INTRODUCTION

GENERAL The diodes and resistors in the electrical system can

be damaged if the following cautions are not
followed:
This section has the repair instructions for the engine.
Removal, disassembly, repair, assembly, installation, • Do not disconnect the battery when the
checks and adjustments and troubleshooting are in- engine is running. The voltage surge can damage
cluded. The specifications are given at the end of the the diodes and resistors.
section. • Do not disconnect an electric wire before the
engine is stopped and the key switch is “OFF”.
Additional information on engine components are in the
• Do not cause a short circuit by connection of
sections for THE CARBURETOR, THE LPG FUEL
the electric wires to the wrong terminals. Make
SYSTEM and THE ELECTRICAL SYSTEM
sure a correct identification is made of the wire
before it is connected.
WARNING
Some gaskets used in this engine can contain • Make sure a battery is the correct voltage and
dangerous fibers. Breathing dust from these fibers is polarity before it is connected.
a cancer or lung disease hazard. Do not create dust! • Do not check for current flow by making a
Use vacuum equipment for asbestos or follow the spark because the transistors can be damaged.
cleaning procedure described below.
DESCRIPTION
• Make sure the gasket material is wet with
water or oil to prevent particles in the air. The Mazda M4–2.0G engine is a four cylinder engine
that has a displacement of 1998 cm3 (121.9 in3). The fir-
• Use a hand scraper to remove old gasket mate- ing order is 1–3–4–2. It is available with either a gaso-
rial. Do not use a power tool or compressed air. line or an LPG fuel system. The number one cylinder is
• Discard all asbestos material in a closed con- toward the end of the engine with the cooling fan.
tainer while it is still wet. The overhead camshaft is driven by a cog belt. The cam-
shaft operates the rocker arms that actuate the valves.
Put a “DANGEROUS FIBERS” warning label on
the container. Discard dangerous fiber material The crankshaft has five main bearings. The main bear-
safely. ing in the center of the crankshaft is also the thrust bear-
ing.
CAUTION The pistons are aluminum alloy and have three piston
Disconnect the battery cables before doing any rings. Each of the two compression rings have a special
disassembly and repair to the engine or parts of the shape designed for its position on the piston. The third
electrical system. piston ring is the oil control ring.

REPAIRS

REMOVAL AND INSTALLATION OF THE CYLINDER HEAD, CAMSHAFT AND

ENGINE VALVE MECHANISM

Removal
NOTE: The removal and installation procedures for the
1. Disconnect the connections at the battery.
engine are not included in this section. See the section
for THE FRAME for more information. 2. Drain the cooling system.

1
3. Remove the air cleaner, the carburetor linkage, the in-
let and exhaust manifolds.

4. Remove the coolant hoses.

5. Remove the bracket for the cooling fan.

6. Remove the upper and lower timing belt covers. See

FIGURE 23.

7. Loosen the capscrews for the timing belt tensioner

and remove the spring. Remove the capscrews and the
timing belt tensioner. FIGURE 2. REMOVE THE CAMSHAFT GEAR

8. Use chalk to mark the direction of rotation of the tim- 11. Remove the nuts and capscrews for the front hous-
ing belt. Remove the timing belt. See FIGURE 1. ing, then remove the housing. See FIGURE 19.
12. Remove the valve cover.
9. Disconnect the wires at the distributor. Remove the
capscrew for the distributor mount and pull the distribu- 13. Loosen the capscrews for the rocker shaft supports
tor from the front housing. in steps. See FIGURE 3. Remove the rocker shaft as-
sembly and the camshaft.

1 5 9 8 4

2 6 10 7 3

FIGURE 3. SEQUENCE FOR REMOVAL OF THE

FIGURE 1. TIMING BELT ROCKER ASSEMBLY

14. Remove the capscrews for the cylinder head in steps.

Remove the capscrews in the sequence shown in
10. See FIGURE 2. Remove the camshaft pulley. Pre-
FIGURE 4.
vent rotation of the pulley and loosen the capscrew. Re-
move the capscrew and the pulley. 15. Lift the cylinder head from the block.

2
 Inspection And Repairs
1 5 9 8 4
CYLINDER HEAD
Check the bottom surface of the cylinder head for distor-
tion. Use a straight edge and a thickness gauge. Do the
measurements at the positions shown in FIGURE 6. The
maximum amount of distortion is 0.15 mm (0.0059 in).
When grinding the cylinder head, the maximum amount
of correction is 0.2 mm (0.008 in).

2 6 10 7 3

FIGURE 4. SEQUENCE FOR REMOVAL OF THE

CYLINDER HEAD

16. Use a valve spring compressor and remove the valve

retainers, springs and valves from the head. See
FIGURE 5.

FIGURE 6. CYLINDER HEAD INSPECTION

ROCKER SHAFT ASSEMBLY

Disassemble the rocker shaft assembly. Put marks on the
rocker arms so that they can be installed on the same
shafts. Clean the oil passages in the rocker shafts and
rocker arms. Check the clearance between the rocker
FIGURE 5. REMOVE THE VALVES arms and the rocker shafts. The maximum clearance is
0.10 mm (0.004 in). The correct dimension for the inside
diameter of a rocker arm is 16.000 to 16.027 mm
WARNING (0.6299 to 0.6311 in). The correct dimension for the out-
side diameter of a rocker shaft is 15.966 to 15.984 mm
Cleaning
(0.6286 to 0.6293 in). If the parts do not meet specifica-
Cleaning solvents can be flammable and toxic and tion, replace the rocker arm(s) or the rocker shaft(s).
can cause skin irritation. When using cleaning sol- CAMSHAFT
vents, always follow the solvent manufacturer’s rec-
ommended safety procedures. Check the camshaft for cracks or damage.
Check the movement of the camshaft in the cylinder
Clean all of the parts in solvent. Make sure that all oil head. Use a dial indicator on the end of the camshaft as
passages are clean. Make sure all machined surfaces are shown in FIGURE 7. The maximum movement is 0.20
smooth. mm (0.008 in).

3
 Measure the camshaft journals at four points A–D as
shown in FIGURE 8. The minimum dimensions for the
journals are as follows:
Front and Rear Journals (Nos. 1 and 5) – 31.940 to
31.965 mm (1.2575 to 1.2585 in)
Center Journals (Nos. 2, 3 and 4) – 31.910 to 31.935
mm (1.2563 to 1.2573 in)
Front Oil Seal Surface – 33.961 to 34.000 mm
(1.3370 to 1.3386 in)
Fuel Pump Lobe – 37.1 mm (1.46 in)

Check the camshaft for being straight. Put the front and
rear journals in V blocks and rotate the camshaft one
complete turn. See FIGURE 9. The maximum amount
FIGURE 7. CHECK THE CAMSHAFT that the dial indicator can indicate is 0.03 mm (0.0012
in).
Measure the height of the camshaft lobes. See
FIGURE 8. The minimum height of the intake and ex-
haust lobes are 36.902 mm (1.4528 in).

A
B FIGURE 9. CHECK THE CAMSHAFT
C
D Measure the clearance between the camshaft and the
1 2 bore in the cylinder head. Install the camshaft in the cyl-
inder head. Put a plastic gauge material between the
camshaft and the cap. Tighten the capscrews for the caps
to 18 to 27 N.m (13 to 20 lbf ft). See FIGURE 10. The
correct clearance for journals Nos. 1 and 5 is 0.035 to
0.085 mm (0.0014 to 0.0033 in). The correct clearance
3 4 5 for journals Nos. 2, 3 and 4 is 0.065 to 0.115 mm (0.0026
1. FRONT OIL SEAL
SURFACE to 0.0045 in). If any of the clearances are greater than
2. FRONT JOURNAL (NO. 1) 0.15 mm (0.0059 in), replace the cylinder head assem-
3. CENTER JOURNALS (NOS. 2, 3 AND 4)
4. REAR JOURNAL (NO, 5)
bly.
5. FUEL PUMP LOBE
Replace the camshaft if there is any damage or it does
FIGURE 8. CAMSHAFT INSPECTION not meet specifications.

4
 VALVE SEATS
1
Inspect the condition of the valve seats. If the valve seats
have cracks, the cylinder head must be replaced. If the
condition of the valve seats is good, check the contact
pattern of the valve and the valve seat. Use a valve seat
grinder to make sure the valve seats are with the specifi-
2 cations shown in FIGURE 12. Use a valve compound to
make sure the valves fit the seats.

EXHAUST INTAKE
2
3

1. PLASTIC GAUGE
2. SCALE 75°
1 75°
1
FIGURE 10. MEASURE THE CLEARANCE FOR 60° 60°
THE CAMSHAFT 15° 25°

VALVE GUIDES 30° 30°

1. VALVE SEAT WIDTH
Measure the clearance between the valve stems and the
2. EXHAUST VALVE SEAT
valve guides. Normal clearance is 0.025 to 0.060 mm 3. INTAKE VALVE SEAT
(0.001 to 0.002 in). Replace the valve or valve guide
when the clearance is more than 0.20 mm (0.008 in). FIGURE 12. VALVE SEAT SPECIFICATIONS

1. DIAMETER
3 2. THICKNESS,
2 VALVE HEAD
1

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

FIGURE 11. VALVE GUIDE

If replacement is necessary, use a tool to remove the 2

valve guide(s). Remove the seal from the valve guide,
then remove the valve guide.

To install a valve guide, install the retaining ring on the FIGURE 13. INSPECT THE VALVES
valve guide. Use the tool and install the valve guide until
the retaining ring contacts the cylinder head. See VALVES
FIGURE 11. The correct height of the valve guide 1. See FIGURE 13. Inspect the stem of each valve for
above the valve spring seat is 19.1 to 19.6 mm (0.75 to wear. Use a micrometer to measure the outside diameter
0.77 in). of the stem. The minimum dimension for an intake valve

5
is 7.980 mm (0.3142 in). The minimum dimension for
an exhaust valve is 7.975 mm (0.3140 in). 10 6 2 3 7

2. Inspect the valves for cracks, burned faces and distor-

tion. Inspect the seat face of the valves for wear and
damage. Measure the thickness of the valve head. See
The minimum thickness for an intake valve is 0.5 mm
(0.020 in). The minimum thickness for an exhaust valve is 1.0
mm (0.040 in).

3. If the valves need grinding the correct surface angle is

30° for both intake and exhaust valves.
1 4 8
VALVE SPRINGS 9 5

Check the valve springs for damage. See FIGURE 14.

FIGURE 15. INSTALLATION OF THE
Measure the free length of the outer valve springs. The
CYLINDER HEAD
minimum length of an intake spring is 44.3 mm (1.74
in). The minimum length of an exhaust spring is 50.8
4. See FIGURE 16. Apply a gasket sealer to the areas
mm (2.00 in). Check the outer valve springs for being
shown by the arrows. Lubricate the camshaft with clean
square. See FIGURE 14. If the measurement is more
engine oil, then install the camshaft. Make sure the dow-
than 1.81 mm (0.071 in), replace the valve spring(s).
el pin is at the top of the camshaft.

MEASURE
HERE

1. DOWEL PIN
2. APPLY SEALANT 2
HERE

FIGURE 14. INSPECT THE VALVE SPRINGS

Cylinder Head, Installation

1. Clean the surface of the cylinder head and the surface

of the block.

2. Install a new cylinder head gasket to the block. Install FIGURE 16. INSTALL THE CAMSHAFT
the cylinder head.
5. Assemble the rocker shaft assembly. See
3. Install the capscrews and washers for the cylinder FIGURE 17. Lubricate the rocker arms and shafts with
head. Tighten the capscrews to 82 to 88 N.m (59 to 64 lbf engine oil. Rocker arms Nos. 1 and 3 are the same and
ft) as shown in FIGURE 15. Nos. 2 and 4 are the same. Put the capscrews in the rock-

6
er shaft supports, then install the assembly on the cylin-
der head. 1. FRONT HOUSING
2. GASKET
3. OIL SEAL
2
NO. 1 AND NO. 3 ARE THE SAME
3

NO. 1 NO. 2 NO. 3 NO. 4

FIGURE 19. FRONT HOUSING

NO. 2 AND NO. 4 ARE THE SAME 8. With the dowel pin at the top of the camshaft, install
FIGURE 17. ASSEMBLE THE ROCKER SHAFT the camshaft pulley. Check that the letter “A” on the
pulley is aligned with the timing mark on the front hous-
ing. See FIGURE 20.
6. Tighten the capscrews for the rocker shaft supports to
18 to 27 N.m (13 to 20 lbf ft) in the sequence shown in 1
FIGURE 18.

10 6 2 3 7 1. TIMING
MARKS
2. CAMSHAFT
PULLEY

9 5 1 4 8

FIGURE 18. INSTALLATION OF THE ROCKER

SHAFT ASSEMBLY

7. If necessary, install the oil seal in the front housing.

See FIGURE 19. Install the front housing and a new
gasket on the cylinder head. Tighten the capscrews for FIGURE 20. INSTALL THE CAMSHAFT
the front housing to 19 to 26 N.m (14 to 19 lbf ft). PULLEY

7
9. Install the capscrew and washer for the camshaft 13. See FIGURE 22. Loosen the lock bolt and apply
pulley. See FIGURE 20. Keep the pulley from turning spring tension on the belt. Rotate the crankshaft pulley
and tighten the capscrew to 48 to 66 N.m (35 to 48 lbf ft). two complete turns clockwise and check the timing
marks. If the timing marks are correct, tighten the lock
10. Align the timing marks for the crankshaft pulley. See bolt for the tensioner to 20 to 35 N.m (14 to 25 lbf ft).
FIGURE 21. Install the crankshaft pulley, tapered ring Check the movement on the tension side of the timing
and the capscrew. Tighten the capscrew to 160 to 170 belt. When the tension is correct the belt will move 12 to
N.m (116 to 123 lbf ft). 14 mm (0.47 to 0.55 in) with 10 kg (20 lb) of force.

14. See FIGURE 23. Install the lower timing belt cover
1. CRANKSHAFT PULLEY and gasket. Tighten the capscrews to 7 to 8 N.m (5 to 6
2. TIMING MARK 2
2 lbf ft). Install the upper timing belt cover and gasket.
Tighten the capscrews to 8 to 12 N.m (6 to 9 lbf ft).

1 1

FIGURE 21. INSTALL THE TIMING BELT

11. Install the timing belt tensioner and spring. Move the
2
tensioner fully toward the intake side of the engine and
temporarily tighten the lock bolt. 2

12. Clean any oil or grease from the pulleys. Install the
timing belt. Install the belt so that it goes in the same
direction as the mark made during removal. See
FIGURE 1.

1. LOWER TIMING BELT COVER

1 4 2. UPPER TIMING BELT COVER
3
FIGURE 23. TIMING BELT COVERS

15. Install the distributor as described in the procedures

for the DISTRIBUTOR.

CRANKSHAFT AND MAIN BEARINGS

1. TENSIONER 3. LOCK BOLT
2. SPRING 4. TENSION SIDE Removal
FIGURE 22. INSTALL THE TIMING BELT 1. Remove the bracket for the cooling fan.

8
2. Remove the six capscrews and plate from the crank- Inspection And Repair
shaft pulley. Remove the six capscrews that hold the
crankshaft pulley to the timing pulley. CRANKSHAFT

3. Remove the capscrew from the timing pulley. Install 1. Visually inspect the crankshaft for wear, cracks or
the special tool on the crankshaft to remove the timing other damage. Replace the crankshaft if it has cracks.
pulley. Rotate the tool until it touches the front of the 2. Use a micrometer to measure the diameter of the jour-
crankshaft. Hit the tool with a hammer to loosen the tim- nals for the crankshaft. See FIGURE 25. Make the
ing pulley. Remove the pulley, dowel pin and the tapered measurement at several locations for each journal. If the
ring. Remove the tool. measurements are less than specifications, grind the
crankshaft and install undersize bearings. The correct
4. Remove the oil pan. Remove the oil strainer.
dimensions for the journals are as follows:
5. Remove the rear cover. Remove the front cover with
the oil pump. 2
1 4
6. Remove the caps for the connecting rods. Put a mark
of identification on each cap so that they will be installed
to the same location.

1. CENTER MAIN
BEARING

1
3
1. REAR OIL SEAL SURFACE
2. CONNECTING ROD JOURNALS
3. MAIN BEARING JOURNALS
4. FRONT OIL SEAL SURFACE

FIGURE 24. MEASURE THE CRANKSHAFT

CLEARANCE

7. Before removing the crankshaft, measure the clear-

ance between the crankshaft and the flange of the center
main bearing. See FIGURE 24. Push the crankshaft
fully forward before making the measurement. The
FIGURE 25. CRANKSHAFT INSPECTION
maximum clearance is 0.30 mm (0.012 in). If the clear-
ance is greater than the specification, replace the center Main Journal Diameter – 59.937 to 59.955 mm
main bearing or the crankshaft. (2.3597 to 2.3604 in)
8. Put marks for identification on the bearing caps. Connecting Rod Journals – 50.940 to 50.955 mm
Loosen the capscrews for the main bearing caps in steps, (2.0055 to 2.0061 in)
then remove the capscrews and the caps. Remove the Rear Oil Seal Surface – 89.946 to 90.000 mm
crankshaft. (3.5412 to 3.5433 in)

9
 Front Oil Seal Surface – 33.961 to 34.000 mm identification marks and install the main bearing caps.
(1.3370 to 1.3386 in) Tighten the capscrews for the main bearing caps to 84 to
90 N.m (61 to 65 lbf ft).
3. Check the crankshaft for being straight. See
FIGURE 25. Put the front and rear journals in V blocks 3. Install the pistons and the connecting rods as de-
and rotate the crankshaft one complete turn. The maxi- scribed in PISTONS AND THE CONNECTING
mum amount that the dial indicator can indicate is 0.03 RODS, Installation.
mm (0.0012 in).
4. Install the oil pump housing. Make sure the O–ring is
4. Check the passages for oil in the crankshaft. Make in the housing. Lubricate the oil seal with engine oil. Use
sure the passages are clean, with no restrictions. an adhesive sealant and install the housing to the block.
Make sure there is no sealant in the oil port. Tighten the
MAIN BEARINGS M10 capscrews to 38 to 53 N.m (27 to 38 lbf ft). Tighten
1. Visually inspect the main bearings for wear and dam- the M8 capscrews to 19 to 26 N.m (14 to 19 lbf ft).
age. Replace the bearings as necessary.
5. Install the oil seal in the rear cover. Lubricate the sur-
2. Measure the clearance between the main bearings and faces of the oil seal with engine oil and use a press to
the crankshaft. Install the crankshaft in the block. Put a install the seal. Install the alignment pin in the cylinder
plastic gauge material on the journals and install the block.
main bearing caps. Tighten the capscrews for the main
6. Install the rear cover and the gasket. See FIGURE 27.
bearing caps to 84 to 90 N.m (61 to 65 lbf ft). Remove
Make sure the dowel pin is installed. Tighten the cap-
the bearing caps. See FIGURE 26. The correct clear-
screws to 8 to 12 N.m (6 to 9 lbf ft). Cut the part of the
ance is 0.031 to 0.049 mm (0.0012 to 0.0019 in). If the
gasket that extends past the bottom of the cylinder
clearance is greater than the specifications, replace the
block.
main bearings.

2 1
2

3
1

1. PLASTIC GAUGE
2. SCALE

FIGURE 26. CHECK THE CLEARANCE FOR 1. REAR COVER

THE MAIN BEARINGS 2. OIL SEAL
3. CRANKSHAFT
FIGURE 27. REAR COVER
Installation

1. Clean the main bearings and the areas at the block for 7. Install the oil strainer. Tighten the M6 capscrews to 8
the main bearings. Install the main bearings and lubri- to 12 N.m (6 to 9 lbf ft). Tighten the M8 capscrews to 16
cate them with oil. to 23 N.m (12 to 17 lbf ft).

2. Install the crankshaft on the bearings. Install the main 8.Install the oil pan and the gasket. Tighten the cap-
bearings in the caps and lubricate them with oil. Use the screws to 7 to 12 N.m (5 to 9 lbf ft).

10
PISTONS AND CONNECTING RODS 2. Measure the outside diameter of the piston as shown
in FIGURE 28. The correct dimension is 85.944 to
Removal And Disassembly 85.964 mm (3.3836 to 3.3844 in). The maximum clear-
ance between the piston and the cylinder bore is 0.15
1. Remove the cylinder head as described in CYL-
mm (0.0059 in).
INDER HEAD, Removal.
PISTON RINGS
2. Remove the oil pan and oil strainer.
1. Measure the end clearance of each piston ring as
3. Put a mark for identification on the top of each piston.
shown in FIGURE 29. Install the piston ring into the
4. Clean the carbon from the top of each cylinder bore. cylinder bore where it will be used. Use a thickness
gauge to measure the amount of end clearance. The cor-
5. Remove the caps and bearings from each connecting rect dimensions are as follows
rod. Keep the caps and bearings with the correct piston
assemblies. Top Piston Ring – 0.20 to 0.35 mm
(0.008 to 0.014 in)
6. Push the connecting rod and piston from the block.
2nd Piston Ring – 0.15 to 0.30 mm
7. Carefully remove the piston rings from the pistons. (0.006 to 0.012 in)
Use a tool to push the piston pin from the connecting Oil Ring – 0.30 to 0.90 mm (0.012 to 0.035 in)
rod.
Maximum clearance is 1.0 mm (0.039 in)
Cleaning
2. Measure the clearance between the piston ring and the
WARNING groove in the piston as shown in FIGURE 29. The cor-
Cleaning solvents can be flammable and toxic and rect dimensions are as follows:
can cause skin irritation. When using cleaning sol-
Top Piston Ring – 0.03 to 0.07 mm (0.0012 to
vents, always follow the solvent manufacturer’s rec-
0.0028 in)
ommended safety procedures.
2nd Piston Ring – 0.03 to 0.07 mm (0.0012 to
Clean all of the parts in solvent. Make sure that all oil 0.0028 in)
passages and grooves are clean. Make sure all machined
Maximum clearance is 0.15 mm (0.0059 in)
surfaces are smooth.

Inspection And Repair

PISTONS
1. PISTON RING END
1. Inspect the pistons for wear and cracks. Replace a pis- CLEARANCE
2. PISTON RING
ton that has damage. GROOVE
CLEARANCE
1

18 mm
(0.71 in)

FIGURE 28. MEASURING THE PISTON FIGURE 29. MEASURING THE PISTON RINGS

11
CONNECTING RODS AND BEARINGS Lubricate the piston pin and bore in the piston with en-
gine oil. Use a press to install the piston pin. The force to
1. Use an alignment tool to check the connecting rods
push the pin into the piston must be 500 to 1500 kg (1100
for being straight. The maximum amount of distortion
to 3300 lb). If the force is not correct, replace the piston
per 100 mm (4.0 in) is 0.04 mm (0.0016 in). If the
pin and/or connecting rod. Use the special tool to make
amount of distortion is greater than the specification,
sure the piston pin is installed to the correct depth. After
install a new rod or use a press to straighten the connect-
installation, check that the piston moves freely on the
ing rod.
piston pin.
2. Check the clearance between the rod bearings and the
2. Install the piston rings on the pistons. During installa-
journals of the crankshaft. Clean the rod bearings and
tion, the writing on each piston ring must be toward the
journals. Use a plastic gauge material between the jour-
top of the piston. Check that the rings rotate freely, then
nal and the bearing. Tighten the capscrews for the rod
put the ends of the rings in the positions shown in
caps to 51 to 56 N.m (37 to 41 lbf ft). Do not rotate the
FIGURE 32. Make sure the ends of the upper and lower
connecting rod. See FIGURE 30. The correct clearance
oil control rings are each 30° from the piston pin. Also
is 0.027 to 0.067 mm (0.0011 to 0.0026 in). If the clear-
make sure that the top and second rings are each 30°
ance is greater than the specifications, replace the bear-
from the piston pin. Lubricate the rings with engine oil.
ings.

1. “F” MARK
2. OIL PORT
FIGURE 30. CHECK THE CLEARANCE OF THE
CONNECTING ROD BEARINGS

FIGURE 31. CONNECTING ROD AND PISTON

Assembly And Installation
3. Apply clean engine oil to the piston assembly. Install
PISTONS AND CONNECTING RODS
the bearings for the connecting rods. Install the piston
1. Align the oil port on the large end of the connecting into the correct cylinder making sure the “F” is toward
rod with the “F” mark on the piston. See FIGURE 31. the front (timing belt end) of the engine.

12
 ° °
1
PISTON 2
PIN

1. EXPANDER RING
2. OIL RING (UPPER)
3. OIL RING (LOWER)
OIL CONTROL 4. TOP RING
RING 5. SECOND RING
° °
4

PISTON
PIN

FIGURE 34. INSPECT THE CYLINDER BLOCK

TOP AND SECOND CYLINDER BLOCK

RINGS

FIGURE 32. PISTON RINGS Repairs

1. After the engine block is cleaned, check its surface for

distortion. See FIGURE 34. If the amount of distortion
is greater than 0.15 mm (0.0059 in), grind the surface of
the engine block. The maximum amount of correction
that is permitted is 0.20 mm (0.008 in).
1. “F” MARK
2. Check the cylinder bores for wear and damage. Meas-
1 ure each bore. The correct dimension is 86.00 to 86.019
mm (3.3858 to 3.3866 in). The wear limit above this di-
mension is 0.15 mm (0.0059 in). Repair the cylinder
block or use bigger pistons as necessary.

OIL PUMP

Before removing the oil pump, check the oil pressure.

Replace the sending unit with a gauge. The minimum oil
FIGURE 33. INSTALL THE PISTON pressure at governed rpm is approximately 275 kPa (40
psi). If the pressure is less than the specification, the oil
pump or the engine bearings need repair.
4. Apply clean engine oil to the bearing then install the
cap to the correct connecting rod. During installation of Removal
the caps, make sure to align the identification marks that
1. Remove the bracket for the cooling fan.
were made during disassembly. Tighten the nuts for the
caps to 51 to 56 N.m (37 to 41 lbf ft). 2. Remove the upper and lower timing belt covers.

13
3. Loosen the capscrews for the timing belt tensioner 2. Remove the outer gear and the inner gear from the
and remove the spring. Remove the capscrews and the pump body.
timing belt tensioner.
3. Remove the snap ring to remove the plunger assembly
4. Use chalk to mark the direction of rotation of the tim- from the housing.
ing belt. Remove the timing belt.
5. Remove the six capscrews and plate from the crank- Cleaning
shaft pulley. Remove the six capscrews that hold the
crankshaft shaft pulley to the timing pulley. WARNING
Cleaning solvents can be flammable and toxic and
6. Remove the capscrew from the timing pulley. Install can cause skin irritation. When using cleaning sol-
the special tool on the crankshaft to remove the timing vents, always follow the solvent manufacturer’s rec-
pulley. Rotate the tool until it touches the front of the ommended safety procedures.
crankshaft. Hit the tool with a hammer to loosen the tim-
ing pulley. Remove the pulley, dowel pin and the tapered Clean all of the parts in solvent. Make sure all machined
ring. Remove the tool. surfaces are smooth.
7. Remove the capscrews that hold the oil pan to the
block and remove the oil pan. Inspection
8. Remove the capscrews that hold the front cover 1. Check the front cover (pump housing) and the pump
(pump housing) to the block. Remove the front cover cover for wear or damage. Check the plunger spring for
and oil pump assembly. damage.
Disassembly (See FIGURE 35.) 2. See FIGURE 36. Measure the parts of the oil pump as
follows:
1. Remove the screws and the pump cover.
a. Measure the clearance between the gears and the
1. SCREW
crescent. The correct clearance is 0.20 to 0.32 mm
1
2. COVER 2 (0.008 to 0.013 in). If the clearance is more than
3. OUTER GEAR 0.35 mm (0.014 in), repair as necessary.
4. INNER GEAR
b. Measure the clearance between the crescent and
the teeth of the inner gear. The correct clearance is
0.267 to 0.380 mm (0.0105 to 0.0150 in). If the
6 clearance is more than 0.40 mm (0.0157 in), repair
3 as necessary.
4 c. Use a straight edge and measure the side clear-
5 ance of the gears. The correct clearance is 0.03 to
0.63 mm (0.0012 to 0.0248 in). If the clearance is
5. FRONT COVER more than 0.10 mm (0.004 in), repair as necessary.
7 8
(HOUSING)
6. OIL SEAL d. Measure the clearance between the body and the
7. PLUNGER outer gear. The correct clearance is 0.090 to 0.184
8. SNAP RING mm (0.0035 to 0.0072 in). If the clearance is more
FIGURE 35. OIL PUMP than 0.20 mm (0.008 in), repair as necessary.

14
 1. CLEARANCE BETWEEN CRESCENT AND INNER GEAR
2. CLEARANCE BETWEEN CRESCENT AND GEARS
3. SIDE CLEARANCE OF GEARS IN THE HOUSING
4. CLEARANCE BETWEEN HOUSING AND OUTER GEAR

2
3

FIGURE 36. MEASURE THE OIL PUMP

Assembly (See FIGURE 35.) Installation (See FIGURE 37.)

1. Install the oil seal in the oil pump housing. Make sure 1. Install the O–ring on the oil pump housing. Use grease
the front edge of the oil seal is even with the outer edge to hold the O–ring in position. Lubricate the oil seal with
of the housing. engine oil.

2. Use an adhesive sealant and install the oil pump hous-

2. Lubricate the gears with engine oil, then install them ing to the block. Make sure there is no sealant in the oil
in the housing. port. Tighten the M10 capscrews to 38 to 53 N.m (27 to
38 lbf ft). Tighten the M8 capscrews to 19 to 26 N.m (14
3. Install the pump cover. Use a thread locking com-
to 19 lbf ft).
pound on the screws for the pump cover, then install the
screws. 3. Install the suction tube assembly. Install the gasket
and the oil pan.
4. Install the plunger assembly and the snap ring.
COOLING SYSTEM
1. O–RING 1
Thermostat

REPLACEMENT (See FIGURE 38.)

1. Drain the cooling system to the level of the thermo-

stat.

2. Disconnect the hose and remove the thermostat hous-

ing. Remove the thermostat.

3. Test the operation of the thermostat. The thermostat

FIGURE 37. OIL PUMP must begin to open at 82 ± 1.5°C (180 ± 3°F). The ther-
mostat must be completely open at 95°C ( 203°F).

15
 ft). Tighten the M10 capscrews to 38 to 64 N.m (27 to 46
1. CYLINDER BLOCK lbf ft).
2. GASKET
3. THERMOSTAT 2. Install the pulley and fan on the hub. Tighten the cap-
4. HOUSING screws to 8 to 11 N.m (6 to 8 lbf ft).

1
4 6
4 5

2 3
1
7

2 3

FIGURE 38. THERMOSTAT

4. Install the thermostat and new gasket. Make sure the

print side of the gasket is toward thermostat. Install the
thermostat housing and tighten the capscrews to 12 to 18 1. FAN 5. SHAFT
2. PULLEY 6. SUPPORT
N.m (9 to 13 lbf ft).
3. HUB BRACKET
4. SNAP RING 7. BRACKET
5. Connect the hose and fill the cooling system. Start the
engine and check for leaks. FIGURE 39. FAN ASSEMBLY

Fan Assembly 3. Install the fan belt. Adjust the tension of the fan belt.
Check the movement of the fan belt between the fan and
REMOVAL the alternator. When the tension is correct a NEW belt
will move 8 to 10 mm (0.32 to 0.38 in) with 10 kg (20 lb)
1. Loosen the alternator and remove the fan belt. of force. The tension for an OLD belt is correct when it
2. Remove the capscrews for the fan. Remove the fan moves 10 to 12 mm (0.38 to 0.50 in).with 10 kg (20 lb)
and pulley from the hub. of force. Tighten the alternator when the tension is cor-
rect.
3. Remove the capscrews that hold the fan bracket to the
engine. Remove the fan bracket. Water Pump
DISASSEMBLY AND REPAIR (See FIGURE 39.) NOTE: If either the shaft or impeller is damaged, the
1. Use a press to remove the fan hub from the shaft. Re- complete water pump must be replaced.
move the snap ring and push the bearing and shaft from REMOVAL
the bracket.
1. Drain the cooling system.
2. Use a press to install the shaft and bearing in the
2. Loosen the alternator and remove the fan belt.
bracket. Push the bearing in until it touches the bracket.
Install the snap ring. Install the hub on the shaft. When 3. Remove the capscrews for the fan. Remove the fan
installed, the shaft must extend 2.1 mm (0.083 in) past and pulley from the hub.
the hub.
4. Remove the capscrews that hold the fan bracket to the
INSTALLATION (See FIGURE 39.) engine. Remove the fan bracket.
1. Install the bracket assembly on the cylinder block. 5. Remove the upper and lower timing belt covers. See
Tighten the M8 capscrews to 32 to 47 N.m (23 to 34 lbf FIGURE 23. Loosen the capscrews for the timing belt

16
tensioner and remove the spring. Remove the capscrews 3. Use a press to install the pulley. Use a press to install
and the timing belt tensioner. the impeller. Make sure the surface of the impeller is
even with the end of the shaft.
CAUTION
INSTALLATION
6. Use chalk to mark the direction of rotation of the tim-
ing belt. See FIGURE 1. Align the timing marks, then 1. Install the water pump with a new gasket. Tighten the
remove the timing belt. capscrews to 19 to 26 N.m (14 to 19 lbf ft).

Do not rotate the camshaft gear or the crankshaft 2. Install the timing belt and the covers as described in
gear while the timing belt is removed. If either of the the procedures for Cylinder Head, Installation.
gears is moved, it will be necessary to align the timing
marks. 3. Install the fan assembly as described in the procedures
for Fan Assembly, Installation.
7. Disconnect the hose at the water pump. Remove the 4. Install the coolant hoses.
capscrews for the water pump, then remove the water
pump from the cylinder block. 5. Fill the coolant system with coolant.

6. Start the engine and check the cooling system for

6
leaks.
4
WARNING
DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator cap is re-
2
moved, the pressure is released from the system. If
5
the system is hot, the steam and boiling coolant can
1
cause burns. DO NOT remove the cover for the ra-
diator when the engine is running.

7. After the engine has been operated, stop the engine. If

3
the coolant is hot, give the engine time to cool. Check
3. WASHER the coolant level.
1. PULLEY 4. HOUSING
2. SHAFT AND BEARING 5. SEAL DISTRIBUTOR
ASSEMBLY 6. IMPELLER

FIGURE 40. WATER PUMP NOTE: This section has only the removal and installa-
tion procedures for the distributor. The service proce-
dures for the ignition system are found in THE ELEC-
DISASSEMBLY AND REPAIR (See FIGURE 40.)
TRICAL SYSTEM.
1. Use a puller to remove the pulley from the shaft.
Removal (See FIGURE 41.)
2. Use a press to remove the impeller from the shaft and
the bearing assembly from the housing. Remove the wa- 1. Rotate the crankshaft until the number one piston is at
ter seal from the housing. TDC on the compression stroke. Make a note of the
position of the distributor rotor.
ASSEMBLY (See FIGURE 40.)
2..Disconnect the wires at the spark plugs.
1. Install the water seal in the housing. Put anti–freeze
on the lip of the seal. 2. Remove the capscrew from the flange of the distribu-
tor shaft housing.
2. Use a press to install the shaft and bearing in the pump
body. Make sure the shaft turns smoothly. 3. Lift the distributor assembly from the engine.

17
Installation (See FIGURE 41.) Ring Gear, Replacement

1. Rotate the crankshaft until the number one piston is at WARNING

TDC on the compression stroke. Put the rotor in the cor- Wear eye protection for this operation to prevent eye
rect position. injury from metal chips. You will be using a hammer
and chisel to break the ring gear.
2. Lubricate the O–ring and the gear on the distributor
with engine oil. Install the distributor, aligning the Before the ring gear is removed, check the position of
marks on the distributor housing, distributor gear and the chamfer on the teeth.
engine.
1. See FIGURE 42. Use a hammer and chisel to break
3. Connect the wires at the spark plugs. the ring gear. Make sure that you do not damage the fly-
wheel.

FIGURE 42. RING GEAR REMOVAL

WARNING
2. The ring gear must be heated before it can be installed
on the flywheel. Make sure that the ring gear is not
heated to more than 200°C (390°F).
Hot parts. Wear protective clothing and gloves to
prevent burns.

3. Install the ring gear on the flywheel. Make sure that

the chamfer on the teeth is in the correct direction to-
FIGURE 41. INSTALLATION OF THE ward the starter.
DISTRIBUTOR
Flywheel, Installation (See FIGURE 43.)
1. If the flywheel housing was removed, install it on the
FLYWHEEL AND RING GEAR,
engine. Tighten the M14 capscrews to 114 to 136 N.m
S/H2.00–3.20XM (S/H40–65XM)
(84 to 100 lbf ft). Tighten the M8 capscrews to 21 to 25
N.m (16 to 19 lbf ft).
Flywheel, Removal (See FIGURE 43.)
2. Install the flywheel on the crankshaft. Install the drive
1. Remove the capscrews for the flywheel, then remove plate and support plate. Apply an adhesive sealant on the
the flywheel and the drive plate. threads of the capscrews. then install the capscrews for
the flywheel. Tighten the capscrews to 96 to 103 N.m
2. If necessary, remove the flywheel housing. (71 to 76 lbf ft) as shown in the sequence in FIGURE 43.

18
 FLYWHEEL, S/H1.50–1.75XM, S/H2.00XMS
2 1 (S/H25–35XM, S/H40XMS)

3
Removal (See FIGURE 44.)

5 1. Remove the capscrews for the flywheel, then remove

the flywheel and the flange.

1 2. If necessary, remove the adapter plate.

6 3
Installation (See FIGURE 44.)
4
4 5
2 1. If the adapter plate for the torque converter housing
6 was removed, install it on the engine. Tighten the cap-
TIGHTENING screws to 43 to 51 N.m (32 to 38 lbf ft).
1. COVER PLATE SEQUENCE
2. FLYWHEEL HOUSING
2. Install the flange and flywheel on the crankshaft. Ap-
3. FLYWHEEL 5. SUPPORT PLATE
4. DRIVE PLATE 6. CAPSCREW ply a thread locking adhesive on the threads of the cap-
screws. then install the capscrews and lock washers.
FIGURE 43. FLYWHEEL ARRANGEMENT Tighten the capscrews to 96 to 103 N.m (71 to 76 lbf ft).

4
5

1 2

6
3

1. FLANGE
2. FLYWHEEL 5. ACCESS COVER 12812
3. DRIVE PLATE 6. TORQUE CONVERTER
4. TORQUE CONVERTER HOUSING

FIGURE 44. FLYWHEEL AND TORQUE CONVERTER

19
 CHECKS AND ADJUSTMENTS
ADJUST THE VALVES (See FIGURE 45.) 2. Rotate the crankshaft clockwise one complete turn
(360 degrees). Now adjust the remaining valves.
1. Rotate the crankshaft until the number one piston is at
TDC on the compression stroke (intake and exhaust
valves closed). Now adjust the clearance of the intake 3. If the valves are adjusted when the engine is cold,
valves for the No. 1 and No. 2 cylinders and the exhaust check the adjustments again after the engine is warm.
valves for the No. 1 and No. 3 cylinders. The correct
clearance for all the valves when the engine is hot is 0.3
mm (0.012 in). To adjust the clearance, loosen the lock CHECK THE COMPRESSION PRESSURE
nut and turn the adjustment screw. Tighten the lock nut (See FIGURE 46.)
to 16 to 21 N.m (12 to 15 lbf ft).
NOTE: During adjustment of the valves, check the po-
sition of the balls that are in the ends of the rocker arms. 1. Remove the spark plugs from the cylinder head. Dis-
The flat surface of the ball must be in contact with the connect the high tension wire at the ignition coil.
stem of the valve.
2. Install a compression gauge in the number 1 cylinder.
INTAKE VALVES Make sure the gauge has a minimum range of 1725 kPa
(250 psi).
NO. 1 NO. 2 NO. 3 NO. 4

3. Use the starter to crank the engine at least six (6) revo-
lutions. Check the pressure reading and release the pres-
sure. Repeat the test again and make a note of the highest
pressure. Do this test for each cylinder.

NO. 1 NO. 2 NO. 3 NO. 4

4. The standard pressure reading is 1130 kPa (164 psi).
EXHAUST VALVES The minimum reading is 793 kPa (115 psi).
2

3 5. If the readings are lower than the minimum reading,

there is a problem with the valves, piston rings or cylin-
der head gasket. Do the following tests to find the prob-
lem:

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

4 0.012 in) to each cylinder at the spark plug hole.

b. Crank the engine approximately ten revolutions

1. CAMSHAFT
2. ROCKER ARM to distribute the oil.
1 3. BALL
4. VALVE STEM
c. Install the compression gauge and do the same
FIGURE 45. ADJUST THE VALVES tests as described in step 3.

20
 d. If the compression pressure increases to a nor-
1. ADAPTER
mal reading, the low pressure was caused by worn
or damaged piston rings. The cylinder bore can also
be damaged. 1

e. If the compression reading does not increase, the

low pressure was caused by worn valves, valve
seats or valve guides.
f. If the low pressure readings are in two cylinders
next to each other, the cylinder head can be leaking.

FIGURE 46. CHECK THE COMPRESSION

PRESSURE
ENGINE SPECIFICATIONS
ITEM SPECIFICATION
Engine Type In–Line, Four Cylinders
Bore x Stroke 86 mm (3.39 in) x 86 mm (3.39 in)
Displacement 1998 cm3 (121.9 in3)
Compression Ratio 8.6 : 1
Compression Pressure 1131 kPa (164 psi) @ 270 rpm
Oil Pressure @ 2400 rpm 226 to 362 kPa (33 to 52 psi)
Thermostat
Starts to Open 82 ± 1.5°C (180 ± 35°F)
Fully Open 95 ± 1.5°C (203 ± 35°F)
Cylinder Head
Height 91.25–92.05 mm (3.620–3.624 in)
Distortion Limit 0.15 mm (0.006 in)
Grinding Limit 0.20 mm (0.008 in)
Valve Mechanism
Inside Dia. of Valve Guide 8.07–8.09 mm (0.3177–0.3185 in)
Clearance in Guide (Exhaust) 0.025–0.060 mm (0.001–0.0024 in)
Clearance in Guide (Intake) 0.025–0.060 mm (0.001–0.0024 in)
Service Limit (Intake & Exhaust) 0.20 mm (0.008 in)
Diameter of Valve Stem (Intake) 8.03–8.045 mm (0.3161–0.3167 in)
Service Limit 7.980 mm (0.3142 in)
Dia. of Valve Stem (Exhaust) 8.025 – 8.045 mm (0.3159– 0.3167 in)
Service Limit 7.975 mm (0.3140 in)
Valve Head Thickness (Intake) 0.5 mm (0.020 in)
Valve Head Thickness (Exhaust) 1.0 mm (0.040 in)
Valve Face Angle (Intake and Exhaust) 30°

21
 ENGINE SPECIFICATIONS
ITEM SPECIFICATION
Valve Mechanism
Spring Free Length (Outer) 52.4 mm (2.063 in)
Service Limit 50.8 mm (2.00 in)
Spring Free Length (Inner) 45.7 mm (1.799 in)
Service Limit 44.3 mm (1.744 in)
Rocker Arm Shaft Diameter 15.966–15.984 mm (0.6286– 0.6293 in)
Rocker Arm Bore Diameter 16.000 –16.027 mm (0.6299 to 0.6311 in)
Clearance Between Rocker Arm and Shaft 0.016–0.061 mm (0.0006–0.0024 in)
Camshaft
Cam Lobes – Production Limit 37.102 mm (1.4607 in)
Cam Lobes – Service Limit 36.902 mm (1.4528 in)
Bearing Journals, 1 and 5 31.940–31.965 mm (1.2575 to 1.2585 in)
Bearing Journals, 2, 3 and 4 31.910–31.935 mm (1.2563 to 1.2573 in)
Bearing Journal Wear Limit 0.05 mm (0.002 in)
Clearance Between Journals and Bore, 1 and 5 0.035–0.085 mm (0.0014–0.0033 in)
Clearance Between Journals and Bore, 2, 3 and 4 0.065–0.115 mm (0.0026–0.0045 in)
End Clearance 0.08–0.16 mm (0.003–0.006 in)
End Clearance (Service Limit) 0.20 mm (0.008 in)
Crankshaft
Distortion less than 0.03 mm (0.0012 in)
Main Bearing Journal Diameter 59.937–59.955 mm (2.3597–2.3604 in)
Service Limit 0.05 mm (0.002in)
Grinding Limit 0.75 mm (0.030 in)
Clearance Between Journals and Main Bearings 0.031–0.049 mm (0.0012–0.0019 in)
Service Limit 0.08 mm (0.003 in)
Connecting Rod Journal Diameter 50.940–50.955 mm (2.0055–2.0061 in)
Service Limit 0.05 mm (0.002 in)
Grinding Limit 0.75 mm (0.030 in)
Thrust Bearing Clearance 0.08–0.18 mm (0.003–0.007 in)
Service Limit 0.30 mm (0.012 in)
Connecting Rods
Small End Bore 21.943–21.961 mm (0.8639–0.8646 in)
Clearance Between Piston Pin and Bore 0.015–0.040 mm (0.0006–0.0016 in)
Clearance Between Crankshaft Journals
and Rod Bearings 0.027–0.067 mm (0.0011–0.0026 in)
Service Limit 0.10 mm (0.004 in)
Cylinder Block
Distortion at Top Surface 0.15 mm (0.0059 in)
Bore Diameter 86.00– 86.019 mm (3.3858–3.3866 in)
Wear Limit 0.15 mm (0.0059 in)

22
 ENGINE SPECIFICATIONS
ITEM SPECIFICATION
Pistons
Diameter 85.944–85.964 mm (3.3836–3.3844 in)
Clearance Between Piston and Bore 0.036–0.075 mm (0.0014–0.0030 in)
Service Limit 0.15 mm (0.0059 in)
Piston Pin Diameter 21.974–21.980 mm (0.8651– 0.8654 in)
Groove Width for Piston Rings Nos. 1 and 2 1.520–1.540 mm (0.0598–0.0606 in)
Groove Width for Oil Ring 4.020–4.040 mm (0.1583–0.1591 in)
Piston Ring Clearance in Groove, Nos. 1 and 2 0.03–0.07 mm (0.0012–0.0028 in)
Service Limit 0.15 mm (0.0059 in)
Piston Ring End Clearance
Top Ring 0.20–0.35 mm (0.008–0.014 in)
Second Ring 0.15–0.30 mm (0.006–0.012 in)
Oil Control Ring 0.30–0.90 mm (0.012–0.035 in)
Service Limit (All Rings) 1.0 mm (0.039 in)
Oil Pump
Clearance Between Inner Gear and Crescent 0.267–0.380 mm (0.0105–0.0150 in)
Service Limit 0.40 mm (0.0157 in)
Clearance Between Crescent and Outer Gear 0.20–0.32 mm (0.008–0.013 in)
Service Limit 0.35 mm (0.014 in)
Clearance Between Outer Gear and Housing 0.090–0.184 mm (0.0035–0.0072 in)
Service Limit 0.20 mm (0.008 in)
Side Clearance Between Gears and Housing 0.03–0.063 mm (0.0012–0.0025 in)
Service Limit 0.10 mm (0.004 in)

23
 TORQUE SPECIFICATIONS
ITEM SPECIFICATION
Flywheel Capscrews 96 to 103 N.m (71 to 76 lbf ft)
Flywheel Housing,
H2.00–3.20XM (H40–65XM)
M10 Capscrews 41 to 49 N.m (30 to 36 lbf ft)
M14 Capscrews 114 to 136 N.m (84 to 101 lbf ft)
Fuel Pump 16 to 22 N.m (12 to 16 lbf ft)
Intake Manifold 19 to 31 N.m (14 to 22 lbf ft)
Main Bearing Cap 84 to 90 N.m (61 to 65 lbf ft)
Oil Pan 7 to 12 N.m (5 to 9 lbf ft)
Oil Pump
M8 Capscrews 19 to 26 N.m (14 to 19 lbf ft)
M10 Capscrews 38 to 53 N.m (27 to 38 lbf ft)
Rocker Cover 30 to 40 N.m (25 to 35 lbf ft)
Rocker Shaft Assembly 18 to 27 N.m (13 to 20 lbf ft)
Spark Plugs 15 to 23 N.m (11 to 17 lbf ft)
Starter 66 to 79 N.m (49 to 58 lbf ft)
Thermostat Cover 12 to 18 N.m (9 to 13 lbf ft)
Timing Belt Cover
Upper Capscrews 8 to 12 N.m (6 to 9 lbf ft)
Lower Capscrews 7 to 8 N.m (5 to 6 lbf ft)
Timing Belt Tension Lock Bolt 20 to 35 N.m (14 to 25 lbf ft)
Torque Converter Housing Adapter
H1.50–1.75XM, H2.00XMS (S/H25–35XM, S/H40XMS)
M8 Capscrews 21 to 25 N.m (16 to 18 lbf ft)
M14 Capscrews 118 to 142 N.m (87 to 105 lbf ft)
Torque Converter Housing
H1.50–1.75XM, H2.00XMS (S/H25–35XM, S/H40XMS)
M10 Capscrews 41 N.m (30 lbf ft)
M12 Capscrews 71 N.m (52 lbf ft)
Water Pump 19 to 26 N.m (14 to 19 lbf ft)

24
 TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
The engine will not start. The fuel tank is empty. Fill fuel tank.
The battery is not fully charged. Charge battery.
The connections at the battery are Check and tighten battery connec-
loose or they have corrosion. tions.
The starter system has a problem. Check electrical circuit for starter.
There are damaged parts in the en- Repair engine.
gine.
The valves are worn or damaged. Install new valves.
The piston rings are worn or have Install new piston rings.
damage.
The fuel system has a problem. Check and repair fuel system.
Ignition timing is not correct. Adjust timing.
Fuel line has a restriction. Clean or use new fuel lines.
Fuel filter has a restriction. Install a new fuel filter.
Ignition system does not operate Check and repair ignition system.
correctly.
The engine does not run smoothly. The valve mechanism does not op- Check and repair valve mechanism.
erate correctly.
The cylinder head has cracks. Install a new cylinder head.
The head gasket has a leak. Install a new gasket.
There is a leak in the intake sys- Check and repair intake system.
tem.
Engine is too hot. Check cooling system.
Fuel lines or fuel filter has a restric- Clean or use new fuel lines.
tion.
The ignition timing is not correct. Adjust timing.
The engine does not have enough The fuel is the wrong type. Fill tank with correct fuel.
power. The air filter is dirty. Install a new air filter.
The ignition timing is not correct. Adjust timing.
The valve mechanism does not Check and repair valve mechanism.
work correctly.
The piston assemblies are worn or Install new pistons.
damaged.
The exhaust system has restric- Clean parts or install new muffler or
tions. pipes.
Fuel lines or fuel filter has a restric- Clean or use new fuel lines and filter.
tion.
Engine is too hot or too cold. Check cooling system.
Cylinder head gasket leaks. Install a new gasket.

25
 TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
There is noise inside the engine. The main bearings are worn or Install new main bearings.
damaged.
Engine is too hot. Check and repair cooling system.
Valves are not adjusted correctly. Adjust valves.
The bearings for the connecting Install new bearings.
rods are worn or damaged.
The pistons are worn or damaged. Install new pistons.
Valve spring is broken. Install new valve springs.
There is not enough oil in the en- Fill engine with correct oil.
gine.
The flywheel is loose. Tighten capscrews for flywheel.
A connecting rod is bent. Repair engine.
There is a leak in the exhaust sys- Repair exhaust system.
tem.
The valve mechanism does not op- Check and repair valve mechanism.
erate correctly.
Spark plugs are dirty. Install new spark plugs.
The engine gets too hot. There is not enough coolant in the Fill cooling system.
cooling system.
The air filter has a restriction. Install a new air filter.
The water pump has damage. Install a new water pump.
The radiator is dirty. Clean or repair the radiator.
The cooling system has restric- Check radiator and hoses.
tions.
The belt for the water pump is worn Check and adjust the belt.
or not adjusted correctly.
The thermostat has damage. Install a new thermostat.
The exhaust system has restric- Check and repair exhaust system.
tions.
Ignition timing is not correct. Adjust timing.
Cylinder head gasket leaks. Install a new head gasket.
Engine compression is not correct. Check and repair engine.

26