PSI 4.

3L V-6 ENGINES
H6.0FT,
H7.0FT [K006];H6.0-7.0FT (H135-155FT) [L006];
H6.0-7.0FT, H7.0FTS6, H7.0FTS9,
H8.0FTS6 (H135-155FT, H155FTS, H170FTS) [N006];
S6.0-7.0FT (S135-155FT) [G024];H80-120FT [U005]

PART NO. 4162986 0600 SRM 1949

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized 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.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or
exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and when
working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:

WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
 Table of Contents

TABLE OF CONTENTS
General................................................................................................................................................................... 1
Engine Removal and Installation......................................................................................................................... 1
Cylinder Head Repair............................................................................................................................................1
Remove and Disassemble................................................................................................................................... 1
Clean and Inspect................................................................................................................................................3
Valve Oil Seals.................................................................................................................................................... 5
Remove and Disassemble.................................................................................................................................5
Cylinder Leak Down Test..............................................................................................................................5
Clean and Inspect.............................................................................................................................................6
Assemble and Install........................................................................................................................................ 6
Valve Guides and Seats, Repairs....................................................................................................................... 8
Valves, Repair..................................................................................................................................................... 9
Valve Seats, Repair...........................................................................................................................................10
Valve Springs.................................................................................................................................................... 10
Assemble and Install.........................................................................................................................................11
Engine Block Cleaning and Inspection...............................................................................................................14
Clean and Inspect..............................................................................................................................................14
Piston Bore Preparation......................................................................................................................................16
Engine Mounts Installation................................................................................................................................ 17
Remove...............................................................................................................................................................17
Clean and Inspect..............................................................................................................................................17
Install.................................................................................................................................................................17
Lubrication System Repair................................................................................................................................. 17
Oil Pump, Remove and Disassemble................................................................................................................17
Clean and Inspect..............................................................................................................................................19
Oil Pump, Assemble and Install.......................................................................................................................20
Oil Pan, Install.................................................................................................................................................. 21
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters....................................................................... 23
Timing Cover..................................................................................................................................................... 23
Remove............................................................................................................................................................ 23
Install.............................................................................................................................................................. 24
Timing Chain and Sprockets............................................................................................................................ 24
Remove............................................................................................................................................................ 24
Install.............................................................................................................................................................. 25
Camshaft........................................................................................................................................................... 26
Remove............................................................................................................................................................ 26
Inspect.............................................................................................................................................................26
Install.............................................................................................................................................................. 26
Balance Shaft.................................................................................................................................................... 27
Remove............................................................................................................................................................ 27
Install.............................................................................................................................................................. 28
Valve Lifters...................................................................................................................................................... 29
Remove............................................................................................................................................................ 29
Clean and Inspect...........................................................................................................................................29
Install.............................................................................................................................................................. 30
Crankshaft Repair............................................................................................................................................... 30
Remove...............................................................................................................................................................30
Inspect and Repair............................................................................................................................................ 31
How to Check Clearance Between Main Bearings and Their Journals.........................................................32
Install.................................................................................................................................................................33
Piston and Connecting Rod Assemblies Repair................................................................................................. 34
Connecting Rod Bearings, Replace.................................................................................................................. 34

©2019 HYSTER COMPANY i

Table of Contents

TABLE OF CONTENTS (Continued)

Piston and Connecting Rod Assemblies, Remove............................................................................................36
Disassemble.......................................................................................................................................................36
Piston, Clean and Inspect.................................................................................................................................36
Cylinder Bores, Inspect and Repair................................................................................................................. 37
Piston Rings.......................................................................................................................................................37
Assemble............................................................................................................................................................38
Piston and Connecting Rod Assemblies, Install..............................................................................................39
Flywheel and Flywheel Housing Repair.............................................................................................................39
Flywheel, Remove............................................................................................................................................. 39
Clean.................................................................................................................................................................. 40
Inspect................................................................................................................................................................40
Flywheel, Install................................................................................................................................................40
Coolant Pump Repair.......................................................................................................................................... 41
Remove...............................................................................................................................................................41
Clean and Inspect..............................................................................................................................................42
Install.................................................................................................................................................................42
Thermostat Replacement.................................................................................................................................... 43
Remove...............................................................................................................................................................43
Thermostat Operation Check........................................................................................................................... 43
Install.................................................................................................................................................................43
Starter Replacement............................................................................................................................................44
Remove............................................................................................................................................................ 44
Install.............................................................................................................................................................. 47
Fan Assembly Replacement................................................................................................................................ 47
Remove...............................................................................................................................................................47
Inspect................................................................................................................................................................49
Install.................................................................................................................................................................49
Drive Belt Installation.........................................................................................................................................50
Remove...............................................................................................................................................................50
Clean.................................................................................................................................................................. 50
Inspect................................................................................................................................................................50
Installation........................................................................................................................................................ 50
Compression Check............................................................................................................................................. 51
Engine Specifications.......................................................................................................................................... 52
Engine Data.......................................................................................................................................................52
Cylinder Head................................................................................................................................................... 52
Hydraulic Valve Lifter...................................................................................................................................... 52
Camshaft........................................................................................................................................................... 52
Pistons............................................................................................................................................................... 53
Crankshaft.........................................................................................................................................................53
Connecting Rods................................................................................................................................................54
Balance Shaft.................................................................................................................................................... 54
Cooling System..................................................................................................................................................54
Lubrication System........................................................................................................................................... 54
Torque Specifications...........................................................................................................................................54

ii
0600 SRM 1949 General

General
• DO NOT cause a short circuit by connection
of the electric wires to the wrong terminals.
CAUTION Make sure a correct identification of the wire
Disconnect the battery cables before doing any is made before it is connected.
disassembly and repair of the engine or parts of
• Make sure a battery is the correct voltage
the electrical system. and polarity before it is connected.
The diodes and resistors in the electrical system • DO NOT check for current flow by making a
can be damaged if the following cautions are not spark because the electronic components
followed: can be damaged.
• DO NOT disconnect the battery when the
This SRM has repair instructions for PSI 4.3 liter,
engine is running. The voltage surge can
damage the diodes and resistors. V-6 engine. Checks and Adjustments and
Specifications are also included.
• DO NOT disconnect an electric wire before
the engine is stopped and the switches are
OFF.

Engine Removal and Installation

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

Cylinder Head Repair

REMOVE AND DISASSEMBLE 3. Remove air cleaner, distributor, intake
manifold, and exhaust manifolds. Remove drive
belt(s) and remove brackets for drive belt
WARNING tensioner and alternator.
Disconnect the battery cables before making
repairs to the engine. 4. Remove spark plugs and spark plug wire
shields.
1. Drain cooling system.
5. Remove valve rocker arm cover bolts and
2. Loosen hose clamp and remove coolant hose grommets. Discard grommets.
from thermostat housing.
6. Remove rocker arm cover. See Figure 1.
NOTE: Prior to removing distributor, mark location
of distributor on distributor and engine to aid in
proper installation. For more information regarding
removal and installation of distributor, see
• High Voltage Switch (HVS) Ignition;
GM4.3L EPA Compliant Engines and
GM5.7L LPG EPA Compliant Engine
2200SRM1097
• High Voltage Switch (HVS) Ignition; PSI
4.3L EPA Compliant Engines
2200SRM1955

1
Cylinder Head Repair 0600 SRM 1949

1. ROCKER COVER BOLTS 1. VALVE ROCKER ARM

2. ROCKER COVER 2. VALVE ROCKER ARM SUPPORT
3. CYLINDER HEAD 3. PUSH ROD

Figure 1. Rocker Cover Removal Figure 2. Remove Valve Rocker Arm and Push Rod

7. Remove valve rocker arms. Organize rocker 10. Remove capscrews that hold cylinder head to
arms so they can be installed in their original block in the sequence shown in Figure 3.
positions. See Figure 2. Remove cylinder head and gasket. Discard
cylinder head gasket.
8. Remove valve rocker arm supports.

9. Remove valve push rods.

A. FAN END

Figure 3. Cylinder Head Capscrew Removal

Sequence

11. Using a valve spring compressor, remove valve

stem keys, caps, springs, and oil seals. Discard
oil seals. Remove valves. Organize valves and
springs so they can be installed in their original
positions. See Figure 4.

2
0600 SRM 1949 Cylinder Head Repair

• Valve
• Cylinder head
When cleaning is complete, dry components
with compressed air. See Figure 5.

1. VALVE STEM KEYS

2. VALVE SPRING CAP
3. VALVE SPRING
4. VALVE
5. VALVE STEM OIL SEAL
6. CYLINDER HEAD
1. VALVE STEM KEYS
Figure 4. Valve Removal 2. VALVE SPRING CAP
3. VALVE SPRING
CLEAN AND INSPECT 4. VALVE
5. VALVE STEM OIL SEAL
1. Clean carbon from valve ports and combustion 6. CYLINDER HEAD
chambers in cylinder head. Use care not to
scuff the combustion chambers. Figure 5. Valve Component Cleaning

3. Clean valve guides.

WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning CAUTION
solvents, always follow the solvent manufacturer's To prevent possible gouging of the cylinder head
recommended safety procedures. surfaces, use care when removing gasket material.

4. Remove all gasket material from surfaces of

cylinder head.
WARNING
Compressed air can move particles so they cause 5. Inspect cylinder head for following defects:
injury to the user or to other personnel. Make sure
• Damage to gasket surfaces
the path of the compressed air is away from all
personnel. Wear protective goggles or a face • Damage to threaded bolt holes
shield to prevent injury to the eyes. • Burnt or eroded areas in combustion chamber
• Cracks in exhaust ports and combustion
2. Using cleaning solvent, clean following items:
chambers
• Valve stem keys • External cracks in water chamber
• Valve spring cap • Restrictions in intake or exhaust passages
• Valve spring

3
Cylinder Head Repair 0600 SRM 1949

• Restrictions in cooling system passages

• Rusted, damaged, or leaking core plugs

6. Measure cylinder head for warpage with a

straight edge and feeler gauge. See Figure 6.
• A cylinder head block deck with warpage in
excess of 0.10 mm (0.004 in.) within a
152.4 mm (6.0 in.) area must be repaired or
replaced.
• A cylinder head exhaust manifold mounting
surface with a warpage in excess of
0.05 mm (0.002 in.) within a
152.4 mm (6.0 in.) area must be repaired or
replaced.
• A cylinder head intake manifold mounting
surface with a warpage in excess of
0.10 mm (0.004 in.) within a
152.4 mm (6.0 in.) area must be repaired or
replaced.

1. BURNT OR DAMAGED AREAS

2. UNDERSIZED MARGIN
3. BENT STEM
4. SCORING/DAMAGE TO THE STEM
5. WORN KEY GROOVE
6. WORN STEM TIP

Figure 7. Valve Inspection

Valve stems with excessive guide clearance

must be repaired or replaced. Refer to Engine
Specifications.

8. Inspect valve contact surface for the

following:See Figure 8.
• Undersized margin
• Pitted surface
• Burnt or eroded areas
• Acceptable edge margin
Figure 6. Cylinder Head Warpage Inspection

7. Inspect valves for:See Figure 7.

• Burnt or damaged areas
• Undersized margin
• Bent stem
• Scoring or other damage to stem
• Worn key groove
• Worn stem tip

4
0600 SRM 1949 Cylinder Head Repair

4. Remove rocker covers. Disconnect the Positive

Crankcase Ventilation valve from the air inlet
hose.

5. Perform cylinder leak down test for each

cylinder. See Cylinder Leak Down Test.

6. Remove valve rocker arms. Organize rocker

arms so they can be installed in their original
positions. Repeat for other side.

7. Using a valve spring compressor, remove valve

stem keys, caps, springs, and oil seals. Discard
oil seals. Organize springs so they can be
installed in their original positions. Repeat for
other each cylinder.

Cylinder Leak Down Test

NOTE: Rotate crankshaft to place piston in cylinder
being tested at top dead center (TDC) of the
1. UNDERSIZED MARGIN compression stroke, with both valves closed. Lock
2. PITTED SURFACE crankshaft balancer in place to prevent piston
3. BURNT OR ERODED AREAS
4. ACCEPTABLE EDGE MARGIN movement.
1. Install the Cylinder Head Leakdown Tester
Figure 8. Valve Contact Surface Inspection (Hyster P/N 4060759 ) tester in the spark plug
port on cylinder to be tested.
Valves with excessive damage must be
replaced. Minor imperfections of valve or valve 2. Apply shop air pressure to Cylinder Head
seat may be repaired. Refer to Valve Guides Leakdown Tester (Hyster P/N 4060759 ) tester
and Seats, Repairs or Valves, Repair. and adjust according to manufactures
instructions.
VALVE OIL SEALS
The following procedure addresses replacement of 3. Record cylinder leakage value. Cylinder
valve oil seals. If ONLY valve oil seals are being leakage exceeding 25 percent is considered
replaced, it is not necessary to remove the cylinder excessive and may require component service.
head. Air leakage from intake or exhaust system may
indicate a worn or burnt valve or a broken
Remove and Disassemble valve spring.
1. Remove spark plug wires from spark plugs and • Ensure that both valves are closed.
position spark plug wires out of way. • Inspect cylinder head for a broken valve
spring.
2. Remove each spark plug and spark plug wire
• Remove and inspect suspect cylinder head.
shield. See Cylinder Head Repair, Remove and
Disassemble.
NOTE: If spark plugs are not being replaced label
each spark plug to its corresponding cylinder. Air leakage from crankcase, oil level indicator,
or oil fill tube may indicate worn piston rings, a
3. Remove rocker cover bolts and grommets. damaged piston, a worn or scored cylinder bore,
Discard grommets. Repeat for other rocker a damaged engine block or a damage cylinder
cover. head.

5
Cylinder Head Repair 0600 SRM 1949

• Remove piston from the suspect cylinder. See

Piston and Connecting Rod Assemblies,
Remove.
• Inspect piston and connecting rod assembly.
See Piston, Clean and Inspect.
• Inspect engine block. See Engine Block, Clean
and Inspect.
• Inspect cylinder head. See Cylinder Head
Repair, Clean and Inspect.
Air bubbles in cooling system may indicate a
damaged cylinder head or a damaged cylinder
head gasket.
• Remove both cylinder heads. See Cylinder
Head Repair, Remove and Disassemble.
• Inspect engine block. See Engine Block, Clean
and Inspect.
• Inspect cylinder head. See Cylinder Head
Repair, Clean and Inspect.

Clean and Inspect 1. VALVE STEM KEYS

2. VALVE SPRING CAP
3. VALVE SPRING
WARNING 4. VALVE
5. VALVE STEM OIL SEAL
Cleaning solvents can be flammable and toxic and 6. CYLINDER HEAD
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufacturer’s Figure 9. Valve Component Cleaning
recommended safety procedures.
3. Clean valve guides.

WARNING Assemble and Install

Compressed air can move particles so they cause 1. Using special tool Hyster P/N 4622265 , install
injury to the user or to other personnel. Make sure oil seal in lower groove. Install shim, damper,
the path of the compressed air is away from all spring, shield, and cap or rotator. Using a
personnel. Wear protective goggles or a face spring compressor, compress assembly and
shield to prevent injury to the eyes. install retainers. Measure height of valve
spring as shown in Figure 10. Measure from
1. Using cleaning solvent, clean the following top of shim to top of retainer cap. Install shims
items: to get correct height shown in Figure 10. The
• Valve stem keys installed height of valve spring must not be less
than minimum height.
• Valve spring cap
• Valve spring

2. When cleaning is complete, dry components

with compressed air. See Figure 9.

6
0600 SRM 1949 Cylinder Head Repair

A. VARIATION FROM VERTICAL: LESS THAN

1.6 mm (0.063 in.) 1. VALVE PUSH ROD SOCKET
B. FREE LENGTH: 50 mm (2.0 in.) 2. ROLLER PIVOT
C. SPRING COMPRESSED TO 265 N (59.5 lbf) AT 3. VALVE STEM TIP
43.2 mm (1.70 in.) CLOSED SPRING 4. ROCKER ARM BOLT
COMPRESSED TO 718 N (161.5 lbf) AT
32.3 mm (1.27 in.) OPEN Figure 11. Lubricate Valve Rocker Arm Surfaces
D. INSTALLED HEIGHT INTAKE:
42.92 TO 43.43 mm (1.670 TO 1.700 in.)
EXHAUST: 3. Install valve rocker arm assemblies as follows:
42.92 TO 43.43 mm (1.670 TO 1.700 in.) Finger start rocker arm bolt at location 1 in
Figure 12.
Figure 10. Valve Spring Specifications
Finger start rocker arm bolt at location 2 in
2. Apply a molybdenum grease or equivalent to Figure 12.
following valve rocker arm contact surfaces: Finger start rocker arm bolt at location 3 in
See Figure 11. Figure 12.
Valve push rod socket Finger start remaining three valve rocker
•
arm bolts.
• Roller pivot
Repeat for other side.
• Valve stem tip

7
Cylinder Head Repair 0600 SRM 1949

NOTE: ONCE THE VALVE ROCKER ARM ASSEM-

1. BOLT AT LOCATION 1 BLIES ARE INSTALLED AND PROPERLY TOR-
2. BOLT AT LOCATION 2 QUED, NO ADDITIONAL VALVE LASH ADJUST-
3. BOLT AT LOCATION 3
MENT IS REQUIRED.
Figure 12. Install Valve Rocker Arm Assemblies
1. CRANKSHAFT BALANCER ALIGNMENT MARK
2. ENGINE FRONT COVER ALIGNMENT TAB
4. Rotate crankshaft balancer to position
crankshaft balancer alignment mark 57 to 63 Figure 13. Rotate Crankshaft Balancer
degrees clockwise or counterclockwise from
engine front cover alignment tab. See 5. Tighten valve rocker arm bolts to 30 N•m (22
Figure 13. lbf ft). See Figure 19. Repeat for other side.

6. Use new gasket and install rocker covers.

Install new grommets on capscrews and install
capscrews into rocker covers. Tighten
capscrews to 12 N•m (107 lbf in). See Figure
22. Repeat for other side.

7. Install air inlet hose on PCV valve. Tighten

clamp.

8. Install each spark plug wire shield and spark

plugs.

9. Install spark plug wires to their appropriate

spark plugs.

VALVE GUIDES AND SEATS, REPAIRS

Measure clearance between valve stem and guide as
follows: See Engine Specifications for maximum
clearances. If clearance is more than maximum
amount, oversize valves or new valve guides must
be installed. Use a reamer of correct size when
installing new valve guides. Use normal service

8
0600 SRM 1949 Cylinder Head Repair

procedures when grinding valve seats. See Engine are using. Valves must be machined to proper
Specifications for dimensions. specifications. See Figure 15.
1. Clamp a dial indicator on exhaust port side of
the cylinder head. See Figure 14.
2. Position dial indicator so that movement of
valve stem from side to side, crosswise to
cylinder head, will cause a direct movement of
dial indicator stem.
The dial indicator stem must contact side of
valve stem just above valve guide.
3. Lower valve head about 1.6 mm (0.063 in.)
below valve seat.
4. Using light pressure, move valve stem from
side to side in order to obtain valve stem-to-
guide clearance reading.
NOTE: SEAT WIDTH DIMENSION APPLIES TO THE
46° FACE ONLY.

1. CYLINDER HEAD

Figure 15. Valve Seat Specifications for Inlet and

Exhaust Valves

Replace a valve if any of the following conditions are

present:
• Valve stem is worn below specifications.
• Valve stem is bent.
• Valve face is warped.
• Any part of valve is cracked.
• Any wear or damage to valve face that cannot
be removed by resurfacing and still meet
specifications shown in Figure 16.
1. VALVE STEM
2. DIAL INDICATOR

Figure 14. Valve Steam Clearance

VALVES, REPAIR
NOTE: Before any work is performed on valve faces
and seats, make sure clearance of valve stems in
their valve guides is within specifications.
A correction for minimum wear and damage to valve
and seat can be done by a process called lapping.
When th valve seats are lapped, keep valve faces
and seats within the specifications. Make sure all of
the lapping compound is removed from the valve
and valve seat when the process is completed.
Valves with minor pits in valve faces can be Figure 16. Valve Head Measurements
machined to proper angle. There are many different
types of equipment for repairing valve faces. Follow
instructions of manufacturer of equipment that you

9
Cylinder Head Repair 0600 SRM 1949

VALVE SEATS, REPAIR • If contact line is too high, it can be made

lower by using a 30° stone.
NOTE: Before any work is done on valve faces and
• If contact line is too low, it can be raised using
seats, make sure clearance of valve stems in their the 46° stone.
valve guides is within specifications.
• If seat is too narrow, it can be made wider
Damaged valve seats can be resurfaced with a tool using a 46° stone.
that is designed to repair valve seats. There are • If seat is too wide, it can be made narrower
many different types of equipment for repairing using a 60° stone.
valve seats. Follow the instructions of the
manufacturer of the equipment that you are using. The correct dimensions for the valve seat widths
and valve/valve seat overlap are shown in
The valve seats are ground at three different angles: Figure 17. The valve seat widths are the dimensions
30°, 46°, and 60°. This method makes a valve seat of 46° face only. The valve/valve seat overlap is
that is proper width and produces the correct distance from the edge of the seat to outside edge of
contact line between the valve and valve seat. The valve.
specifications for valve seats are shown in the
Engine Specifications section and in Figure 15.

A. EXHAUST VALVE B. INTAKE VALVE

1. CYLINDER HEAD 2. VALVE

Figure 17. Valve Seat Widths and Valve/Valve Seat Overlap

VALVE SPRINGS
Measure length of valve springs. The correct length WARNING
is 51.6 mm (2.03 in.). Be careful when testing the valve springs. These
springs can come loose with enough force to
cause an injury. Always use equipment that was
designed to test springs. Always wear eye and
face protection while testing valve springs.

Use a special tool to check tension of valve springs.

Compress the spring to correct height and check

10
0600 SRM 1949 Cylinder Head Repair

tension. For correct specifications, see Figure 18. 3. Install cylinder head gasket and cylinder head.
Replace valve springs that are not within Make sure cylinder head is aligned with pins in
specifications. block.

4. Use sealant Hyster P/N 1451215 on threads of

capscrews for cylinder head. Install capscrews
as follows:

a. Tighten all capscrews to 30 N•m (22 lbf ft).

Use sequence shown in Figure 19.

b. Tighten capscrews 11, 7, 3, 2, 6, 10 an

additional 55 degrees. Tighten capscrews 12
and 13 an additional 65 degrees. Tighten
capscrews 1, 4, 8, 5, 9 an additional 75
degrees.

A. VARIATION FROM VERTICAL: LESS THAN

1.6 mm (0.063 in.)
B. FREE LENGTH: 50 mm (2.0 in.)
C. SPRING COMPRESSED TO 265 N (59.5 lbf) AT
43.2 mm (1.70 in.) CLOSED SPRING
COMPRESSED TO 718 N (161.5 lbf) AT
32.3 mm (1.27 in.) OPEN
D. INSTALLED HEIGHT INTAKE:
42.92 TO 43.43 mm (1.670 TO 1.700 in.)
EXHAUST: A. FAN END
42.92 TO 43.43 mm (1.670 TO 1.700 in.)
Figure 19. Cylinder Head Tightening Sequence
Figure 18. Valve Spring Specifications
5. Apply RTV sealant (Hyster P/N 280472) to
ASSEMBLE AND INSTALL front and rear surfaces between intake
1. Install each valve in correct port. Install oil seal manifold and engine block. See Figure 20. The
in lower groove. Install shim, damper, spring, bead of sealant must be 5 mm (0.2 in.) thick
shield, and cap or rotator. Using a spring and extend up sides of heads 13 mm (0.5 in.) to
compressor, compress assembly and install seal and retain gaskets.
retainers. Measure height of valve spring as
shown in Figure 18. Measure from top of shim
to top of retainer cap. Install shims to get
correct height shown in Figure 18. The
installed height of valve spring must not be less
than minimum height.

2. Clean surface of cylinder head and top of

cylinder block. Make sure threads in block are
clean. If threads are not clean, use a thread
chaser to clean threads.

11
Cylinder Head Repair 0600 SRM 1949

1. EXTEND BEAD 13 mm (0.5 in.) UP HEADS

(FRONT AND REAR).
2. REAR
3. FRONT
Figure 22. Install Valve Push Rod
Figure 20. Intake Manifold Sealant Locations

6. Install gaskets and intake manifold. Tighten CAUTION

capscrews in sequence shown in Figure 21.
Be sure that the arrow on the valve rocker arm
Tighten capscrews on first pass to
support is in the up position. See Figure 23.
3 N•m (27 lbf in). Tighten capscrews on second
pass to 12 N•m (106 lbf in). Tighten capscrews 8. Install valve rocker arm supports.
on final pass to 15 N•m (133 lbf in).

A. FAN END
Figure 23. Install Valve Rocker Arm Supports
Figure 21. Intake Manifold Tightening Sequence
9. Apply a molybdenum grease or equivalent to
7. Install valve push rods. See Figure 22. following valve rocker arm contact surfaces:
See Figure 24.
• Valve push rod socket

12
0600 SRM 1949 Cylinder Head Repair

• Roller pivot
• Valve stem tip

1. BOLT AT LOCATION 1
2. BOLT AT LOCATION 2
3. BOLT AT LOCATION 3
1. VALVE PUSH ROD SOCKET
2. ROLLER PIVOT Figure 25. Install Valve Rocker Arm Assemblies
3. VALVE STEM TIP
4. ROCKER ARM BOLT 11. Rotate crankshaft balancer to position
crankshaft balancer alignment mark 57 to 63
Figure 24. Lubricate Valve Rocker Arm Surfaces degrees clockwise or counterclockwise from
engine front cover alignment tab. See
10. See Figure 25. Install valve rocker arm Figure 26.
assemblies as follows:

a. Finger start rocker arm bolt at location 1 in

Figure 25.

b. Finger start rocker arm bolt at location 2 in

Figure 25.

c. Finger start rocker arm bolt at location 3 in

Figure 25.

d. Finger start remaining three valve rocker

arm bolts.

1. CRANKSHAFT BALANCER ALIGNMENT MARK

2. ENGINE FRONT COVER ALIGNMENT TAB

Figure 26. Rotate Crankshaft Balancer

13
Engine Block Cleaning and Inspection 0600 SRM 1949

NOTE: Once valve rocker arm assemblies are 14. Install spark plugs.
installed and properly torqued, no additional valve
lash adjustment is required. 15. Install throttle body, air cleaner, and
distributor. Install brackets for drive belt
12. Tighten valve rocker arm bolts to
tensioner and alternator. Install drive belt(s).
30 N•m (22 lbf ft). See Figure 24.
16. Install exhaust manifolds. Tighten capscrews
13. Use new gasket and install valve covers. Install
in two steps; first to 15 N•m (133 lbf in), then
new grommets on capscrews and install
to 31 N•m (274 lbf in). If used, bend lock tabs
capscrews into valve covers. Tighten capscrews
against heads of capscrews.
to 12 N•m (107 lbf in). See Figure 27.
17. Install coolant hose to housing for thermostat
and tighten hose clamp. Fill coolant system
with coolant. See Periodic Maintenance for
your lift truck.

1. CAPSCREW
2. ROCKER COVER
3. CYLINDER HEAD

Figure 27. Valve Cover Installation

Engine Block Cleaning and Inspection

CLEAN AND INSPECT
WARNING
Cleaning solvents can be flammable and toxic and
CAUTION
can cause skin irritation. When using cleaning
To prevent possible gouging of the engine block solvents, always follow the solvent manufacturer's
surfaces, use care when removing gasket and recommended safety procedures.
sealing material.
2. Clean engine block with solvent.
1. Clean all remaining sealing or gasket material
from sealing surfaces. 3. Flush engine block with water or steam.

14
0600 SRM 1949 Engine Block Cleaning and Inspection

CAUTION
Clean all, debris and coolant from the engine block
cylinder head bolt holes. Failure to do so may
result in damaged threads, improperly tightened
fasteners or damage to components.

4. Clean following engine block components:

• Cylinder bores
• Oil galleries and oil passages
• Scale and deposits from coolant passages
• Engine block cylinder head bolt holes.

5. After cleaning engine block, spray or wipe

cylinder bores and machined surfaces with
clean engine oil.

6. Inspect following areas, see Figure 28:

• Coolant jackets for cracks.
• Cylinder bores for scratches or gouging.
• Valve lifter bores for excessive scoring or
wear.
• Threaded holes for damage
• Crankshaft bearing webs for cracks
• Crankshaft bearing caps and bores for
damage
Crankshaft bearing bores should be 1. COOLANT JACKET
round and uniform when measuring 2. CYLINDER BORE
inside diameter (ID). 3. VALVE LIFTER BORES
The surface where crankshaft bearings 4. THREADED HOLES
contact crankshaft bearing bore should 5. CRANKSHAFT BEARING WEBS
6. CRANKSHAFT BEARING CAPS
be smooth. 7. CRANKSHAFT BEARING BORES
If a crankshaft bearing cap is damaged 8. ENGINE BLOCK HOLE PLUG BORE
and requires replacement, replace 9. ENGINE BLOCK
bearing cap first, then re-bore engine 10. ENGINE MOUNT BOSSES
block crankshaft bearing bores and check
for proper alignment. Finally, check Figure 28. Engine Block Inspection
crankshaft for proper clearances.
7. Measure cylinder bores for taper and out-of-
• Engine block core hole plug for damage
round. See Figure 29.
• Engine block for cracks for damage
• Engine mount bosses for damage

15
Piston Bore Preparation 0600 SRM 1949

Legend for Figure 29.

1. PISTON CYLINDER BORE

2. BORE MEASURING DEVICE

Figure 29. Cylinder Bore Taper and Out-of-Round

Inspection

Piston Bore Preparation

NOTE: It is important that piston bores are
prepared correctly before new piston rings are
installed. Incorrect preparation can cause parts to
wear quickly.
Use a hone in piston bores when installing new
rings. Use hone as follows:

1. Use a hone with a 280-grit stone. Make sure

stone is clean and will not damage bore.

2. Move hone quickly (approximately 60 times per

minute) up and down in bore. Make sure hone
makes a cross pattern of 45 to 60 degrees. Use
hone until entire length of bore has this
pattern. See Figure 30.

3. After using hone, clean cylinder block with hot

water and detergent. Make sure all metal
particles are removed from block. Dry bores
and lubricate them with engine oil. 1. CYLINDER BORE
2. HONING PATTERN

Figure 30. Correct Honing Pattern

16
0600 SRM 1949 Engine Mounts Installation

Engine Mounts Installation

REMOVE INSTALL
1. Remove six capscrews and support bracket 1. Using four capscrews, install motor mount on
from motor mounts. See Figure 31. engine. Tighten capscrews to
90 N•m (66 lbf ft). See Figure 31.
2. Remove four capscrews and motor mount from
engine. See Figure 31. 2. Repeat Step 1 to install motor mount on
opposite side of engine.
3. Repeat Step 2 to remove motor mount on
opposite side of engine. 3. Using six capscrews, install support bracket on
motor mount. Tighten capscrews to
CLEAN AND INSPECT 90 N•m (66 lbf ft). See Figure 31.

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.

WARNING
Compressed air can move particles so they cause
injury to the user or to other personnel. Make sure NOTE: EXHAUST MANIFOLD NOT SHOWN FOR
the path of the compressed air is away from all CLARITY.
personnel. Wear protective goggles or a face
shield to prevent injury to the eyes. 1. MOTOR MOUNT
2. CAPSCREW
Clean all components with cleaning solvent and dry 3. SUPPORT BRACKET
with compressed air.
Figure 31. Engine Mount Removal
Inspect support bracket and motor mounts for
cracks or other damage. If damaged, replace.

Lubrication System Repair

OIL PUMP, REMOVE AND DISASSEMBLE
1. Remove oil pan capscrews, nuts, and gasket
from engine. Discard gasket. See Figure 32.

17
Lubrication System Repair 0600 SRM 1949

1. CAPSCREW
2. OIL PUMP ASSEMBLY
3. ENGINE
4. DRIVE SHAFT RETAINER
1. CAPSCREW 5. DRIVE SHAFT
2. NUT
3. OIL PAN Figure 33. Oil Pump Removal
4. GASKET
5. ENGINE
6. THREADED STUD 3. Remove cover for oil pump. Put marks on gear
teeth to show their correct location during
Figure 32. Oil Pan Removal assembly. See Figure 34.

2. Remove capscrew at mount for pump. Remove 4. Do not remove tube and screen assembly unless
oil pump assembly from engine. Remove drive it is damaged. The tube and screen must be
shaft retainer and drive shaft from oil pump replaced as an assembly.
assembly. See Figure 33.
5. Remove and discard retaining pin, pressure
relief spring, and pressure relief valve from
pump cover.

18
0600 SRM 1949 Lubrication System Repair

WARNING
Compressed air can move particles so they cause
injury to the user or to other personnel. Make sure
the path of the compressed air is away from all
personnel. Wear protective goggles or a face
shield to prevent injury to the eyes.

Clean parts of oil pump and oil pan in solvent and

dry with compressed air.
Inspect oil pump for following conditions, see
Figure 35:.
• Scoring on top of gears
• Damaged Gears for following:
Chipping
Galling
Wear
• Scoring or damage to body
• Damaged or scored gear shaft(s)
• Damaged capscrew hole threads
• Worn oil pump driveshaft bore
Minor imperfections or scratches may be removed
with a fine oil stone.
1. CAPSCREW
2. SCREEN
3. DRIVEN GEAR
4. DRIVE GEAR
5. RETAINER
6. SHAFT
7. HOUSING
8. PRESSURE VALVE RELIEF SPRING
9. PRESSURE RELIEF VALVE
10. COVER
11. RETAINING PIN

Figure 34. Oil Pump Disassembly

CLEAN AND INSPECT

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.

19
Lubrication System Repair 0600 SRM 1949

1. CAPSCREW
2. SCREEN
3. DRIVEN GEAR
4. DRIVE GEAR
1. SCORED GEAR 5. RETAINER
2. DAMAGED GEAR 6. SHAFT
3. OIL PUMP BODY 7. HOUSING
4. GEAR SHAFT 8. PRESSURE VALVE RELIEF SPRING
5. CAPSCREW HOLE 9. PRESSURE RELIEF VALVE
6. DRIVESHAFT HOLE 10. COVER
11. RETAINING PIN
Figure 35. Oil Pump Inspection
Figure 36. Oil Pump Assembly
OIL PUMP, ASSEMBLE AND INSTALL
3. Use a sealant when replacement of tube and
1. Install NEW pressure relief valve and spring screen assembly is necessary. The tube and
into pump cover. Install retaining pin. See screen assembly must have a good press fit into
Figure 36. the oil pump body. Do not damage tube during
installation. Make sure surface of screen
2. Install gears in body of pump. Make sure to assembly is parallel to bottom surface of
align identification marks. Install cover for oil cylinder block. See Figure 37.
pump and tighten capscrews to
12 N•m (106 lbf in). Turn oil pump shaft to
check for smooth operation.

20
0600 SRM 1949 Lubrication System Repair

Figure 37. Oil Pump Tube and Screen Installation

4. Install oil pump shaft and NEW retainer. See

Figure 38.

5. Install oil pump assembly to engine. Make sure

shaft is aligned with slot in distributor shaft.
Tighten capscrew to 90 N•m (66 lbf ft).

1. CAPSCREW
2. OIL PUMP ASSEMBLY
3. ENGINE
4. DRIVE SHAFT RETAINER
5. DRIVE SHAFT

Figure 38. Oil Pump Installation

OIL PAN, INSTALL

1. Install oil pan as follows:

a. Apply an RTV sealant to surfaces of engine

block as shown in Figure 39.

21
Lubrication System Repair 0600 SRM 1949

A. FAN END

Figure 39. Sealant Application

b. Install gasket and oil pan. Make sure

vertical surfaces at back of engine block and
oil pan are even. See Figure 40.
1. CAPSCREW
2. NUT
3. OIL PAN
4. GASKET
5. ENGINE
6. THREADED STUD

Figure 40. Oil Pan Installation

c. Tighten capscrews and nuts for oil pan in

sequence shown in Figure 41 to
25 N•m (221 lbf in).

22
0600 SRM 1949 Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters

Figure 41. Oil Pan Tightening Sequence

Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters

TIMING COVER 3. Remove crankshaft position sensor from timing
cover. See Figure 43.
Remove
1. Remove fan assembly and belts.

2. Remove crankshaft pulley and vibration

damper. See Figure 42. Use a tool that pulls on
center of vibration damper. DO NOT pull on
outside diameter of vibration damper.

1. CRANKSHAFT POSITION SENSOR BOLT

2. CRANKSHAFT POSITION SENSOR
3. TIMING COVER

Figure 43. Crankshaft Position Sensor

4. Remove capscrews and stud for timing cover.

Remove timing cover from engine. See
1. TIMING COVER Figure 44.
2. VIBRATION DAMPER
3. TOOL FOR REMOVING VIBRATION DAMPER

Figure 42. Timing Cover

23
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 0600 SRM 1949

Install
NOTE: The plastic timing cover can be used only
once. When engine has a plastic timing cover,
always install a new one.
1. Install crankcase position sensor reluctor ring
on crankshaft. See Figure 45. Make sure open
side of seal is toward inside of cover.

2. During installation of cover, use a special tool

to align oil seal with crankshaft. The vibration
damper will damage oil seal if it is not installed
correctly. Tighten capscrews for cover to
12 N•m (106 lbf in). See Figure 44.

3. Install crankshaft position sensor. Tighten

crankshaft position sensor bolt to
8 N•m (71 lbf in). See Figure 43.

4. Lubricate lips of seal with clean engine oil

1. TIMING COVER
2. ENGINE before vibration dampener is installed. Use a
special tool to push vibration damper onto
Figure 44. Timing Cover crankshaft. See Figure 46. Tighten capscrew
for damper to 95 N•m (70 lbf ft).
5. Remove crankshaft position sensor reluctor
ring from crankshaft. See Figure 45. 5. Install crankshaft pulley, belts, and fan
assembly.

1. SPECIAL TOOL
2. VIBRATION DAMPER

Figure 46. Timing Cover

1. CRANKSHAFT POSITION SENSOR RELUCTOR
RING TIMING CHAIN AND SPROCKETS
2. CRANKSHAFT
Remove
Figure 45. Crankshaft Position Sensor Reluctor
Ring 1. Remove timing covers described in section
Timing Cover, Remove.

24
0600 SRM 1949 Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters

2. Before removing the timing chain and • Measure the slack of camshaft timing chain.
sprockets, perform the following: See Figure 47. If the timing chain can be
moved back and forth more than
• Clean components with cleaning solvent. 11 mm (0.43 in.), installing a new chain and
• Dry components with compressed air. sprockets durring assembly is recommended.
• Inspect camshaft timing chain for binding or
wear. See Figure 47.
• Rotate camshaft sprocket counterclockwise
untill all slack is removed from the camshaft
timing chain.

A. TIMING MEASURMENT B. TIMING GEAR COMPONENTS

1. TIMING MARKS 5. TIMING CHAIN

2. GUIDE 6. CAMSHAFT SPROCKET
3. BOLT 7. CRANKSHAFT SPROCKET
4. GUIDE 8. SPROCKET CAPSCREW

Figure 47. Timing Marks

3. Remove bolt from guides. Remove guides from Install

engine block.
1. If removed, install crankshaft sprocket. Install
NOTE: Ensure timing chain is removed with timing chain on camshaft sprocket. Install
sprockets. camshaft sprocket with chain. Make sure
marks are aligned as shown in Figure 47. The
4. Remove capscrews and camshaft sprocket, and number 4 cylinder will be at top dead center
timing chain. See Figure 47 (TDC) on the compression stroke. Tighten
capscrews to camshaft sprocket to
5. Use a puller to remove crankshaft sprocket, if 28 N•m (21 lbf ft).
damaged. See Figure 47.

25
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 0600 SRM 1949

2. Lubricate chain and sprockets with new engine

oil. Tighten shaft retainer bolt. Install timing
cover as described in section for Timing Cover,
Install.

CAMSHAFT
Remove
1. Remove intake manifold, push rods, lifter
guides, and valve lifters.

2. Remove timing cover as described in section

Timing Cover, Remove. Align timing marks.
Remove timing chain, sprockets, and camshaft
retainer. 1. TOOL FOR CAMSHAFT BEARINGS

3. Install two or three 5/16-18 capscrews that are Figure 49. Camshaft Bearings
100 to 125 mm (4 to 5 in.) long into camshaft.
See Figure 48. These capscrews will make the Inspect
camshaft easier to control. Carefully rotate the
camshaft and remove camshaft from cylinder Inspect entire camshaft for any signs of wear or
block. All camshaft bearings are the same size. damage. Measure diameter of each bearing surface
Do not damage bearings or camshaft during on camshaft. Do measurement at different positions
removal. on surface of the bearing to see if they are round. If
the difference of the readings for each bearing is
more than 0.025 mm (0.001 in.), replace camshaft.
Check for a bent camshaft or excessive camshaft
runout. If runout exceeds 0.065 mm (0.0026 in.),
replace camshaft.

Install
NOTE: Camshaft bearings are numbered 1-4
starting at the fan end of the engine.
NOTE: Camshaft bearings 4 and 1 must be
installed first. They will serve as a guide for
installation of bearings 2 and 3.
1. Use a special tool as shown in Figure 49 to
install camshaft bearings. Use a sealant on
rear camshaft plug and install plug in block.
Figure 48. Camshaft Make sure plug is even with or
0.80 mm (0.03 in.) below surface of block.
4. If necessary, use a special tool as shown in
Figure 49 to remove camshaft bearings. a. Install number 4 camshaft bearing on
Remove front and rear bearings last. installation tool. Orient bearing so that
lubrication hole in camshaft bearing bore at
rear of engine block and camshaft bearing
are aligned. Install camshaft bearing into
engine block. Remove installation tool from
bearing.

26
0600 SRM 1949 Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters

b. Install number 1 camshaft bearing on

installation tool. Orient bearing so that
lubrication hole in camshaft bearing bore at
front of engine block and camshaft bearing
are aligned. Install camshaft bearing into
engine block. Remove installation tool from
bearing.

c. Slide installation tool into engine block until

installation tool is located between number 2
and 3 camshaft bearing positions. Install
number 3 camshaft bearing on installation
tool. Orient bearing so that lubrication hole
in camshaft bearing bore at front of engine
block and camshaft bearing are aligned.
Install camshaft bearing into engine block.
Remove installation tool from bearing.
1. RETAINER
d. Slide installation tool into engine block until 2. CAMSHAFT
installation tool is located between number 2
and 1 camshaft bearing positions. Install Figure 50. Camshaft and Retainer
number 2 camshaft bearing on installation
tool. Orient bearing so that lubrication hole 5. Install timing sprockets, chain, and cover as
in camshaft bearing bore at front of engine described in procedures for Timing Cover.
block and camshaft bearing are aligned.
6. Lubricate valve lifters with a molybdenum
Install camshaft bearing into engine block.
lubricant. Install lifters in block. Install push
Remove installation tool from engine block.
rods and adjust valve mechanism.
2. Lubricate camshaft lobes with a molybdenum
lubricant. Lubricate camshaft bearings with BALANCE SHAFT
engine oil. Install two or three 5/16-18 Remove
capscrews that are 100 to 125 mm (4 to 5 in.)
long into camshaft. See Figure 48. These 1. Remove intake manifold.
capscrews will make camshaft easier to control.
Carefully install camshaft in cylinder block. 2. Remove retainer for lifters.

3. Lubricate and install retainer for camshaft. 3. Remove timing cover as described in section
Tighten capscrews to 12 N•m (106 lbf in). See Timing Cover.
Figure 50.
4. Remove timing chain, sprocket, and balance
4. Install gear for balance shaft as described in shaft drive gear from camshaft. See Figure 51.
procedures for Balance Shaft.
5. Remove driven gear from balance shaft.
Remove retainer. See Figure 51.

6. Remove timing chain guide plate and timing

chain guide (not shown).

7. Use a soft-faced hammer to remove balance

shaft. See Figure 52.

NOTE: The balance shaft and front bearing are

serviced as a unit.
8. Use a special tool to remove rear bearing.

27
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 0600 SRM 1949

Install
1. Lubricate rear bearing with new engine oil. Use
a special tool to push rear bearing into block.
See Figure 51 and Figure 53.

A. FRONT

1. HAMMER
2. BEARING DRIVER

Figure 53. Balance Shaft Installation

2. Lubricate front bearing with new engine oil.

Use a driver to install balance shaft into engine
block.

3. Install retainer for balance shaft. Tighten

1. CAMSHAFT SPROCKET
2. BALANCE SHAFT DRIVE GEAR screws for retainer to 12 N•m (106 lbf in).
3. BALANCE SHAFT DRIVEN GEAR
4. BALANCE SHAFT 4. Install balance shaft driven gear onto balance
5. RETAINER shaft. Tighten bolt to 20 N•m (177 lbf in), plus
an additional 35 degrees of rotation. Rotate
Figure 51. Balance Shaft Components balance shaft by hand to make sure there is
clearance between retainer and shaft. If the
balance shaft does not rotate freely, check that
retaining ring on front bearing is in its seat.

5. Temporarily install balance shaft drive gear on

camshaft. Turn camshaft until timing mark on
balance shaft drive gear is in the straight up
(12:00 O'clock) position. Remove balance shaft
drive gear and rotate balance shaft until mark
on balance shaft driven gear is in the straight
down (6:00 O'clock) position. Install balance
shaft drive gear on camshaft. Make sure timing
marks are aligned in the position shown in
Figure 54.
A. FRONT 6. Install timing chain guide plate and timing
chain guide. Tighten timing chain guide bolt to
Figure 52. Balance Shaft Removal
12 N•m (106 lbf in).

28
0600 SRM 1949 Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters

7. Install timing chain and sprocket on camshaft. 3. The push rods must be removed as described in
Make sure timing marks are in the position Cylinder Head Repair, Remove and
shown in Figure 47. Tighten capscrews that Disassemble.
attach sprocket to camshaft to
25 N•m (18 lbf ft). 4. Remove valve lifter push rod guide.

8. Install timing cover as described in section NOTE: Valve lifters must be placed in the rack in
Timing Cover. upright position to maintain oil in valve lifters.
5. Remove valve lifters. Put lifters in a rack so
they can be installed in their original positions.

Clean and Inspect

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.

WARNING
Compressed air can move particles so they cause
1. ALIGNMENT OF TIMING MARKS injury to the user or to other personnel. Make sure
2. BALANCE SHAFT DRIVEN GEAR, the path of the compressed air is away from all
3. BALANCE SHAFT DRIVE GEAR personnel. Wear protective goggles or a face
shield to prevent injury to the eyes.
Figure 54. Balance Shaft Timing Marks
1. Clean all parts in a cleaning solvent and dry
9. Make sure all lifters and guides for lifters are
with compressed air.
properly installed. Install retainer for lifters.
Tighten bolts for retainer to 2. Inspect valve lifterfor following. See Figure 55:
16 N•m (142 lbf in).
• Broken or damaged clip
10. Install intake manifold as described in the • Worn push rod socket
section Cylinder Head Repair, Assemble and
• Scuffed or worn lifter body
Install.
If valve lifter shows scuffing or wear,
VALVE LIFTERS inspect engine block valve lifter bores for
wear.
Remove • Worn roller
1. The valve lifters normally do not need repair If valve lifter roller is worn or damaged,
unless they become dirty, causing them to inspect camshaft lobe for wear and
malfunction or the roller does not operate damage.
properly. The valve lifters must be clean to • Loose or damaged pin
operate correctly. If a valve lifter must be • Plugged oil hole
disassembled, make sure small parts are
handled carefully to prevent loss or damage.

2. Remove air bonnet, distributor, and intake

manifold.

29
Crankshaft Repair 0600 SRM 1949

1. CLIP
2. PUSH ROD SOCKET
3. VALVE LIFTER BODY
4. ROLLER
5. PIN
6. OIL HOLE

Figure 55. Valve Lifter Inspection

3. If any parts are damaged or worn, complete

hydraulic valve lifter must be replaced.

Install
1. Lubricate all roller and valve lifter surfaces
with new engine oil. Install valve lifters in their
original positions. Install valve lifter push rod
guide. Tighten valve lifter push rod guide bolts 1. CYLINDER BLOCK
2. VALVE LIFTER
to 16 N•m (142 lbf in). See Figure 56. 3. VALVE LIFTER PUSH ROD GUIDE

Figure 56. Valve Lifter Installation

2. Install push rods as described in Cylinder Head

Repair, Assemble and Install.

Crankshaft Repair
REMOVE 3. Mark caps for connecting rods so they can be
installed in their correct locations. Remove caps
1. Remove oil pan, oil pump, and flywheel. and bearing inserts for connecting rods. Make
sure all parts from each rod assembly remain
2. Remove timing cover as described in procedure
together.
Timing Cover, Remove.

30
0600 SRM 1949 Crankshaft Repair

4. Mark caps for main bearings so they can be

installed in their correct locations. Remove caps
for main bearings. Make sure all parts from
each bearing assembly remain together.

5. Remove crankshaft with extreme care to

prevent damage to journals and thrust flanges
of crankshaft.

INSPECT AND REPAIR

WARNING
Commercial cleaning solvents can be flammable
and toxic and can cause severe skin irritation.
When using commercial cleaning solvents, always
comply with the solvent manufacturer's
recommended safety precautions.
Compressed air can move particles so they cause
injury to the user or to other personnel. Make sure
the path of the compressed air is away from all
personnel. Wear protective goggles or a face
shield to prevent injury to the eyes.

1. Clean crankshaft with solvent and dry it with

Figure 57. Crankshaft Inspection
compressed air. Make sure oil passages are not
plugged. 5. If crankshaft journals must be repaired, they
can be ground to following diameters smaller
2. Inspect crankshaft for cracks or other damage.
(undersize) than original size:
3. Inspect bearing journals and thrust surfaces for 0.254 mm (0.010 in.)
scratches or damage caused by a lack of 0.508 mm (0.020 in.)
lubrication.
NOTES ABOUT MAIN BEARINGS: Main
4. Inspect crankshaft for wear and damage. See bearings are an insert bearing that do not use shims
Figure 57. Use a micrometer to measure for adjustment. Main bearings are available in a
journals for bearings of crankshaft. Do standard size and the following undersizes:
measurement at different positions to see if 0.0254 mm (0.001 in.), 0.0508 mm (0.002 in.),
surface of bearing is round. The correct sizes 0.2286 mm (0.009 in.), 0.254 mm (0.010 in.), and
are given in Engine Specifications section. 0.508 mm (0.020 in.). If a bearing on a journal is
worn, both upper and lower half of the bearing must
be replaced.
When crankshaft is assembled by manufacturer,
main bearings are specially selected to obtain close
tolerances. For this reason, you can find one-half of
a standard size insert with one-half of a
0.0254 mm (0.001 in.) undersize insert. This
combination will decrease the clearance
0.0127 mm (0.0005 in.) from using a full standard
bearing.
When a production crankshaft cannot be fitted with
this method, main journal is then ground
0.2286 mm (0.009 in.) undersize. Only those main

31
Crankshaft Repair 0600 SRM 1949

bearing journals that cannot be fitted with

standard, 0.0254 mm (0.001 in.), or
0.0508 mm (0.002 in.) undersize main bearing will
be ground. A 0.2286 mm (0.009 in.) and a
0.254 mm (0.010 in.) undersize bearings will be
selected as described to obtain close tolerances.
A production crankshaft that has been ground will
have the following identification:
• The crankshaft journal that has been ground
will have a 9 marked in the metal of
crankshaft next to journal. A spot of light
green paint is also added to crankshaft.
• The main bearing cap is also marked with Figure 58. Plastigage on Bearing Journal®
green paint.
5. Install main bearing cap and tighten
HOW TO CHECK CLEARANCE BETWEEN capscrews. See Torque Specifications. The
MAIN BEARINGS AND THEIR JOURNALS capscrews must be tightened to their final
torque or there will be an error in the
1. Use Plastigage® or equivalent to check
measurement.
clearance. The procedure is similar for both
connecting rod bearings and main bearings. If 6. Remove main bearing cap. The Plastigage® will
engine has been removed from lift truck, put
be compressed and wider and will adhere to
engine so crankshaft is up. The weight of
either bearing or its journal. Use scale on
crankshaft is against upper bearing half and
total clearance can be measured correctly. If envelope for Plastigage® to measure width of
engine is still in lift truck, crankshaft must plastic at its widest point. The scale will
have a support to remove any additional indicate clearance in millimeters or
clearance between upper bearing half and its thousandths of an inch. See Figure 59.
journal.

2. All main bearing caps must be installed and

their capscrews tightened to specifications.

3. Check rear main bearing first. Remove cap for

rear main bearing. The procedure for checking
clearance of other bearings is similar.

4. Clean oil from bearing half and journal to be

checked. Put a piece of Plastigage across full
width of bearing journal as shown in Figure 58.
Do not rotate crankshaft when Plastigage is
between main bearing and its journal.
Figure 59. Measuring Plastigage on Bearing
Journal®

7. If clearance is greater than specifications,

select a new undersize bearing set and install
it. Measure clearance again. If clearance cannot
meet specifications with available undersize
bearings, bearing journal must be ground to a
new undersize. If bearing journal is already at
maximum undersize, crankshaft must be
replaced.

32
0600 SRM 1949 Crankshaft Repair

8. If clearance is within specifications, lubricate NOTE: With use of special tools, main bearings and
bearing with engine oil and install main rear crankshaft seal (two-piece) can be replaced
bearing and bearing cap. Tighten capscrews on without removing crankshaft.
main bearing cap to correct specifications.
2. Install main bearings in cylinder block and
bearing caps. Lubricate bearings with engine
9. Turn crankshaft to make sure it rotates
oil and carefully install crankshaft in cylinder
smoothly.
block.
10. Check axial clearance between rear main
3. Install bearing caps. Make sure arrows on
bearing and thrust surface. Push crankshaft
bearing caps are toward front (fan end) of
forward. See Figure 60. Measure clearance
engine. Push crankshaft forward and measure
between crankshaft and thrust surface of rear
clearance at front side of rear main bearing.
bearing. See Engine Specifications for correct
The correct clearance is
clearances.
0.050 to 0.20 mm (0.002 to 0.008 in.). See
Figure 60.

4. Tighten capscrews for bearing caps to

70 N•m (52 lbf ft). Move crankshaft forward
and backward to align rear main bearing.
Tighten capscrews for all bearing caps to
106 N•m (78 lbf ft). On late model engines,
tighten capscrews for bearing caps to
20 N•m (177 lbf in) on the first pass. Move
crankshaft forward and backward to align rear
main bearing. Tighten capscrews for all bearing
caps an additional 73 degrees on the final pass.

5. Install connecting rods, oil pump, and oil pan.

Install flywheel and other parts.

6. Install seal in retainer. Use new gasket and

install seal retainer. See Figure 61. Tighten
A. FAN END
screws and nut to 15 N•m (133 lbf in).
1. MEASURE CLEARANCE

Figure 60. Measuring Crankshaft Axial Clearance

INSTALL
1. On engines with a two-piece rear seal, install
seal halves so lips are toward fan end of engine.
Apply sealant to ends of seal halves. Apply
engine oil to seal during installation. Do not get
any oil on ends of seal.

33
Piston and Connecting Rod Assemblies Repair 0600 SRM 1949

A. SEAL REMOVAL NOTCHES

1. CRANKSHAFT 5. GASKET
2. OIL SEAL 6. STUD
3. SEAL RETAINER 7. SCREW
4. ENGINE BLOCK 8. NUT

Figure 61. Rear Seal Installation

Piston and Connecting Rod Assemblies Repair

CONNECTING ROD BEARINGS, REPLACE 3. Push connecting rod away from crankshaft and
remove upper bearing half. Wipe oil from
NOTE: Connecting rod bearings are insert bearings bearing halves and bearing journal. Make sure
that do not use shims for adjustment. These all parts from each rod assembly remain
bearings are available in a standard size and the together.
following undersizes: 0.025 mm (0.001 in.),
0.051 mm (0.002 in.), 0.254 mm (0.010 in.), and 4. Use a micrometer to measure bearing journal.
0.508 mm (0.020 in.). If a bearing on a journal is The bearing journal must be within the
worn, both upper and lower half of bearing must be following specifications:
replaced.
Out-of-round less than 0.0254 mm (0.001 in.)
1. Remove oil pan and oil pump.
Taper less than 0.0254 mm (0.001 in.)
2. Mark caps for connecting rods so they can be
installed in their correct locations and
positions.

34
0600 SRM 1949 Piston and Connecting Rod Assemblies Repair

If bearing journals are not within

specifications, crankshaft must be removed and
bearing journal ground to an undersize. If
bearing journal cannot be repaired so bearing
journal is a correct undersize, crankshaft must
be replaced. See Engine Specifications,
Crankshaft.

5. If bearing journal is within specifications,

measure clearance between new bearing and
crankshaft. Use Plastigage® or equivalent to
check clearance:

a. Put a piece of Plastigage across the full Figure 63. Measuring Plastigage on Bearing
width of the bearing journal as shown in Journal
Figure 62. Do not rotate crankshaft when
Plastigage is between bearing and its d. If clearance is greater than specifications,
journal. select a new undersize bearing set and
install it. Measure clearance again. If
b. Install bearing cap and tighten connecting clearance cannot meet specifications with
rod bolts first to 27 N•m (240 lbf in) and available undersize bearings, bearing journal
then an additional 70 degrees. must be ground to a new undersize. If
bearing journal is already at maximum
c. Remove bearing cap. The Plastigage will be undersize, crankshaft must be replaced.
compressed and wider and will adhere to
either bearing or its journal. Use scale on e. If clearance is within specifications, lubricate
envelope for Plastigage to measure width of bearing with engine oil and install bearing
plastic at its widest point. The scale will and bearing cap. First tighten connecting rod
indicate the clearance in millimeters or bolts on bearing caps to 27 N•m (240 lbf in).
thousandths of an inch. See Figure 63. After this step, tighten connecting rod bolts
an additional 70 degrees.

6. When all rod bearings have been replaced, use

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

a. Use a hammer to lightly hit connecting rod

parallel to crankshaft journal to make sure
there is clearance.

b. Measure side clearance between caps for

connecting rods and crankshaft. See
Figure 64 and Engine Specifications.

Figure 62. Plastigage on Bearing Journal

35
Piston and Connecting Rod Assemblies Repair 0600 SRM 1949

tolerances. Use a tool made to clean the grooves

of the piston rings. DO NOT use a wire brush to
clean a piston.

1. Remove piston rings from pistons.

2. Use a press to remove piston pins from piston.

See Figure 65.

Figure 64. Measuring Connecting Rods Side

Clearance

PISTON AND CONNECTING ROD

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

2. Remove cylinder head as described in Cylinder

Head Repair, Remove and Disassemble.

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

ridge can be worn in top of cylinder. This ridge
can be removed with a ridge reamer tool. Turn
crankshaft to lower piston to bottom of stroke
in its cylinder. Put cloth on top of piston for a
collector of metal particles. Use a ridge reamer
to remove ridge at top of cylinder.

4. Clean carbon from top of each cylinder.

5. Put an identification mark on top of each

piston.

6. Remove caps and bearings from each Figure 65. Piston Pin Removal
connecting rod. Keep caps and bearings with
their original piston assemblies. Mark caps so PISTON, CLEAN AND INSPECT
they will be installed again in their original
positions. DO NOT mix parts.
WARNING
7. Push connecting rod and piston from cylinder. Commercial cleaning solvents can be flammable
Temporarily install bearing cap on connecting and toxic and can cause severe skin irritation.
rod to keep parts together. When using commercial cleaning solvents, always
comply with the solvent manufacturer's
DISASSEMBLE recommended safety precautions.
Compressed air can move particles so they cause
injury to the user or to other personnel. Make sure
CAUTION the path of the compressed air is away from all
The pistons are aluminum alloy and can be personnel. Wear protective goggles or a face
damaged if they are hit with a hard object. The shield to prevent injury to the eyes.
grooves for the piston rings are machined to close

36
0600 SRM 1949 Piston and Connecting Rod Assemblies Repair

1. Use solvent to clean pistons and connecting must have a new bore. A tool called a hone can be
rods. Use compressed air to dry parts. used to remove a small amount of taper from a
cylinder bore. Use a boring machine to repair a
2. Clean piston ring grooves with a ring groove badly worn cylinder. The boring machine will make
cleaning tool. a more accurate cylinder bore. The hone is then
used to finish surface of cylinder bore.
3. Clean piston oil lubrication holes and slots.

4. Inspect pistons for wear, cracks, and damage.

Replace a piston that is worn or damaged.

NOTE: If cylinder bore must be repaired, piston

must be changed to correct oversize. Check
clearance of piston in its cylinder after surface of
cylinder bore has been finished with a hone.
5. Check clearance of piston pin in piston. The
normal clearance is shown in Engine
Specifications. The piston pin will normally fall
from the hole in piston by its own weight. The
piston pin is a press fit in connecting rod. The Figure 67. Pattern for Normal Cylinder Wear
piston and piston pin are a matched set and
must be replaced as a unit if clearances are A cylinder bore that has been repaired with a hone
greater than specifications. or a boring machine must be fitted with a piston
that is correct size. Measure outer diameter of
CYLINDER BORES, INSPECT AND piston and inner diameter of cylinder bore as shown
REPAIR in Figure 68. Using different oversize pistons in
engine does not affect dynamic balance of engine.
Inspect cylinder bores for wear and damage.
Replacement pistons from standard size to
Measure cylinder bores in several positions as
0.508 mm (0.020 in.) oversize normally have same
shown in Figure 66. Measure cylinder bore at right
weight. The clearance specifications between a
angles to centerline to find any distortion from
piston and its cylinder bore is shown in Engine
wear. A cylinder that is out-of-round greater than
Specifications.
0.05 mm (0.002 in.) must be repaired.
PISTON RINGS
NOTE: Check clearance of piston rings in cylinder
after surface of cylinder has been finished with a
hone. New piston rings are available for the
following piston sizes: standard size, and
0.127 mm (0.005 in.), 0.254 mm (0.010 in.),
0.508 mm (0.020 in.), and 0.762 mm (0.030 in.)
oversize. The piston rings must match the size of
the piston on which they are installed. Check side
clearance and end clearance of piston rings as
described in the following paragraphs.
Each compression ring has a mark on one surface.
This mark must be toward the top of cylinder when
Figure 66. Cylinder Bore Measurement
piston ring is installed. The No. 1 compression ring
Measure cylinder bore in positions from top to normally has a chrome or molybdenum surface.
bottom to find any taper from wear. A normal wear
pattern for a cylinder bore is shown in Figure 67. A
cylinder that has a taper (measurement A that is
0.127 mm (0.005 in.) greater than measurement B)

37
Piston and Connecting Rod Assemblies Repair 0600 SRM 1949

Figure 69. Piston Ring and Groove Clearance

A. PISTON GAUGE POINT Check
B. BORE GAUGE POINT

Figure 68. Piston and Cylinder Bore Gauge Points

The oil control ring has three pieces. There are two
thin steel rings separated by a spacer.

1. Measure clearance between piston ring and

groove in piston as shown in Figure 69. The
clearances are shown in Engine Specifications.
Replace piston if clearances are greater than
specifications.

2. Measure end clearance of each piston ring as

shown in Figure 70. The end clearances are
shown in Engine Specifications. Install piston
Figure 70. Piston Rings End Clearance Check
ring into cylinder where it will be used. Use a
thickness gauge to measure the amount of end
clearance. Replace piston if clearances are
ASSEMBLE
greater than specifications. NOTE: There are notches cast in top of all pistons
to indicate correct assembly and installation. The
pistons must always be installed with this notch
toward fan end of engine. See Table 1.
The connecting rods have a notch cast in the
bearing journal as shown in Figure 71. This notch
must be opposite notch on top of piston when piston
and connecting rod are assembled. On later engines

38
0600 SRM 1949 Flywheel and Flywheel Housing Repair

flanges on connecting rods and caps should face to

front of engine on left bank and to rear of engine on Table 1. Piston Rings Arrangement on Piston
right bank.
A Position of Gap for Fan End of Engine
Spacer of Oil Ring
B Position of Gap for
Oil Ring
C Position of Gap for
Second Compression
Ring
D Position of Gap for
First Compression
Ring

PISTON AND CONNECTING ROD

ASSEMBLIES, INSTALL
1. NOTCHES ON ROD OPPOSITE NOTCH IN 1. Lubricate assembly with engine oil during
PISTON installation. Arrange piston rings on piston as
shown in Table 1. Install ring compressor on
Figure 71. Connecting Rod Identification piston.
1. Assemble connecting rod to piston. Make sure 2. Make sure notch in piston is toward fan end of
orientation of connecting rod and piston are engine. Install piston and connecting rod
correct as described in NOTE above. Use a assemblies in cylinder bores.
press to install piston pin into piston and
connecting rod. Lubricate piston pin with 3. Install bearings and caps for connecting rods.
engine oil during installation. Tighten nuts. See the procedure in Connecting
Rod Bearings, Replace.
2. Check clearances of piston rings as described in
Piston Rings. Install piston rings on piston as 4. Check side clearance of each connecting rod
shown in Table 1. after bearing cap is installed. See the procedure
in Connecting Rod Bearings, Replace.

5. Install cylinder head as described in Cylinder

Head Repair, Assemble and Install.

6. Install oil pump and oil pan.

Flywheel and Flywheel Housing Repair

FLYWHEEL, REMOVE
1. Remove six flywheel capscrews and flywheel
from engine.

2. Remove bearing from flywheel.

3. Remove nine flywheel housing capscrews and

flywheel housing from engine. See Figure 72.

39
Flywheel and Flywheel Housing Repair 0600 SRM 1949

• Stress cracks around flywheel-to-crankshaft

bolt hole locations
• Welded areas that retain ring gear onto
flywheel for cracking, if present
• Damaged ring gear teeth
• Damaged bearing

1. FLYWHEEL HOUSING CAPSCREW

2. FLYWHEEL CAPSCREW
3. FLYWHEEL
4. FLYWHEEL HOUSING
5. FLYWHEEL BEARING

Figure 72. Flywheel Removal

CLEAN

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. 1. STRESS CRACK FLYWHEEL-TO-TORQUE
CONVERTER BOLT HOLE
2. STRESS CRACK FLYWHEEL-TO-CRANKSHAFT
BOLT HOLE
WARNING 3. STRESS CRACK FLYWHEEL-TO-CRANKSHAFT
BOLT HOLE
Compressed air can move particles so they cause 4. RING GEAR TO FLYWHEEL WELD
injury to the user or to other personnel. Make sure 5. RING GEAR TEETH
the path of the compressed air is away from all
personnel. Wear protective goggles or a face Figure 73. Flywheel Inspection
shield to prevent injury to the eyes.
FLYWHEEL, INSTALL
Clean flywheel, bearing, and flywheel housing with
cleaning solvent and dry using compressed air. 1. Using nine flywheel housing capscrews, install
flywheel housing on engine. Tighten capscrews
INSPECT to 38 N•m (28 lbf ft). See Figure 72.

NOTE: DO NOT attempt to repair welded areas, if 2. Install bearing in flywheel.

present, that hold ring gear to flywheel plate. If
welded area is damaged, replace flywheel assembly. 3. Install flywheel to crankshaft, and align locator
hole to alignment pin. See Figure 74.
1. Inspect flywheel for following, see Figure 73:
• Stress cracks around flywheel-to-torque 4. Install six flywheel capscrews and tighten in
converter bolt hole locations sequence shown in Figure 74 to
• Missing balance weights 100 N•m (74 lbf ft).

40
0600 SRM 1949 Coolant Pump Repair

Legend for Figure 74.

1. FLYWHEEL
2. ALIGNMENT HOLE

Figure 74. Tightening Sequence

Coolant Pump Repair

REMOVE 3. Remove four capscrews, water pump, and two
gaskets from engine. Discard gaskets. See
1. Remove four flange head bolts and fan clutch Figure 76.
from water pump. See Figure 75.

2. Disconnect inlet hose from water pump.

1. CAPSCREW
1. FLANGE HEAD BOLT 2. WATER PUMP
2. FAN CLUTCH 3. GASKET
3. INLET HOSE 4. ENGINE
4. WATER PUMP
Figure 76. Water Pump Removal
Figure 75. Fan Clutch Removal

41
Coolant Pump Repair 0600 SRM 1949

CLEAN AND INSPECT

1. Remove all old gasket material from sealing
surfaces using care not to damage sealing
surfaces.

2. Clean all dirt and debris from water pump.

3. Inspect water pump for following (see

Figure 77):If any of above items are apparent
during inspection, replace water pump.
• Leakage or damage to housing cover
• Excessive scratches or gouging to gasket
sealing surfaces
• Leakage from water pump vent hole
A stain around vent hole is acceptable. If
leakage occurred (dripping) with engine
operating and cooling system
pressurized, replace water pump.
1. HOUSING COVER
• Damaged bolt hole threads 2. GASKET SURFACES
• Excessive side-to-side movement of water 3. VENT HOLE
pump shaft 4. BOLT HOLE THREADS
5. PUMP SHAFT
• Leakage around water inlet pipe 6. INLET PIPE
• Leakage around heater hose pipe 7. HEATER HOSE PIPE
• Restrictions within internal coolant passages Figure 77. Water Pump Inspection

INSTALL
1. Using four capscrews, install two new gaskets
and water pump on engine. Tighten capscrews
to 45 N•m (33 lbf ft). See Figure 76.

2. Connect inlet hose to water pump.

3. Using four flange head bolts, install fan clutch

on water pump. Tighten flange head bolts to
35 N•m (26 lbf ft). See Figure 75.

42
0600 SRM 1949 Thermostat Replacement

Thermostat Replacement
REMOVE THERMOSTAT OPERATION CHECK
1. Mix a solution (33% antifreeze and water).
CAUTION Heat solution to 14°C (25°F) above temperature
DO NOT operate the engine without a thermostat. indicated on top of thermostat.
The engine and cooling system can be damaged.
2. Hold thermostat with a wire and put it in
1. Remove two flange head bolts and thermostat solution. Stir solution. When operating
housing from engine. See Figure 78. correctly, thermostat will open.

2. Remove thermostat from engine. 3. Remove thermostat and put in a solution (33%
antifreeze and water) that is 12°C (22°F) below
the temperature on indicated on top of the
thermostat. When operating correctly, the
thermostat will close. The valve must close
completely.

INSTALL
1. Install thermostat in engine.

CAUTION
To prevent possible damage to the thermostat
seal, make sure the seal is completely seated in
the engine groove before installing the thermostat
housing.

2. Using two flange head bolts install thermostat

housing on engine. Tighten flange bolts to
25 N•m (221 lbf in). See Figure 78.

1. FLANGE HEAD BOLTS

2. THERMOSTAT HOUSING
3. GASKET
4. THERMOSTAT
5. ENGINE

Figure 78. Thermostat Removal

43
Starter Replacement 0600 SRM 1949

Starter Replacement
Remove
1. Remove six locknuts, six washers, manifold
exhaust pipe (6), and two gaskets from exhaust
manifold. See Figure 79.

1. EXHAUST MANIFOLD 5. CAPSCREW

2. GASKET 6. MANIFOLD EXHAUST PIPE
3. INTERMEDIATE EXHAUST PIPE 7. WASHER
4. LOCK NUT

Figure 79. Exhaust Pipe

2. Remove two capscrews, manifold exaust pipe 3. Disconnect positive battery (B+) cable from
(6), two lock nuts and two gaskets from starter motor. See Figure 80.
intermediate exhaust pipe (3). See Figure 79.

44
0600 SRM 1949 Starter Replacement

1. CAPSCREW 3. POSITIVE (B+) BATTERY CABLE

2. LEFT SIDE ENGINE MOUNT 4. ENGINE

Figure 80. Positive Battery Cable

4. Remove six capscrews and left side engine 5. Remove two nuts and heat shield from starter
mount from engine to access starter motor. See See Figure 81.
Figure 80.

45
Starter Replacement 0600 SRM 1949

1. STARTER 3. NUT
2. HEAT SHIELD

Figure 81. Heat Shield

6. Remove two starter bolts and starter from

engine block. See Figure 82.

46
0600 SRM 1949 Fan Assembly Replacement

1. ENGINE BLOCK 3. STARTER

2. STARTER BOLT

Figure 82. Starter

Install 4. Connect positive battery (b+) cable to starter

motor. Tighten terminal nut to
1. Install starter and two starter bolts on engine 8 to 11 N•m (71 to 97 lbf in). See Figure 80.
block. Tighten bolts to 52 N•m (38 lbf ft). See
Figure 82. 5. Install two gaskets, manifold exhaust pipe (6),
and two capscrews on intermediate exhaust
2. Install heat shield and two nuts on starter. pipe (3). Tighten capscrews to
Tighten nuts to 90 N•m (66 lbf ft). See Figure 79
18 to 24 N•m (159 to 212 lbf in). See Figure 81.
6. Install two gaskets, manifold exhaust pipe (6),
3. Install left side engine mount and six six washers and six locknuts on exhaust
capscrews on engine. Tighten capscrews to manifold. Tighten lock nuts to
90 N•m (66 lbf ft). See Figure 80. 29 N•m (29 lbf ft). See Figure 79.

Fan Assembly Replacement

REMOVE
WARNING
WARNING The radiator or other parts of the cooling system
During engine operation, be careful not to touch may be hot or under pressure and can cause
the fan, pulleys, or drive belts. Contact with these serious injury. Wait 30 minutes for the radiator to
parts can cause serious injury. cool. Do a touch test by touching the radiator with

47
Fan Assembly Replacement 0600 SRM 1949

your hand. If the radiator is still hot to the touch, 3. Release LPG tank bracket and swing tank
wait another 30 minutes before attempting to away from lift truck.
check or fix any part of the cooling system.
4. Release steering tilt latch and move steering
wheel forward.
WARNING
5. Release seat latch and move seat forward.
The radiator fins on the radiator are very sharp and
can cause serious injury. Wear gloves while 6. Release engine cover latch on engine cover and
removing fan assembly. swing engine cover up.
NOTE: The fan that is used is a puller type fan. DO 7. Disconnect negative battery cable from
NOT replace with a pusher type fan. negative battery terminal.
1. Turn OFF lift truck.
8. Remove screws and washers from radiator
2. Turn LPG tank valve to OFF position. shroud. See Figure 83. Lean radiator shroud
toward fan.

1. FAN 5. SCREW
2. SPACER 6. RADIATOR SHROUD
3. WASHER 7. RADIATOR
4. CAPSCREW

Figure 83. PSI 4.3L Fan Removal

48
0600 SRM 1949 Fan Assembly Replacement

9. Remove capscrews, washers, and spacer from 2. Install spacer, washers, and capscrews to fan.
fan pulley. Tighten capscrews to 55 N•m (40.5 lbf). See
Figure 83.
10. Remove fan.
3. Lean radiator shroud back toward radiator.
INSPECT Install radiator shroud cover.

4. Install screws and washers and tighten.

WARNING
DO NOT try to repair a damaged fan. If a fan has a 5. Reconnect negative battery cable to negative
bent blade or is cracked, install a new fan. A terminal of battery.
damaged fan can break during use and cause
damage or serious injury. 6. Pull engine cover down and re-latch with
engine cover latch.
1. Inspect fan for any damage.
7. Move seat back.
2. If fan is damaged, replace entire fan.
8. Release steering wheel tilt latch and move
INSTALL steering wheel back.

9. If equipped, swing LPG tank bracket back

WARNING toward truck and re-latch.
The radiator fins on the radiator are very sharp and
can cause serious injury. Wear gloves while 10. If equipped, turn LPG tank valve to ON
installing fan assembly. position.

1. Install lower portion of shroud in the retaining

clips and lean shroud toward engine. See
Figure 83.

49
Drive Belt Installation 0600 SRM 1949

Drive Belt Installation

REMOVE Metal components (except the alternator) may be
wiped down using a cloth with cleaning solvent.
1. Remove drive belt from engine. See Figure 84.

2. Remove lock nut, tensioner pulley, and

INSPECT
tensioner from bracket. 1. Inspect drive belt for wear and damage. See
Figure 85. A few small cracks that run across
NOTE: Remove bracket only if it is damaged. the belt are acceptable. A belt with cracks that
3. Remove three capscrews, bracket, and run the length of the belt or a belt with pieces
alternator from engine. missing is not acceptable. Replace a drive belt
that is damaged.

1. ACCEPTABLE CRACKS
2. NOT ACCEPTABLE CRACKS AND DAMAGE

Figure 85. Drive Belt Inspection

2. Inspect all other components for cracks or other

1. DRIVE BELT damage that would render part as non-usable.
2. LOCK NUT
3. TENSIONER PULLEY Replace damaged parts or assemblies.
4. CAPSCREW
5. TENSIONER INSTALLATION
6. BRACKET
7. ALTERNATOR NOTE: Perform step 1 only if the bracket was
8. ENGINE removed.
1. Using three capscrews, install alternator and
Figure 84. Drive Belt Tensioner
bracket on engine. Tighten capscrews to
90 N•m (66 lbf ft).
CLEAN
2. Install tensioner, tensioner pulley, and lock nut
on bracket.
WARNING
Cleaning solvents can be flammable and toxic and 3. Install drive belt on engine. See Figure 84.
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufacturer's 4. Ensure that drive belt is routed correctly. See
recommended safety procedures. Figure 86.
Clean all components thoroughly.
Clean rubber components with warm soapy water.

50
0600 SRM 1949 Compression Check

Legend for Figure 86.

1. FAN PULLEY
2. WATER PUMP PULLEY
3. CRANKSHAFT PULLEY
4. DRIVE BELT
5. TENSIONER CENTERING PULLEY
6. ALTERNATOR PULLEY

Figure 86. Drive Belt Arrangement

Compression Check
Check the compression as follows: b. Crank engine approximately ten revolutions
to distribute oil.
1. Remove all spark plugs.
c. Install compression gauge and do the same
2. Make sure battery is fully charged. tests as described in Step 3.

3. Install a compression gauge. Hold throttle open d. If compression pressure increases to a

and crank engine with starter. The minimum normal reading, the low pressure was caused
pressure is 690 kPa (100 psi). The lowest by worn or damaged piston rings. The
pressure in a cylinder must not be less than cylinder bore can also be damaged.
70% of highest pressure.
e. If compression pressure does not increase,
4. If readings are lower than minimum readings, low pressure was caused by worn valves,
there is a problem with valves, piston rings, or valve seats, or valve guides.
cylinder head gasket. Do following tests to find
problem: f. If low pressure readings are in two cylinders
next to each other, cylinder head gasket can
a. Add approximately 30 ml (1 oz) of engine oil be leaking.
to each cylinder at spark plug hole.

51
Engine Specifications 0600 SRM 1949

Engine Specifications
ENGINE DATA

Number of cylinders 6
Firing order 1−6−5−4−3−2
Bore 101.62 to 101.64 mm (4.0008 to 4.0016 in.)
Stroke 88.39 mm (3.480 in.)
Compression Ratio 9.4:1
Displacement 4.3 liter (262.4 in.3)
Governor speed See Periodic Maintenance section for each model
of lift truck.

CYLINDER HEAD

Valve seat specifications See Figure 15 and Figure 17.

Valve seat width (inlet valves) 0.89 to 1.52 mm (0.035 to 0.060 in.)
Valve Seat Width (exhaust valves) 1.57 to 2.36 mm (0.062 to 0.093 in.)
Clearance between inlet valve and guide 0.0254 mm (0.001 in.) max
Clearance between exhaust valve and guide 0.0508 mm (0.002 in.) max
Valve spring, free length See Figure 10.

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.)

CAMSHAFT

Variation from front to rear of a cam lobe Taper with larger dimension away from No. 1 piston
Bearing journals, diameter 47.45 to 47.48 mm (1.8681 to 1.8693 in.)
Bearing journals, clearance 0.01778 to 0.9685 mm (0.0007 to 0.0381 in.)
Variation of a bearing journal in either diameter or
axial direction 0.03 mm (0.001 in.)
Axial clearance 0.10 to 0.30 mm (0.004 to 0.012 in.)

52
0600 SRM 1949 Engine Specifications

PISTONS

Piston diameter (see gauge points in Figure 68

Cylinder Bore Out-of-round (see Figure 66) 0.0508 mm (0.002 in.)
Maximum cylinder taper 0.025 mm (0.001 in.)
Clearance at bottom of cylinder 0.068 mm (0.0027 in.)
Piston ring to groove clearance for piston rings (see Figure 69)
Compression rings 0.107 mm (0.0042 in.)
Oil ring to groove clearance 0.508 to 2.032 mm (0.02 to 0.08 in.)
Piston ring end clearance (see Figure 70)
Compression rings 1.524 to 0.88 mm (0.06 to 0.035 in.)
Oil ring 0.23 to 1.65 mm (0.009 to 0.065 in.)
Piston pin to piston clearance 0.025 mm (0.001 in.)
Piston pin to connecting rod clearance 0.020 to 0.040 mm (0.0008 to 0.0016 in.)

CRANKSHAFT

Diameter of main bearing journal

Number 1 62.20 to 62.22 mm (2.4488 to 2.4496 in.)
Number 2, 3 62.20 to 62.21 mm (2.4488 to 2.4492 in.)
Number 4 62.18 to 62.20 mm (2.4480 to 2.4488 in.)
Out-of-round of main bearing journal (maximum) 0.0254 mm (0.001 in.)
Taper of main bearing journal (maximum) 0.0254 mm (0.001 in.)
Clearance between journals and main bearings
Number 1 0.0254 to 0.05 mm (0.0010 to 0.0020 in.)
Number 2, 3, 4 0.025 to 0.006 mm (0.0010 to 0.0002 in.)
Available undersize main bearings −0.0254 mm (−0.001 in.)
−0.0508 mm (−0.002 in.)
−0.2285 mm (−0.009 in.)
−0.25 mm (−0.010 in.)
−0.50 mm (−0.020 in.)
Axial Clearance (crankshaft to thrust surface main 0.050 to 0.20 mm (0.002 to 0.008 in.)
bearing)

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Torque Specifications 0600 SRM 1949

CONNECTING RODS

Diameter of connecting rod journals 57.12 to 57.14 mm (2.2488 to 2.2496 in.)

Out-of-round of bearing journal (maximum) 0.0254 mm (0.001 in.)
Taper of bearing journal (maximum) 0.0254 mm (0.001 in.)
Clearance between crankshaft journals and 0.076 mm (0.0030 in.)
connecting rod bearings
Side clearance of connecting rod to crankshaft 0.15 to 0.44 mm (0.006 to 0.017 in.)

BALANCE SHAFT

Front bearing journal diameter 54.99 to 55.00 mm (2.1650 to 2.1654 in.)

Rear Bearing Journal Diameter 38.08 to 38.10 mm (1.4992 to 1.500 in.)
Rear Bearing Journal Clearance 0.025 to 0.091 mm (0.001 to 0.0036 in.)

COOLING SYSTEM

Lift Truck Models H6.0-7.0FT Lift Truck Model S6.0-7.0FT

(H135-155FT) (L006), H6.0FT, (S135- S155FT) (G024)
H7.0FT, H7.0FTS6, H7.0FTS9,
H8.0FTS6 (H135FT, H155FT,
H155FTS, H170FTS) (N006) and
Thermostat H4.0FT5, H4.0FT6, H4.5FTS5,
H4.5FT6, H5.0-5.5FT (H80-120FT)
(U005)
Start to open 82°C (180°F) Start to open78.5°C (173°F)
Fully open 92°C (198°F) Fully open86.5°C (188°F)

LUBRICATION SYSTEM

Oil pressure @ 2000 rpm 207 to 380 kPa (30 to 55 psi)

Minimum oil pressure
Oil pressure @ 1000 rpm 34 kPa (5 psi)
Oil pressure switch ON 20 to 39 kPa (2.9 to 5.7 psi)

Torque Specifications
Alternator Pulley Balance Shaft Retainer Capscrews
61 N•m (45 lbf ft) 12 N•m (106 lbf in)

Balance Shaft Gear Capscrew Camshaft Retainer Screws

20 N•m (177 lbf in) 12 N•m (106 lbf in)

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0600 SRM 1949 Torque Specifications

Camshaft Sprocket Capscrews Oil Screen Support to Crankcase

28 N•m (21 lbf ft) 50 N•m (37 lbf ft)

Camshaft Sprocket Nut Oil Pan to Crankcase

25 N•m (18 lbf ft) 25 N•m (18 lbf ft)
25 N•m (18 lbf ft)
Chain Control Block for Hydraulic Pump Drive
19 N•m (168 lbf in) Rear Oil Seal Retainer Screws and Nut
15 N•m (133 lbf in)
Connecting Rod Bolt
27 N•m (240 lbf in) Rocker Arm Cover
After this step, tighten nuts an additional 70 12 N•m (106 lbf in)
degrees.
Rocker Arm Nuts
Coolant Pump to Engine Block 25 N•m (18 lbf ft)
41 N•m (30 lbf ft)
Rocker Arm Studs
Cooling Fan to Pulley 47 N•m (35 lbf ft)
24 N•m (212 lbf in)
Rocker Arm Bolts
Cylinder Head 30 N•m (22 lbf ft)
See the section Cylinder Head Repair for torque
value and for tightening sequence. Thermostat Housing
25 N•m (18 lbf ft)
Distributor Mount Capscrew
25 N•m (18 lbf ft) Timing Cover
12 N•m (106 lbf in)
Exhaust Manifold
15 N•m (133 lbf in) Valve Lifter Retainer Capscrews
30 N•m (22 lbf ft) 16 N•m (142 lbf in)

Flywheel Vibration Damper

100 N•m (74 lbf ft) 95 N•m (70 lbf ft)

Flywheel Housing Starter Bolts

48 N•m (35 lbf ft) 52 N•m (38 lbf ft)

Inlet Manifold to Cylinder Head Starter Heat Shield Nuts

3 N•m (27 lbf in) 18 to 24 N•m (158 lbf in)
12 N•m (106 lbf ft)
15 N•m (133 lbf in) Engine Mount Capscrews
90 N•m (66 lbf ft)
Main Bearing Cap
105 N•m (77 lbf ft) Exhaust Locknuts
39 N•m (29 lbf ft)
Motor Mount to Engine
31 N•m (23 lbf ft)

Oil Pump Cover

12 N•m (106 lbf in)

Oil Pump to Crankcase

90 N•m (66 lbf ft)

Oil Pressure Switch

27 N•m (20 lbf ft)

55
 TECHNICAL PUBLICATIONS

0600 SRM 1949 11/19 (7/19)(9/18)(5/16)