MAZDA ENGINE

2.0L AND 2.2L

S30FT, S35FT, S40FTS [E010];
H1.6FT, H1.8FT, H2.0FTS
(H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
H2.0-3.5FT (H40-70FT) [L177]; S50CT [A267];
H2.0-2.5CT (H50CT) [A274]

PART NO. 1580504 600 SRM 1122

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

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

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

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

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

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

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

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

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

On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Mazda Engine Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Serial Number................................................................................................................................................ 1
Engine Removal and Installation ..................................................................................................................... 2
Cylinder Head, Camshaft, and Valve Mechanism Repair ............................................................................... 2
Remove ........................................................................................................................................................... 2
Clean .............................................................................................................................................................. 4
Inspect and Repair......................................................................................................................................... 4
Cylinder Head............................................................................................................................................ 4
Rocker Shaft Assembly ............................................................................................................................. 4
Camshaft.................................................................................................................................................... 5
Valve Guides .............................................................................................................................................. 6
Valve Seats................................................................................................................................................. 6
Valves ......................................................................................................................................................... 6
Valve Springs............................................................................................................................................. 7
Install ............................................................................................................................................................. 8
Crankshaft and Main Bearings Repair ............................................................................................................ 12
Remove ........................................................................................................................................................... 12
Inspect and Repair......................................................................................................................................... 12
Crankshaft ................................................................................................................................................. 12
Main Bearings ........................................................................................................................................... 13
Install ............................................................................................................................................................. 14
Pistons and Connecting Rods Repair................................................................................................................ 14
Remove and Disassemble .............................................................................................................................. 14
Clean .............................................................................................................................................................. 14
Inspect and Repair......................................................................................................................................... 15
Pistons........................................................................................................................................................ 15
Piston Rings............................................................................................................................................... 15
Connecting Rods and Bearings................................................................................................................. 15
Assemble and Install ..................................................................................................................................... 16
Cylinder Block Repair........................................................................................................................................ 17
Oil Pump Repair ................................................................................................................................................ 18
Remove ........................................................................................................................................................... 18
Disassemble ................................................................................................................................................... 19
Clean .............................................................................................................................................................. 19
Inspect ............................................................................................................................................................ 19
Assemble ........................................................................................................................................................ 20
Install ............................................................................................................................................................. 20
Cooling System Repair ...................................................................................................................................... 22
Thermostat..................................................................................................................................................... 22
Replace ....................................................................................................................................................... 22
Fan Assembly ................................................................................................................................................. 22
Remove and Disassemble.......................................................................................................................... 22
Assemble and Install................................................................................................................................. 22
Water Pump ................................................................................................................................................... 23
Remove....................................................................................................................................................... 23
Install ......................................................................................................................................................... 24
Flywheel and Ring Gear Repair........................................................................................................................ 24
Remove ........................................................................................................................................................... 24
Install ............................................................................................................................................................. 24
Valve Adjustment............................................................................................................................................... 25
Compression Pressure Check ............................................................................................................................ 26

©2012 HYSTER COMPANY i

Table of Contents Mazda Engine

TABLE OF CONTENTS (Continued)

Engine Timing Adjustment ............................................................................................................................... 26
Engine Specifications......................................................................................................................................... 27
Engine Data ................................................................................................................................................... 27
Engine Speeds................................................................................................................................................ 27
2007, and Later, Emission Compliant Engines ....................................................................................... 27
All Engines Except 2007, and Later, Emission Compliant Engines....................................................... 27
Thermostat..................................................................................................................................................... 28
Cylinder Head ................................................................................................................................................ 28
Valve Mechanism........................................................................................................................................... 28
Camshaft ........................................................................................................................................................ 29
Crankshaft ..................................................................................................................................................... 29
Connecting Rods ............................................................................................................................................ 30
Cylinder Block ............................................................................................................................................... 30
Pistons ............................................................................................................................................................ 30
Oil Pump ........................................................................................................................................................ 30
Torque Specifications ......................................................................................................................................... 31

This section is for the following models:

S30FT, S35FT, S40FTS [E010];

H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
H2.0-3.5FT (H40-70FT) [L177];
S50CT [A267];
H2.0-2.5CT (H50CT) [A274]

ii
600 SRM 1122 General

General
This section has the instructions for removal, dis-
assembly, repair, assembly, installation, checks, and
adjustments for the Mazda 2.0L and 2.2L engines.
The engine specifications are given at the end of the
section.
Additional information on the Mazda 2.0L and 2.2L
2007 emissions compliant engine components and for
lift trucks built after January, 2010, can be found in
the following:
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
See section LPG Fuel System, Mazda 2.0L and
2.2L Engines 900 SRM 1125 for lift truck models
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS)
(F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)

See section Gasoline Fuel System, Mazda 2.0L See section Electrical System, Mazda 2.0L and
and 2.2LEmission Compliant Engines 900 SRM 2.2L 2200 SRM 1143 for lift truck models
1325 for lift truck models • S30FT, S35FT, S40FTS (E010)
• S30FT, S35FT, S40FTS (E010) • H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS)
• H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS) (F001)
(F001) • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187) • H2.0-3.5FT (H40-70FT) (L177)
• H2.0-3.5FT (H40-70FT) (L177)
SERIAL NUMBER
See section LPG Fuel System, Mazda 2.0L and
2.2L Emission Compliant Engines 900 SRM 1326 The engine serial number is located on the top left
for lift truck models hand side of the cylinder head cover. See Figure 1.
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS)
(F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)

See section Electrical System, Mazda 2.0L and

2.2L Emission Compliant Engines 2200 SRM
1327 for lift truck models
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS)
(F001)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)

Additional information on all other Mazda 2.0L and

2.2L engine components, for lift trucks built before
2007, can be found in the following:

See section Gasoline Fuel System, Mazda 2.0L

and 2.2L 900 SRM 1127 for lift truck models Figure 1. Engine Serial Number Location
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS)
(F001)

1
Cylinder Head, Camshaft, and Valve Mechanism Repair 600 SRM 1122

Engine Removal and Installation

The removal and installation procedures for the en- • S2.0-3.5FT (S40-70FT, S55FTS) (F187)
gine are not included in this section. • H2.0-3.5FT (H40-70FT) (L177)

See section Frame 100 SRM 1120 for lift truck mod- See section Frame 100 SRM 1423 for lift truck mod-
els els
• S30FT, S35FT, S40FTS (E010) • S50CT (A267)
• H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS) • H2.0-2.5CT (H50CT) (A274)
(F001)

Cylinder Head, Camshaft, and Valve Mechanism Repair

REMOVE emissions compliant and lift trucks built after
January, 2010.
1. Disconnect connections at battery.
15. Remove camshaft pulley. Keep pulley from rotat-
2. Drain cooling system. ing and loosen capscrew. Remove capscrew and
pulley. See Figure 4.
3. Remove air cleaner, throttle cable (if equipped),
intake manifold, and exhaust manifold.

4. Remove coolant hoses.

5. Remove the V belt.

6. Remove the cooling fan.

7. Remove bracket for cooling fan.

8. Remove the six capscrews retaining the crank-

shaft pulley to the timing pulley and remove the
crankshaft pulley.

9. Remove the spark plugs from the cylinder head.

10. Remove upper and lower timing belt covers. See

Figure 2.

11. Loosen capscrews for timing belt tensioner and

remove spring. Remove capscrews and timing
belt tensioner.

12. Use chalk to mark direction of timing belt rota-

tion. See Figure 3. Remove timing belt.

13. If equipped with a distributor, remove the dis-

tributor. Refer to the section Electrical System,
Mazda 2.0L and 2.2L 2200 SRM 1143 for lift
trucks built before 2007.
1. LOWER TIMING BELT COVER
14. If equipped with a CAM angle sensor, remove the 2. UPPER TIMING BELT COVER
CAM angle sensor. Refer to the section Electri- 3. TIMING BELT TENSIONER
cal System, Mazda 2.0L and 2.2L Emission
Compliant Engines 2200 SRM 1327 for 2007 Figure 2. Timing Belt Covers

2
600 SRM 1122 Cylinder Head, Camshaft, and Valve Mechanism Repair

16. Remove nuts and capscrews for front housing.

Then remove housing. See Figure 5.

17. Remove valve cover.

18. Loosen capscrews for rocker shaft supports in

proper sequence. See Figure 6. Remove rocker
shaft assembly and camshaft.

19. Remove capscrews for cylinder head in proper se-

quence. See Figure 7.

20. Lift cylinder head from the block.

21. Use valve spring compressor to remove valve re-

tainers, springs, and valves from head. See Fig-
ure 8.

Figure 3. Timing Belt

Figure 4. Camshaft Gear Removal

Figure 6. Rocker Assembly Removal Sequence

1. FRONT HOUSING
2. GASKET Figure 7. Cylinder Head Removal Sequence
3. OIL SEAL

Figure 5. Front Housing

3
Cylinder Head, Camshaft, and Valve Mechanism Repair 600 SRM 1122

Maximum amount of distortion is 0.15 mm

(0.0059 in.). If grinding of cylinder head is neces-
sary, maximum amount of correction is 0.2 mm
(0.008 in.).

Rocker Shaft Assembly

1. Disassemble rocker shaft assembly. Put marks
on rocker arms so they can be installed on correct
shafts.

2. Clean oil passages in rocker shafts and rocker

arms.

3. Check clearance between rocker arms and

rocker shafts. Maximum clearance is 0.10 mm
Figure 8. Valve Removal (0.004 in.).

Correct dimension for inside diameter of rocker

CLEAN
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the solvent
manufacturer’s recommended safety proce-
dures.
arm is 16.000 to 16.027 mm (0.6299 to 0.6311 in.).
Correct dimension for outside diameter of
rocker shaft is 15.966 to 15.984 mm (0.6286
to 0.6293 in.). If components do not meet specifi-
cations, replace rocker arm(s) or rocker shaft(s)
as necessary.

CAUTION
DO NOT damage machined surfaces when
cleaning.

Clean all parts in solvent. Make sure all oil passages

are clean and all machined surfaces are smooth.

INSPECT AND REPAIR

Cylinder Head
1. Use straight edge and thickness gauge to check
bottom surface of cylinder head for distortion. Do
the measurements at the positions shown in Fig-
ure 9.

Maximum amount of distortion is 0.15 mm

(0.0059 in.). If grinding of cylinder head is neces-
sary, maximum amount of correction is 0.2 mm
(0.008 in.). Figure 9. Cylinder Head Inspection
2. For the intake and exhaust manifold mounting
surfaces, use the same inspection procedures and
correct if there are any faults.

4
600 SRM 1122 Cylinder Head, Camshaft, and Valve Mechanism Repair

Camshaft c. Tighten capscrews for caps to 18 to 27 N•m

1. Check camshaft for cracks or damage.
2. Use dial indicator on end of camshaft to check
movement of camshaft in cylinder head. See
Figure 10. Maximum movement is 0.20 mm
(0.008 in.).
(13 to 20 lbf ft). See Figure 13.
Correct clearance for journals No. 1 and 5
is 0.035 to 0.085 mm (0.0014 to 0.0033 in.).
Correct clearance for journals No. 2, 3, and
4 is 0.065 to 0.115 mm (0.0026 to 0.0045 in.).
If any clearances are greater than 0.15 mm
(0.0059 in.), replace cylinder head assembly.

7. Replace camshaft if there is any damage or if it

does not meet specifications.

Figure 10. Camshaft Check

3. Measure height of camshaft lobes. See Figure 11.

Minimum height of intake and exhaust lobes is
37.170 mm (1.4634 in.).

4. Measure camshaft journals at four points (A-D)

as shown in Figure 11. Minimum dimensions for
the journals are as follows:
Front and Rear Journals (Nos. 1 and 5) - 1. FRONT OIL SEAL SURFACE
31.940 to 31.965 mm (1.2575 to 1.2585 in.) 2. FRONT JOURNAL (NO. 1)
Center Journals (Nos. 2, 3 and 4) - 31.910 to 3. CENTER JOURNALS (NOS. 2, 3, AND 4)
4. REAR JOURNAL (NO. 5)
31.935 mm (1.2563 to 1.2573 in.)
Front Oil Seal Surface - 33.961 to 34.000 mm Figure 11. Camshaft Inspection
(1.3371 to 1.3386 in.)

5. Check camshaft for straightness. Put front and

rear journals in V blocks and rotate camshaft one
complete turn. See Figure 12. Maximum amount
that the dial indicator should indicate is 0.03 mm
(0.0012 in.).

6. Measure clearance between camshaft and bore in

cylinder head as follows:

a. Install camshaft in cylinder head.

b. Put plastic gauge material between each

camshaft journal and cap. Do not allow
camshaft to rotate. Figure 12. Camshaft Check

5
Cylinder Head, Camshaft, and Valve Mechanism Repair 600 SRM 1122

Valves
1. Measure length of each valve.

Minimum length for intake valve is 111.19 mm

(4.378 in.).

Minimum length for exhaust valve is 110.99 mm

(4.370 in.).

1. PLASTIC GAUGE 2. SCALE

Figure 13. Camshaft Clearance Measurement

Valve Guides
1. Measure clearance between valve stems and
valve guides.

Normal clearance for intake valve guides is 0.025

to 0.060 mm (0.001 to 0.002 in.). 1. CYLINDER HEAD 3. VALVE GUIDE
2. RETAINING RING
Normal clearance for exhaust valve guides is
0.030 to 0.065 mm (0.0012 to 0.0026 in.). Figure 14. Valve Guide Inspection
If clearance is more than 0.10 mm (0.004 in.),
replace valve or valve guide.

2. If replacement is necessary, remove seal from

valve guide(s). Then use tool to remove valve
guide(s) from the combustion chamber side.

3. To install valve guide, install retaining ring on

valve guide. Use valve guide installation tool to
install valve guide so that retaining ring contacts
cylinder head. See Figure 14.

Correct height of valve guide above valve spring

seat is 19.1 to 19.6 mm (0.75 to 0.77 in.).
A. EXHAUST B. INTAKE
Valve Seats 1. VALVE SEAT WIDTH
2. EXHAUST VALVE SEAT
1. Inspect condition of valve seats. If valve seats 3. INTAKE VALVE SEAT
have cracks, cylinder head must be replaced.
Figure 15. Valve Seat Specifications
2. If valve seats are in good condition, check contact
pattern of valve and valve seat. Use valve seat
grinder to make sure valve seats are within spec-
ifications shown in Figure 15. Use valve com-
pound to make sure valves fit seats.

6
600 SRM 1122 Cylinder Head, Camshaft, and Valve Mechanism Repair

2. Inspect stem of each valve for wear. Use microm-

eter to measure outside diameter of stem at dif-
ferent points (A - E). See Figure 16.

Minimum dimension for intake valve is

7.980 mm (0.3142 in.). Minimum dimension
for exhaust valve is 7.975 mm (0.3140 in.).

3. Inspect valves for cracks, burned faces, and dis-

tortion. Inspect seat face of valves for wear and
damage.

4. Measure thickness of valve head. Minimum

thickness for intake valve is 0.5 mm (0.020 in.).
Minimum thickness for exhaust valve is 1.0 mm
(0.040 in.).

If valves need grinding, correct surface angle is

30° for both intake and exhaust valves.

Valve Springs
1. Check valve springs for damage. 1. VALVE STEM
2. THICKNESS, VALVE HEAD
2. Measure free length of valve springs. See Fig-
ure 17. Figure 16. Valve Inspection

Minimum length of inner valve spring is 46.3 mm

(1.823 in.). Minimum length of outer valve spring
is 50.6 mm (1.992 in.).

3. Check valve springs for squareness. See Fig-

ure 17.

Correct squareness of inner valve spring is

1.66 mm (0.065 in.).

Correct squareness of outer valve spring is

1.82 mm (0.072 in.).

If measurement is more than specification, re-

place valve spring(s).

A. MEASURE HERE

Figure 17. Valve Springs Inspection

7
Cylinder Head, Camshaft, and Valve Mechanism Repair 600 SRM 1122

INSTALL 6. Apply gasket sealer to areas shown by arrows.

1. Clean surface of cylinder head and surface of en-
gine block.
2. Using the appropriate seal installer tool, insert
valve seals into valve guides. See Figure 18.
Lubricate camshaft with clean engine oil. Then
install camshaft. Make sure dowel pin is at top
of camshaft. See Figure 21.

1. TOOL
2. CYLINDER HEAD
3. VALVE GUIDE Figure 20. Cylinder Head Installation
4. VALVE SEAL

Figure 18. Valve Seal Installation

3. Use valve spring compressor to install valve re-

tainers, springs, and valves into head. See Fig-
ure 19.

Figure 19. Valve Installation

4. Install new gasket and cylinder head on engine

block.

5. Install capscrews and washers for cylinder

head. Tighten capscrews to 82 to 88 N•m (60 to 1. DOWEL PIN
65 lbf ft) in proper sequence. See Figure 20. 2. APPLY SEALANT HERE

Figure 21. Camshaft Installation

8
600 SRM 1122 Cylinder Head, Camshaft, and Valve Mechanism Repair

7. Assemble rocker shaft assembly. See Figure 22. 9. If necessary, install oil seal in front housing. See
Lubricate rocker arms and shafts with engine oil. Figure 24. Use new gasket and install front hous-
Put capscrews in rocker shaft supports. Then ing on cylinder head. Tighten capscrews for front
install assembly on cylinder head. housing to 19 to 26 N•m (168 to 230 lbf in).

10. With dowel pin at top of camshaft, install

camshaft pulley.

For 2.0L engines, check that number 1 on pul-

ley is aligned with timing mark on front housing.
See Figure 25.

For 2.2L engines, check that number 1 on pulley

is positioned approximately 2.5° in the retard di-
rection.

11. Install capscrew and washer for camshaft pulley.

See Figure 25. Keep pulley from turning and
tighten capscrew to 48 to 66 N•m (35 to 49 lbf ft).

A. NO. 1 AND NO. 3 ARE THE SAME

B. NO. 2 AND NO. 4 ARE THE SAME

Figure 22. Rocker Shaft Assembly

8. Tighten capscrews for rocker shaft supports to 18

to 27 N•m (13 to 20 lbf ft) in proper sequence. See
Figure 23.

1. FRONT HOUSING
2. GASKET
3. OIL SEAL

Figure 24. Front Housing

Figure 23. Rocker Shaft Assembly Installation

9
Cylinder Head, Camshaft, and Valve Mechanism Repair 600 SRM 1122

13. Install timing belt tensioner and spring. Move

tensioner fully toward intake side of engine and
temporarily tighten lock bolt.

14. Clean any oil or grease from pulleys. Install tim-

ing belt so that it goes in same direction as mark
made during removal.

15. Loosen lock bolt and apply spring tension on belt.

Rotate crankshaft pulley clockwise two complete
turns and check timing marks.

If timing marks are correct, tighten lock bolt for

tensioner to 20 to 35 N•m (15 to 26 lbf ft). Be
sure tensioner does not move together with lock
bolt rotation. Check movement on tension side of
timing belt. See Figure 27.

For both 2.0L and 2.2L engines, if tension is cor-

rect, belt will move 9 to 10 mm (0.36 to 0.39 in.)
with 10 kg (22 lb) of force.

1. TIMING MARKS
2. CAMSHAFT PULLEY

Figure 25. Camshaft Pulley Installation

12. Align timing marks for crankshaft timing pulley.

See Figure 26.

1. TENSIONER 3. LOCK BOLT

2. SPRING 4. TENSION SIDE

Figure 27. Timing Belt Installation

16. Install lower timing belt cover and new gasket.

Tighten capscrews to 7 to 8 N•m (5 to 6 lbf ft).
Install upper timing belt cover and new gasket.
Tighten capscrews to 8 to 12 N•m (6 to 9 lbf ft).
See Figure 28.
1. CRANKSHAFT TIMING PULLEY
2. TIMING MARK

Figure 26. Timing Belt Installation

10
600 SRM 1122 Cylinder Head, Camshaft, and Valve Mechanism Repair

21. If equipped with a distributor, install the distrib-

utor. Refer to the section Electrical System,
Mazda 2.0L and 2.2L 2200 SRM 1143 for lift
trucks built before 2007.

22. If equipped with a CAM angle sensor, install the

CAM angle sensor. Refer to the section Electri-
cal System, Mazda 2.0L and 2.2L Emission
Compliant Engines 2200 SRM 1327 for 2007
emissions compliant engines and lift trucks built
after January, 2010.

23. Install bracket for cooling fan.

24. Install coolant hoses.

25. Install air cleaner, throttle linkage (if equipped),

intake manifold, and exhaust manifold.

CAUTION
Additives may damage the cooling system. Be-
fore using additives, contact your local Hyster
dealer.

26. Fill cooling system.

27. Connect connections at battery.

1. LOWER TIMING BELT COVER

2. UPPER TIMING BELT COVER
3. TIMING BELT TENSIONER

Figure 28. Timing Belt Covers

17. Install crankshaft pulley and six capscrews to re-

tain pulley. Tighten pulley to 12 to 17 N•m (9 to
13 lbf ft).

18. Apply gasket sealer to the areas shown in Fig-

ure 29. Install new gasket and valve cover.

19. Install valve cover capscrews and tighten to 6 to Figure 29. Valve Cover Installation
8 N•m (52 to 70 lbf in).

20. Install spark plugs in cylinder head. Tighten

spark plugs to 15 to 23 N•m (11 to 16 lbf ft).

11
Crankshaft and Main Bearings Repair 600 SRM 1122

Crankshaft and Main Bearings Repair

REMOVE
1. Remove the V belt.

2. Remove the cooling fan.

3. Remove bracket for cooling fan.

4. Remove six capscrews that hold crankshaft pul-

ley to timing pulley.

5. Remove capscrew from crankshaft timing pulley.

Install special tool with spacer on crankshaft to
remove timing pulley. Rotate tool until it touches
front of crankshaft. Hit tool with hammer to
loosen timing pulley. Remove pulley, dowel pin,
tapered ring, and spacer. Remove tool. See Fig-
ure 30.

6. Remove oil pan and oil strainer.

1. CENTER MAIN BEARING

Figure 31. Crankshaft Clearance Measurement

10. Put identification marks on bearing caps. Loosen

capscrews for main bearing caps in steps. Then
remove capscrews, caps, and crankshaft.

INSPECT AND REPAIR

Crankshaft
1. Inspect crankshaft for wear, cracks, or other
damage. Replace crankshaft if it has cracks.

2. Use micrometer to measure diameter of journals

1. SPACER 2. TOOL
Figure 30. Crankshaft Timing Pulley Removal
7. Remove rear cover. Remove front cover with oil
pump.
8. Remove caps for connecting rods. Put identifica-
tion mark on each cap so they will be installed in
correct location.
9. Before removing crankshaft, measure clearance
between crankshaft and flange of center main
bearing. See Figure 31. Push crankshaft fully
forward before making measurement.
Maximum clearance is 0.30 mm (0.012 in.). If
clearance is greater than specification, replace
center main bearing or grind crankshaft and in-
stall new main bearing.
for crankshaft. See Figure 32. Make measure-
ment at several locations for each journal. Cor-
rect dimensions for journals are as follows:
Main Journal Diameter - 59.937 to 59.995 mm
(2.3597 to 2.3620 in.)
Connecting Rod Journals - 50.940 to
50.955 mm (2.0055 to 2.0061 in.)
Rear Oil Seal Surface - 89.946 to 90.000 mm
(3.5412 to 3.5433 in.)
Front Oil Seal Surface - 33.961 to 34.000 mm
(1.3371 to 1.3386 in.)
If measurements are less than specifications,
grind crankshaft and install oversize bearings.
Refer to the Parts Manual for the different
bearing sizes.

12
600 SRM 1122 Crankshaft and Main Bearings Repair

3. Check crankshaft for straightness. See Fig- Main Bearings

ure 32. Put front and rear journals in V blocks
and rotate crankshaft one complete turn. Maxi- NOTE: Inspect main bearings for damage. If any
mum amount that dial indicator should indicate main bearing is damaged, all main bearings must be
is 0.03 mm (0.0012 in.). replaced.

4. Check oil passages crankshaft. Make sure pas- 1. To inspect main bearings for wear, measure
sages are clean and have no restrictions. clearance between main bearings and crank-
shaft using plastic gauge. See Figure 33.

a. Reinstall crankshaft in cylinder block.

b. Put plastic gauge material on journals and

install main bearing caps. Tighten cap-
screws for bearing caps to 84 to 90 N•m (62
to 66 lbf ft).

c. Remove bearing caps. Plastic gauge material

will adhere to journals or bearing caps.

d. Use graduations on scale to measure width

of plastic gauge material at its widest point.

Correct clearance for journals No. 1, 2,

4, and 5 is 0.025 to 0.043 mm (0.00099 to
0.00169 in.).

Correct clearance for journal No. 3 is 0.031

to 0.049 mm (0.00123 to 0.00192 in.).

If any clearance is greater than specification,

replace all main bearings.

1. REAR OIL SEAL SURFACE

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

Figure 32. Crankshaft Inspection

1. PLASTIC GAUGE MATERIAL

2. SCALE

Figure 33. Main Bearings Clearance Check

13
Pistons and Connecting Rods Repair 600 SRM 1122

INSTALL part of gasket that extends past bottom of cylin-

der block.
1. Clean areas of cylinder block around main bear-
ings. Carefully install bottom half of new main 8. Install oil strainer. Tighten capscrews to 8 to
bearings if necessary. Lubricate bearings with 12 N•m (70 to 106 lbf in).
clean engine oil.
9. Apply adhesive sealant to a new oil pan gasket
2. Install crankshaft. and install new gasket and oil pan. Tighten cap-
screws to 8 to 12 N•m (71 to 106 lbf in).
3. Install top half of main bearings in caps and
lubricate with oil. Use identification marks to
install main bearing caps in correct locations.
Tighten capscrews for main bearing caps to 84
to 90 N•m (62 to 66 lbf ft).

4. Install pistons and connecting rods as described

in Pistons and Connecting Rods Repair.

5. Make sure O-ring is in oil pump housing. Lubri-

cate oil seal with engine oil. Use adhesive sealant
to install housing to cylinder block. Make sure
there is no sealant in oil port. Tighten M10 cap-
screws to 38 to 53 N•m (28 to 39 lbf ft). Tighten
M8 capscrews to 19 to 26 N•m (14 to 19 lbf ft).

6. Lubricate surfaces of oil seal with engine oil. Use

press to install oil seal in rear cover. Install align- 1. REAR COVER
ment pin in cylinder block. 2. OIL SEAL
3. CRANKSHAFT
7. Install new gasket and rear cover. See Figure 34.
Make sure dowel pin is installed. Tighten cap- Figure 34. Rear Cover
screws to 8 to 12 N•m (70 to 106 lbf in). Cut off

Pistons and Connecting Rods Repair

REMOVE AND DISASSEMBLE
1. Remove cylinder head as described in Cylinder
Head, Camshaft, and Valve Mechanism Repair.
2. Remove oil pan and oil strainer.
CAUTION
DO NOT damage top of piston when placing
identification mark. DO NOT place a deep
identification mark in top of piston.
3. Put identification mark on top of each piston.
4. Clean carbon from top of each cylinder bore.
5. Remove caps and bearings from each connecting
rod. Keep caps and bearings with correct piston
assemblies.
NOTE: Measure and record the pin depth in the pis-
ton for correct reassembly.
6. Push connecting rod and piston from cylinder
block.
7. Carefully remove piston rings from pistons. Use
tool to push piston pin from connecting rod.
CLEAN
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow solvent man-
ufacturer’s recommended safety procedures.
Clean all parts in solvent. Make sure all oil passages
and grooves are clean. Make sure all machined sur-
faces are smooth.

14
600 SRM 1122 Pistons and Connecting Rods Repair

INSPECT AND REPAIR a. Put plastic gauge material on crankshaft

journals and install rod caps. Tighten cap-
Pistons screws for rod caps to 51 to 56 N•m (48 to
51 lbf ft). Do not rotate connecting rod.
1. Inspect pistons for wear and cracks. Replace any
piston that is damaged. b. Remove rod caps. Plastic gauge material will
adhere to journals or rod caps.
2. Measure outside diameter of piston. See
Figure 35. Correct dimension is 85.943 to c. Use graduations on scale to measure width
85.965 mm (3.3836 to 3.3844 in.). Maximum of plastic gauge material at its widest point.
clearance between piston and cylinder bore is
0.15 mm (0.0059 in.). Correct clearance is 0.027 to 0.067 mm
(0.0011 to 0.0026 in.). If any clearance is
Piston Rings greater than specification, replace all rod
bearings.
1. Install piston ring into cylinder bore where it will
be used. Use thickness gauge to measure amount
of end clearance of each piston ring. See Fig-
ure 36. Correct dimensions are as follows:
Top Piston Ring - 0.20 to 0.35 mm (0.008 to
0.014 in.)
2nd Piston Ring - 0.15 to 0.30 mm (0.006 to
0.012 in.)
Oil Ring - 0.20 to 0.70 mm (0.008 to 0.027 in.)
Maximum clearance is 1.0 mm (0.039 in.)

2. Measure clearance between piston ring and

groove in piston. See Figure 36. Correct dimen-
sions are as follows:
Top Piston Ring - 0.03 to 0.07 mm (0.0012 to Figure 35. Piston Measurement
0.0028 in.)
2nd Piston Ring - 0.03 to 0.07 mm (0.0012 to
0.0028 in.)
Maximum clearance is 0.15 mm (0.0059 in.)

Connecting Rods and Bearings

1. Use alignment tool to check connecting rods for
straightness. Contact your local machine shop.

Maximum amount of distortion per 50 mm

(1.97 in.) is 0.18 mm (0.007 in.).

Maximum amount of bending per 50 mm

(1.97 in.) is 0.075 mm (0.003 in.).

If amount of distortion is greater than specifica-

tion, install new connecting rod.

2. Clean rod bearings and crankshaft journals. To

check bearings for wear, measure clearance be-
tween rod bearings and journals. See Figure 37.
1. PISTON RING END CLEARANCE
2. PISTON RING GROOVE CLEARANCE

Figure 36. Piston Rings Measurement

15
Pistons and Connecting Rods Repair 600 SRM 1122

3. Install piston rings on pistons. During instal-

lation, writing on each piston ring must be to-
ward top of piston. Check that rings rotate freely.
Then put ends of rings in positions shown in Fig-
ure 39. Make sure ends of upper and lower oil
control rings are each 30° from piston pin. Also
make sure that top and second rings are each 30°
from piston pin. Lubricate rings with engine oil.

4. Apply clean engine oil to piston assembly. Install

bearings for connecting rods. Install piston into
correct cylinder, making sure F is toward front
(timing belt end) of engine. See Figure 40.

5. Apply clean engine oil to bearing. Then install

1. PLASTIC GAUGE 2. SCALE
each cap to correct connecting rod. During in-
Figure 37. Connecting Rod Bearings Clearance stallation of caps, make sure to align identifi-
Check cation marks that were made during disassem-
bly. Tighten nuts for caps to 51 to 56 N•m (38 to
ASSEMBLE AND INSTALL 41 lbf ft).

1. Align oil port on large end of connecting rod with

F mark on piston. See Figure 38. Lubricate pis-
ton pin and bore in piston with engine oil.

2. Use press to install piston pin. Amount of force

required to push pin into piston must be 500 to
1500 kg (1102 to 3306 lb). If force is not correct,
replace piston pin and/or connecting rod.

Make sure piston pin is installed to correct depth,

recorded earlier. After installation, check that
piston moves freely on piston pin.

Figure 39. Piston Rings

1. F MARK 2. OIL PORT

Figure 38. Connecting Rod and Piston

16
600 SRM 1122 Cylinder Block Repair

Legend for Figure 39

A. OIL CONTROL RING
B. TOP AND SECOND RINGS
1. EXPANDER RING
2. OIL RING (UPPER)
3. OIL RING (LOWER)
4. TOP RING
5. SECOND RING

1. F MARK

Figure 40. Piston Installation

Cylinder Block Repair

1. After cylinder block is cleaned, check surface for
distortion. See Figure 41.

If amount of distortion is greater than 0.15 mm

(0.0059 in.), grind surface of cylinder block. Max-
imum amount of correction permitted is 0.20 mm
(0.008 in.).

2. Check cylinder bores for wear and damage. Mea-

sure each bore. Correct dimension is 86.00 to
86.019 mm (3.3858 to 3.3866 in.). Wear limit
above this dimension is 0.15 mm (0.0059 in.).

Repair cylinder block or use bigger pistons as

necessary.

Refer to Parts Manual for available sizes.

Figure 41. Cylinder Block Inspection

17
Oil Pump Repair 600 SRM 1122

Oil Pump Repair

Before removing oil pump, replace sending unit with
pressure gauge and check oil pressure. Minimum oil
pressure at governed rpm is approximately 275 kPa
(40 psi). If pressure is less than specification, oil
pump or engine bearings need repair.
REMOVE
1. Remove the V belt.
7. Loosen capscrews for timing belt tensioner and
remove spring. Remove capscrews and timing
belt tensioner.
8. Use chalk to mark direction of rotation of timing
belt. See Figure 43. Remove timing belt.

2. Remove the cooling fan.

3. Remove bracket for cooling fan.

4. Remove six capscrews that hold crankshaft shaft

pulley to timing pulley.

5. Remove upper and lower timing belt covers. See

Figure 42.

6. Align engine timing marks.

Figure 43. Timing Belt

9. Remove capscrew from crankshaft timing pulley.

Install special tool with spacer on crankshaft to
remove timing pulley. Rotate tool until it touches
front of crankshaft. Hit tool with hammer to
loosen timing pulley. Remove pulley, dowel pin,
tapered ring, and spacer. Remove tool. See Fig-
ure 44.

1. SPACER 2. TOOL
1. LOWER TIMING BELT COVER
2. UPPER TIMING BELT COVER Figure 44. Crankshaft Timing Pulley Removal
3. TIMING BELT TENSIONER

Figure 42. Timing Belt Covers

18
600 SRM 1122 Oil Pump Repair

10. Remove capscrews that hold oil pan to cylinder CLEAN

block. Remove oil pan.

11. Remove the capscrew retaining the oil strainer

assembly and remove the oil strainer assembly.
12. Remove capscrews that hold front cover (pump
housing) to cylinder block. Remove front cover
and oil pump assembly.
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the solvent
manufacturer’s recommended safety proce-
dures.

DISASSEMBLE CAUTION
1. Remove screws and pump cover. See Figure 45. DO NOT damage machined surface when
cleaning.

Clean all parts in solvent. Make sure all machined

surfaces are smooth.

INSPECT
1. Check front cover (pump housing) and pump
cover for wear or damage. Check plunger spring
for damage.

2. Measure parts of oil pump. See Figure 46.

a. Measure clearance between inner rotor tip

and outer rotor. Maximum clearance is
0.18 mm (0.007 in.). If clearance is more
than 0.18 mm (0.007 in.), repair as neces-
sary.
1. SCREW
2. COVER b. Measure clearance between housing and
3. OUTER GEAR outer rotor. Correct clearance is 0.090 to
4. INNER GEAR 0.176 mm (0.0035 to 0.0069 in.). If clearance
5. FRONT COVER (HOUSING) is more than 0.20 mm (0.008 in.), repair as
6. OIL SEAL
7. PLUNGER necessary.
8. SNAP RING
c. Use straight edge to measure side clear-
Figure 45. Oil Pump ance of rotors. Correct clearance is 0.03 to
0.09 mm (0.0012 to 0.0035 in.). If clearance
2. Remove outer gear and inner gear from pump is more than 0.10 mm (0.004 in.), repair as
body. necessary.

3. Remove snap ring and plunger assembly from

housing.

19
Oil Pump Repair 600 SRM 1122

1. CLEARANCE BETWEEN INNER ROTOR TOOTH TIP AND OUTER ROTOR

2. CLEARANCE BETWEEN HOUSING AND OUTER ROTOR
3. SIDE CLEARANCE OF ROTORS IN HOUSING

Figure 46. Oil Pump Measurement

ASSEMBLE 3. Install new gasket for strainer and install

1. Install oil seal in oil pump housing. Make sure
front edge of oil seal is even with outer edge of
housing. See Figure 45.
2. Lubricate gears with clean engine oil. Install
gears in housing.
3. Install pump cover. Apply thread-locking com-
pound on screws for pump cover. Then install
screws.
strainer assembly. Tighten capscrews to 8 to
12 N•m (70 to 106 lbf in). See Figure 48.
4. Apply adhesive sealant to a new oil pan gasket
and install new gasket and oil pan. Tighten cap-
screws to 8 to 12 N•m (70 to 106 lbf in). See Fig-
ure 48.

4. Install plunger assembly and snap ring.

INSTALL
1. Install O-ring on oil pump housing. Use grease
to hold O-ring in position. Lubricate oil seal with
engine oil. See Figure 47.

2. Use adhesive sealant to install oil pump hous-

ing on cylinder block. Make sure there is no
sealant in oil port. Tighten M10 capscrews to 38
to 53 N•m (28 to 39 lbf ft). Tighten M8 capscrews 1. O-RING
to 19 to 26 N•m (14 to 19 lbf ft).
Figure 47. Oil Pump

20
600 SRM 1122 Oil Pump Repair

1. CAPSCREW 5. GASKET
2. OIL STRAINER 6. CAPSCREW
3. CAPSCREW 7. GASKET
4. OIL PAN 8. OIL PUMP

Figure 48. Oil Strainer and Oil Pan

21
Cooling System Repair 600 SRM 1122

Cooling System Repair

THERMOSTAT FAN ASSEMBLY
Replace Remove and Disassemble
1. Drain cooling system to level of thermostat. 1. Loosen alternator and remove fan belt.

2. Disconnect hose and remove thermostat housing. 2. Remove capscrews for fan. Remove fan and pul-
Remove thermostat. See Figure 49. ley from hub.

3. Remove capscrews that hold fan bracket to en-

gine. Remove fan bracket.

4. Use press to remove fan hub from shaft. Remove

snap ring, push bearing, and shaft from bracket.
See Figure 50.

1. CYLINDER BLOCK 3. THERMOSTAT

2. GASKET 4. HOUSING

Figure 49. Thermostat

3. Test operation of thermostat. See the section

Cooling System 700 SRM 1123.

Thermostat must begin to open at 82 ±1.5°C (180

±3°F). Thermostat must be completely open at
1. FAN 4. SNAP RING
95°C (203°F). 2. PULLEY 5. SHAFT
3. HUB 6. BRACKET
4. Install thermostat and new gasket. Make sure
print side of gasket is toward thermostat. Figure 50. Fan Assembly
5. Install thermostat housing and tighten cap- Assemble and Install
screws to 19 to 26 N•m (14 to 19 lbf ft).
1. Use press to install shaft and bearing in bracket.
CAUTION See Figure 50. Push bearing in until it touches
bracket. Install snap ring. Install hub on shaft.
Additives may damage the cooling system. Be-
fore using additives, contact your local Hyster 2. Install bracket assembly on cylinder block.
dealer. Tighten M10 and M12 capscrews to 38 to 64 N•m
(28 to 47 lbf ft).
6. Connect hose and fill cooling system. Start en-
gine and check for leaks. 3. Install pulley and fan on hub. Tighten capscrews
to 27 N•m (20 lbf ft).

22
600 SRM 1122 Cooling System Repair

4. Install fan belt. Adjust tension of the fan belt.

Check movement of fan belt between fan and al-
ternator.

NOTE: Tension for belt is correct when it moves 17 to

19 mm (0.67 to 0.75 in.) with 10 kg (22 lb) of force.
Tighten alternator when tension is correct.

WATER PUMP
Remove
1. Drain cooling system.

2. Loosen alternator and remove fan belt.

3. Remove capscrews for the fan. Remove fan and

pulley from the hub.

4. Remove capscrews that hold fan bracket to en-

gine. Remove fan bracket.

5. Remove six capscrews that hold crankshaft shaft

pulley to timing pulley.

6. Remove upper and lower timing belt covers. See

Figure 51.

7. Align engine timing marks.

8. Loosen capscrews for timing belt tensioner and 1. LOWER TIMING BELT COVER
remove spring. Remove capscrews and timing 2. UPPER TIMING BELT COVER
3. TIMING BELT TENSIONER
belt tensioner.
Figure 51. Timing Belt Covers
CAUTION
DO NOT rotate the camshaft gear or the crank-
shaft gear while the timing belt is removed. If
either of the gears is moved, it will be neces-
sary to align the timing marks.

9. Use chalk to mark direction of rotation of timing

belt. See Figure 52. Then remove timing belt.

10. Disconnect hose at water pump. Remove cap-

screws for water pump. Then remove water
pump from cylinder block.

Figure 52. Timing Belt

23
Flywheel and Ring Gear Repair 600 SRM 1122

Install 7. Start engine and check cooling system for leaks.

1. Install water pump with a new gasket. Tighten

capscrews to 19 to 26 N•m (14 to 19 lbf ft).
2. Clean any oil or grease from pulleys. Install tim-
ing belt so that it goes in same direction as mark
made during removal.
3. Loosen lock bolt and apply spring tension on belt.
Rotate crankshaft pulley clockwise two complete
turns and check timing marks.
If timing marks are correct, tighten lock bolt for
tensioner to 38 to 53 N•m (28 to 39 lbf ft). Check
movement on tension side of timing belt. See
Figure 53.
WARNING
DO NOT remove the radiator cap from the ra-
diator when the engine is hot. When the radi-
ator 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 en-
gine is running.
8. After engine has been operated, stop engine. If
coolant is hot, give engine time to cool. Check
coolant level and add coolant if necessary.

For both 2.0L and 2.2L engines, if tension is cor-

rect, belt will move 9 to 10 mm (0.36 to 0.39 in.)
with 10 kg (22 lb) of force.

4. Install lower timing belt cover and gasket.

Tighten capscrews to 7 to 10 N•m (62 to
89 lbf in). Install upper timing belt cover and
gasket. Tighten capscrews to 7 to 10 N•m (62 to
89 lbf in). See Figure 51.

5. Install fan assembly as described in the proce-

dure for Fan Assembly, Assemble and Install.

CAUTION 1. TENSIONER 3. LOCK BOLT

Additives may damage the cooling system. Be- 2. SPRING 4. TENSION SIDE
fore using additives, contact your local Hyster
dealer. Figure 53. Timing Belt Installation

6. Install coolant hoses. Fill cooling system with

coolant.

Flywheel and Ring Gear Repair

REMOVE
1. Remove capscrews for flywheel. Then remove fly-
wheel and adapter plate. See Figure 54.
2. If necessary, remove flywheel housing.
INSTALL
1. If flywheel housing was removed, install it on en-
gine. Tighten M14 capscrews to 114 to 136 N•m
(84 to 100 lbf ft). Tighten M10 capscrews to
38 N•m (28 lbf ft).
2. Install adapter plate on crankshaft. Install the
flywheel.
3. Apply Loctite® 222 or equivalent on threads of
capscrews. Then install capscrews for flywheel.
Tighten capscrews to 96 to 103 N•m (71 to
76 lbf ft) in proper sequence. See Figure 54.

24
600 SRM 1122 Valve Adjustment

Legend for Figure 54

A. TIGHTENING SEQUENCE
1. FLYWHEEL HOUSING
2. WASHER
3. CAPSCREW
4. ADAPTER PLATE
5. CAPSCREW
6. WASHER
7. FLYWHEEL
8. PIN
9. CAPSCREW
10. CAPSCREW

Figure 54. Flywheel Arrangement

Valve Adjustment
1. Rotate crankshaft until No. 1 piston is at TDC on
compression stroke (intake and exhaust valves
closed).

2. Adjust clearance of intake valves for No. 1 and

No. 2 cylinders and exhaust valves for the No. 1
and No. 3 cylinders. See Figure 55. Correct clear-
ance for intake valves when engine is cold is 0.15
±0.05 mm (0.0059 ±0.002 in.). Correct clearance
for exhaust valves when engine is cold is 0.35
±0.05 mm (0.0138 ±0.002 in.).

To adjust clearance, loosen lock nut and turn ad-

justment screw. Tighten lock nut to 16 to 21 N•m
(12 to 15 lbf ft).

NOTE: During adjustment of valves, check position

of balls in ends of rocker arms. Flat surface of ball
must be in contact with stem of valve.

3. Rotate crankshaft clockwise one complete turn.

Adjust remaining valves.

Legend for Figure 55

A. INTAKE VALVES
B. EXHAUST VALVES
C. INTAKE (ENGINE COLD): 0.15 mm (0.0059 in.),
EXHAUST (ENGINE COLD): 0.35 mm (0.0138 in.)
1. CAMSHAFT
2. ROCKER ARM
3. BALL
4. VALVE STEM Figure 55. Valve Adjustment

25
Engine Timing Adjustment 600 SRM 1122

Compression Pressure Check

• If pressure reading does not increase, low
CAUTION pressure was caused by worn valves, valve
When removing or installing the spark plugs seats, or valve guides.
from the aluminum cylinder head, it is impor- • If low pressure readings are in two cylin-
tant that you use care because of the dissimi- ders next to each other, cylinder head may
lar metals. Penetrating oil may need to be used be leaking.
when removing the spark plugs. Apply a cou-
ple of drops of engine oil to the spark plugs be- Table 1. Pressure Specifications
fore installation.
Pressure Gasoline LPG
1. Remove spark plugs from cylinder head. Discon-
nect high tension wire at ignition coil. Standard 1130 kPa 1130 kPa
Pressure (164 psi) @ (164 psi) @
2. Install compression gauge in No. 1 cylin- 270 rpm 270 rpm
der. Make sure gauge has minimum range Minimum 793 kPa 793 kPa
of 1725 kPa (250 psi). See Figure 56. Pressure (115 psi) @ (115 psi) @
3. Use starter to crank engine at least six revolu- 270 rpm 270 rpm
tions. Check pressure reading and release pres- Maximum
sure. Repeat test again and make note of highest Difference
196 kPa (28 psi)
pressure. Do this test for each cylinder. Between
Cylinders
The standard and minimum pressure specifica-
tions are shown in Table 1.

4. If the readings are lower than minimum reading,

there is a problem with the valves, piston rings,
or cylinder head gasket. Do the following tests to
find the problem:

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

oil to each cylinder at spark plug hole.

b. Crank engine approximately 10 revolutions

to distribute oil.

c. Install compression gauge and do same tests

as described in Step 3.
• If pressure reading increases to normal 1. ADAPTER
reading, low pressure was caused by worn
or damaged piston rings. Cylinder bore Figure 56. Compression Pressure Check
may also be damaged.

Engine Timing Adjustment

For Mazda 2.0L and 2.2L 2007 emission compliant
engines and for lift trucks built after January, 2010,
see Ignition System in the section Electrical Sys-
tem, Mazda 2.0L and 2.2L Emission Compliant
Engines 2200 SRM 1327 for the adjustment proce-
dure for engine timing.
The correct timing is as follows:
• Gasoline Engine = 6° ±1° BTDC @ 800 ±25 rpm
(orange mark)
• LPG Engine = 6° ±1° BTDC @ 800 ±25 rpm (or-
ange mark)

26
600 SRM 1122
For all other Mazda 2.0L and 2.2L engines, see
Ignition System in the section Electrical System,
Mazda 2.0L and 2.2L 2200 SRM 1143 for the ad-
justment procedure for engine timing.
Engine Specifications
ENGINE DATA
Engine Type ....................... In-line, Four Cylinders
Bore × Stroke (2.0L)........... 86 mm (3.39 in.) ×
86 mm (3.39 in.)
Bore × Stroke (2.2L)........... 86 mm (3.39 in.) ×
94 mm (3.70 in.)
Displacement (2.0L) ........... 1998 cm 3 (121.9 in. 3 )
Displacement (2.2L) ........... 2184 cm 3 (133.2 in. 3 )
Firing Order ....................... 1 - 3 - 4 - 2
Valve Clearance (Exhaust, 0.35 ±0.05 mm (0.0138
Engine Cold) ....................... ±0.002 in.)
Valve Clearance (Intake, 0.15 ±0.05 mm (0.0059
Engine Cold) ....................... ±0.002 in.)
Compression Ratio
– Gasoline....................... 8.6:1
Compression Ratio
– LPG (2.0L)................... 9.3:1
Compression Ratio
– LPG (2.2L)................... 10.1:1
Compression Pressure
– Gasoline....................... 1130 kPa (164 psi) @
270 rpm
Compression Pressure
– LPG.............................. 1130 kPa (164 psi) @
270 rpm
Maximum Difference
Between Cylinders ............. 196 kPa (28 psi)
Engine Timing (No. 1 Cylinder):
– Gasoline....................... 6° BTDC
(Orange Mark)
– LPG.............................. 6° BTDC
(Orange Mark)
Oil Pressure @ 2400 rpm ... 226 to 362 kPa
(33 to 53 psi)
Engine Specifications
The correct timing is as follows:
• Gasoline Engine = 6° ±1° BTDC @ 800 ±25 rpm
(orange mark)
• LPG Engine = 6° ±1° BTDC @ 800 ±25 rpm (or-
ange mark)
ENGINE SPEEDS
2007, and Later, Emission Compliant
Engines
Engine Speed, 1.5 to 2 Ton Lift Trucks, 2.0L and
2.2L:
– Idle Speed.................... 800 ±25 rpm
– Governed Speed .......... 2400 ±25 rpm
Engine Speed, 2.0 to 3.5 Ton Lift Trucks, 2.0L and
2.2L:
– Idle Speed.................... 800 ±25 rpm
– Governed Speed .......... 2700 ±25 rpm
Stall Speed (New 2.0L Engine):
– Gasoline....................... 1875 ±100 rpm
– LPG.............................. 1820 ±100 rpm
Stall Speed (2.0L Engine With 30 Hours or More):
– Gasoline....................... 1900 ±100 rpm
– LPG.............................. 1865 ±100 rpm
Stall Speed (New 2.2L Engine):
– Gasoline....................... 1990 ±100 rpm
– LPG.............................. 2010 ±100 rpm
Stall Speed (2.2L Engine With 30 Hours or More):
– Gasoline....................... 2010 ±100 rpm
– LPG.............................. 2050 ±100 rpm
All Engines Except 2007, and Later,
Emission Compliant Engines
Engine Speed, 1.5 to 2 Ton Lift Trucks, 2.0L and
2.2L:
– Idle Speed.................... 800 ±25 rpm
– Governed Speed .......... 2400 ±25 rpm
27
Engine Specifications 600 SRM 1122

Engine Speed, 2.0 to 3.5 Ton Lift Trucks, 2.0L and Valve Length (Intake) ........ 111.49 to 112.29 mm
2.2L: (4.390 to 4.420 in.)
– Idle Speed.................... 800 ±25 rpm – Service Limit............... 111.19 mm (4.378 in.)
– Governed Speed .......... 2700 ±25 rpm Valve Length (Exhaust) ..... 111.29 to 112.09 mm
(4.382 to 4.412 in.)
Stall Speed (New 2.0L Engine):
– Service Limit............... 110.99 mm (4.370 in.)
– Gasoline....................... 2000 ±100 rpm
Diameter of Valve Stem
– LPG.............................. 1875 ±100 rpm
(Intake) ............................... 8.03 to 8.045 mm
Stall Speed (2.0L Engine With 30 Hours or More): (0.3161 to 0.3167 in.)
– Gasoline....................... 2106 ±100 rpm – Service Limit............... 7.980 mm (0.3142 in.)
– LPG.............................. 1974 ±100 rpm Diameter of Valve Stem
(Exhaust) ............................ 8.025 to 8.045 mm
Stall Speed (New 2.2L Engine): (0.3159 to 0.3167 in.)
– Gasoline....................... 2073 ±100 rpm – Service Limit............... 7.975 mm (0.3140 in.)
– LPG.............................. 1995 ±100 rpm Valve Head Thickness
Stall Speed (2.2L Engine With 30 Hours or More): (Intake) ............................... 0.5 mm (0.020 in.)
– Gasoline....................... 2183 ±100 rpm Valve Head Thickness
(Exhaust) ............................ 1.0 mm (0.040 in.)
– LPG.............................. 2100 ±100 rpm
Valve Face Angle
(Intake and Exhaust) ......... 30°
THERMOSTAT
Spring Free Length
Starts to Open .................... 82 ±1.5°C (180 ±35°F) - Outer ................................ 52.2 mm (2.055 in.)
Fully Open.......................... 95 ±1.5°C (203 ±35°F) – Service Limit .............. 50.6 mm (1.992 in.)
Spring Free Length
CYLINDER HEAD - Inner ................................ 47.7 mm (1.878 in.)
Height ................................. 91.95 to 92.05 mm – Service Limit .............. 46.3 mm (1.823 in.)
(3.620 to 3.624 in.)
Spring Out of Square
Distortion Limit ................. 0.15 mm (0.006 in.) - Outer ................................ More than 1.82 mm
(0.072 in.)
Grinding Limit ................... 0.20 mm (0.008 in.)
Spring Out of Square
VALVE MECHANISM - Inner ................................ More than 1.66 mm
(0.065 in.)
Inside Diameter of Valve Rocker Arm Shaft
Guide................................... 8.07 to 8.09 mm Diameter............................. 15.966 to 15.984 mm
(0.3177 to 0.3185 in.) (0.6286 to 0.6293 in.)
Clearance in Guide Rocker Arm Bore
(Exhaust) ............................ 0.030 to 0.065 mm Diameter............................. 16.000 to 16.027 mm
(0.0012 to 0.0026 in.) (0.6299 to 0.6311 in.)
Clearance in Guide Clearance Between
(Intake) ............................... 0.025 to 0.060 mm Rocker Arm and
(0.001 to 0.0024 in.) Shaft ................................... 0.016 to 0.061 mm
– Service Limit (0.0006 to 0.0024 in.)
(Intake and Exhaust)..... 0.10 mm (0.004 in.) – Service Limit .............. 0.10 mm (0.004 in.)

28
600 SRM 1122 Engine Specifications

CAMSHAFT 0.50 mm (0.02 in.)

Undersize (Nos. 1, 2,
Runout ................................ Less than 0.03 mm
4, and 5) .............................. 59.429 to 59.486 mm
(0.0012 in.) (2.3398 to 2.3419 in.)
Cam Lobes to 0.50 mm (0.02 in.)
Production Limit ................ 37.370 mm (1.4713 in.) Undersize (No. 3) ............... 59.423 to 59.480 mm
Cam Lobes to Service (2.3395 to 2.3417 in.)
Limit ................................... 37.170 mm (1.4634 in.) 0.75 mm (0.03 in.)
Bearing Journals Undersize (Nos. 1, 2,
(Nos. 1 and 5) ..................... 31.940 to 31.965 mm 4, and 5) .............................. 59.179 to 59.236 mm
(1.2575 to 1.2585 in.) (2.3299 to 2.3321 in.)
Bearing Journals 0.75 mm (0.03 in.)
(Nos. 2, 3, and 4) ................ 31.910 to 31.935 mm Undersize (No. 3) ............... 59.173 to 59.230 mm
(1.2563 to 1.2573 in.) (2.3297 to 2.3318 in.)
Bearing Journal Wear – Grinding Limit ............ 0.75 mm (0.030 in.)
Limit ................................... 0.03 mm (0.0012 in.) Clearance Between
Clearance Between Journals and Main
Journals and Bore Bearings
(Nos. 1 and 5) ..................... 0.035 to 0.085 mm (Nos. 1, 2, 4, and 5) ............
(0.0014 to 0.0033 in.) 0.025 to 0.043 mm
(0.000099 to 0.00169 in.)
Clearance Between
Journals and Bore Clearance Between
(Nos. 2, 3, and 4) ................ 0.065 to 0.115 mm Journals and Main
(0.0026 to 0.0045 in.) Bearings
(No. 3) .................................
– Service Limit .............. 0.15 mm (0.006 in.) 0.031 to 0.049 mm
End Clearance .................... 0.08 to 0.16 mm (0.0012 to 0.0019 in.)
(0.003 to 0.006 in.) – Service Limit............... 0.08 mm (0.003 in.)
– Service Limit............... 0.20 mm (0.008 in.) Connecting Rod Journal
Diameter, Standard............ 50.940 to 50.955 mm
CRANKSHAFT (2.0055 to 2.0061 in.)

Runout ................................ less than 0.03 mm 0.25 mm (0.01 in.)

(0.0012 in.) Undersize............................ 50.690 to 50.705 mm
(1.9957 to 1.9962 in.)
Main Bearing Journal
Diameter, Standard............ 59.937 to 59.955 mm 0.50 mm (0.02 in.)
(2.3597 to 2.3604 in.) Undersize............................ 50.440 to 50.455 mm
(1.9859 to 1.9864 in.)
– Service Limit............... 0.05 mm (0.002 in.)
0.75 mm (0.03 in.)
0.25 mm (0.01 in.) Undersize............................ 50.190 to 50.205 mm
Undersize (Nos. 1, 2, (1.9760 to 1.9765 in.)
4, and 5) .............................. 59.679 to 59.736 mm
(2.3496 to 2.3518 in.) – Service Limit............... 0.05 mm (0.002 in.)

0.25 mm (0.01 in.) – Grinding Limit ............ 0.75 mm (0.030 in.)

Undersize (No. 3) ............... 59.673 to 59.730 mm Thrust Bearing Thickness,
(2.3494 to 2.3515 in.) Standard ............................. 27.94 to 27.99 mm
(1.1000 to 1.1019 in.)

29
Engine Specifications 600 SRM 1122

0.25 mm (0.01 in.) 0.50 mm (0.02 in.)

Undersize............................ 28.04 to 28.09 mm Oversize .............................. 86.443 to 86.465 mm
(1.1040 to 1.1060 in.) (3.4033 to 3.4041 in.)
0.50 mm (0.02 in.) Clearance Between
Undersize............................ 28.12 to 28.17 mm Piston and Bore .................. 0.035 to 0.076 mm
(1.1071 to 1.1090 in.) (0.0014 to 0.0030 in.)
0.75 mm (0.03 in.) – Service Limit............... 0.15 mm (0.0059 in.)
Undersize............................ 28.20 to 28.25 mm
Piston Pin Diameter .......... 21.988 to 21.998 mm
(1.1103 to 1.1122 in.)
(0.8657 to 0.8660 in.)
Thrust Bearing
Groove Width for Piston
Clearance............................ 0.08 to 0.18 mm
Rings Nos. 1 and 2 ............. 1.520 to 1.540 mm
(0.003 to 0.007 in.)
(0.0598 to 0.0606 in.)
– Service Limit............... 0.30 mm (0.012 in.)
Groove Width for
Oil Ring............................... 4.020 to 4.040 mm
CONNECTING RODS (0.1583 to 0.1591 in.)

Distortion Limit ................. 0.18 mm (0.007 in.) per
50 mm (1.97 in.)
Bending Limit .................... 0.075 mm (0.003 in.) per
50 mm (1.97 in.)
Piston Ring Clearance in
Groove (Nos. 1 and 2) ........ 0.03 to 0.07 mm
(0.0012 to 0.0028 in.)
– Service Limit............... 0.15 mm (0.0059 in.)

Small End Bore .................. 21.943 to 21.961 mm Piston Ring End Clearance:
(0.8639 to 0.8646 in.) – Top Ring ...................... 0.20 to 0.35 mm
Interference Between (0.008 to 0.014 in.)
Piston Pin and – Second Ring................. 0.15 to 0.30 mm
Bore..................................... 0.037 to 0.013 mm (0.006 to 0.012 in.)
(0.0014 to 0.0006 in.)
– Oil Control Ring.......... 0.20 to 0.70 mm
Clearance Between (0.008 to 0.027 in.)
Crankshaft Journals
and Rod Bearings ............... 0.027 to 0.067 mm – Service Limit
(0.0011 to 0.0026 in.) (All Rings) ...................... 1.0 mm (0.039 in.)

– Service Limit............... 0.10 mm (0.004 in.)

OIL PUMP
CYLINDER BLOCK Clearance Between Inner Rotor Tip and Outer Rotor

Distortion at Top Surface .. 0.15 mm (0.0059 in.) – Service Limit............... 0.18 mm (0.007 in.)

Grinding Limit ................... 0.20 mm (0.008 in.) Clearance Between

Housing and Outer Rotor .. 0.090 to 0.176 mm
Bore Diameter .................... 86.00 to 86.019 mm (0.0036 to 0.0069 in.)
(3.3858 to 3.3866 in.)
– Service Limit............... 0.20 mm (0.008 in.)
– Wear Limit .................. 0.15 mm (0.0059 in.)
Side Clearance Between
Rotors and Housing ........... 0.03 to 0.09 mm
PISTONS (0.0012 to 0.0035 in.)
Diameter, Standard............ 85.945 to 85.965 mm – Service Limit............... 0.10 mm (0.004 in.)
(3.3836 to 3.3844 in.)
0.25 mm (0.01 in.)
Oversize .............................. 86.193 to 86.215 mm
(3.394 to 3.3943 in.)

30
600 SRM 1122 Torque Specifications

Torque Specifications
Camshaft Pulley Lock Bolt Oil Pan
48 to 66 N•m (35 to 49 lbf ft) 8 to 12 N•m (71 to 106 lbf in)

Camshaft Cap Oil Pressure Switch

18 to 27 N•m (13 to 20 lbf ft) 12 to 17 N•m (9 to 13 lbf ft)

Cooling Fan Oil Pan Drain Plug

27 N•m (20 lbf ft) 30 to 41 N•m (22 to 30 lbf ft)

Connecting Rod Cap Oil Pump

66 to 70 N•m (49 to 52 lbf ft) M8 Capscrews 19 to 26 N•m (14 to 19 lbf ft)
M10 Capscrews 38 to 53 N•m (28 to 39 lbf ft)
Crankshaft Pulley
12 to 17 N•m (9 to 13 lbf ft) Oil Strainer
8 to 12 N•m (71 to 106 lbf in)
Cylinder Head
81 to 88 N•m (60 to 65 lbf ft) Rocker Cover
6 to 8 N•m (52 to 70 lbf in)
Engine Mount to Engine
55 N•m (41 lbf ft) Rear Cover
8 to 12 N•m (70 to 106 lbf in)
Engine Mount Capscrew
150 N•m (111 lbf ft) Rocker Shaft Assembly
18 to 27 N•m (13 to 20 lbf ft)
Exhaust Manifold
22 to 29 N•m (16 to 21 lbf ft) Spark Plugs
15 to 23 N•m (11 to 16 lbf ft)
Flywheel
96 to 103 N•m (71 to 76 lbf ft) Starter
38 N•m (28 lbf ft)
Flywheel Housing
M10 Capscrews 38 N•m (28 lbf ft) Thermostat Housing Capscrews
M14 Capscrews 114 to 136 N•m (84 to 100 lbf ft) 19 to 26 N•m (14 to 19 lbf ft)

Front Housing Timing Belt Cover Capscrews

19 to 26 N•m (14 to 19 lbf ft) 7 to 10 N•m (62 to 89 lbf in)

Heat Gauge Unit Timing Belt Tension Lock Bolt

11.8 to 17.6 N•m (105 to 156 lbf in) 38 to 53 N•m (28 to 39 lbf ft)

Intake Manifold Timing Pulley Lock Bolt

19 to 31 N•m (14 to 23 lbf ft) 157 to 167 N•m (116 to 123 lbf ft)

Main Bearing Cap Water Pump

84 to 90 N•m (62 to 66 lbf ft) 19 to 26 N•m (14 to 19 lbf in)

31
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32
 TECHNICAL PUBLICATIONS

600 SRM 1122 3/12 (7/11)(5/10)(12/09)(8/09)(12/06)(8/05)(5/05)(12/04) Printed in U.S.A.