Maintenance

GM ENGINE REPAIR
GM 2.4 LITER ENGINE
GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) [A910];
GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) [B875]

PART NO. 524223755 600 YRM 1121

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

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

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.

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

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

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

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

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

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

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

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

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

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

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

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange background.
The CAUTION symbol and word are on yellow background.
GM Engine Repair Table of Contents

TABLE OF CONTENTS

General................................................................................................................................................................ 1
Engine Serial Number ......................................................................................................................................... 1
Engine Removal and Installation ......................................................................................................................... 3
Intake Manifold .................................................................................................................................................... 3
Remove ........................................................................................................................................................... 3
Clean and Inspect ........................................................................................................................................... 4
Install............................................................................................................................................................... 4
Exhaust Manifold ................................................................................................................................................. 5
Remove ........................................................................................................................................................... 5
Clean and Inspect ........................................................................................................................................... 5
Install............................................................................................................................................................... 5
Camshaft and Cylinder Head Repair................................................................................................................... 6
Rocker Arm Cover........................................................................................................................................... 6
Remove....................................................................................................................................................... 6
Install .......................................................................................................................................................... 6
Camshaft Timing Pulley and/or Front Seal...................................................................................................... 6
Remove....................................................................................................................................................... 6
Install .......................................................................................................................................................... 7
Camshaft Carrier and Cylinder Head .............................................................................................................. 7
Remove....................................................................................................................................................... 7
Disassemble ............................................................................................................................................... 9
Camshaft Carrier .................................................................................................................................... 9
Cylinder Head......................................................................................................................................... 10
Clean and Inspect ....................................................................................................................................... 11
Camshaft Carrier .................................................................................................................................... 11
Cylinder Head......................................................................................................................................... 11
Valve and Valve Seat .................................................................................................................................. 13
Assemble .................................................................................................................................................... 14
Cylinder Head......................................................................................................................................... 14
Camshaft Carrier .................................................................................................................................... 14
Install .......................................................................................................................................................... 14
Timing Belt........................................................................................................................................................... 16
Timing Belt Front Cover................................................................................................................................... 16
Remove....................................................................................................................................................... 16
Install .......................................................................................................................................................... 17
Timing Belt and Timing Belt Tensioner............................................................................................................ 17
Remove....................................................................................................................................................... 17
Install .......................................................................................................................................................... 18
Timing Belt Rear Cover ................................................................................................................................... 19
Remove....................................................................................................................................................... 19
Install .......................................................................................................................................................... 19
Lubrication System Repair .................................................................................................................................. 20
Oil Pan............................................................................................................................................................. 20
Remove....................................................................................................................................................... 20
Install .......................................................................................................................................................... 20
Oil Pump ......................................................................................................................................................... 22
Remove....................................................................................................................................................... 22
Clean and Inspect ....................................................................................................................................... 23
Install .......................................................................................................................................................... 24
Piston and Piston Rod Assemblies Repair .......................................................................................................... 25
Piston Rod Bearings, Replace ........................................................................................................................ 25

©2010 Yale Materials Handling Corp. i

Table of Contents GM Engine Repair

TABLE OF CONTENTS (Continued)

Piston and Piston Rod Assemblies ................................................................................................................. 27
Remove....................................................................................................................................................... 27
Disassemble ............................................................................................................................................... 27
Pistons, Clean and Inspect ......................................................................................................................... 28
Cylinder Bores, Inspect and Repair ............................................................................................................ 28
Piston Rings, Inspect .................................................................................................................................. 29
Assemble .................................................................................................................................................... 30
Install .......................................................................................................................................................... 31
Crankshaft and Main Bearings ............................................................................................................................ 32
Crankshaft Timing Pulley and/or Front Seal.................................................................................................... 32
Remove....................................................................................................................................................... 32
Install .......................................................................................................................................................... 33
Crankshaft Rear Main Oil Seal........................................................................................................................ 33
Remove....................................................................................................................................................... 33
Install .......................................................................................................................................................... 33
Crankshaft/RPM Sensor ................................................................................................................................. 34
Remove....................................................................................................................................................... 34
Install .......................................................................................................................................................... 34
Crankshaft Reluctor Wheel ............................................................................................................................. 34
Remove and Install ..................................................................................................................................... 34
Crankshaft and Main Bearings........................................................................................................................ 35
Remove....................................................................................................................................................... 35
Inspect and Repair...................................................................................................................................... 36
Bearing Selection........................................................................................................................................ 36
Main Bearings and Journal Clearance, Check............................................................................................ 37
Install .......................................................................................................................................................... 39
Flywheel and Flywheel Housing .......................................................................................................................... 40
Remove ........................................................................................................................................................... 40
Install............................................................................................................................................................... 40
Cooling System Repair........................................................................................................................................ 41
Serpentine Belt ............................................................................................................................................... 41
Remove....................................................................................................................................................... 41
Inspect ........................................................................................................................................................ 41
Install .......................................................................................................................................................... 41
Water Pump .................................................................................................................................................... 42
Remove....................................................................................................................................................... 42
Inspect ........................................................................................................................................................ 44
Install .......................................................................................................................................................... 44
Thermostat ...................................................................................................................................................... 45
Remove....................................................................................................................................................... 45
Check.......................................................................................................................................................... 46
Install .......................................................................................................................................................... 46
Thermostat Housing........................................................................................................................................ 47
Remove....................................................................................................................................................... 47
Clean and Inspect ....................................................................................................................................... 47
Install .......................................................................................................................................................... 48
Sensors and Switches ......................................................................................................................................... 49
Crankshaft Position (CKP) Sensor .................................................................................................................. 49
Remove....................................................................................................................................................... 49
Install .......................................................................................................................................................... 49
Camshaft Position (CMP) Sensor ................................................................................................................... 49

ii
GM Engine Repair Table of Contents

TABLE OF CONTENTS (Continued)

Remove for Lift Trucks Built Before January, 2010 ..................................................................................... 49
Assembly ................................................................................................................................................ 49
Sensor Only............................................................................................................................................ 50
Install for Lift Trucks Built Before January, 2010 ......................................................................................... 51
Assembly ................................................................................................................................................ 51
Sensor Only............................................................................................................................................ 51
Remove for Lift Trucks Built After January, 2010 ........................................................................................ 51
Install for Lift Trucks Built After January, 2010 ............................................................................................ 52
Oil Pressure Sensor ........................................................................................................................................ 52
Remove....................................................................................................................................................... 52
Install .......................................................................................................................................................... 52
Ignition System .................................................................................................................................................... 52
Spark Plug Wire Inspection............................................................................................................................. 52
Spark Plug Wire Replacement ........................................................................................................................ 52
Remove....................................................................................................................................................... 52
Install .......................................................................................................................................................... 53
Spark Plug Replacement ................................................................................................................................ 53
Remove....................................................................................................................................................... 53
Install .......................................................................................................................................................... 54
Spark Plug Inspection ..................................................................................................................................... 54
Usage ......................................................................................................................................................... 54
Inspect ........................................................................................................................................................ 54
Visual Inspection......................................................................................................................................... 56
Coil Pack ......................................................................................................................................................... 56
Remove....................................................................................................................................................... 56
Install .......................................................................................................................................................... 56
Alternator Repair ................................................................................................................................................. 57
Alternator......................................................................................................................................................... 57
Remove....................................................................................................................................................... 57
Install .......................................................................................................................................................... 57
Alternator Fuse, Replace ................................................................................................................................ 58
Starter Repair ...................................................................................................................................................... 58
Remove ........................................................................................................................................................... 58
Install............................................................................................................................................................... 58
Engine Specifications .......................................................................................................................................... 59
Engine Data .................................................................................................................................................... 59
Cylinder Bore .................................................................................................................................................. 59
Piston .............................................................................................................................................................. 59
Piston Rings .................................................................................................................................................... 59
Wrist Pin.......................................................................................................................................................... 60
Crankshaft....................................................................................................................................................... 60
Piston Rod....................................................................................................................................................... 60
Camshaft and Camshaft Carrier ..................................................................................................................... 61
Valve System................................................................................................................................................... 61
Cylinder Head Warpage.................................................................................................................................. 62
Lubrication System.......................................................................................................................................... 62
Cooling System ............................................................................................................................................... 62
Torque Specifications .......................................................................................................................................... 62
Special Tools ....................................................................................................................................................... 64

iii
Table of Contents GM Engine Repair

TABLE OF CONTENTS (Continued)

This section is for the following models:

GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) [A910];

GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875]

iv
600 YRM 1121 Engine Serial Number

General
This section has the repair instructions for the GM 2.4 liter engine.

Engine Serial Number

The location of the engine serial number is shown in
Figure 1 and Figure 2.

1. ENGINE SERIAL NUMBER

Figure 1. Engine Serial Number Prior to January, 2010

1
Engine Serial Number 600 YRM 1121

1. ENGINE SERIAL NUMBER

Figure 2. Engine Serial Number After January, 2010

2
600 YRM 1121
Engine Removal and Installation
CAUTION
Disconnect the battery cables before doing any dis-
assembly and repair to the engine or parts of the
electrical system.
The diodes and resistors in the electrical system
can be damaged if the following cautions are not
followed:
• Do not disconnect the battery when the engine
is running. The voltage surge can damage the
diodes and resistors.
• Do not disconnect an electric wire before the en-
gine is stopped and the switches are OFF.
• Do not cause a short circuit by connection of the
electric wires to the wrong terminals. Make sure
a correct identification is made of the wire before
it is connected.
• Make sure a battery is the correct voltage and po-
larity before it is connected.
Intake Manifold
REMOVE
NOTE: Step 1 is for gasoline engines only.
1. Disconnect the electrical connector from the fuel
pump.
NOTE: Step 2 is for LPG fuel systems only.
2. Close the fuel valve on the propane tank.
3. Start the engine and let it idle until the engine shuts
down from the lack of fuel.
NOTE: Step 4 is for gasoline engines only.
4. Crank the engine for approximately five seconds for
full pressure relief from the fuel system.
5. Disconnect the negative battery cable.
6. Remove the left rear side cover. Refer to the section
Frame 100 YRM 1120.
7. Disconnect the air intake hoses from the air filter
assembly.
NOTE: The ECM assembly must be disconnected from
the air filter assembly before removing the air filter
assembly. For gasoline engines, refer to the section
Intake Manifold
• Do not check for current flow by making a spark
because the electronic components can be dam-
aged.
CAUTION
Many parts of the engine assembly are made of alu-
minum. Use care not to damage mating surfaces or
threads. To prevent possible damage to mating sur-
faces, do not clean with wire brushes, steel wool,
or sharp objects. Do not overtighten parts that are
aluminum or mount to an aluminum part, as this can
cause damage to the threads or part.
The procedures to remove and install the engine are
not included in this section. See the section Frame 100
YRM 1120 for these procedures.
Gasoline Fuel System, GM 2.4L Engine 900 YRM
1126. For LPG fuel systems, refer to the section LPG
Fuel System, GM 2.4L Engine 900 YRM 1124.
8. Remove the three bolts that attach the air filter as-
sembly mounting bracket to the frame and remove
air filter assembly with mounting bracket.
9. Disconnect the electrical connections to the throttle
body.
10. Disconnect the fuel delivery hoses and return
hoses, or LPG vapor hose.
11. Disconnect the vacuum hose from the intake man-
ifold.
12. Disconnect the air intake hoses and positive
crankcase ventilation (PCV) valve hoses from the
intake manifold.
13. Disconnect the wiring harness connectors to the
fuel injectors.
14. Disconnect the electrical connector to the MAP
sensor.
15. Remove the nuts retaining the intake manifold to the
cylinder head. See Figure 3.
3
Intake Manifold
1. INTAKE MANIFOLD
2. NUT
3. CYLINDER HEAD
Figure 3. Intake Manifold
16. Remove the intake manifold.
17. Remove the intake manifold gasket and discard.
18. Remove and replace fuel system components as
needed. For gasoline engines, refer to the sec-
tion Gasoline Fuel System, GM 2.4L Engine 900
YRM 1126. For LPG fuel systems, refer to the sec-
tion LPG Fuel System, GM 2.4L Engine 900 YRM
1124.
CLEAN AND INSPECT
CAUTION
Use caution not to scratch the gasket mating sur-
faces when cleaning the intake manifold and cylin-
der head.
Carefully remove all gasket residue from the intake
manifold and cylinder head. Inspect the intake manifold
for scratches, cracks, or any other damage. Repair or
replace as needed.
INSTALL
1. Verify the mating surfaces are clean and not dam-
aged.
2. If necessary, install fuel system components. For
gasoline engines, refer to the section Gasoline
Fuel System, GM 2.4L Engine 900 YRM 1126.
For LPG fuel systems, refer to the section LPG
Fuel System, GM 2.4L Engine 900 YRM 1124.
4
600 YRM 1121
3. Place a new gasket in position between the intake
manifold and the cylinder head.
4. Place the intake manifold into position on the cylin-
der head.
5. Install the retaining nuts on the studs. Tighten the
nuts to 18 to 22 N•m (13 to 16 lbf ft).
6. Connect the electrical connector to the MAP sen-
sor.
7. Connect the wiring harness connectors to the fuel
injectors.
8. Connect the air intake hoses and PCV valve hoses
to the intake manifold.
9. Connect the vacuum hose to the intake manifold.
10. Connect the fuel delivery hose to the intake mani-
fold.
11. Connect the breather hose to the intake manifold.
12. Connect the fuel delivery hoses and return hoses,
or LPG vapor hose.
13. Connect the electrical connections to the throttle
body.
NOTE: Step 14 is for gasoline engines only.
14. Connect the electrical connector to the fuel pump.
NOTE: Step 15 is for LPG fuel systems only.
15. Slowly open the fuel valve on the propane tank.
NOTE: The ECM assembly must be connected to the air
filter assembly after installing the air filter assembly. For
gasoline engines, refer to the section Gasoline Fuel
System, GM 2.4L Engine 900 YRM 1126. For LPG
fuel systems, refer to the section LPG Fuel System,
GM 2.4L Engine 900 YRM 1124.
16. Place the air filter assembly with mounting bracket
in position on the frame. Install bolts and tighten to
20 N•m (15 lbf ft).
17. Connect the air intake hoses to the air filter assem-
bly.
18. Install the left rear side cover. Refer to the section
Frame 100 YRM 1120.
19. Connect the negative battery cable.
600 YRM 1121
WARNING
During engine operation, be careful not to touch the
fan, pulleys, or drive belts. Contact with these parts
can cause serious injury.
Exhaust Manifold
REMOVE
1. Remove the battery, battery tray, and power distri-
bution module (PDM). Refer to the section Electri-
cal System 2200 YRM 1142.
2. Tag and disconnect the spark plug wires.
3. Disconnect the electrical connection to the coil
pack.
4. Remove the coil pack and coil pack mounting
bracket.
5. Remove the capscrews retaining the exhaust man-
ifold heat shield and remove the heat shield.
6. Disconnect the oxygen sensor electrical connec-
tion.
7. Remove and discard the locking nuts retaining the
exhaust manifold adapter to the exhaust manifold.
8. Remove and discard the gasket between the ex-
haust manifold adapter and the exhaust manifold.
9. Remove and discard the locking nuts retaining the
exhaust manifold to the cylinder head. See Fig-
ure 4.
10. Remove the exhaust manifold.
11. Remove the gasket and discard.
CLEAN AND INSPECT
CAUTION
Use caution not to scratch the gasket mating sur-
faces when cleaning the exhaust manifold and
cylinder head.
Carefully remove all gasket residue from the exhaust
manifold and cylinder head. Inspect the exhaust mani-
fold for scratches, cracks, or any other damage. Repair
or replace as needed.
Exhaust Manifold
WARNING
The radiator or other parts of the cooling system
may be hot or under pressure and can cause seri-
ous injury.
20. Start the engine and check for proper operation and
leaks.
INSTALL
1. Verify the mating surfaces are clean and not dam-
aged.
2. Place a new gasket in position between the exhaust
manifold and the cylinder head.
3. Place the exhaust manifold into position on the
cylinder head.
1. GASKET
2. EXHAUST MANIFOLD
3. NUT
Figure 4. Exhaust Manifold Removal/Installation
4. Install new locking nuts on the studs. Tighten the
nuts to 18 to 22 N•m (13 to 16 lbf ft).
5. Place a new gasket in position between the exhaust
manifold adapter and the exhaust manifold.
6. Connect the exhaust manifold adapter to the ex-
haust manifold and secure with new locking nuts.
Tighten the nuts to 14 to 20 N•m (10 to 15 lbf ft).
7. Connect the oxygen sensor electrical connection.
5
Camshaft and Cylinder Head Repair 600 YRM 1121

8. Place the exhaust manifold heat shield in position
and secure with capscrews. Tighten the capscrews
to 6 to 8 N•m (53 to 71 lbf in).
9. Install the coil pack mounting bracket and coil pack.
10. Connect the electrical connection to the coil pack.
11. Connect the spark plug wires and remove tags.
12. Install the battery, battery tray, and PDM. Refer to
the section Electrical System 2200 YRM 1142.
13. Start the engine and check for proper operation and
leaks.

Camshaft and Cylinder Head Repair

ROCKER ARM COVER
Remove
1. Disconnect the two hoses from the PCV valve.
2. Disconnect the crankcase vent tube from the rocker
arm cover.
3. Remove the capscrews retaining the rocker arm
cover to the camshaft carrier assembly. See Fig-
ure 5.
4. Remove the rocker arm cover and gasket. Discard
gasket.
Install
1. Clean the mating surfaces of the rocker arm cover
and the camshaft carrier assembly.
2. Place a new gasket in position in the rocker arm
cover.
3. Place the rocker arm cover in position on the
camshaft carrier assembly.
4. Install the capscrews to retain the rocker arm cover
to the camshaft carrier assembly. Tighten the cap-
screws to 8 N•m (71 lbf in).
5. Connect the crankcase vent tube to the rocker arm
cover.

6. Connect the two hoses to the PCV valve.

CAMSHAFT TIMING PULLEY AND/OR

FRONT SEAL
Remove
NOTE: Before removing the timing belt, make sure
the alignment mark on the crankshaft timing pulley
is aligned with the alignment mark on the oil pump
case flange, with the No. 1 cylinder in the combustion
stroke; the camshaft timing pulley alignment mark is
aligned with the timing mark on the rear timing belt
cover; and the camshaft pin is in the top hole of the
camshaft timing pulley. See Timing Belt and Timing
Belt Tensioner, Remove.

1. Remove the timing belt. See Timing Belt and Tim-

1. CAPSCREW ing Belt Tensioner, Remove.
2. OIL FILLER CAP
3. ROCKER ARM COVER 2. Remove the rocker arm cover. See Rocker Arm
4. CAMSHAFT CARRIER ASSEMBLY Cover, Remove.
Figure 5. Rocker Arm Cover 3. Use a 22-mm, open-end wrench and lock the
camshaft. Using a 17-mm wrench, remove the bolt
retaining the camshaft timing pulley. See Figure 6.

6
600 YRM 1121
1. CAMSHAFT TIMING PULLEY
2. 22-MM, OPEN-END WRENCH
3. 17-MM WRENCH
Figure 6. Camshaft Timing Pulley
4. Remove the camshaft timing pulley.
5. Drill a small hole into the front seal face. Install a
fine thread screw. Using a pair of pliers, pull the
seal outward, and remove the seal. See Figure 7.
Figure 7. Camshaft Front Seal Removal
Install
1. Using a special tool, a camshaft seal installer, install
new front seal. See Figure 8.
Camshaft and Cylinder Head Repair
Figure 8. Camshaft Front Seal Installation
2. Use a 22-mm, open-end wrench and lock the
camshaft.
3. Place the camshaft timing pulley in position. Install
the retaining bolt and tighten bolt to 40 to 50 N•m
(30 to 37 lbf ft). See Figure 6.
NOTE: Before installing the timing belt, verify the align-
ment mark on the crankshaft timing pulley is aligned
with the alignment mark on the oil pump case flange,
with the No. 1 cylinder in the combustion stroke; the
camshaft timing pulley alignment mark is aligned with
the timing mark on the rear timing belt cover; and the
camshaft pin is in the top hole of the camshaft timing
pulley. See Timing Belt and Timing Belt Tensioner, In-
stall.
4. Install the timing belt. See Timing Belt and Timing
Belt Tensioner, Install.
5. Install the rocker arm cover. See Rocker Arm
Cover, Install.
CAMSHAFT CARRIER AND CYLINDER
HEAD
Remove
1. Turn the ignition switch to the OFF position.
2. Disconnect the negative battery cable.
7
Camshaft and Cylinder Head Repair 600 YRM 1121

10. Remove the timing belt rear cover. See Timing Belt
WARNING Rear Cover, Remove.
DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator cap is re- 11. Remove the thermostat housing. See Thermostat
moved, pressure will release from the coolant sys- Housing, Remove.
tem. If the coolant system is hot, the steam and
boiling coolant can cause severe burns. 12. Disconnect the electrical connector for the
camshaft sensor.

WARNING 13. Remove the rocker arm cover. See Rocker Arm
The radiator or other parts of the cooling system Cover, Remove.
may be hot or under pressure and can cause seri-
ous injury. Wait 30 minutes for the radiator and en- CAUTION
gine to cool before performing maintenance to the
Since there is spring tension on the camshaft and
cooling system. After 30 minutes, do a touch test
carrier, use caution when removing camshaft car-
by touching the radiator with your hand. If the radia-
rier/cylinder head bolts. Remove the bolts in the
tor is still hot to the touch, wait another 30 minutes
sequence shown in Figure 9 in even increments
before attempting any maintenance to the cooling
to prevent possible damage to the camshaft and
system.
camshaft carrier.

CAUTION 14. Remove and discard the camshaft carrier/cylinder

head bolts in sequence and in even increments.
Disposal of lubricants must meet local environmen-
See Figure 9 and Figure 10.
tal regulations.

3. Remove the radiator cap.

4. Loosen the lower radiator hose and drain the

coolant from the coolant system.

5. Remove the intake manifold. See Intake Manifold,

Remove.

6. Remove the exhaust manifold. See Exhaust Mani-

fold, Remove.

7. Remove the spark plugs.

8. Remove the fan belt. See Serpentine Belt, Re-

move.

NOTE: Before removing the timing belt, make sure Figure 9. Removal Sequence
the alignment mark on the crankshaft timing pulley
is aligned with the alignment mark on the oil pump
case flange, with the No. 1 cylinder in the combustion
15. Remove the camshaft carrier assembly from the
stroke; the camshaft timing pulley alignment mark is
cylinder head.
aligned with the timing mark on the rear timing belt
cover; and the camshaft pin is in the top hole of the NOTE: Organize camshaft followers and keepers so
camshaft timing pulley. See Timing Belt and Timing they can be installed in their original positions.
Belt Tensioner, Remove.
16. Remove the camshaft followers and keepers from
9. Remove the timing belt. See Timing Belt and Tim- the cylinder head. See Figure 11.
ing Belt Tensioner, Remove.

8
600 YRM 1121 Camshaft and Cylinder Head Repair

NOTE: Organize camshaft lifters so they can be in-

stalled in their original positions.

17. Remove the camshaft lifters from the cylinder head.

18. Remove the cylinder head from the engine block.

19. Remove the cylinder head gasket and discard.

Disassemble
Camshaft Carrier

1. Remove the camshaft sensor assembly.

2. Remove the capscrews from the camshaft retainer.

See Figure 12.

1. WASHER
2. BOLT
3. CAMSHAFT CARRIER ASSEMBLY
4. CYLINDER HEAD

Figure 10. Camshaft Carrier Assembly

1. RETAINER 2. CAPSCREW

Figure 12. Camshaft Retainer

3. Carefully move the camshaft slightly out of the

camshaft carrier and remove the camshaft re-
tainer.

CAUTION
All camshaft journals are the same diameter. Be
careful when removing the camshaft to avoid dam-
1. CAMSHAFT FOLLOWER age to the camshaft carrier.
2. KEEPERS
3. LIFTERS 4. Carefully rotate and remove the camshaft out of the
4. CYLINDER HEAD camshaft carrier. See Figure 13.
5. CYLINDER HEAD GASKET
6. CYLINDER BLOCK

Figure 11. Cylinder Head

9
Camshaft and Cylinder Head Repair 600 YRM 1121

2. Remove the valve stem keys. See Figure 15.

1. CAMSHAFT 2. CAMSHAFT
CARRIER

Figure 13. Camshaft Removal/Installation

5. Remove the front camshaft seal. See Camshaft 1. VALVE STEM KEYS
Timing Pulley and/or Front Seal, Remove. 2. RETAINER
3. VALVE SPRING
Cylinder Head 4. VALVE STEM OIL SEAL
5. VALVE SEAT (INLET)
NOTE: Keep cylinder head components in order so they 6. VALVE INLET
will be installed in the same positions during assembly. 7. VALVE EXHAUST
8. CYLINDER HEAD
1. Using a valve spring compressor, compress the 9. VALVE SPRING ROTATOR ASSEMBLY
(EXHAUST)
valve spring. See Figure 14.
Figure 15. Valve Removal/Installation

3. Remove the retainers from the valve spring.

4. Remove the valve springs.

5. Using a special tool, remove the valve stem oil

seals.

6. Remove valve spring seat (Inlet).

7. Remove the valve spring rotator assembly.

8. Remove the exhaust valve.

9. Remove the inlet valve.

10. Repeat Step 1 through Step 9 for remaining valves.

1. VALVE SPRING COMPRESSOR

Figure 14. Valve Spring Compressor

10
600 YRM 1121 Camshaft and Cylinder Head Repair

Clean and Inspect

Camshaft Carrier

CAUTION
Use care not to damage the mating surfaces when
removing old gaskets and sealant residues.

1. Clean all debris, old gaskets, and sealants from the

mating surfaces of the camshaft carrier. See Fig-
ure 16.

1. CAMSHAFT BORE

Figure 17. Camshaft Bores Inspection

7. Using a dial indicator, measure the camshaft bore

surfaces. See Engine Specifications for the correct
measurements. If not within specifications, replace
camshaft carrier.

Cylinder Head

CAUTION
Do not use a wire brush to clean the combustion
chambers. This can damage the seats and possibly
the sealing surface at the edge of the combustion
1. THREADED HOLE
2. MATING SURFACE chamber.
3. BOLT HOLE
Use a soft brush and cleaner to remove the carbon from
Figure 16. Camshaft Carrier the combustion chambers and the valve ports. Be care-
ful not to scuff the chamber.
2. Clean the bolt holes and threads in the camshaft
carrier. 1. Clean the following areas:

3. Inspect the camshaft carrier mating surfaces for a. Carbon and sludge from the lifters, followers,
damage. Replace as needed. and keepers.

4. Inspect the camshaft carrier for cracks or any other b. Valve stems and heads.
damage. Replace as needed.
c. Cylinder head and engine block gasket sur-
5. Inspect the bottom mating surface of the camshaft faces.
carrier for warpage. Replace as needed.
d. Bolt holes and threads in the cylinder head and
6. Inspect the bores in the camshaft carrier for dam- the engine block.
age. Replace as needed. See Figure 17.

11
Camshaft and Cylinder Head Repair 600 YRM 1121

2. Inspect the following areas: valve with an oversize stem must be installed.
Use a reamer to make the bore the correct di-
a. Cylinder head for cracks in the exhaust ports ameter for the next oversize valve. See Fig-
and the combustion chambers. ure 19. See the Parts Manual for oversize
valves.
b. Cylinder head for external cracks in the water
chamber.

c. Valves for burned heads, cracked faces, or

damaged stems.

3. Check the valve stem-to-bore clearance of each

valve and valve guide. Use the following procedure:

a. Install the dial indicator into the valve guide and

measure the inner diameter of the valve guide.
See Figure 18.

Figure 19. Valve Guide Reaming

4. Inspect the valve springs for squareness. See Fig-

ure 20.

Figure 18. Valve Guide Inner Diameter

Measurement

b. Measure the outside diameter of the valve stem

with a micrometer.

c. Determine the difference between the outer di-

ameter of the valve stem and the inner diameter
of the valve guide.

d. The maximum clearance between the valve

stems and their valve guides is shown in En-
gine Specifications.

NOTE: If the valve stem to valve guide clearance cannot

be obtained using an oversized valve stem, the cylinder Figure 20. Valve Springs Inspection
head must be replaced.
5. Measure the valve seat runout. The valve seats
e. If the clearance between the valve stem and its should be centered to within 0.05 mm (0.002 in.).
valve guide is greater than the specification, a See Figure 21.

12
600 YRM 1121 Camshaft and Cylinder Head Repair

seats, make sure the clearance of the valve stems in

their valve guides is within specifications.

A correction for minimum wear and damage to the

valve and seat can be done by a process called lap-
ping. When the valve seats are lapped, keep the valve
seats within the specifications. Make sure all of the
lapping compound is removed from the valve and valve
seat when the process is completed.

Damaged valve seats can be repaired with a 45 ±30’

cutter tool. See Figure 23. If the valve seat cannot be
repaired so that the valve depth is within specifications,
the cylinder head must be replaced. The specifications
for the valve seats are listed in Engine Specifications.

Figure 21. Valve Seat Runout Measurement

6. Inspect the cylinder head and measure it for

warpage. A cylinder head with excessive warpage
must be repaired or replaced. Refer to Engine
Specifications for cylinder head dimensions. Also,
see Figure 22.

Figure 22. Cylinder Head Measurement

Valve and Valve Seat

The condition of the valves and alignment of the valves Figure 23. Valve Seat Repair
to their valve seats are important for the correct opera-
tion of the engine. Before any work is done on the valve

13
Camshaft and Cylinder Head Repair
Assemble
Cylinder Head
1. Install the valves into the proper ports. See Fig-
ure 15.
2. Install the valve seat (inlet) on the inlet valve.
3. Install the valve seat (exhaust) on the exhaust
valve.
4. Install the inlet valve and exhaust valve into the
cylinder head.
5. Install the valve spring rotator assembly over the
valve guide.
6. Lubricate the valve stem oil seal with clean engine
oil.
7. Using a special tool, install the valve stem oil seal
onto the exhaust valve.
8. Lubricate the valve stem oil seal with clean engine
oil.
9. Using a special tool, install the valve stem oil seal
onto the inlet valve.
10. Install the valve springs.
11. Install the retainers onto the valve spring.
12. Using a valve spring compressor, compress the
valve spring.
NOTE: Make sure the keys seat properly in the upper
groove of the valve stem. If necessary, tap the end
of the valve stem with a plastic-faced hammer, making
sure the valves will not come into contact with the work
bench, in order to seat the keys.
13. Install the valve stem keys.
14. Remove the valve spring compressor.
15. Repeat Step 1 through Step 14 for remaining
valves.
Camshaft Carrier
1. Using a special tool, a camshaft seal installer, install
new front seal. See Figure 8.
14
600 YRM 1121
CAUTION
All camshaft journals are the same diameter. Be
careful when installing the camshaft to avoid dam-
age to the camshaft carrier.
2. Carefully rotate and install the camshaft into the
camshaft carrier.
NOTE: The camshaft may need to be pulled slightly out
of the camshaft carrier to place the camshaft retainer in
position.
3. Install the camshaft retainer.
4. Install the capscrews to retain the camshaft re-
tainer. Tighten capscrews to 8 N•m (71 lbf in).
5. Install the camshaft sensor assembly.
Install
NOTE: Verify the cylinder head locators are installed in
the engine block.
1. Install the new cylinder head gasket over the loca-
tors onto the engine block with the TOP mark fac-
ing upward and toward the front end of the engine
block. See Figure 11.
2. Install the cylinder head over the locators onto the
gasket.
3. Coat the bottom of the valve lifters with molybde-
num lubricant.
NOTE: If using the old valve lifters, install the lifters in
original positions.
4. Install valve lifters.
5. Install the camshaft follower keepers and followers.
6. Apply RTV sealant (Yale part number 520039889)
to the mating surface of the cylinder head for the
carrier assembly.
7. Place the camshaft carrier assembly in position on
the cylinder head.
8. Install new camshaft carrier/cylinder head bolts and
washers. Tighten bolts finger tight only.
9. Tighten the camshaft carrier/cylinder head bolts in
sequence to 25 N•m (18 lbf ft). See Figure 24.
600 YRM 1121
Figure 24. Tightening Sequence
10. Tighten the cylinder head bolts in sequence an ad-
ditional 180 degrees.
11. Tighten the cylinder head bolts in sequence an ad-
ditional 10 degrees.
12. Install the rocker arm cover. See Rocker Arm
Cover, Install.
13. Connect the electrical connector for the camshaft
sensor.
14. Install the thermostat housing. See Thermostat
Housing, Install.
15. Install the timing belt rear cover. See Timing Belt
Rear Cover, Install.
NOTE: Before installing the timing belt, verify the align-
ment mark on the crankshaft timing pulley is aligned
with the alignment mark on the oil pump case flange,
with the No. 1 cylinder in the combustion stroke; the
camshaft timing pulley alignment mark is aligned with
the timing mark on the rear timing belt cover; and the
camshaft pin is in the top hole of the camshaft timing
pulley. See Timing Belt and Timing Belt Tensioner, In-
stall.
16. Install the timing belt. See Timing Belt and Timing
Belt Tensioner, Install.
Camshaft and Cylinder Head Repair
17. Install the fan belt. See Serpentine Belt, Install.
18. Install the spark plugs.
19. Install the exhaust manifold. See Exhaust Manifold,
Install.
20. Install the intake manifold. See Intake Manifold,
Install.
21. Connect the lower radiator hose and tighten the
clamp.
CAUTION
Additives may damage the cooling system. Before
using additives, contact your local Yale dealer.
22. Connect the bottom radiator hose. Fill cooling sys-
tem with coolant. Refer to the section Periodic
Maintenance 8000 YRM 1150 for correct coolant
amount and type.
23. Install radiator cap on radiator.
WARNING
During engine operation, be careful not to touch the
fan, pulleys, or drive belts. Contact with these parts
can cause serious injury.
WARNING
The radiator or other parts of the cooling system
may be hot or under pressure and can cause seri-
ous injury.
24. Start engine and check cooling system for leaks.
25. Bleed air from the cooling system by opening the
bleed screw located on the left side behind the al-
ternator. When the air has been bled from the sys-
tem, close the bleed screw.
15
Timing Belt 600 YRM 1121

Do a touch test by touching the radiator with your

WARNING
DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator cap is
removed, the pressure is released from the system.
If the system is hot, the steam and boiling coolant
can cause burns. DO NOT remove the cover for the
radiator when the engine is running.
WARNING
The radiator or other parts of the cooling system
may be hot or under pressure and can cause seri-
ous injury. Wait 30 minutes for the radiator to cool.
hand. If the radiator is still hot to the touch, wait an-
other 30 minutes before attempting to check or fix
any part of the cooling system.
CAUTION
Additives may damage the cooling system. Before
using additives, contact your local Yale dealer.
26. Stop engine. If coolant is hot, give engine time to
cool. Check coolant level and fill as required be-
tween the ADD and FULL marks on the coolant
reservoir.

Timing Belt
TIMING BELT FRONT COVER 13. Remove the bolts retaining the crankshaft fan pul-
ley and remove the crankshaft fan pulley and the
Remove crankshaft pulley spacer. See Figure 25.

1. Turn the ignition to the OFF position.

2. Remove the battery, battery tray, and PDM. Refer

to the section Electrical System 2200 YRM 1142.

3. Remove the auxiliary coolant reservoir.

4. Remove the fan shroud. Refer to the section Cool-

ing System 700 YRM 1123.

5. Place a piece of cardboard over the radiator surface

to prevent damage to the radiator.

6. Remove the four bolts retaining the fan assembly.

7. Remove the fan assembly.

8. Remove the serpentine belt. See Serpentine Belt,

Remove.

9. Remove the spacer and the pulley.

1. CRANKSHAFT PULLEY HUB
10. Disconnect the electrical connections to the alter- 2. CRANKSHAFT PULLEY SPACER
nator. 3. CRANKSHAFT PULLEY
4. SERPENTINE BELT
11. Remove the alternator mounting bolts and remove 5. OIL PUMP HOUSING
6. ALIGNMENT MARK
the alternator.
Figure 25. Crankshaft Pulley Arrangement
12. Remove the alternator bracket bolts, fan hub
bracket bolts, and fan hub bracket. 14. Remove the front timing belt cover bolts and remove
the front timing belt cover.
NOTE: Before removing the crankshaft pulley and
the crankshaft pulley hub, make alignment marks on
the crankshaft hub, crankshaft pulley, and crankshaft
spacer.

16
600 YRM 1121 Timing Belt

Install
1. Place the timing belt cover over the timing belt and
install bolts. Tighten bolts to 6 N•m (53 lbf in).

NOTE: Before installing the crankshaft pulley and

crankshaft spacer, align these components with the
alignment marks made when disassembled.

2. Install the crankshaft spacer and crankshaft pulley,

ensuring that all alignment marks made during re-
moval are lined up properly. Tighten crankshaft pul-
ley bolts to 15 to 25 N•m (11 to 18 lbf ft).

3. Install fan hub bracket and retaining bolts. Tighten

Figure 26. Crankshaft Timing Pulley Alignment
bolts to 52 N•m (38 lbf ft).
Mark
4. Install alternator bracket and retaining bolts.
Tighten bolts to 38 N•m (28 lbf ft). CAUTION
The camshaft pin must be in the top hole of the
5. Install the alternator. See the section Alternator
camshaft timing pulley.
Repair.
3. Position the camshaft timing pulley alignment mark
6. Install the fan spacer and the pulley.
with the timing mark on the rear timing belt cover.
7. Install the serpentine belt. See Serpentine Belt, Verify that the camshaft pin is located in the 12
Install. o’clock position. See Figure 27.

8. Place the fan in position on the pulley and install

the four retaining bolts. Tighten the bolts to 26 N•m
(19 lbf ft).

9. Remove cardboard from the radiator surface.

10. Install the fan shroud. Refer to the section Cooling

System 700 YRM 1123.

11. Install the auxiliary coolant reservoir.

12. Install the battery, battery tray, and PDM. Refer to

the section Electrical System 2200 YRM 1142.

TIMING BELT AND TIMING BELT

TENSIONER
Remove
1. Remove the timing belt front cover. See Timing Belt
Front Cover, Remove.

2. Turn the crankshaft until the alignment mark on the
crankshaft timing pulley is aligned with the align-
ment mark on the oil pump case flange, with the
No. 1 cylinder in the combustion stroke. See Fig-
ure 26.
1. CAMSHAFT PIN
Figure 27. Camshaft Timing Pulley and Crankshaft
Timing Pulley Alignment Marks
4. Use chalk to mark direction of timing belt rotation.
See Figure 28.

17
Timing Belt 600 YRM 1121

Install
1. Align the camshaft timing pulley alignment mark
with the timing mark on the rear timing belt cover.
See Figure 27.

CAUTION
The camshaft pin must be in the top hole of the
camshaft timing pulley.

2. Verify that the camshaft pin is located in the 12

o’clock position. See Figure 27.

3. Verify the alignment mark on the crankshaft timing

Figure 28. Timing Belt
NOTE: Before removing the timing belt tensioner, verify
the tensioner tab is between the two locator tabs at the
7 o’clock position. See Figure 29.
5. Remove the bolt retaining the timing belt tensioner.
pulley is aligned with the alignment mark on the oil
pump case flange, with the No. 1 cylinder in the
combustion stroke. See Figure 27.
NOTE: The timing belt tensioner tab must be placed in
the 7 o’clock position between the locators. See Fig-
ure 29.
4. Install the timing belt tensioner, but do not tighten
the bolt.

5. Place the timing belt over the pulleys and the timing
belt tensioner.

6. Tighten the tensioner to the appropriate reference

mark with the crankshaft timing pulley hub timing
mark aligned with the oil pump housing timing mark
and the camshaft timing belt pulley timing mark
aligned with the timing mark located on the plas-
tic timing belt housing.

NOTE: The timing belt tensioner has two markings,

NEW and USED, for the appropriate timing belt. The
tensioner pointer will need to be aligned with the correct
timing belt installed. See Figure 29.
1. WATER PUMP BOLT 7. If timing belt is too tight and cannot be adjusted with
2. WATER PUMP
3. WATER PUMP TAB (11 O’CLOCK POSITION) the tensioner, loosen water pump bolts (see Fig-
4. TIMING BELT TENSIONER POINTER ure 29) and turn water pump counterclockwise un-
5. LOCATORS til proper tension is achieved. Tighten water pump
6. TENSIONER TAB (7 O’CLOCK POSITION) bolts to 20 to 30 N•m (15 to 22 lbf ft).
7. USED TIMING BELT MARK
8. NEW TIMING BELT MARK 8. If timing belt is too loose and cannot be adjusted
9. TENSIONER
with the tensioner, loosen water pump bolts and
Figure 29. Tensioner Tab and Locators turn water pump clockwise until proper tension is
reached. Tighten water pump bolts to 20 to 30 N•m
6. Remove the timing belt and the timing belt ten- (15 to 22 lbf ft).
sioner.

18
600 YRM 1121
9. Tighten the timing belt tensioner bolt to 20 N•m
(15 lbf ft). Verify the timing belt tensioner pointer is
aligned with the appropriate mark after tightening.
Recheck tensioner and timing belt marks to make
sure they are still aligned correctly.
10. Install the timing belt front cover. See Timing Belt
Front Cover, Install
TIMING BELT REAR COVER
Remove
1. Remove the timing belt front cover. See Timing Belt
Front Cover, Remove.
NOTE: Before removing the timing belt, verify the align-
ment mark on the crankshaft timing pulley is aligned
with the alignment mark on the oil pump case flange,
with the No. 1 cylinder in the combustion stroke, the
camshaft timing pulley alignment mark is aligned with
the timing mark on the rear timing belt cover, and the
camshaft pin is in the top hole of the camshaft timing
pulley. See Timing Belt and Timing Belt Tensioner, Re-
move.
2. Remove the timing belt and timing belt tensioner.
See Timing Belt and Timing Belt Tensioner, Re-
move.
3. Remove the rocker arm cover.
4. Remove the camshaft timing pulley. See Camshaft
Timing Pulley and/or Front Seal, Remove.
5. Remove the crankshaft timing pulley. See Crank-
shaft Timing Pulley and/or Front Seal, Remove.
6. Remove the Torx head capscrews retaining front
bracket and remove front bracket.
Timing Belt
7. Remove the capscrews retaining the timing belt
rear cover.
8. Remove timing belt rear cover.
Install
1. Place timing belt rear cover in position on engine.
2. Install bolts to retain timing belt rear cover. Tighten
capscrews to 6 N•m (53 lbf in).
3. Place front bracket in position and install Torx
head capscrews. Tighten Torx head capscrews to
25 N•m (18 lbf ft).
4. Install the camshaft timing pulley. See Camshaft
Timing Pulley and/or Front Seal, Install.
5. Install crankshaft timing pulley and retaining bolt.
See Crankshaft Timing Pulley and/or Front Seal,
Install.
NOTE: Before installing the timing belt, verify the align-
ment mark on the crankshaft timing pulley is aligned
with the alignment mark on the oil pump case flange,
with the No. 1 cylinder in the combustion stroke; the
camshaft timing pulley alignment mark is aligned with
the timing mark on the rear timing belt cover; and the
camshaft pin is in the top hole of the camshaft timing
pulley. See Timing Belt and Timing Belt Tensioner, In-
stall.
6. Install the timing belt and timing belt tensioner. See
Timing Belt and Timing Belt Tensioner, Install.
7. Install the timing belt front cover. See Timing Belt
Front Cover, Install.
19
Lubrication System Repair 600 YRM 1121

Lubrication System Repair

OIL PAN
Remove
1. Remove the engine from the lift truck. Refer to the
section Frame 100 YRM 1120 for the procedures
to remove the engine.
2. Remove the oil pan drain plug and drain the engine
oil into a suitable container.
6. Carefully remove old sealant residue from the mat-
ing surfaces of the oil pan and cylinder block.
7. Thoroughly clean the outside and inside surfaces
of the oil pan.
Install
1. Apply a 3.175 mm (0.125 in.) continuous bead of
sealant around the sealing surface of the oil pan.

3. If necessary, remove the oil filter.
4. Remove the capscrews retaining the oil pan to the
engine block. See Figure 30.
2. Place the oil pan into position on the cylinder block
using the locating pins.
3. Remove the right side bell housing alignment bush-
ing. See Figure 31.

1. BUSHING
1. OIL PAN 2. BELL HOUSING
2. DRAIN PLUG 3. REMOVAL TOOL

Figure 30. Oil Pan Figure 31. Bell Housing Alignment Bushing

5. Remove the oil pan. 4. Install special tool, rear flange alignment tool, to
keep the alignment of the oil pan to the cylinder
block. See Figure 32.
CAUTION
Use care not to damage the mating surfaces when
removing old gaskets and sealant residues.

20
600 YRM 1121 Lubrication System Repair

1. OIL PAN
2. REAR FLANGE ALIGNMENT TOOL
3. BELL HOUSING

Figure 32. Rear Flange Alignment Tool

5. Install capscrews, except the two capscrews where

the alignment tool is using the mounting holes.

6. Verify the alignment of the oil pan and cylinder block

is correct. The edge of the oil pan should be a
maximum distance of 0.15 mm (0.006 in.) from the
edge of the cylinder block. See Figure 33. Adjust
the oil pan as needed.

7. Tighten the capscrews to 18 to 22 N•m (13 to

16 lbf ft).

8. Remove the special tool.

9. Install the remaining two capscrews and tighten to

18 to 22 N•m (13 to 16 lbf ft).

10. Install the right side bell housing alignment bushing.

11. Install the drain plug and tighten to 18 to 22 N•m 1. CYLINDER BLOCK
(13 to 16 lbf ft). 2. OIL PAN
12. If removed, install new oil filter. Figure 33. Oil Pan Alignment
13. Install the engine into the lift truck. Refer to the 14. Fill the engine oil to the correct level. Refer to the
section Frame 100 YRM 1120. section Periodic Maintenance 8000 YRM 1150 for
correct oil amount and type.

21
Lubrication System Repair 600 YRM 1121

OIL PUMP
Remove
1. Remove the oil pan. See Oil Pan, Remove.

2. Remove the timing belt rear cover. See Timing Belt

Rear Cover, Remove.

3. Disconnect the electrical connector for the crank-

shaft sensor.

4. Disconnect the electrical connector for the oil pres-

sure sensor. See Figure 34 and Figure 35.

1. ELECTRICAL CONNECTOR
2. OIL PRESSURE SENSOR
3. OIL FILTER

Figure 35. Oil Pressure Sensor and Oil Filter

Without Adaptor

5. Remove the oil pressure sensor.

6. Remove the oil filter.

NOTE: Step 7 and Step 8 are for engines with an oil

filter adapter only.

7. Using vise grips, remove the banjo bolt retaining the

oil filter adapter and remove oil filter adapter.

8. Discard the seal washer and the banjo bolt.

9. Remove the capscrew from the oil pump suction

1. OIL FILTER tube bracket. See Figure 36.
2. OIL PRESSURE SENSOR
3. BANJO BOLT 10. Remove the capscrews from the suction tube.
4. OIL FILTER ADAPTER
5. ELECTRICAL CONNECTOR NOTE: The oil suction tube and screen are to be ser-
viced as an assembly. Do not attempt to repair the wire
Figure 34. Oil Pressure Sensor and Oil Filter With mesh portion of the tube and screen assembly.
Adaptor
11. Remove the suction tube and O-ring. Discard
O-ring.

12. Remove the capscrews retaining the oil pump to the

engine block. See Figure 37.

22
600 YRM 1121 Lubrication System Repair

Clean and Inspect

NOTE: The internal components of the oil pump are not
serviceable. If the oil pump components are damaged
or worn, replace the oil pump as an assembly.

1. Remove the screws retaining the oil pump cover

and remove oil pump cover. See Figure 38.

1. O-RING
2. BRACKET
3. SUCTION TUBE
4. CAPSCREWS

Figure 36. Oil Suction Tube

1. SCREW
2. OIL PUMP COVER

Figure 38. Oil Pump Cover

WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning sol-
vents, always follow the recommendations of the
manufacturer.

WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
1. CAPSCREW Make sure that the path of the compressed air is
2. SAFETY VALVE
3. SPACER away from all personnel. Wear protective goggles
4. GASKET or a face shield to prevent injury to the eyes.
5. OIL PUMP
NOTE: The internal parts of the oil pump are not ser-
Figure 37. Oil Pump viced separately. If the oil pump components are worn
or damaged, replace the oil pump as an assembly. If
NOTE: Be sure to retain the spacers for installation. the drive gear and drive shaft are worn, replace the en-
tire oil pump.
13. Remove the oil pump, gasket, and spacers. Dis-
card gasket. The oil suction tube and screen are to be serviced as
an assembly. Do not attempt to repair the wire mesh
14. Remove the safety valve.
portion of the tube and screen assembly.

23
Lubrication System Repair 600 YRM 1121

2. Clean all of the parts in cleaning solvent. Dry the 6. Install the oil pump suction tube bracket capscrew.
parts with compressed air. Tighten capscrew to 18 to 22 N•m (13 to 16 lbf ft).

3. Inspect the gears and the pump body for wear and
damage. If the parts are worn or damaged, replace
the oil pump.
4. Check the gap of the gears with a feeler gauge and
a straight edge. The dimension should be 0.03 to
0.10 mm (0.0011 to 0.004 in.). See Figure 39.
NOTE: Step 7 is for engines with an oil filter adapter
only.
7. Install the oil filter adapter, new seal washer, and
new shear banjo bolt. Tighten banjo bolt with an
open-end, 10-mm wrench until the head of the bolt
completely shears off. See Figure 40.

1. STRAIGHT EDGE 2. FEELER GAUGE

Figure 39. Gear Inspection 1. SEAL WASHER

2. BANJO BOLT
5. Attach the oil pump cover to the oil pump. Install 3. SHEAR HEAD
the retaining screws. Tighten retaining screws to 4. OIL FILTER ADAPTER
6 N•m (53 lbf in).
Figure 40. Shear Banjo Bolt Installation
Install
8. Install new oil filter.
1. Install safety valve with a new O-ring. Tighten
safety valve to 37 N•m (27 lbf ft). 9. Install the oil pressure sensor. Tighten sensor to
20 N•m (15 lbf ft).
2. Install new oil pump gasket.
10. Connect the electrical connector for the oil pressure
3. Install the oil pump and spacers. sensor.

4. Install the capscrews to retain the oil pump to en-
gine block. Tighten capscrews to 6 to 10 N•m (53
to 89 lbf in).
5. Install new O-ring on oil pump suction tube. Install
the oil pump suction tube and capscrews. Tighten
the capscrews to 8 N•m (71 lbf in).
11. Install the timing belt rear cover. See Timing Belt
Rear Cover, Install.
12. Connect the electrical connector for the crankshaft
sensor.
13. Install the oil pan. See Oil Pan, Install.

24
600 YRM 1121
Piston and Piston Rod Assemblies Repair
PISTON ROD BEARINGS, REPLACE
NOTE: The piston rod bearings are available in a stan-
dard size and several undersizes. See the Parts Man-
ual for bearing sizes. If a bearing on a journal is worn,
both the upper and lower halves of the bearing must be
replaced.
1. Remove the oil pan and oil pump. See Lubrication
System Repair.
2. Remove the capscrews retaining the baffle plate
and remove baffle plate.
3. Remove the remaining capscrews from the bearing
bracket and remove the bearing bracket.
4. Before the cap for the piston rod is removed, mark
the piston rod and cap with the cylinder number
so that the parts will be installed in their original
positions.
5. Remove the capscrews retaining the cap and re-
move cap for the piston rod bearing and the lower
bearing half. See Figure 41.
Figure 41. Piston Rod Cap Removal
Piston and Piston Rod Assemblies Repair
Legend for Figure 41
1. BEARING CAP
2. BEARING
3. CRANKSHAFT
6. Push the piston rod away from the crankshaft and
remove the upper bearing half. Wipe the oil from
the bearing halves and the bearing journal.
7. Inspect bearings for craters, pockets, excessive
scoring, and dirt or debris imbedded into the bear-
ing material. Replace as needed. Replace the
upper and lower halves as a set.
8. Inspect the bearings for improper seating indicated
by bright, polished sections of the bearing. Replace
as needed. Replace the upper and lower halves as
a set.
9. Use a micrometer to measure the bearing journal.
The bearing journal must be within the following
specification:
• Out-of-roundness less than 0.004 mm
(0.00016 in.); taper less than 0.005 mm
(0.0002 in.)
If the bearing journals are not within specifications,
the crankshaft must be removed and the bearing
journal ground to an undersize. If the bearing jour-
nal cannot be repaired so that the bearing journal
is a correct undersize, the crankshaft must be re-
placed. See Engine Specifications.
10. If the bearing journal is within specifications, mea-
sure the clearance between the new bearing and
the crankshaft. Use Plastigage®, or equivalent, to
check the clearance as described below:
a. Put a piece of Plastigage® across the full width
of the bearing journal as shown in Figure 42.
Do not rotate the crankshaft when the Plasti-
gage® is between the bearing and its journal.
25
Piston and Piston Rod Assemblies Repair
1. BEARING CAP 2. PLASTIGAGE®
Figure 42. Bearing Journal Plastigage® Placement
b. Install the bearing and bearing cap. Tighten the
capscrews to 30 to 40 N•m (22 to 29.5 lbf ft).
Tighten the capscrews an additional 40 to 45
degrees.
c. Remove the bearing and bearing cap. The
Plastigage® will be compressed and wider and
it will adhere to either the bearing or its journal.
Use the scale on the envelope for the Plasti-
gage® to measure the width of the plastic at its
widest point. The scale will indicate the clear-
ance in millimeters or thousandths of an inch.
See Figure 43.
d. If the clearance is greater than the specifica-
tions, select a new undersize bearing set and
install it. Measure the clearance again. If the
clearance cannot meet specifications with the
available undersize bearings, the bearing jour-
nal must be ground to a new undersize. If the
bearing journal is already at the maximum un-
dersize, the crankshaft must be replaced.
26
600 YRM 1121
Figure 43. Bearing Journal Plastigage®
Measurement
e. If the clearance is within specifications, lubri-
cate the bearing with engine oil and install the
bearing and bearing cap. Tighten the cap-
screws to 30 to 40 N•m (22 to 29.5 lbf ft).
Tighten the capscrews an additional 40 to 45
degrees.
11. When all of the connecting rod bearings have been
replaced, use the following procedure to check the
side clearances between the piston rods and the
crankshaft (refer to Engine Specifications for clear-
ance specifications):
a. Use a hammer to lightly hit the piston rod paral-
lel to the crankshaft journal to make sure there
is a clearance.
b. Measure the clearance between the caps for
the piston rods and the crankshaft. See Fig-
ure 44.
600 YRM 1121 Piston and Piston Rod Assemblies Repair

Figure 44. Piston Rods Side Clearance

Measurement

PISTON AND PISTON ROD ASSEMBLIES

Remove
1. Remove the oil pan and oil pump. See Lubrication
Figure 45. Ridge Reamer
System Repair.
5. Clean the carbon from the top of each cylinder.
2. Remove the capscrews retaining the baffle plate
and remove baffle plate. 6. Put an identification mark on the top of each piston.
3. Remove the cylinder head. See Camshaft Carrier 7. Remove the caps and bearings from each piston
and Cylinder Head, Remove. rod. Keep the caps and bearings with their original
piston assemblies. Mark the caps so that they will
4. If the engine has been in service for many hours, a
be installed again in their original positions. Do not
ridge can be worn in the top of the cylinder. This
mix the parts.
ridge can be removed with a ridge reamer tool (see
Figure 45) using the procedures described below: 8. Push the piston rod and piston from the cylinder.
Temporarily install the bearing cap on the piston rod
a. Turn the crankshaft to lower the piston to the
to keep the parts together.
bottom of the stroke in its cylinder.

b. Put a cloth on top of the piston to collect metal Disassemble

particles.
CAUTION
c. Remove the ridge at the top of the cylinder.
The pistons are aluminum alloy and can be dam-
d. Turn the crankshaft so the piston is at the top aged if they are hit with a hard object. The grooves
of the stroke. for the piston rings are machined to close toler-
ances. Use a tool made to clean the grooves of the
e. Remove the cloth. piston rings. Do not use a wire brush to clean a pis-
ton.
f. Remove the cutting debris.
1. Remove the piston rings from the pistons. See Fig-
ure 46.

27
Piston and Piston Rod Assemblies Repair 600 YRM 1121

1. UPPER COMPRESSION RING

2. LOWER COMPRESSION RING
3. OIL CONTROL RING
4. PISTON

Figure 46. Piston Rings

2. Use a press to remove the wrist pins from the pis-

tons. See Figure 47. Figure 47. Wrist Pin Removal

Pistons, Clean and Inspect

WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning sol-
vents, always follow the recommendations of the
manufacturer.
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
3. Use solvent to clean the pistons and piston rods.
Use compressed air to dry the parts. Make sure
that the holes for oil passages are clean.
Inspect the pistons for wear, cracks, and damage. Re-
place a piston that is worn or damaged.
NOTE: If the cylinder bore must be repaired, the piston
must be changed to the correct oversize piston. Check
the clearance of the piston in its cylinder after the sur-
face of the cylinder bore has been finished with a hone.
Check the clearance of the wrist pin in the piston. The
normal clearance is shown in Engine Specifications.
The wrist pin will normally fall from the hole in the piston
by its own weight.
The wrist pin is a press fit in the piston rod. The piston
and wrist pin are a matched set and must be replaced
as a unit if the clearances are greater than the specifi-
cations.

Cylinder Bores, Inspect and Repair

Inspect the cylinder bores for wear and damage. Mea-
sure the cylinder bores with a bore gauge in several po-
sitions as shown in Figure 48. Measure the cylinder
bore at right angles to the centerline to find any distor-
tion from wear. A cylinder that is out of round greater

28
600 YRM 1121
than 0.127 mm (0.005 in.) must be rebored and honed
until it is possible to install an oversize piston.
Figure 48. Cylinder Bore Measurement
A tool called a hone can be used to remove a small
amount of taper from a cylinder bore. Use a boring
machine to repair a badly worn cylinder. The boring
machine will make a more accurate cylinder bore. The
hone is then used to finish the surface of the cylinder
bore.
A cylinder bore that has been repaired with a hone or a
boring machine must be fitted with a piston that is the
correct size.
Use the following procedure to determine the clearance
between the pistons and cylinders.
1. Measure the inner diameter of the cylinder bore as
shown in Figure 48.
2. Using a micrometer, measure the bore gauge and
record the reading. See Figure 49.
Figure 49. Bore Gauge Measurement
Piston and Piston Rod Assemblies Repair
3. Using a micrometer, measure the outer diameter of
the piston. See Figure 50.
Figure 50. Piston Measurement
4. Subtract the piston diameter from the bore diameter
to determine the piston to bore clearance.
Using an oversize piston in the engine does not affect
the dynamic balance of the engine. Replacement
pistons are available in standard size and 0.50 mm
(0.020 in.) oversize. The clearance between a pis-
ton and its cylinder bore should be between 0.010 to
0.030 mm (0.00039 to 0.00118 in.).
Piston Rings, Inspect
NOTE: Check the clearance of the piston rings in the
cylinder after the surface of the cylinder has been fin-
ished with a hone. New piston rings are available for the
different piston sizes. See the Parts Manual for sizes.
The piston rings must match the size of the piston on
which they are installed. Check the side clearance and
the end clearance of the piston rings as described in the
following paragraphs.
Each compression ring has a dimple or orientation mark
on one surface. This mark must be toward the top of
the cylinder when the piston ring is installed. The lower
compression ring also has a bevel edge that faces the
bottom of the piston. The upper compression ring has
a molybdenum filling and no bevelled edge.
The oil control ring has three pieces. There are two thin
steel rings separated by a spacer. The oil control ring
has no dimple or orientation mark and may be installed
in either direction.
29
Piston and Piston Rod Assemblies Repair
1. Measure the clearance between the piston ring and
the groove in the piston as shown in Figure 51. The
clearances are shown in Engine Specifications.
Replace the piston if the clearances are greater
than the specifications.
Figure 51. Piston Ring and Groove Clearance
Check
2. Measure the end clearance of each piston ring as
shown in Figure 52. The end clearances are shown
in Engine Specifications. Install the piston ring into
the cylinder where it will be used. Use a thickness
gauge to measure the amount of end clearance.
Replace the piston ring if the clearances are greater
than the specifications.
Figure 52. Piston Ring End Clearance Check
30
600 YRM 1121
Assemble
NOTE: There are notches cast in the top of all pistons
to indicate the correct assembly and installation. The
pistons must always be installed with this notch toward
the fan end of the engine. See Figure 56.
The piston rods have a notch cast in the bearing journal
as shown in Figure 53. This notch must be opposite the
notch on the top of the piston when the piston and piston
rod are assembled.
1. NOTCHES ON ROD OPPOSITE NOTCH IN
PISTON
Figure 53. Piston Rod Identification
1. Assemble the piston rod to the piston. Make sure
the orientation of the piston rod and piston are cor-
rect as described in the NOTE above. Use a press
to install the wrist pin into the piston and piston rod.
Lubricate the wrist pin with engine oil during instal-
lation.
NOTE: Each compression ring has a dimple or orien-
tation mark on one surface. This mark must be toward
the top of the cylinder when the piston ring is installed.
The lower compression ring also has a bevel edge that
faces the bottom of the piston. The upper compression
ring has a molybdenum filling and no bevelled edge.
The oil control rings do not have a dimple or orientation
mark and may be installed in either direction.
2. Check the clearances of the piston rings as de-
scribed in Piston Rings, Inspect. Install the piston
rings on the piston as shown in Figure 54, consid-
ering that the vertical dash line corresponds to the
wrist pin position.
600 YRM 1121 Piston and Piston Rod Assemblies Repair

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

fan end of the engine as shown in Figure 56. Install
the piston and piston rod assemblies in the cylinder
bores.

NOTE: CAST NOTCH MUST BE TOWARD FAN END

OF ENGINE.
A. FAN END OF ENGINE
B. POSITION OF GAP FOR OIL RING
C. POSITION OF GAP FOR SPACER OF OIL RING Figure 56. Piston Position Inside Cylinder
D. POSITION OF GAP FOR OIL RING
E. POSITION OF GAP FOR LOWER 3. Install the bearings and the caps for the piston
COMPRESSION RING rods. Tighten the capscrews to 30 to 40 N•m (22
F. POSITION OF GAP FOR UPPER COMPRESSION to 29.5 lbf ft). Tighten the capscrews an additional
RING 40 to 45 degrees. Check the side clearance of
each piston rod after the bearing cap is installed.
Figure 54. Piston Ring Arrangement
See the paragraphs in the procedure Piston Rod
Bearings, Replace.
Install
4. Install the cylinder head. See Camshaft Carrier and
1. Lubricate the assembly with engine oil during in-
Cylinder Head, Install.
stallation. Arrange the piston rings on the piston as
shown in Figure 54. Install a ring compressor on 5. Place the bearing bracket in position on the engine
the piston as shown in Figure 55. block.

6. Place the baffle plate in position on the bearing

bracket and install capscrews. Tighten capscrews
to 20 to 24 N•m (15 to 17.7 lbf ft).

7. Install the oil pump and oil pan. See Lubrication

System Repair.

Figure 55. Ring Compressor Installation

31
Crankshaft and Main Bearings 600 YRM 1121

Crankshaft and Main Bearings

CRANKSHAFT TIMING PULLEY AND/OR
FRONT SEAL
Remove
1. Remove the timing belt. See Timing Belt and Tim-
ing Belt Tensioner, Remove.

2. Using a special tool to hold the pulley, remove the

crankshaft timing pulley retaining bolt. See Fig-
ure 57.

1. KEYWAY 2. SPACER

Figure 59. Crankshaft Keyway and Spacer

5. With an electric drill and a 2-mm drill bit, drill a hole

in the front face of the seal.

6. Install a special tool, crankshaft front seal puller, on

a universal sliding mallet. Thread the end of the
special tool into the hole previously drilled in the
seal. Remove the seal. See Figure 60.
Figure 57. Crankshaft Timing Pulley Retaining Bolt
Removal/Installation

3. Using the special tool, piston flange universal puller,

remove the crankshaft timing pulley. See Figure 58.

1. SEAL PULLER
2. END OF SLIDING MALLET

Figure 60. Crankshaft Front Seal Removal

Figure 58. Crankshaft Timing Pulley Removal

4. Remove the crankshaft keyway and the spacer.

See Figure 59.

32
600 YRM 1121
Install
1. Install a special tool, protective sleeve, onto the
crankshaft end with the outer surface lubricated
with clean engine oil and the chamfered end of the
sleeve facing away from the engine. See Figure 61.
1. CRANKSHAFT FRONT SEAL INSTALLER
2. SEAL
3. PROTECTIVE SLEEVE
4. CRANKSHAFT END
Figure 61. Crankshaft Front Seal Installation
2. Install the front seal onto the protective sleeve.
3. Using a special tool, crankshaft front seal installer,
install the front seal into its lodging.
4. Remove the special tools.
5. Install the spacer and the keyway.
6. Install the crankshaft timing pulley onto the crank-
shaft end.
7. Using the special tool to hold the crankshaft timing
pulley, install the retaining bolt. See Figure 57. Ini-
tially tighten bolt to 130 N•m (96 lbf ft). Tighten the
bolt an additional 45 degrees.
8. Install the timing belt. See Timing Belt and Timing
Belt Tensioner, Install.
Crankshaft and Main Bearings
CRANKSHAFT REAR MAIN OIL SEAL
Remove
1. Remove the engine. Refer to the section Frame
100 YRM 1120.
2. Remove the flywheel. See Flywheel and Flywheel
Housing.
3. With an electric drill and a 2-mm drill bit, drill a hole
in the front face of the seal.
4. Install a special tool, crankshaft rear main oil seal
puller, on a sliding mallet. Tighten the nut on the
sliding mallet against the special tool. Thread the
end of the special tool into the previously-drilled
hole in the seal. Remove the seal. See Figure 62.
1. SEAL PULLER
2. NUT
3. END OF SLIDING MALLET
Figure 62. Crankshaft Rear Main Oil Seal Removal
Install
1. Remove the excess sealer from the oil seal recess.
2. Using a special tool, crankshaft rear main oil seal
installer, press the new oil seal into the housing.
See Figure 63.
33
Crankshaft and Main Bearings 600 YRM 1121

3. Remove the capscrew retaining the crankshaft/rpm

sensor.

4. Remove the crankshaft/rpm sensor.

Install
1. Install the crankshaft/rpm sensor into the engine
block.

2. Install the capscrew to retain the crankshaft/rpm

sensor. Tighten capscrew to 8 N•m (71 lbf in).

3. Connect the crankshaft/rpm sensor electrical har-

ness.

4. Install the timing belt front cover. See Timing Belt

Front Cover, Install
Figure 63. Crankshaft Rear Main Oil Seal
Installation CRANKSHAFT RELUCTOR WHEEL
3. Install the flywheel. See Flywheel and Flywheel
Housing. Remove and Install

4. Install the engine. Refer to the section Frame 100 1. Remove the crankshaft. See Crankshaft and Main
YRM 1120. Bearings, Remove.

2. Make an alignment mark on the crankshaft and the

CRANKSHAFT/RPM SENSOR reluctor wheel to properly align the reluctor wheel
in the original position during installation.
Remove
3. Remove the capscrews retaining the reluctor wheel
1. Remove the timing belt front cover. See Timing Belt
to the crankshaft. See Figure 65.
Front Cover, Remove.

2. Disconnect the crankshaft/rpm sensor electrical

harness. See Figure 64.

1. CAPSCREW
2. RELUCTOR WHEEL
3. CRANKSHAFT

Figure 65. Reluctor Wheel

4. Remove the reluctor wheel.

1. CRANKSHAFT/RPM SENSOR 5. Inspect the reluctor wheel for wear and damage.
2. ELECTRICAL HARNESS Replace as needed.

Figure 64. Crankshaft Sensor

34
600 YRM 1121 Crankshaft and Main Bearings

6. Place the reluctor wheel in position on the crank-

shaft.

7. Verify the alignment mark on the reluctor wheel is

aligned with the alignment mark on the crankshaft.

8. Install capscrews to retain reluctor wheel to

the crankshaft. Tighten capscrews to 10 N•m
(88.5 lbf in).

9. Install the crankshaft. See Crankshaft and Main

Bearings, Install.

CRANKSHAFT AND MAIN BEARINGS

Remove
1. Remove the engine. Refer to the section Frame
100 YRM 1120.

2. Remove the flywheel and flywheel housing. See 1. MAIN BEARING 3. CAP CAPSCREWS
Flywheel and Flywheel Housing. 2. BEARING CAPS 4. BEARINGS (HALF)

3. Remove the oil pan and oil pump. See Lubrication Figure 66. Crankshaft Bearings
System Repair.

4. Remove the capscrews retaining the baffle plate

and remove baffle plate.

5. Remove the remaining capscrews from the bearing

bracket and remove the bearing bracket.

6. Remove caps for connecting rods. Put identification

marks on bearing caps so they can be installed in
the original locations during assembly. See Piston
and Piston Rod Assemblies Repair.

7. Remove the capscrews for bearing caps and re-

move caps. See Figure 66.

8. Remove the crankshaft and rear main oil seal. Re-

move and discard rear main oil seal. See Figure 67.

9. Remove the bearings from the bearing caps and

from the engine block.

10. If necessary, remove the reluctor wheel. See 1. CRANKSHAFT

Crankshaft Reluctor Wheel, Remove and Install. 2. REAR MAIN OIL SEAL

Figure 67. Crankshaft Removal

35
Crankshaft and Main Bearings 600 YRM 1121

Inspect and Repair

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

WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning sol-
vents, always follow the recommendations of the
manufacturer.

1. Clean the crankshaft with solvent and dry it with

compressed air.

2. Inspect the crankshaft for cracks, wear, and dam-

age.

3. Inspect bearings for craters, pockets, excessive

scoring, and dirt or debris imbedded into the bear-
ing material. Replace as needed. Replace the
upper and lower halves as a set. Figure 68. Crankshaft Journal Measurement

4. Inspect the bearings for improper seating indicated Bearing Selection

by bright, polished sections of the bearing. Replace
as needed. Replace the upper and lower halves as
a set.
5. Use a micrometer to measure the journals for the
bearings of the crankshaft. See Figure 68. Take
the measurement at different positions to see if the
surface of the bearing is round. The correct sizes
are given in Engine Specifications.
NOTE: The dimensions of a new crankshaft main bear-
ing journal, or one that was not subjected to recondition
procedures, can be identified by means of the crank-
shaft color code.
The shell selection is performed by matching the block
main bearing diameter, identified by digits 0 and 1, and
the crankshaft color code. See Figure 69.

6. If the crankshaft journals must be repaired, they can
be ground to a smaller (undersize) than the original
size. See the Parts Manual for available bearing
sizes.
At one end of the main bearing the color code (5)
and standard or oversize [0.25 to 0.50 mm (0.0098 to
0.0197 in.)] identification (6) is located. The identifica-
tion code (365N - 366N) is located at the other end of
the bearing.

36
600 YRM 1121 Crankshaft and Main Bearings

code, you should install to the engine block main bear-

ing (with an identification number 0) a brown color upper
bearing half, and to the main bearing cap a brown color
lower bearing half.

For a main bearing having an identification number 1 on

the engine block, and a crankshaft with a brown color
code, you should install to the engine block main bear-
ing (with an identification number 0) a green color upper
bearing half, and to the main bearing cap a brown color
lower bearing half.

For a main bearing having an identification number 0 on

the engine block, and a crankshaft with a green color
code, you should install to the engine block main bear-
ing (with an identification number 0) a brown color upper
bearing half, and to the main bearing cap a green color
lower bearing half.

For a main bearing having an identification number 1 on

1. MAIN BEARING JOURNAL the engine block, and a crankshaft with a green color
2. CONNECTING ROD BEARING JOURNAL code, you should install to the engine block main bear-
3. CENTER BEARING ing (with an identification number 0) a green color upper
4. CRANKSHAFT COLOR CODE bearing half, and to the main bearing cap a green color
5. BEARING COLOR CODE
6. BEARING IDENTIFICATION lower bearing half.

Figure 69. Crankshaft and Bearing Identification
The diameter of the block main bearings is identified
by means of digits 0 and 1. See Figure 70. The diame-
ter identification numbers engraved on the engine block
main bearing direction are 01001.
Example: For a brown color crankshaft (standard size)
and a block having an identification number 01001 on
the main bearings, use:
• For the bearing having identification 0, a brown upper
bearing half and a brown lower bearing half.
• For the bearing having identification 1, a green upper
bearing half and a brown lower bearing half.

See the Parts Manual for available bearing sizes.

Main Bearings and Journal Clearance,

Check
NOTE: Crankshaft main bearings are a precision-insert
type. Main bearing caps are machined with the engine
block for proper clearance and cannot be shimmed or
filed for bearing fit. If crankshaft bearing clearances are
not within specifications, new bearings and/or engine
block and cap repair may be required.

1. Place the upper bearing halves in position in the

cylinder block.

2. Install all the main bearings and caps. Initially

Figure 70. Engine Block Main Bearing Identification
The standard crankshaft has a brown color code.
For a main bearing having an identification number 0 on
the engine block, and a crankshaft with a brown color
tighten the capscrews to 50 N•m (37 lbf ft). Second,
tighten the capscrews an additional 45 degrees.
Finally, tighten the capscrews an additional 15
degrees.

37
Crankshaft and Main Bearings
3. Check the rear main bearing first. Remove the cap
for the rear main bearing. See Figure 66. The
procedure for checking the clearance of the other
bearings is similar.
4. Clean the oil from the bearing half and journal to be
checked. Put a piece of Plastigage® across the full
width of the bearing journal as shown in Figure 71.
Do not rotate the crankshaft when the Plastigage®
is between the main bearing and its journal.
Figure 71. Bearing Journal Plastigage® Placement
5. Install the main bearing and main bearing cap. Ini-
tially tighten the capscrews to 50 N•m (37 lbf ft).
Second, tighten the capscrews an additional 45 de-
grees. Finally, tighten the capscrews an additional
15 degrees. The capscrews must be tightened to
their final torque or there will be an error in the mea-
surement.
6. Remove the main bearing cap. The Plastigage®
will be compressed and wider and it will adhere to
either the bearing or its journal. Use the scale on
the envelope for the Plastigage® to measure the
38
600 YRM 1121
width of the plastic at its widest point. The scale will
indicate the clearance in millimeters or thousandths
of an inch. See Figure 72.
Figure 72. Plastigage® Measurement
7. Refer to Engine Specifications for clearances. If the
clearance is greater than the specifications, select
a new undersize bearing set and install it. Mea-
sure the clearance again. If the clearance can-
not meet specifications with the available undersize
bearings, the bearing journal must be ground to a
new undersize. If the bearing journal is already at
the maximum undersize, the crankshaft must be re-
placed.
8. Check the crankshaft end clearance. Install a dial
indicator so that the probe touches the crankshaft
end. See Figure 73. Using a flat blade screw-
driver, push forward and backward and read the dial
gauge. The correct end play clearance is 0.050
to 0.152 mm (0.002 to 0.006 in.). If clearance is
greater than specification, replace main bearings or
crankshaft.
600 YRM 1121
Figure 73. Crankshaft End Clearance Measurement
Install
1. If removed, install the reluctor wheel. See Crank-
shaft Reluctor Wheel, Remove and Install.
2. Lubricate new main bearing halves with engine oil
and install them in the bearing housing of the en-
gine block.
3. Carefully install the crankshaft in the engine block.
See Figure 61.
4. Lubricate the lower halves of the main bearings and
install them in their caps. Fill the side grooves of
the rear main bearing cap with sealant. See Fig-
ure 74. Install each main bearing cap in its position
on the engine block. Make sure each main bear-
ing cap is installed in its original position. If a main
bearing cap is not installed correctly, there can be
an alignment problem, which can cause rapid wear
and damage to the engine.
5. Install the capscrew for the main bearing caps and
tighten the capscrews handtight. Use a soft ham-
mer or plastic mallet to hit the crankshaft lightly
and move it forward against the rear main bearing.
Then, use the hammer to hit the crankshaft lightly
and move it backward against the rear main bear-
ing. This procedure is to align the thrust surfaces
on the rear main bearing. Initially tighten the main
bearing capscrews to 50 N•m (37 lbf ft). Second,
tighten the capscrews an additional 45 degrees. Fi-
nally, tighten the capscrews an additional 15 de-
grees.
Crankshaft and Main Bearings
6. Check the crankshaft end clearance. See Fig-
ure 73.
1. SIDE GROOVE
Figure 74. Rear Main Bearing Cap Side Grooves
7. Check the clearance between the main bearing and
its crankshaft journal. See Main Bearings and Jour-
nal Clearance, Check.
8. Install the piston assemblies. See Piston and Pis-
ton Rod Assemblies Repair.
9. Place the bearing bracket in position on the engine
block. Install the three central capscrews and hand
tighten only.
10. Place the baffle plate in position on the bearing
bracket and install remaining capscrews. Initially
tighten capscrews to 20 N•m (15 lbf ft). Then
tighten the capscrews an additional 45 degrees.
This includes the three central capscrews previ-
ously hand tightened.
11. Install the oil pump and oil pan. See Lubrication
System Repair.
12. Install the flywheel and flywheel housing. See Fly-
wheel and Flywheel Housing.
13. Install the engine. Refer to the section Frame 100
YRM 1120.
39
Flywheel and Flywheel Housing 600 YRM 1121

Flywheel and Flywheel Housing

REMOVE
1. Remove the engine. See Engine Removal and In-
stallation.
2. Remove capscrews for flywheel. Then remove fly-
wheel and adapter plate. See Figure 75.
3. If necessary, remove flywheel housing.
INSTALL
1. If flywheel housing was removed, install it on en-
gine. Tighten M10 capscrews to 38 N•m (28 lbf ft).
Tighten M12 capscrews to 66 N•m (48.7 lbf ft). See
Figure 75.
2. Install adapter plate on crankshaft. Install the fly-
wheel.
3. Apply Loctite® 222 or equivalent on threads of
capscrews. Then install capscrews for flywheel.
Tighten capscrews to 52 N•m (38.35 lbf ft) in proper
sequence. See Figure 75.
4. Install the engine. See Engine Removal and Instal-
lation.

A. TIGHTENING SEQUENCE
1. ENGINE BLOCK 6. CAPSCREW
2. M10 CAPSCREWS 7. FLYWHEEL
3. LOCKWASHERS 8. M12 CAPSCREW
4. FLYWHEEL HOUSING 9. LOCKWASHER
5. ADAPTER PLATE

Figure 75. Flywheel Arrangement

40
600 YRM 1121 Cooling System Repair

Cooling System Repair

SERPENTINE BELT
Remove

WARNING
During engine operation, be careful not to touch the
fan, pulleys, or drive belts. Contact with these parts
can cause serious injury.

WARNING
The radiator or other parts of the cooling system
may be hot or under pressure and can cause seri-
ous injury. Wait 30 minutes for the radiator to cool.
Do a touch test by touching the radiator with your
hand. If the radiator is still hot to the touch, wait an-
other 30 minutes before attempting to check or fix
any part of the cooling system.

1. Turn the ignition switch to the OFF position.

2. Remove the four bolts retaining the fan assembly. 1. CHECK TENSION HERE
2. DRIVE TOOL SLOT
3. Remove the fan assembly. 3. SELF-TENSIONING DEVICE

4. Place the truck up on blocks. Refer to How to Put a
Truck on Blocks in the Operating Manual or to the
section Periodic Maintenance 8000 YRM 1150.
NOTE: The belt tensioner is a nonadjustable, self-ten-
sioning device with two positions, tension applied and
tension relieved.
Figure 76. Serpentine Belt Check
Install
NOTE: The belt tensioner is a nonadjustable, self-ten-
sioning device with two positions, tension applied and
tension relieved.

NOTE: The drive tool slot will accommodate the drive NOTE: The drive tool slot will accommodate the drive
end of either a 3/8-in. ratchet or breaker bar. end of either a 3/8-in. ratchet or breaker bar.

5. Using a drive tool, placed in the drive tool slot lo-
cated on the self-tensioning device, move the self-
tensioning device in a downward motion to relieve
tension on the serpentine belt. See Figure 76.
6. Remove the serpentine belt from the pulleys.
Inspect
1. Using a drive tool, placed in the drive tool slot
located on the self-tensioning device, move the
self-tensioning device in a downward motion to
relieve tension on the self-tensioning device. See
Figure 76.
2. Place the serpentine belt over the pulleys, and re-
lease the self-tensioning device.

Inspect the serpentine belt. If there are any cracks or 3. Remove truck from the blocks. Refer to How to
damage to the serpentine belt, replace the serpentine Put a Truck on Blocks in the Operating Manual
belt. or to the section Periodic Maintenance 8000 YRM
1150.

4. Replace the fan assembly.

41
Cooling System Repair
WARNING
During engine operation, be careful not to touch the
fan, pulleys, or drive belts. Contact with these parts
can cause serious injury.
5. Start the engine to make sure the serpentine belt is
operating correctly.
WATER PUMP
Remove
1. Turn the ignition switch to the OFF position.
2. Disconnect the negative battery cable at the bat-
tery.
3. Disconnect the air intake hoses from the air filter
assembly.
NOTE: The ECM assembly must be disconnected from
the air filter assembly before removing the air filter
assembly. For gasoline engines, refer to the section
Gasoline Fuel System, GM 2.4L Engine 900 YRM
1126. For LPG fuel systems, refer to the section LPG
Fuel System, GM 2.4L Engine 900 YRM 1124.
4. Remove the three bolts that attach the air filter as-
sembly mounting bracket to the frame and remove
air filter assembly with mounting bracket.
WARNING
DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator cap is re-
moved, pressure will release from the coolant sys-
tem. If the coolant system is hot, the steam and
boiling coolant can cause severe burns.
WARNING
The radiator or other parts of the cooling system
may be hot or under pressure and can cause seri-
ous injury. Wait 30 minutes for the radiator and en-
gine to cool before performing maintenance to the
cooling system. After 30 minutes, do a touch test
by touching the radiator with your hand. If the radia-
tor is still hot to the touch, wait another 30 minutes
42
600 YRM 1121
before attempting any maintenance to the cooling
system.
CAUTION
Disposal of lubricants must meet local environmen-
tal regulations.
5. Remove the radiator cap.
6. Loosen the lower radiator hose and drain the
coolant from the coolant system.
7. Remove the fan shroud. Refer to the section Cool-
ing System 700 YRM 1123.
8. Place a piece of cardboard over the radiator surface
to prevent damage to the radiator.
9. Remove the four bolts retaining the fan assembly.
10. Remove the fan assembly.
11. Remove the serpentine belt. See Serpentine Belt,
Remove.
12. Remove the spacer and the pulley.
13. Disconnect the electrical connections to the alter-
nator.
14. Remove the alternator mounting bolts and remove
the alternator.
15. Remove the alternator bracket bolts, fan hub
bracket bolts, and fan hub bracket.
16. Remove the timing belt and timing belt tensioner.
See Timing Belt and Timing Belt Tensioner, Re-
move.
NOTE: Before loosening the water pump bolts, make
alignment marks on the water pump and cylinder block
to identify the correct alignment position of the water
pump. See Figure 77.
17. Remove the water pump bolts.
600 YRM 1121 Cooling System Repair

Figure 77. Water Pump Alignment

43
Cooling System Repair 600 YRM 1121

Legend for Figure 77

1. WATER PUMP 9. CRANKSHAFT TIMING BELT PULLEY
2. WATER PUMP TAB (11 O’CLOCK POSITION) 10. CRANKSHAFT TIMING PULLEY BOLT
3. WATER PUMP BOLT 11. CRANKSHAFT PULLEY HUB MARK
4. TENSIONER 12. OIL PUMP HOUSING TIMING MARK
5. TENSIONER BOLT 13. TIMING MARK (LOCATED ON PLASTIC TIMING
6. TENSIONER TAB (7 O’CLOCK POSITION) BELT HOUSING)
7. TIMING BELT TENSIONER POINTER 14. CAMSHAFT TIMING BELT MARK
8. USED AND NEW TIMING BELT MARKS

18. Remove the water pump O-ring. Discard O-ring. 2. Place the water pump into position and verify that
See Figure 78. the alignment marks are properly aligned. Install
the water pump bolts and tighten to 20 to 30 N•m
(15 to 22 lbf ft).

3. Install the timing belt and timing belt tensioner. See

Timing Belt and Timing Belt Tensioner, Install.

4. Install the timing belt front cover. See Timing Belt

Front Cover, Install.

NOTE: Before installing the crankshaft pulley and

crankshaft spacer, align these components with the
alignment marks made when disassembled.

5. Install the crankshaft spacer and crankshaft pulley,

1. WATER PUMP BOLT
2. WATER PUMP
3. O-RING
Figure 78. Water Pump
Inspect
Inspect the water pump for the following:
• Inspect the pulley for wear and damage
• Worn or damaged gasket sealing surfaces
• Side-to-side play in the pulley shaft
• Leakage at the water inlet housing or rear cover gas-
ket areas
• Leakage at the water pump vent hole. A stain around
the vent hole is acceptable. If leakage occurs at the
vent hole with the engine running and the cooling sys-
tem pressurized, replace the water pump.
ensuring that all alignment marks made during re-
moval are lined up properly. Tighten crankshaft pul-
ley bolts to 135 N•m (99 lbf ft).
6. Install fan hub bracket and retaining bolts. Tighten
bolts to 52 N•m (38 lbf ft).
7. Install alternator bracket and retaining bolts.
Tighten bolts to 38 N•m (28 lbf ft).
8. Install the alternator. See the section Alternator
Repair.
9. Install the fan spacer and the pulley.
10. Install the serpentine belt. See Serpentine Belt,
Install.
11. Place the fan in position on the pulley and install
the four retaining bolts. Tighten the bolts to 26 N•m
(19 lbf ft).

12. Remove cardboard from the radiator surface.

Install
13. Install the fan shroud. Refer to the section Cooling
1. Install a new O-ring onto the water pump.
System 700 YRM 1123.
NOTE: Before installing a new water pump and tighten-
ing the water pump bolts, make sure the water pump
tab is in the 11 o’clock position for proper alignment of
the timing belt tensioner.

44
600 YRM 1121
CAUTION
Additives may damage the cooling system. Before
using additives, contact your local Yale dealer.
14. Connect the bottom radiator hose. Fill cooling sys-
tem with coolant. Refer to the section Periodic
Maintenance 8000 YRM 1150 for correct coolant
amount and type.
15. Install radiator cap on radiator.
NOTE: The ECM assembly must be connected to the air
filter assembly after installing the air filter assembly. For
gasoline engines, refer to the section Gasoline Fuel
System, GM 2.4L Engine 900 YRM 1126. For LPG
fuel systems, refer to the section LPG Fuel System,
GM 2.4L Engine 900 YRM 1124.
16. Place the air filter assembly with mounting bracket
in position on the frame. Install bolts and tighten to
20 N•m (15 lbf ft).
17. Connect the air intake hoses to the air filter assem-
bly.
18. Connect the negative battery cable.
WARNING
During engine operation, be careful not to touch the
fan, pulleys, or drive belts. Contact with these parts
can cause serious injury.
WARNING
The radiator or other parts of the cooling system
may be hot or under pressure and can cause seri-
ous injury.
19. Start engine and check cooling system for leaks.
20. Bleed air from the cooling system by opening the
bleed screw located on the left side behind the al-
ternator. When the air has been bled from the sys-
tem, close the bleed screw.
WARNING
DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator cap is
removed, the pressure is released from the system.
If the system is hot, the steam and boiling coolant
Cooling System Repair
can cause burns. DO NOT remove the cover for the
radiator when the engine is running.
WARNING
The radiator or other parts of the cooling system
may be hot or under pressure and can cause seri-
ous injury. Wait 30 minutes for the radiator to cool.
Do a touch test by touching the radiator with your
hand. If the radiator is still hot to the touch, wait an-
other 30 minutes before attempting to check or fix
any part of the cooling system.
CAUTION
Additives may damage the cooling system. Before
using additives, contact your local Yale dealer.
21. Stop engine. If coolant is hot, give engine time to
cool. Check coolant level and fill as required be-
tween the ADD and FULL marks on the coolant
reservoir.
THERMOSTAT
Remove
WARNING
The radiator or other parts of the cooling system
may be hot or under pressure and can cause seri-
ous injury. Wait 30 minutes for the radiator to cool.
Do a touch test by touching the radiator with your
hand. If the radiator is still hot to the touch, wait an-
other 30 minutes before attempting to check or fix
any part of the cooling system.
CAUTION
DO NOT operate the engine without a thermostat.
The engine and cooling system can be damaged.
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
1. Drain the cooling system to the level of the thermo-
stat.
2. Remove the capscrew that holds the oxygen sensor
wire clamp to thermostat cover. See Figure 79.
45
Cooling System Repair 600 YRM 1121

Check

WARNING
The radiator or other parts of the cooling system
may be hot or under pressure and can cause seri-
ous injury.

CAUTION
DO NOT operate the engine without a thermostat.
The engine and cooling system can be damaged.

1. Inspect the thermostat and O-ring that connects to

the thermostat housing. If the O-ring is damaged,
replace the O-ring.

2. Inspect the two inner discs on the thermostat that

seal the water flow. Verify that they are clean and
in good condition. If damaged, replace thermostat.

NOTE: While performing the test of the thermostat in

Step 3, make sure that the thermostat and thermometer
do not touch the sides or the bottom of the container
used for heating the water.

3. Hold thermostat with a wire and place in the water.

Slowly heat the water to 82 C (180 F). At this tem-
perature, the thermostat should be starting to open.
Continue to heat the water to 97 C (207 F). At this
temperature, the thermostat should be fully open.
If not, replace the thermostat.

4. Cool the water to 70 C (158 F). The thermostat

must close completely. If it does not, replace the
thermostat.

Install
1. Install a new O-ring and install the thermostat into
the thermostat housing.

2. Install the thermostat cover and tighten the cap-

screws to 20 N•m (15 lbf ft).
1. CAPSCREW
2. OXYGEN SENSOR WIRE CLAMP 3. Connect the capscrew that holds the oxygen sensor
3. THERMOSTAT COVER wire clamp to thermostat cover.
4. THERMOSTAT
5. THERMOSTAT AND THERMOSTAT COVER
(ONE-PIECE) CAUTION
6. O-RING
7. THERMOSTAT HOUSING Additives may damage the cooling system. Before
using additives, contact your local Yale dealer.
Figure 79. Thermostat Replacement
4. Connect the bottom radiator hose. Fill cooling sys-
3. Remove the capscrews retaining the thermostat tem with coolant. Refer to the section Periodic
cover to the thermostat housing. Maintenance 8000 YRM 1150 for correct coolant
amount and type.
4. Remove the thermostat and O-ring. See Figure 79.

46
600 YRM 1121 Cooling System Repair

5. Install radiator cap on radiator.
WARNING
During engine operation, be careful not to touch the
fan, pulleys, or drive belts. Contact with these parts
can cause serious injury.
WARNING
The radiator or other parts of the cooling system
may be hot or under pressure and can cause seri-
ous injury.
6. Start the engine and check cooling system for
leaks.
7. Bleed air from the cooling system by opening the
bleed screw located on the left side behind the al-
ternator. When the air has been bled from the sys-
tem, close the bleed screw.
2. Loosen the lower radiator hose and drain the
coolant.
3. Disconnect the electrical connector from the engine
coolant temperature sensor.
4. Disconnect the upper radiator hose to the thermo-
stat cover.
5. Remove the timing belt rear cover. See Timing Belt
Rear Cover, Remove.
6. Disconnect the coolant hoses, below the intake
manifold, from the thermostat housing to the
coolant manifold.
7. Remove the bolts retaining the thermostat housing
to the cylinder head. See Figure 80.

WARNING
DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator cap is
removed, the pressure is released from the system.
If the system is hot, the steam and boiling coolant
can cause burns. DO NOT remove the cover for the
radiator when the engine is running.

WARNING
The radiator or other parts of the cooling system
may be hot or under pressure and can cause seri-
ous injury. Wait 30 minutes for the radiator to cool.
Do a touch test by touching the radiator with your
hand. If the radiator is still hot to the touch, wait an-
other 30 minutes before attempting to check or fix
any part of the cooling system. 1. BOLT
2. ENGINE COOLANT TEMPERATURE SENSOR
(ECT)
CAUTION 3. THERMOSTAT HOUSING
Additives may damage the cooling system. Before Figure 80. Thermostat Housing
using additives, contact your local Yale dealer.
8. Remove the thermostat housing.
8. Stop engine. If coolant is hot, give engine time to
cool. Check coolant level and fill as required be- 9. Remove and discard the O-ring from the thermostat
tween the ADD and FULL marks on the coolant housing.
reservoir.
Clean and Inspect
THERMOSTAT HOUSING
Remove all debris and residue from the thermostat
Remove housing. Inspect the thermostat housing for cracks and
other damage. Inspect the coolant hoses for wear and
1. Disconnect the negative battery cable at the bat- damage. Repair or replace as needed.
tery.

47
Cooling System Repair
Install
1. Install a new O-ring in the thermostat housing.
2. Place the thermostat housing in position.
3. Install the bolts to retain the thermostat housing and
tighten to 11 N•m (97 lbf in).
4. Connect the coolant hoses, below the intake mani-
fold, to the thermostat housing. Tighten the clamps
to 4 to 5 N•m (35 to 44 lbf in).
5. Install the timing belt rear cover. See Timing Belt
Rear Cover, Install.
6. Install the timing belt and timing belt tensioner. See
Timing Belt and Timing Belt Tensioner, Install.
7. Install timing belt front cover. See Timing Belt Front
Cover, Install.
8. Install fan hub bracket and retaining bolts. Tighten
bolts to 52 N•m (38 lbf ft).
9. Install alternator bracket and retaining bolts.
Tighten bolts to 38 N•m (28 lbf ft).
10. Install the alternator. See the section Alternator
Repair.
11. Install the fan spacer and pulley.
12. Install the serpentine belt. See Serpentine Belt,
Install.
13. Connect the upper radiator hose to the thermostat
housing. Tighten the clamp to 4 to 5 N•m (35 to
44 lbf in).
14. Connect the electrical connection to the engine
coolant temperature sensor.
15. Connect the negative battery cable to the battery.
CAUTION
Additives may damage the cooling system. Before
using additives, contact your local Yale dealer.
16. Connect the lower radiator hose. Fill cooling sys-
tem with coolant. Refer to the section Periodic
Maintenance 8000 YRM 1150 for correct coolant
amount and type.
48
600 YRM 1121
17. Install radiator cap on radiator.
WARNING
During engine operation, be careful not to touch the
fan, pulleys, or drive belts. Contact with these parts
can cause serious injury.
WARNING
The radiator or other parts of the cooling system
may be hot or under pressure and can cause seri-
ous injury.
18. Start engine and check cooling system for leaks.
19. Bleed air from the cooling system by opening the
bleed screw located on the left side behind the al-
ternator. When the air has been bled from the sys-
tem, close the bleed screw.
WARNING
DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator cap is
removed, the pressure is released from the system.
If the system is hot, the steam and boiling coolant
can cause burns. DO NOT remove the cover for the
radiator when the engine is running.
WARNING
The radiator or other parts of the cooling system
may be hot or under pressure and can cause seri-
ous injury. Wait 30 minutes for the radiator to cool.
Do a touch test by touching the radiator with your
hand. If the radiator is still hot to the touch, wait an-
other 30 minutes before attempting to check or fix
any part of the cooling system.
CAUTION
Additives may damage the cooling system. Before
using additives, contact your local Yale dealer.
20. Stop engine. If coolant is hot, give engine time to
cool. Check coolant level and fill as required be-
tween the ADD and FULL marks on the coolant
reservoir.
600 YRM 1121 Sensors and Switches

Sensors and Switches

CRANKSHAFT POSITION (CKP) SENSOR 4. Connect the battery and lower the hood.

Remove CAMSHAFT POSITION (CMP) SENSOR

1. Raise the hood and disconnect the battery. Remove for Lift Trucks Built Before
2. Disconnect the crankshaft sensor electrical har- January, 2010
ness. See Figure 81. Assembly

1. Open the hood. Disconnect the negative battery

cable.

2. Disconnect the CMP sensor electrical connector.

See Figure 82.

1. CRANKSHAFT SENSOR
2. ELECTRICAL HARNESS

Figure 81. Crankshaft Sensor, GM 2.4L Engine

3. Remove the capscrew retaining the crankshaft sen-

sor. 1. CMP SENSOR
2. WIRE HARNESS CLAMP
4. Remove the crankshaft sensor. 3. ELECTRICAL CONNECTOR

Install Figure 82. CMP Sensor Electrical Connector for

Lift Trucks Built Before January, 2010
1. Install new crankshaft sensor into the engine block.
3. Remove harness clamp from CMP sensor support
2. Install the capscrew to secure the crankshaft sen- plate.
sor. Tighten capscrew to 8 N•m (71 lbf in).
4. Remove retaining screws, CMP sensor assembly,
3. Connect the crankshaft sensor electrical harness. and O-ring from engine block. See Figure 83.
See Figure 81.

49
Sensors and Switches 600 YRM 1121

4. Remove screw, lockwasher, and CMP sensor from

CMP sensor plate. Remove and discard O-ring
from CMP sensor. See Figure 84.

1. RETAINING SCREW
2. CMP SENSOR ASSEMBLY
3. O-RING

Figure 83. CMP Sensor Assembly for Lift Trucks

Built Before January, 2010

Sensor Only

1. Open the hood. Disconnect the negative battery 1. SCREW

cable. 2. LOCKWASHER
3. CMP SENSOR
2. Disconnect the CMP sensor electrical connector. 4. O-RING
See Figure 82. 5. CMP SENSOR
PLATE
3. Remove harness clamp from CMP sensor support
plate. Figure 84. CMP Sensor for Lift Trucks Built Before
January, 2010

50
600 YRM 1121
Install for Lift Trucks Built Before January,
2010
Assembly
1. Lubricate new O-ring with clean engine oil. Install
O-ring into groove in CMP sensor plate. See Fig-
ure 83.
2. Install CMP sensor assembly onto engine block.
See Figure 83.
NOTE: Before installing lockwasher and screw, verify
CMP sensor is fully seated.
3. Install lockwasher and screw onto CMP sensor.
See Figure 83. Tighten to 10 N•m (88.5 lbf in).
4. Connect the electrical connectors. Verify that the
connectors click/lock into place. See Figure 82.
5. Install harness clamp onto CMP sensor plate. See
Figure 82.
6. Connect the negative battery cable. Close the
hood.
1. CMP SENSOR ELECTRICAL CONNECTOR
2. SCREW
3. CMP SENSOR ASSEMBLY
Figure 85. CMP Sensor Assembly for Lift Trucks Built After January, 2010
Sensors and Switches
Sensor Only
1. Lubricate new O-ring with clean engine oil. Install
O-ring onto sensor. See Figure 84.
2. Install CMP sensor, lockwasher, and screws onto
CMP sensor plate. See Figure 84. Tighten screw
to 6 N•m (53 lbf in).
3. Connect the electrical connectors. Verify that the
connectors click/lock into place. See Figure 82.
4. Install harness clamp onto CMP sensor plate. See
Figure 82.
5. Connect the negative battery cable. Close the
hood.
Remove for Lift Trucks Built After January,
2010
1. Open the hood. Disconnect the negative battery
cable.
2. Disconnect the CMP sensor electrical connector.
See Figure 85.
3. Remove screw and CMP sensor assembly from en-
gine. See Figure 85.
51
Ignition System 600 YRM 1121

Install for Lift Trucks Built After January,

2010
1. Install CMP sensor assembly and screw onto en-
gine. See Figure 85.

2. Connect CMP sensor electrical connector. See Fig-

ure 85.

3. Connect negative battery cable. Close the hood.

OIL PRESSURE SENSOR

Remove
1. Raise hood and disconnect the battery.

2. Disconnect the electrical connector for the oil pres-

sure sensor. See Figure 86.

3. Remove the oil pressure sensor.

Install
1. Install new oil pressure sensor onto engine. Tighten 1. ELECTRICAL CONNECTOR
sensor to 20 N•m (177 lbf in). 2. OIL PRESSURE SENSOR
3. OIL FILTER
2. Connect the electrical connector for the oil pressure 4. ADAPTER, O-RING, AND RETAINING RING
sensor. See Figure 86. Figure 86. Oil Pressure Sensor, GM 2.4L Engine
3. Connect battery and lower the hood.

Ignition System
SPARK PLUG WIRE INSPECTION
Spark plug wire integrity is vital for proper engine oper-
ation. A thorough inspection will be necessary to accu-
rately identify conditions that may affect engine opera-
tion. Inspect for the following conditions:
1. Correct routing of the spark plug wires. Incorrect
routing may cause cross-firing.
2. Any signs of cracks or splits in the wires.
3. Inspect each boot for the following conditions:
• Tearing
• Piercing
• Arcing
• Carbon tracking
• Corroded terminal
If corrosion, carbon tracking, or arcing is indicated on a
spark plug wire boot or on a terminal, replace the wire
and the component connected to the wire.
SPARK PLUG WIRE REPLACEMENT
Remove
1. Disconnect the spark plug wire at each spark plug.
See Figure 87.
a. Twist the boots 1/2 turn before removing the
boots.
b. Pull only on the boot or use a tool designed for
this purpose in order to remove the wire from
each spark plug.

52
600 YRM 1121 Ignition System

b. Reinstall any loose boot. You should feel the

terminal snap onto the spark plug or coil when
installing the spark plug wire. Inspect and re-
place component that is damaged.

c. Wire routings must be kept intact during service

and followed exactly when wires have been dis-
connected or when replacement of the wires is
necessary. Failure to route the wires properly
can lead to radio ignition noise and cross fir-
ing of the plugs or shorting of the leads to the
ground.

d. Any time the spark plug wires or boots are

installed on the spark plugs, new dielectric
grease needs to be applied inside the boot.
1. ELECTRICAL CONNECTOR SPARK PLUG REPLACEMENT
2. COIL PACK
3. NO. 1 CYLINDER SPARK PLUG WIRE
4. NO. 2 CYLINDER SPARK PLUG WIRE Remove
5. NO. 3 CYLINDER SPARK PLUG WIRE
6. NO. 4 CYLINDER SPARK PLUG WIRE 1. Remove the spark plug wires. Refer to Spark Plug
Wire Replacement.
Figure 87. Spark Plug Wire Removal/Installation
2. Loosen each spark plug 1 or 2 turns.
2. Disconnect the spark plug wire from the coil pack.
3. Brush or air blast away any dirt from around the
a. Twist each spark plug boot 1/2 turn. spark plugs.
b. Pull only on the boot or use a tool designed for 4. Remove the spark plugs 1 at a time. Place each
this purpose in order to remove the wires from plug in a tray marked with the corresponding cylin-
the coil pack. der number. See Figure 88.

Install
NOTE: If the boot-to-wire movement has occurred, the
boot will give a false visual impression of being fully
seated. Ensure that the boots have been properly as-
sembled by pushing sideways on the installed boots.
Failure to properly seat the terminal onto the spark plug
will lead to wire core erosion and result in an engine mis-
fire or crossfire condition and possible internal damage
to the engine.

1. Install the spark plug wires at the coil pack. You

should feel the terminal snap onto the coil.

2. Install the spark plug wire to each spark plug. You

should feel the terminal snap onto the spark plug.
See Figure 87.

3. Inspect the wires for proper installation: 1. NO. 1 CYLINDER SPARK PLUG
2. NO. 2 CYLINDER SPARK PLUG
a. Push sideways on each boot in order to inspect 3. NO. 3 CYLINDER SPARK PLUG
the seating. 4. NO. 4 CYLINDER SPARK PLUG

Figure 88. Spark Plug Removal/Installation

53
Ignition System 600 YRM 1121

5. Inspect each spark plug. See Spark Plug Inspec- a. Inspect for a bent or broken terminal post.
tion.

Install
1. Properly position each spark plug washer.

2. Inspect each spark plug gap. Adjust each plug as

needed.

Specification
Spark plug gap: 0.8 to 0.9 mm (0.031 to
0.035 in.)

3. Hand start the spark plugs in the corresponding

cylinders. See Figure 88.

CAUTION
Only use a spark plug socket or wrench to tighten
the spark plugs. Do not force the spark plug into
the cylinder head. Any misalignment can damage
the aluminum threads in the cylinder head and may 1. TERMINAL POST 3. ELECTRODE
require the replacement of the cylinder head. 2. INSULATOR 4. ELECTRODE
4. Tighten the spark plugs to 20 N•m (15 lbf ft). Figure 89. Spark Plug

SPARK PLUG INSPECTION b. Test for a loose terminal post by twisting and
pulling the post. The terminal post should NOT
Usage move.

1. Ensure that the correct spark plug is installed. An
incorrect spark plug causes driveability conditions.
The correct spark plug type is NGK BPR5EY.
2. Ensure that the spark plug has the correct heat
range. An incorrect heat range causes the follow-
ing conditions:
• Spark plug fouling - Colder plug
• Pre-ignition causing spark plug and/or engine
damage - Hotter plug
Inspect
2. Inspect the insulator for flashover or carbon tracking
soot. See Figure 90. This is caused by the electri-
cal charge traveling across the insulator between
the terminal post and ground. Inspect for the fol-
lowing conditions:
a. Inspect the spark plug boot for damage.
b. Inspect the spark plug recess area of the cylin-
der head for moisture, such as oil, coolant,
or water. A spark plug boot that is saturated
causes arcing to ground.

1. Inspect the terminal post for damage. See Fig-

ure 89.

54
600 YRM 1121 Ignition System

torque can prevent correct spark plug opera-

tion. An over-torqued spark plug causes the
insulator to crack.

1. TERMINAL POST 3. ELECTRODE

2. INSULATOR 4. ELECTRODE

Figure 90. Spark Plug With Flashover or Carbon

Tracking 1. TERMINAL POST
2. INSULATOR
3. Inspect the insulator for cracks. All or part of the
electrical charge may arc through the crack instead
of the electrodes. See Figure 91.
4. Inspect for evidence of improper arcing. See Fig-
ure 92.
a. Measure the gap between the center electrode
(4) and the side electrode (3) terminals. An ex-
cessively wide electrode gap can prevent cor-
rect spark plug operation. Refer to Engine
Specifications for the proper gap. Adjust as
necessary.
b. Inspect for the correct spark plug torque. The
correct torque is 20 N•m (15 lbf ft). Insufficient
3. ELECTRODE
4. ELECTRODE
Figure 91. Spark Plug Arcing Through a Crack
c. Inspect for signs of tracking that occurred near
the insulator tip instead of the center electrode
(4).
d. Inspect for a broken or worn side electrode (3).
e. Inspect for a broken, worn, or loose center elec-
trode (4) by shaking the spark plug.
(1) A rattling sound indicates internal dam-
age.
(2) A loose center electrode (4) reduces the
spark intensity.

55
Ignition System 600 YRM 1121

• Excessive idling or slow speeds under light loads

can keep spark plug temperatures so low that
normal combustion deposits may not burn off.

3. Deposit fouling - Oil, coolant, or additives that in-

clude substances such as silicone, very white coat-
ing, reduce the spark intensity. Most powdery de-
posits will not effect spark intensity unless they form
into a glazing over the electrode.

COIL PACK
Remove
1. Tag and disconnect the spark plug wires.

2. Disconnect the electrical connection to the coil

pack.

3. Remove the capscrews retaining the coil pack to

1. TERMINAL POST 3. ELECTRODE the mounting bracket and remove coil pack. See
2. INSULATOR 4. ELECTRODE Figure 93.
Figure 92. Spark Plug Arcing Improperly

f. Inspect for bridged electrodes (3, 4). Deposits

on the electrodes (3, 4) reduce or eliminate the
gap.

g. Inspect for worn or missing platinum pads on

the electrodes (3, 4), if equipped.

h. Inspect for excessive fouling.

5. Inspect the spark plug recess area of the cylinder

head for debris. Dirty or damaged threads can
cause the spark plug not to seat correctly during
installation.

Visual Inspection 1. SPARK PLUG WIRES

2. COIL PACK
1. Normal operation - Brown to grayish-tan with small 3. CAPSCREW
amounts of white powdery deposits are normal 4. MOUNTING BRACKET
combustion by-products from fuels with additives. 5. NUTS

2. Carbon fouled - Dry, fluffy, black carbon or soot Figure 93. Coil Pack Removal/Installation
caused by the following conditions:
4. Remove the nuts retaining the mounting bracket to
• Rich fuel mixtures
the camshaft carrier assembly and remove mount-
– Leaking fuel injectors
ing bracket.
– Excessive fuel pressure
– Restricted air filter element Install
– Incorrect combustion
• Reduced ignition system voltage output 1. Place the coil pack mounting bracket in position
– Weak coil pack on the camshaft carrier assembly. Install the two
– Worn ignition wires nuts to retain the mounting bracket. Tighten nuts to
– Incorrect spark plug gap 38 N•m (28 lbf ft).

56
600 YRM 1121 Alternator Repair

2. Place the coil pack in position on the mounting 3. Connect the electrical connector to the coil pack.
bracket and install capscrews. Tighten capscrews
to 10 N•m (88.5 lbf in). 4. Connect the spark plug wires.

Alternator Repair
ALTERNATOR 3. Attach the upper alternator boss to the strap on
the fan mount bracket and tighten the upper bolt to
Remove 20 N•m (15 lbf ft).

4. Tighten lower bolt to 20 N•m (15 lbf ft).

WARNING
Always disconnect the battery ground cable before
making repairs to prevent possible damage and in-
jury. Install a tag on the battery terminal so that no
one connects the cable on the terminal.
5. Tighten the bolts retaining the alternator mounting
bracket to the cylinder block to 38 N•m (28 lbf ft).
6. Connect electrical connectors to alternator.

1. Disconnect battery cable at negative terminal. In- 7. Install the serpentine belt. See Serpentine Belt,
stall a tag on battery terminal to warn against con- Install.
necting cable.
8. Connect battery cable at negative terminal.
2. Remove the serpentine belt. See Serpentine Belt,
Remove.

3. Put labels on electrical connectors and wires prior

to disconnecting to aid in correct installation.

4. Disconnect electrical connectors and wires from al-

ternator.

5. Remove the lower bolt and spacer from the alterna-

tor. See Figure 94.

6. Remove the upper bolt from the alternator and re-

move alternator.

Install

CAUTION
The bolts retaining the alternator mounting bracket
to the cylinder block must be loosened to achieve
proper alignment when the alternator is installed or
damage may occur.
1. UPPER BOLT 3. LOWER BOLT
1. Loosen the bolts retaining the alternator mounting 2. ALTERNATOR 4. SPACER
bracket to the cylinder block.
Figure 94. Alternator
2. Place alternator in position on the mounting bracket
and install the lower bolt and spacer finger tight
only.

57
Starter Repair 600 YRM 1121

ALTERNATOR FUSE, REPLACE

1. Remove the cover from the fuse holder. See Fig-
ure 95.

2. Remove fuse from the fuse holder and discard the

fuse.

3. Install new fuse into fuse holder.

4. Install cover onto fuse holder.

1. FUSE HOLDER
2. FUSE
3. COVER

Figure 95. Alternator Fuse

Starter Repair
REMOVE
WARNING
Always disconnect the cables at the battery before
you make repairs to the engine. Disconnect the ca-
ble at the negative terminal first. Install a tag on the
battery terminals so that no one connects the ca-
bles on the terminals.
1. Disconnect battery negative cable at negative ter-
minal.
2. Disconnect the battery positive cable at positive ter-
minal.
3. Put labels on wires and cables prior to disconnect-
ing to aid in correct installation.
5. Hold starter so it won’t fall. Remove capscrews that
fasten the starter to the flywheel housing. Remove
starter from flywheel housing.
INSTALL
1. Place starter in position in flywheel housing. Install
capscrews to fasten the starter to the flywheel hous-
ing. Tighten capscrews to 38 N•m (28 lbf ft).
2. Connect wires and cables as labeled in removal.
3. Connect the battery positive cable at positive termi-
nal.
4. Connect battery negative cable at negative termi-
nal.

4. Disconnect wires and cables from starter.

58
600 YRM 1121 Engine Specifications

Engine Specifications
ENGINE DATA
Number of Cylinders 4
Displacement 2405 cm 3 (146.46 in. 3 )
Bore 87.5 mm (3.445 in.)
Stroke 100 mm (3.937 in.)
Compression Ratio 9.53:1
Firing Order 1-3-4-2
Idle Speed 800 ±25
Governor Speed (No Load) 2700 ±25
Converter Stall Speed - LPG
New Engine 1950 ±100 rpm
Broken-in Engine 2053 ±100 rpm
Converter Stall Speed - Gasoline
New Engine 1914 ±100 rpm
Broken-in Engine 2015 ±100 rpm
Spark Plug Gap 0.8 to 0.9 mm (0.031 to 0.035 in.)

CYLINDER BORE
Bore Diameter
Bore Out-of-Round Service Limit
Bore Taper Thrust Side Service Limit
Bore Taper Relief Side Service Limit
87.5 mm (3.44 in.)
0.127 mm (0.005 in.) Maximum
0.076 mm (0.003 in.) Maximum
0.076 mm (0.003 in.) Maximum

PISTON
Piston-to-Bore Clearance
Production 0.010 to 0.030 mm (0.00040 to 0.0012 in.)
Service Limit 0.060 mm (0.0024 in.)

PISTON RINGS
Piston Compression Ring Groove
Clearance Production Top 0.030 to 0.050 mm (0.0012 to 0.0020 in.)
Clearance Production 2nd 0.020 to 0.040 mm (0.0008 to 0.0016 in.)
Piston Compression Ring Gap Top
*Measured in Cylinder Bore

59
Engine Specifications 600 YRM 1121

Production* 0.25 to 0.45 mm (0.010 to 0.018 in.)

Service Limit* 0.55 mm (0.022 in.) Maximum
Piston Compression Ring Gap 2nd
Production* 0.30 to 0.50 mm (0.012 to 0.020 in.)
Service Limit* 0.60 mm (0.024 in.) Maximum
Piston Oil Ring Gap
Production* 0.40 to 0.56 mm (0.016 to 0.022 in.)
Service Limit* 0.64 mm (0.025 in.) Maximum
*Measured in Cylinder Bore

WRIST PIN
Diameter 20.995 to 21.00 mm (0.8266 to 0.8268 in.)
Clearance in Piston
Production 0.011 to 0.014 mm (0.0004 to 0.0006 in.)
Service Limit 0.023 mm (0.0009 in.) Maximum
Fit in Piston Rod (Interference) 0.024 to 0.041 mm (0.00095 to 0.0016 in.) Interference

CRANKSHAFT
Crankshaft Maximum Warping
Crankshaft Main Journal Diameter (All)
Crankshaft Main Journal Taper
Crankshaft Main Journal Out-of-Round
Crankshaft Main Bearing Clearance
Production
Service Limit
Crankshaft Rod Journal Diameter
Crankshaft Rod Journal Taper
Crankshaft End Play - Production
0.03 mm (0.00118 in.)
57.981 to 57.988 mm (2.2827 to 2.2830 in.)
0.005 mm (0.00020 in.) Maximum
0.004 mm (0.00016 in.) Maximum
0.015 to 0.041 mm (0.0006 to 0.0016 in.)
0.018 to 0.046 mm (0.0007 to 0.0018 in.)
48.971 to 48.987 mm (1.9280 to 1.9286 in.)
0.020 mm (0.0008 in.)
0.050 to 0.152 mm (0.002 to 0.006 in.)

PISTON ROD
Rod Bearing Clearance
Production 0.019 to 0.063 mm (0.0007 to 0.0025 in.)
Service 0.020 to 0.074 mm (0.0008 to 0.0029 in.)
Rod Side Clearance 0.070 to 0.242 mm (0.0028 to 0.010 in.)

60
600 YRM 1121
CAMSHAFT AND CAMSHAFT CARRIER
Camshaft Carrier Bores
Number 1 Bore
Number 2 Bore
Number 3 Bore
Number 4 Bore
Number 5 Bore
Camshaft Journal Diameter
Number 1 Journal
Number 2 Journal
Number 3 Journal
Number 4 Journal
Number 5 Journal
Maximum Camshaft Warpage
Camshaft End Play
Lobe Lift Intake
Lobe Lift Exhaust
VALVE SYSTEM
Valve Lash Intake
Valve Lash Exhaust
Face Angle
Seat Angle
Seat Runout
Seat Width Intake
Seat Width Exhaust
Stem Clearance Intake
Production
Service Limit
Stem Clearance Exhaust
Production
Service Limit
Valve Spring Free Length
Valve Spring Load - Closed
Valve Spring Load - Open
Valve Spring Installed Height
Engine Specifications
42.500 to 42.525 mm (1.6732 to 1.6742 in.)
42.750 to 42.775 mm (1.6831 to 1.6841 in.)
43.000 to 43.025 mm (1.6929 to 1.6939 in.)
43.250 to 43.275 mm (1.7028 to 1.7037 in.)
43.500 to 43.525 mm (1.7126 to 1.7136 in.)
42.455 to 42.470 mm (1.6715 to 1.6720 in.)
42.705 to 42.720 mm (1.6813 to 1.6819 in.)
42.955 to 42.970 mm (1.6911 to 1.6917 in.)
43.205 to 43.220 mm (1.7010 to 1.7016 in.)
43.455 to 43.470 mm (1.7108 to 1.7114 in.)
0.04 mm (0.0016 in.)
0.79 to 0.91 mm (0.031 to 0.036 in.)
6.67 mm (0.263 in.)
6.67 mm (0.263 in.)
Not applicable - engine utilizes hydraulic lash adjusters
to maintain zero lash.
46 degrees from vertical (stem centerline)
45 degrees
0.05 mm (0.002 in.) Maximum
1.3 to 1.4 mm (0.051 to 0.055 in.)
1.6 to 1.8 mm (0.063 to 0.070 in.)
0.018 to 0.052 mm (0.0007 to 0.0020 in.)
0.052 mm (0.0020 in.)
0.038 to 0.072 mm (0.0015 to 0.0028 in.)
0.072 mm (0.0028 in.)
Approximately 48 mm (1.89 in.)
241 ±18 N (54 ±4 lbf) at 37.5 mm (1.48 in.)
615 ±29 N (138 ±7 lbf) at 26.5 mm (1.04 in.)
61
Torque Specifications 600 YRM 1121

Intake 37.5 mm (1.48 in.)

Exhaust 37.5 mm (1.48 in.)
Valve Lift
Intake 11.0 mm (0.433 in.)
Exhaust 11.0 mm (0.433 in.)

CYLINDER HEAD WARPAGE

Maximum Cylinder Head Warpage 0.015 mm (0.0006 in.) in 150 mm (5.9 in.) distance

LUBRICATION SYSTEM
Oil Pressure @ 80 C (176 F) 800 rpm: 186 ±34.5 kPa (27 ±5 psi) [oil temperature
approximately 60 C (140 F)]
NOTE: As engine oil temperature increases, oil pres- 2700 rpm: 345 ±69 kPa (50 ±10 psi) [oil temperature
sure will decrease. approximately 76.7 to 104.4 C (170 to 220 F)]
Oil Capacity (With Oil Filter Change) 5.0 liter (5.3 qt)
Oil Pump Type Internal Crescent Gear Pump

COOLING SYSTEM
Thermostat
Start to Open 82 ±1.5 C (179.6 ±34.7 F)
Fully Open 97 ±1.5 C (206.6 ±34.7 F)

Torque Specifications
Camshaft Carrier/Cylinder Head Bolts Crankshaft Timing Pulley Retaining Bolt
First Pass 25 N•m (18 lbf ft) First Pass 130 N•m (96 lbf ft)
Second Pass - Additional 180 degrees Final Final Pass - Additional 45 degrees
Pass - Additional 10 degrees
Crankshaft Pulley Bolts
Camshaft Timing Pulley Bolt 15 to 25 N•m (11 to 18 lbf ft)
40 to 50 N•m (30 to 37 lbf ft)
Crankshaft/RPM Sensor Capscrew
Camshaft Sensor Retaining Screws 8 N•m (71 lbf in)
10 N•m (88.5 lbf in)
Coil Mounting Capscrews
Camshaft Retainer Capscrews 10 N•m (88.5 lbf in)
8 N•m (71 lbf in)
Flywheel Capscrews
Crankshaft Main Bearing Cap Capscrews 52 N•m (38.35 lbf ft)
First Pass 50 N•m (37 lbf ft)
Second Pass - Additional 45 degrees Final Flywheel Housing Capscrews
Pass - Additional 15 degrees M10 Capscrews 38 N•m (28 lbf ft)
M12 Capscrews 66 N•m (48.7 lbf ft)

62
600 YRM 1121 Torque Specifications

Coil Mounting Bracket Attaching Nuts Reluctor Wheel Capscrews

38 N•m (28 lbf ft) First Pass 10 N•m (88.5 lbf in)
Final Pass - Additional 40 to 45 degrees
Exhaust Manifold to Head Nuts
18 to 22 N•m (13 to 16 lbf ft) Rocker Arm Cover Bolts
8 N•m (71 lbf in)
Exhaust Manifold Adapter to Exhaust Manifold
14 to 20 N•m (10 to 15 lbf ft) Spark Plugs
20 N•m (15 lbf ft)
Intake Manifold to Head Nuts
18 to 22 N•m (13 to 16 lbf ft) Starter mounting Bolts
38 N•m (28 lbf ft)
Lift Bracket Bolt
20 N•m (15 lbf ft) Timing Belt Front Cover Bolts
6 N•m (53 lbf in)
Lift Bracket Nut
20 N•m (15 lbf ft) Timing Belt Front Bracket Capscrews
25 N•m (18 lbf ft)
Oil Pump Safety Valve
37 N•m (27 lbf ft) Timing Belt Rear Cover Bolts
6 N•m (53 lbf in)
Oil Pan Capscrews
18 to 22 N•m (13 to 16 lbf ft) Timing Belt Tensioner Bolt
20 N•m (15 lbf ft)
Oil Pan Drain Plug
18 to 22 N•m (13 to 16 lbf ft) Thermostat Cover Capscrews
20 N•m (15 lbf ft)
Oil Pump Cover
6 N•m (53 lbf in) Thermostat Housing Capscrews
11 N•m (97 lbf in)
Oil Pump to Engine Block
8 N•m (71 lbf in) Water Pump Bolts
20 to 30 N•m (15 to 22 lbf ft)
Oil Pump Suction Tube Capscrews
6 to 10 N•m (53 to 89 lbf in) Cooling System Hose Clamps
4 to 5 N•m (35 to 44 lbf in)
Oil Pump Suction Tube Bracket Capscrew
18 to 22 N•m (13 to 16 lbf ft) Fan Hub Bracket Bolts
52 N•m (38 lbf ft)
Oil Pressure Sensor
20 N•m (15 lbf ft) Fan Retaining Bolts
26 N•m (19 lbf ft)
Baffle Plate Capscrews
First Pass 20 to 24 N•m (15 to 17.6 lbf ft) Alternator Bracket Bolts
Final Pass - Additional 45 degrees 38 N•m (28 lbf ft)

Bearing Bracket Capscrews Alternator Mounting Bolts

20 to 24 N•m (15 to 17.6 lbf ft) 20 N•m (15 lbf ft)

Piston Rod Bearing Cap Capscrews

First Pass 30 to 40 N•m (22 to 29.5 lbf ft)
Final Pass - Additional 40 to 45 degrees

63
Special Tools 600 YRM 1121

Special Tools
Valve Spring Compressor
Used to remove and install valve springs.

Valve Stem Oil Seal Tool

Used to remove and install valve stem oil seals.

Camshaft Seal Installer

Used to install the camshaft seal.

Wrench
Used to lock the crankshaft timing pulley.

64
600 YRM 1121 Special Tools

Piston Flange Universal Puller

Used to remove the crankshaft timing pulley.

Crankshaft Front and Rear Oil Seal Puller

Used with sliding mallet to remove oil seals.

Universal Sliding Mallet

Used with crankshaft front and rear oil seal puller to
remove oil seals.

65
Special Tools 600 YRM 1121

Crankshaft Front Seal Installer

Used to install crankshaft front oil seal.

Crankshaft Rear Main Oil Seal Installer

Used to install the crankshaft rear main oil seal.

Rear Flange Alignment Tool

Used to align the oil pan with the cylinder block.

66
 Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011

600 YRM 1121 2/10 (11/08)(6/07)(1/07)(5/06)(1/06)(5/05)(12/04) Printed in U.S.A.