

Figure 20. Assemble the Rocker Shaft Figure 21. Installation of the Rocker Shaft Assembly

8. If necessary, install the oil seal in the front housing. See Figure 22. Install the front housing
and a new gasket on the cylinder head. Tighten the capscrews for the front housing to 19 to
25 N·m (190 to 260 kgf·cm).
9. With the dowel pin at the top of the camshaft, install the camshaft pulley. Check that the letter
“A” for M4-2.0G or the letter “1” for M4-2.2G on the pulley is aligned with the timing mark on
the front husing. See Figure 23.
10. Install the capscrew and washer for the camshaft pulley. See Figure 23. Keep the pulley from
turning and tighten the capscrew to 47 to 65 N·m (480 to 660 kgf·cm).

1. TIMING
MARKS
2. CAMSHAFT
PULLEY

1. FRONT HOUSING
2. GASKET
3. OIL SEAL

Figure 22. Front Housing Figure 23. Install the Camshaft Pulley

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11. Align the timing marks for the timing pulley.
See Figure 24. Install the crankshaft 1. TIMING PULLEY
pulley, tapered ring and the capscrew. 2. TIMING MARK
Tighten the capscrew to 177 to 196 N·m
(1800 to 2000 kgf·cm).
12. Install the timing belt tensioner and spring.
Move the tensioner fully toward the intake
side of the engine and temporarily tighten
the lock bolt. On M4-2.2G engine, install
the idler and tighten the capscrew to 37 to
52 N·m (380 to 530 kgf·cm).
13. Clean any oil or grease from the pulleys.
Install the timing belt. Install the belt so Figure 24. Install the Timing Pulley
that it goes in the same direction as the
mark made during removal. See Figure 1.
14. See Figure 25. Loosen the lock bolt and
apply spring tension on the belt. Rotate
the crankshaft pulley two complete turns
clockwise and check the timing marks. If
the timing marks are correct, tighten the
lock bolt for the tensioner to 37 to 52 N·m
(380 to 530 kgf·cm). Check the movement
on the tension side of the timing belt.
When the tension is correct the belt will M4-2.0G/M4-2.2G
move 9 to 10 mm with 98 N (10 kgf) of
force. 1. TENSIONER
2. SPRING
3. LOCK BOLT
4. TENSION SIDE
5. IDLER

Figure 25. Install the Timing Belt

15. See Figure 26. Install the lower timing belt

cover and gasket. Tighten the capscrews
to 6.9 to 9.8 N·m (70 to 100 kgf·cm). Install
the upper timing belt cover and gasket.
Tighten the capscrews to 6.9 to 9.8 N·m
(70 to 100 kgf·cm) for M4-2.2G engine.
16. Install the distributor as described in the
procedures for the DISTRIBUTOR.

1. LOWER TIMING BELT COVER

2. UPPER TIMING BELT COVER

Figure 26. Timing Belt Covers

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 17. See Figure 27. Apply a gasket sealer to
the areas shown by the arrows. Install the
cylinder head covr and the gasket. Tighten
the capscrews to 3.9 to 5.9 N·m (40 to 60
kgf·cm).
18. Install the exhaust manifold and the
gasket. Tighten the capscrews to 22 to 28
N·m (220 to 290 kgf·cm).
19. Install the inlet manifold and the gasket.
Tighten the capscrews to 19 to 30 N·m
(190 to 310 kgf·cm).
20. Install the air cleaner and the carburetor
linkage. Tighten the capscrews for the
air cleaner to 19 to 25 N·m (190 to 260
kgf·cm). Figure 27. Install the Cylinder Head Cover
21. Install the alternator bracket. Tighten the
capscrews to 37 to 52 N·m (380 to 530
kgf·cm).

[3] Crankshaft and Main Bearings

(1) Removal

1. Remove the bracket for the cooling fan.

2. Prevent rotation of the crankshaft pulley. Remove the six capscrews and plate from the
crankshaft pulley. Remove the six capscrews that hold the crankshaft pulley to the timing
pulley.
3. Remove the capscrew from the timing pulley. Install the special tool on the crankshaft to
remove the timing pulley. Rotate the tool until it touches the front of the crankshaft. Hit the
tool with a hammer to loosen the timing pulley. Remove the pulley, dowel pin and the tapered
ring. Remove the tool.
4. Remove the oil pan. For M4-2.2G engine, remove the baffle plate. Remove the oil strainer.
5. Remove the rear cover. Remove the front cover with the oil pump.
6. Remove the caps for the connecting rods. Put a mark of identification on each cap so that
they will be installed to the same location.
7. Before removing the crankshaft, measure
the clearance between the crankshaft
and the flange of the center main bearing. 1. CENTER MAIN
See Figure 28. Push the crankshaft fully BEARING
forward before making the measurement.
The maximum clearance is 0.30 mm. If the
clearance is greater than the specification,
replace the center main bearing or the
crankshaft.
8. Put marks for identification on the bearing
caps. Loosen the capscrews for the main
bearing caps in steps, then remove the
capscrews and the caps. Remove the
crankshaft.

Figure 28. Measure the Crankshaft Clearance

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(2) Inspection and Repairs
Crankshaft
1. Visually inspect the crankshaft for wear,
cracks or other damage. Replace the
crankshaft if it has cracks.
2. U s e a m i c r o m e t e r t o m e a s u r e t h e
diameter of the journals for the crankshaft.
See Figure 29. Make the measurement
at several locations for each journal.
If the measurements are less than
specifications, grind the crankshaft and
1. REAR OIL SEAL SURFACE
install undersize bearings. The correct 2. CONNECTING ROD JOURNALS
dimensions for the journals are as follows: 3. MAIN BEARING JOUNALS
Main Journal Diameter — 4. FRONT OIL SEAL SURFACE
59.937 to 59.955 mm
Connecting Rod Journals —
50.940 to 50.955 mm
Rear Oil Seal Surface —
89.946 to 90.000 mm
Front Oil Seal Surface —
33.961 to 34.000 mm
3. Check the crankshaft for being straight.
See Figure 29. Put the front and rear
jour nals in V blocks and rotate the
c ra n k s h a f t o n e c o m p l e t e t u r n . T h e
maximum amount that the dial indicator
can indicate is 0.03 mm. Figure 29. Crankshaft Inspection
4. Check the passages for oil in the crank-
shaft. Make sure the passages are clean,
with no restrictions.

Main Bearings
1. Visually inspect the main bearings for
wear and damage. Replace the bearings
as necessary.
2. Measure the clearance between the
main bearings and the crankshaft. Install
the crankshaft in the block. Put a plastic
gauge mater ial on the jour nals and
install the main bearing caps. Tighten
the capscrews for the main bearing caps
to 82 to 88 N·m (840 to 900 kgf·cm).
Remove the bearing caps. See Figure 30.
The correct clearance is 0.031 to 0.049
mm. If the clearance is greater than the
Figure 30. Check the Clearance
specifications, replace the main bearings.
for the Main Bearings

(3) Installation

1. Clean the main bearings and the areas at the block for the main bearings. Install the main
bearings and lubricate them with oil.
2. Install the crankshaft on the bearings. Install the main bearings in the caps and lubricate

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 them with oil. Use the identification marks and install the main bearing caps. Tighten the
capscrews for the main bearing caps to 82 to 88 N·m (840 to 900 kgf·cm).
3. Install the pistons and the connecting rods as described in Pistons and the Connecting Rods,
Installation.
4. Install the oil pump housing. Make sure the O-ring is in the housing. Lubricate the oil seal
with engine oil. Use an adhesive sealant and install the housing to the block. Make sure there
is no sealant in the oil port. Tighten the
M10 capscrews to 37 to 52 N·m (380 to
530 kgf·cm). Tighten the M8 capscrews to
19 to 25 N·m (190 to 260 kgf·cm).
5. Install the oil seal in the rear cover.
Lubricate the surfaces of the oil seal
with engine oil and use a press to install
the seal. Install the alignment pin in the
cylinder block.
6. Install the rear cover and the gasket. See
Figure 31. Make sure the dowel pin is
installed. Tighten the capscrews to 8 to 12
N·m (80 to 120 kgf·cm). Cut the part of the
gasket that extends past the bottom of the
1. REAR COVER
cylinder block.
2. OIL SEAL
7. Install the oil strainer. Tighten the M6 3. CRANKSHAFT
capscrews to 8 to 12 N·m (80 to 120
kgf·cm). Tighten the M8 capscrews to 16
to 23 N·m (160 to 230 kgf·cm). Figure 31. Rear Cover
8. For M4-2.2G engine, install the baffle
plate and tighten the capscrews to 8 to 11
N·m (80 to 110 kgf·cm). Install the oil pan
and the gasket. Tighten the capscrews to
7 to 12 N·m (70 to 120 kgf·cm).
9. Install the crankshaft pulley. Align the
tip of timing indicator plate with the top
mark, left one of two. See Figure 32.
Prevent rotation of the crankshaft pulley.
Put the plain washers on the capscrews
for the crankshaft pulley and tighten the
capscrews to 29 to 32 N·m (300 to 330
kgf·cm) for M4-2.0G, to 32 to 37 N·m (330
to 380 kgf·cm) for M4-2.2G engine.
10. Install the drive plate on the crankshaft
pulley end. Tighten the capscrews to 24 to Figure 32. Crankshaft Pulley Alignment
26 N·m (240 to 270 kgf·cm).

[4] Pistons and Connecting Rods

(1) Removal and Disassembly

1. Remove the cylinder head as described in Cylinder Head, Removal.

2. Remove the oil pan, baffle plate (M4-2.2G) and oil strainer.
3. Put a mark for identification on the top of each piston.
4. Clean the carbon from the top of each cylinder bore.
5. Remove the caps and bearings from each connecting rod. Keep the caps and bearings with
the correct piston assemblies.

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 6. Push the connecting rod and piston from the block.
7. Carefully remove the piston rings from the pistons. Use a tool to push the piston pin from the
connecting rod.

(2) Cleaning

WARNING
Cleaning solvents can be flammable and toxic and can cause skin irritation. When
using cleaning solvents, always follow the solvent manufacturer’s recommended safety
procedures.

Clean all of the parts in solvent. Make sure that all oil passages and grooves are clean. Make
sure all machined surfaces are smooth.

(3) Inspection and Repairs

Pistons
1. Inspect the pistons for wear and cracks.
Replace a piston that has damage.
2. Measure the outside diameter of the
piston as shown in Figure 33. The correct
dimension is 85.944 to 85.964 mm. The
maximum clearance between the piston
and the cylinder bore is 0.15 mm.

Piston Rings
1. Measure the end clearance of each piston Figure 33. Measuring the Piston
ring as shown in Figure 34. Install the
piston ring into the cylinder bore where
it will be used. Use a thickness gauge to
measure the amount of end clearance.
The correct dimensions are as follows:
Top Piston Ring - 0.20 to 0.35 mm 1. PISTON RING END
CLEARANCE
2nd Piston Ring - 0.15 to 0.30 mm
2. PISTON RING
Oil Ring - 0.30 to 0.90 mm GROOVE
Maximum clearance is 1.0 mm CLEARANCE
2. Measure the clearance between the piston
ring and the groove in the piston as shown
in Figure 34. The correct dimensions are
as follows:
Top Piston Ring - 0.03 to 0.07 mm
2nd Piston Ring - 0.03 to 0.07 mm
Maximum clearance is 0.15 mm

Figure 34. Measuring the Piston Rings

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 Connecting Rods and Bearings
1. Use an alignment tool to check the
connecting rods for being straight. The
maximum amount of distortion per 100
mm is 0.04 mm. If the amount of distortion
is greater than the specification, install a
new rod or use a press to straighten the
connecting rod.
2. C h e ck t h e c l e a r a n c e b e t w e e n t h e 1. PLASTIC GAUGE
rod bearings and the journals of the 2. SCALE
crankshaft. Clean the rod bearings and
journals. Use a plastic gauge material Figure 35. Check the Clearance of
between the journal and the bearing. the Connecting Rod Bearings
Tighten the capscrews for the rod caps
to 50 to 55 N·m (510 to 560 kgf·cm) for
M4-2.0G, to 65 to 69 N·m (660 to 700
kgf·cm) for M4-2.2G engine. Do not
rotate the connecting rod. See Figure 35.
The correct clearance is 0.027 to 0.067
mm. If the clearance is greater than the
specifications, replace the bearings.

(4) Assembly And Installation

1. “F” MARK
Pistons and Connecting Rods 2. OIL PORT

1. Align the oil port on the large end of the

connecting rod with the “F” mark on the
piston. See Figure 36. Lubricate the piston
pin and bore in the piston with engine oil. Figure 36. Connecting Rod and Piston
Use a press to install the piston pin. The
force to push the pin into the piston must
be 5 to 15 kN (500 to 1500 kg). If the force
is not correct, replace the piston pin and/
or connecting rod. Use the special tool to
make sure the piston pin is installed to the
correct depth. After installation, check that
the piston moves freely on the piston pin.
2. Install the piston rings on the pistons. 1. EXPANDER RING
During installation, the writing on each 2. OIL RING (UPPER)
piston ring must be toward the top of the 3. OIL RING (LOWER)
piston. Check that the rings rotate freely, 4. TOP RING
then put the ends of the rings in the 5. SECOND RING
positions shown in Figure 37. Make sure
the ends of the upper and lower oil control
rings are each 30° from the piston pin.
Also make sure that the top and second
rings are each 30° from the piston pin.
Lubricate the rings with engine oil.
3. Apply clean engine oil to the piston
assembly. Install the bearings for the
connecting rods. Install the piston into
the correct cylinder making sure the “F”
is toward the front (timing belt end) of the Figure 37. Piston Rings

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 engine. See Figure 38.
4. Apply clean engine oil to the bearing then 1. “F” MARK
install the cap to the correct connecting
rod. During installation of the caps, make
sure to align the identification marks that
were made during disassembly. Tighten
the nuts for the caps to 50 to 55 N·m
(510 to 560 kgf·cm) for M4-2.0G, to 65 to
69 N·m (660 to 700 kgf·cm) for M4-2.2G
engine.

[5] Cylinder Block

Figure 38. Install the Piston
(1) Repairs

1. After the engine block is cleaned, check its surface for distortion. See Figure 39. If the amount
of distortion is greater than 0.15 mm, grind the surface of the engine block. The maximum
amount of correction that is permitted is 0.20 mm.
2. Check the cylinder bores for wear and damage. Measure each bore. The correct dimension
is 86.000 to 86.019 mm. The wear limit above this dimension is 0.15 mm. Repair the cylinder
block or use bigger pistons as necessary.

Figure 39. Inspect the Cylinder Block

[6] Oil Pump

Before removing the oil pump, check the oil pressure. Replace the sending unit with a gauge. The
minimum oil pressure at governed rpm is approximately 0.29 MPa (3.0kgf/cm2). If the pressure is
less than the specification, the oil pump or the engine bearings need repair.

(1) Removal

1. Remove the bracket for the cooling fan.

2. Remove the upper and lower timing belt covers.
3. Loosen the capscrews for the timing belt tensioner and remove the spring. Remove the
capscrews and the timing belt tensioner.
4. Use chalk to mark the direction of rotation of the timing belt. Remove the timing belt.
5. Prevent rotation of the crankshaft pulley. Remove the six capscrews and plate from the
crankshaft pulley. Remove the six capscrews that hold the crankshaft shaft pulley to the

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 timing pulley.
6. Remove the capscrew from the timing pulley. Install the special tool on the crankshaft to
remove the timing pulley. Rotate the tool until it touches the front of the crankshaft. Hit the
tool with a hammer to loosen the timing pulley. Remove the pulley, dowel pin and the tapered
ring. Remove the tool.
7. Remove the capscrews that hold the oil pan to the block and remove the oil pan. For M4-
2.2G engine, remove the baffle plate. Remove the oil strainer.
8. Remove the capscrews that hold the front cover (pump housing) to the block. Remove the
front cover and oil pump assembly.

(2) Disassembly (See Figure 40.)

1. SCREW
1. Remove the screws and the pump cover. 2. COVER
2. Remove the outer gear and the inner gear 3. OUTER GEAR
4. INNER GEAR
from the pump body.
5. FRONT COVER
3. Remove the snap ring to remove the (HOUSING)
plunger assembly from the housing. 6. OIL SEAL
7. PLUNGER
(3) Cleaning 8. SNAP RING

WARNING
Cleaning solvents can be flammable and
toxic and can cause skin irritation. When
using cleaning solvents, always follow the
solvent manufacturer’s recommended safety
procedures.

Clean all of the parts in solvent. Make sure all

machined surfaces are smooth.
Figure 40. Oil Pump
(4) Inspection
1. Check the front cover (pump housing) and
the pump cover for wear or damage. Check the plunger spring for damage.
2. See Figure 41. Measure the parts of the oil pump as follows:
a. Measure the clearance between the teeth of the outer gear and the teeth of the inner gear.

1. CLEARANCE BETWEEN INNER GEAR AND OUTER GEAR

2. CLEARANCE BETWEEN HOUSING AND OUTER GEAR
3. SIDE CLEARANCE OF GEARS IN THE HOUSING

Figure 41. Mesure the Oil Pump

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 If the clearance is more than 0.18 mm, repair as necessary.
b. Use a straight edge and measure the side clearance of the gears. The correct clearance is
0.03 to 0.63 mm. If the clearance is more than 0.10 mm, repair as necessary.
c. Measure the clearance between the body and the outer gear. The correct clearance is 0.090
to 0.184 mm. If the clearance is more than 0.20 mm, repair as necessary.

(5) Assembly (See Figure 40.)

1. Install the oil seal in the oil pump housing. Make sure the front edge of the oil seal is even
with the outer edge of the housing.
2. Lubricate the gears with engine oil, then install them in the housing.
3. Install the pump cover. Use a thread locking compound on the screws for the pump cover,
then install the screws.
4. Install the plunger assembly and the snap ring.

(6) Installation (See Figure 42.)

1. Install the O-ring on the oil pump housing.
1. O-RING
Use grease to hold the O-ring in position.
Lubricate the oil seal with engine oil.
2. Use an adhesive sealant and install the
oil pump housing to the block. Make sure
there is no sealant in the oil port. Tighten
the M10 capscrews to 37 to 52 N·m (380
to 530 kgf·cm). Tighten the M8 capscrews
to 19 to 25 N·m (190 to 260 kgf·cm).
3. Install the suction tube assembly. Install
the gasket and the oil pan.

Figure 42. Oil Pump

[7] Cooling System

(1) Thermostat
Replacement (See Figure 43.)
1. Drain the cooling system to the level of the
thermostat.
2. D i s c o n n e c t t h e h o s e a n d r e m o v e
the thermostat housing. Remove the
thermostat.
3. Test the operation of the thermostat. The
thermostat must begin to open at 82 ±
1.5°C. The thermostat must be completely
open at 95°C.
4. Install the thermostat and new gasket.
Make sure the print side of the gasket is
toward thermostat. Install the thermostat
housing and tighten the capscrews to 19
to 30 N·m (190 to 310 kgf·cm).
5. Connect the hose and fill the cooling system. 1. CYLINDER BLOCK
2. GASKET
Start the engine and check for leaks.
3. THERMOSTAT
4. HOUSING
(2) Fan Assembly
Removal
Figure 43. Thermostat
1. Loosen the alternator and remove the fan

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 belt.
2. Remove the capscrews for the fan. Remove the fan and pulley from the hub.
3. Remove the capscrews that hold the fan bracket to the engine. Remove the fan bracket.

Disassembly and Repair (See Figure 44.)

1. Use a press to remove the fan hub from
the shaft. Remove the snap ring and push
the bearing and shaft from the bracket.
2. Use a press to install the shaft and
bearing in the bracket. Push the bearing in
until it touches the bracket. Install the snap
ring. Install the hub on the shaft. When
installed, the shaft must extend 2.1 mm
past the hub.

Installation (See Figure 44.)

1. Install the bracket assembly on the
cylinder block. For M4-2.0G engine, 1. FAN 5. SHAFT
2. PULLEY 6. SUPPORT
tighten the M8 capscrews to 19 to 30
3. HUB BRACKET
N·m (190 to 310 kgf·cm). Tighten the M10 4. SNAP RING 7. BRACKET
capscrews to 37 to 52 N·m (380 to 530
kgf·cm). For M4-2.2G engine, tighten the
capscrews to 64 to 89 N·m (650 to 910 Figure 44. Fan Assembly
kgf·cm).
2. Install the pulley and fan on the hub.
Tighten the capscrews to 8 to 11 N·m (80
to 110 kgf·cm).
3. Install the fan belt. Adjust the tension of the fan belt. Check the movement of the fan belt
between the fan and the alternator. When the tension is correct a NEW belt will move 7 to 8
mm with 98 N (10 kg) of force. The tension for an OLD belt is correct when it moves 10 to 12
mm with 98 N (10 kg) of force. Tighten the alternator when the tension is correct.

(3) Water Pump

NOTE: If either the shaft or impeller is damaged, the complete water pump must be replaced.

Removal
1. Drain the cooling system.
2. Loosen the alternator and remove the fan belt.
3. Remove the capscrews for the fan. Remove the fan and pulley from the hub.
4. Remove the capscrews that hold the fan bracket to the engine. Remove the fan bracket.
5. Remove the upper and lower timing belt covers. See Figure 26. Loosen the capscrews for
the timing belt tensioner and remove the spring. Remove the capscrews and the timing belt
tensioner.
6. Use chalk to mark the direction of rotation of the timing belt. See Figure 1. Align the timing
marks, then remove the timing belt.

CAUTION
Do not rotate the camshaft gear or the crankshaft gear while the timing belt is removed. If
either of the gears is moved, it will be necessary to align the timing marks.

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 7. Disconnect the hose at the water pump. Remove the capscrews for the water pump, then
remove the water pump from the cylinder block.
NOTE: The water pump assembly can not be disassembled.

Installation
1. Install the water pump with a new gasket. Tighten the capscrews to 19 to 25 N·m (190 to 260
kgf·cm).
2. Install the timing belt and the covers as described in the procedures for Cylinder Head,
Installation.
3. Install the fan assembly as described in the procedures for Fan Assembly, Installation.
4. Install the coolant hoses.
5. Fill the coolant system with coolant.
6. Start the engine and check the cooling system for leaks.

WARNING
DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator
cap is removed, the pressure is released from the 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.

7. After the engine has been operated, stop the engine. If the coolant is hot, give the engine
time to cool. Check the coolant level.

[8] Distributor
NOTE: This section has only the removal and installation procedures for the distributor. The service
procedures for the ignition system are found in The
Electrical System.

(1) Removal (See Figure 46.)

1. Rotate the crankshaft until the number

one piston is at TDC on the compression
stroke. Make a note of the position of the
distributor rotor.
2. Disconnect the wires at the spark plugs.
3. Remove the capscrew from the flange of
the distributor shaft housing.
4. Lift the distributor assembly from the
engine.

(2) Installation (See Figure 46.)

1. Rotate the crankshaft until the number

one piston is at TDC on the compression
stroke. Put the rotor in the correct position.
2. Lubricate the O-ring and the gear on
the distributor with engine oil. Install the
distributor, aligning the marks on the
distributor housing, distributor gear and Figure 46. Installation of the Distributor

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 engine.
3. Connect the wires at the spark plugs.

[9] Flywheel for Powershift Transmission

(1) Removal (See Figure 47.)

1. Remove the capscrews for the flywheel, then remove the flywheel and the flange.
2. If necessary, remove the engine end plate.

(2) Installation (See Figure 47.)

1. If the engine end plate was removed, install it on the engine. Tighten the M14 capscrews to
114 to 136 N·m (1160 to 1390 kgf·cm). Tighten the M8 capscrews to 21 to 25 N·m (210 to
250 kgf·cm).
2. Install the flange and the flywheel on the crankshaft. Apply an adhesive sealant on the
threads of the capscrews. Then install the capscrews, washers and the backplate. Tighten the
capscrews to 96 to 103 N·m (980 to 1050 kgf·cm).

1. ENGINE END PLATE 6. FLANGE

2. M14 CAPSCREW 7. CAPSCREW
3. M8 CAPSCREW 8. BACK PLATE
4. COVER PLATE 9. TORQUE CONVERTER
5. FLYWHEEL

Figure 47. End Plate, Flywheel and Torque Converter

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 CHECKS AND ADJUSTMENTS

[1] Adjust the Valves (See Figure 50.)

1. Rotate the crankshaft until the number

one piston is at TDC on the compression
stroke (intake and exhaust valves closed).
Now adjust the clearance of the intake
valves for the No. 1 and No. 2 cylinders
and the exhaust valves for the No. 1 and
No. 3 cylinders. The correct clearance for
all the valves when the engine is hot is 0.3
mm. To adjust the clearance, loosen the
lock nut and turn the adjustment screw.
Tighten the lock nut to 16 to 21 N·m (160
to 210 kgf·cm).

NOTE: During adjustment of the valves, check

the position of the balls that are in the ends of the
rocker arms. The flat surface of the ball must be in
contact with the stem of the valve.

2. Rotate the crankshaft clockwise one 1. CAMSHAFT

complete turn (360 degrees). Now adjust 2. ROCKER ARM
3. BALL
the remaining valves.
4. VALVE STEM

Figure 50. Adjust the Valves

[2] Check the Compression Pressure (See Figure 51.)

1. Remove the spark plugs from the cylinder

head. Disconnect the high tension wire at 1. ADAPTER
the ignition coil.
2. Install a compression gauge in the number
1 cylinder. Make sure the gauge has a
minimum range of 2 MPa (20 kgf/cm2).
3. Use the starter to crank the engine at least
six (6) revolutions. Check the pressure
reading and release the pressure. Repeat
the test again and make a note of the
highest pressure. Do this test for each
cylinder.
4. The standard pressure reading is 1.13
MPa (11.5 kgf/cm2). The minimum reading
is 0.79 MPa (8.1 kgf/cm2). The maximum Figure 51. Check the Compression Pressure
variation between cylinders is 0.20 MPa (2
kgf/cm2).
5. If the readings are lower than the minimum reading, there is a problem with the valves, piston
rings or cylinder head gasket. Do the following tests to find the problem:

a. Add approximately 30 ml of engine oil to each cylinder at the spark plug hole.

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b. Crank the engine approximately ten revolutions to distribute the oil.
c. Install the compression gauge and do the same tests as described in step 3.
d. If the compression pressure increases to a normal reading, the low pressure was caused
by worn or damaged piston rings. The cylinder bore can also be damaged.
e. If the compression reading does not increase, the low pressure was caused by worn
valves, valve seats or valve guides.
f. If the low pressure readings are in two cylinders next to each other, the cylinder head can
be leaking.

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 ENGINE SPECIFICATIONS
Model M4-2.0G M4-2.2G
Item
Numbers and arrangement of cylinders In-line four cylinders ←
Bore x Stroke mm 86.0 x 86.0 86.0 x 94.0
Displacement cc 1998 2184
Compression ratio 8.6 ←
Valve opening/closing timing
Open (BTDC) −2° ←
Intake
Close (ABDC) 42° ←
Open (BBDC) 32° ←
Exhaust
Close (ATDC) 8° ←
Standard 1.13 (11.5) −270 ←
Compression pressure
Limit 0.79 (8.1) −270 ←
MPa (kgf/cm2) −rpm
Variation between cylinders 0.20 (2.0) or less ←
Valve clearance

Valve side Intake 0.15 ←

mm
(Cold condition) Exhaust 0.35 ←
Numbers of teeth of timing belt 109 110
Height 91.95 ~ 92.05 ←
Cylinder head mm Distortion limit 0.15 ←
Grinding limit 0.20 ←
Valve seat
Standard 46.5 ←
Intake
Depth amount mm Limit 48.0 ←
(Length) Standard 46.5 ←
Exhaust
Limit 48.0 ←
Intake 45° ←
Valve seat angle
Exhaust 45° ←
Intake 1.2 ~ 1.6 ←
Valve seat width mm
Exhaust 1.2 ~ 1.6 ←
Valve guide, valve, and valve spring
Intake 0.025 ~ 0.060 ←
Gap between the valve Standard
Exhaust 0.025 ~ 0.060 ←
stem and guide mm
Limit 0.20 ←
Valve guide inside diameter mm 8.07 ~ 8.09 ←
Standard 8.030 ~ 8.045 ←
Intake
Limit 7.980 ←
Valve stem diameter mm
Standard 8.025 ~ 8.040 ←
Exhaust
Limit 7.975 ←

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 ENGINE SPECIFICATIONS
Model M4-2.0G M4-2.2G
Item
Intake 0.5 ←
Valve head thickness mm
Exhaust 1.0 ←
Intake 45° ←
Valve face angle
Exhaust 45° ←
Standard 52.2 ←
Valve spring outer free length mm
Limit 50.6 ←
Standard 47.7 ←
Valve spring inner free length mm
Limit 46.3 ←
Valve spring squareness mm 1.81 or less ←
Rocker arm and shaft
Gap between the arm and shaft Standard 0.016 ~ 0.061 ←
mm Limit 0.10 ←
Rocker arm shaft diameter mm 15.966 ~ 15.984 ←
Rocker arm inside diameter mm 16.000 ~ 16.027 ←
Cam shaft
Cam shaft deflection limit mm 0.03 ←
Standard 0.08 ~ 0.16 ←
Cam shaft end play mm
Limit 0.20 ←
No. 1 0.035 ~ 0.085 ←
No. 2 0.065 ~ 0.115 ←
Journal oil clearance mm No. 3 0.065 ~ 0.115 ←
No. 4 0.065 ~ 0.115 ←
No. 5 0.035 ~ 0.085 ←
Oil clearance limit mm 0.15 ←
No. 1 31.940 ~ 31.965 ←
No. 2 31.910 ~ 31.935 ←
Standard journal diameter mm No. 3 31.910 ~ 31.935 ←
No. 4 31.910 ~ 31.935 ←
No. 5 31.940 ~ 31.965 ←
Journal wear limit mm 0.05 ←
Standard 37.102 ←
Intake
Limit 36.902 ←
Cam height mm
Standard 37.102 ←
Exhaust
Limit 36.902 ←
Connecting rod and bearing
Length (distance between the holes) mm 135.95 ~ 136.05 158.45 ~ 158.55
Bending limit (for every 100mm) mm 0.04 ←
Small end diameter mm 21.943 ~ 21.961 ←
Clearance between the small end and piston pin mm 0.015 ~ 0.010 ←

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 ENGINE SPECIFICATIONS
Model M4-2.0G M4-2.2G
Item
Standard 0.110 ~ 0.262 ←
Large end play
Limit 0.30 ←
Standard 0.027 ~ 0.067 ←
Oil clearance on large end mm
Limit 0.10 ←
Bearing under-size mm 0.025, 0.50, 0.75 ←
Crank shaft and bearing
Standard 50.940 ~ 50.955 ←
Crank pin diameter mm Wearing limit 0.05 ←
Grinding limit 0.75 ←
Standard 59.937 ~ 59.955 ←
Main journal diameter mm Wearing limit 0.05 ←
Grinding limit 0.75 ←
Standard 0.031 ~ 0.049 ←
Main journal oil clearance mm
Limit 0.08 ←
Main bearing under-size mm 0.25, 0.50, 0.75 ←
Crank shaft deflection limit mm 0.03 ←
Standard 0.08 ~ 0.18 ←
End play mm
Limit 0.30 ←
Thrust bearing over-size mm 0.25, 0.50, 0.75 ←
Cylinder block, piston, and piston pin
Block surface distortion limit mm 0.15 ←
Standard 86.000 ~ 86.019 ←
Cylinder bore diameter mm
Wearing limit 0.15 ←
Cylinder boring amount mm 0.25, 0.50 ←
Piston diameter mm 85.944 ~ 85.964 ←
Gap between piston and cylinder Standard 0.036 ~ 0.075 ←
mm Limit 0.15 ←
Piston over-size mm 0.25, 0.50 ←
Top compression ring 0.03 ~ 0.07 ←
Gap between piston ring
Second compression ring 0.03 ~ 0.07 ←
and ring groove mm
Limit 0.15 ←
Top compression ring 1.520 ~ 1.540 ←
Piston ring groove width mm Second compression ring 1.520 ~ 1.540 ←
Oil control ring 4.020 ~ 4.040 ←
Top compression ring 0.20 ~ 0.35 ←
Second compression ring 0.15 ~ 0.30 ←
Piston ring end clearance mm
Oil control ring 0.3 ~ 0.9 ←
Limit 1.0 ←
Piston ring over-size mm 0.25, 0.50 ←
Diameter mm 21.947 ~ 21.980 ←
Piston pin
Installation pressure kN (kg) 5 ~ 15 (500 ~ 1500) ←

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 TORQUE SPECIFICATIONS Unit: N·m (kgf·cm)
Model M4-2.0G M4-2.2G
Item
Cylinder head cover 3.9 ~ 5.9 (40 ~ 60) ←
Rocker shaft assy 18 ~ 26 (180 ~ 270) ←
Cold 80 ~ 86 (820 ~ 880) ←
Cylinder head
Hot 93 ~ 98 (950 ~ 1000) ←
Upper 6.9 ~ 9.8 (70 ~ 100) ←
Timing belt cover
Lower 6.9 ~ 9.8 (70 ~ 100) ←
Cam shaft pulley lock bolt 47 ~ 65 (480 ~ 660) ←
Timing tensioner lock bolt 37 ~ 52 (380 ~ 530) ←
Drive plate 24 ~ 26 (240 ~ 270) ←
Crank shaft pulley 32 ~ 37 (330 ~ 380) ←
Timing belt crank pulley bolt 177 ~ 196 (1800 ~ 2000) ←
Front housing assy 19 ~ 25 (190 ~ 260) ←
Rear cover assy 8 ~ 12 (80 ~ 120) ←
Oil pan 7 ~ 12 (70 ~ 120) ←
M6 8 ~ 12 (80 ~ 120) ←
Oil strainer
M8 16 ~ 23 (160 ~ 230) ←
M8 19 ~ 25 (190 ~ 260) ←
Oil pump
M10 37 ~ 52 (380 ~ 530) ←
Oil pressure switch 12 ~ 18 (120 ~ 180) ←
Main bearing cap 82 ~ 88 (840 ~ 900) ←
Connecting rod cap 50 ~ 55 (510 ~ 560) 65 ~ 69 (660 ~ 700)
Intake manifold 19 ~ 30 (190 ~ 310) ←
Exhaust manifold 22 ~ 28 (220 ~ 290) ←
Spark plug 15 ~ 23 (150 ~ 230) ←
Cooling fan 8 ~ 11 (80 ~ 110) ←
M8 19 ~ 30 (190 ~ 310) ←
Cooling fan bearing
M 10 37 ~ 52 (380 ~ 530) ←
Cooling fan bracket 64 ~ 89 (650 ~ 910) ←
Water pump 19 ~ 25 (190 ~ 260) ←
Thermostat cover 19 ~ 30 (190 ~ 310) ←
Alternator bracket 37 ~ 52 (380 ~ 530) ←
Alternator strap 19 ~ 25 (190 ~ 260) ←
Alternator flange bolt 19 ~ 30 (190 ~ 310) ←
Air cleaner bracket 19 ~ 25 (190 ~ 260) ←
Carburetor 12 ~ 17 (120 ~ 170) ←
Fuel pump 16 ~ 22 (160 ~ 220) ←

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 TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

The engine will not start. The fuel tank is empty. Fill fuel tank.
The battery is not fully charged. Charge battery.
The connections at the battery Check and tighten battery
are loose or they have corrosion. connections.
The starter system has a Check electrical circuit for starter.
problem.
There are damaged parts in the Repair engine.
engine.
The valves are worn or damaged. Install new valves.
The piston rings are worn or have Install new piston rings.
damage.
The fuel system has a problem. Check and repair fuel system.
Ignition timing is not correct. Adjust timing.
Fuel line has a restriction. Clean or use new fuel lines.
Fuel filter has a restriction. Install a new fuel filter.
Ignition system does not operate Check and repair ignition system.
correctly.

The engine does not run The valve mechanism does not Check and repair valve mechan-
smoothly. operate correctly. ism.
The cylinder head has cracks. Install a new cylinder head.
The head gasket has a leak. Install a new gasket.
There is a leak in the intake Check and repair intake system.
system.
Engine is too hot. Check cooling system.
Fuel lines or fuel filter has a Clean or use new fuel lines.
restriction.
The ignition timing is not correct. Adjust timing.

The engine does not have The fuel is the wrong type. Fill tank with correct fuel.
enough power. The air filter is dirty. Install a new air filter.
The ignition timing is not correct. Adjust timing.
The valve mechanism does not Check and repair valve mechan-
work correctly. ism.
The piston assemblies are worn Install new pistons.
or damaged.
The exhaust system has Clean parts or install new muffler
restrictions. or pipes.
Fuel lines or fuel filter has a Clean or use new fuel lines and
restriction. filter.
Engine is too hot or too cold. Check cooling system.
Cylinder head gasket leaks. Install a new gasket.

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 TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

There is noise inside the engine. The main bearings are worn or Install new main bearings.
damaged.
Engine is too hot. Check and repair cooling
system.
Valves are not adjusted correctly. Adjust valves.
The bearings for the connecting Install new bearings.
rods are worn or damaged.
The pistons are worn or Install new pistons.
damaged.
Valve spring is broken. Install new valve springs.
There is not enough oil in the Fill engine with correct oil.
engine.
The flywheel is loose. Tighten capscrews for flywheel.
A connecting rod is bent. Repair engine.
There is a leak in the exhaust Repair exhaust system.
system.
The valve mechanism does not Check and repair valve mechan-
operate correctly. ism.
Spark plugs are dirty. Install new spark plugs.

The engine gets too hot. There is not enough coolant in Fill cooling system.
the cooling system.
The air filter has a restriction. Install a new air filter.
The water pump has damage. Install a new water pump.
The radiator is dirty. Clean or repair the radiator.
The cooling system has restric- Check radiator and hoses.
tions.
The belt for the water pump is Check and adjust the belt.
worn or not adjusted correctly.
The thermostat has damage. Install a new thermostat.
The exhaust system has restric- Check and repair exhaust
tions. system.
Ignition timing is not correct. Adjust timing.
Cylinder head gasket leaks. Install a new head gasket.
Engine compression is not Check and repair engine.
correct.

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