0$='$ (1*,1(

M4-2.0G AND M4-2.2G

H1.50-1.75XM (S/H25-35XM)
[C010, D001, D010, E001];
H2.00XMS (S/H40XMS)
[C010, D001, D010, E001]; S/H2.00-3.20XM
(S/H40-65XM)
[D177, D187, H177]

PART NO. 897477 600 SRM 496

 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 Mainte-
nance 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 condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
Mazda Engine Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Engine Removal and Installation ..................................................................................................................... 1
Cylinder Head, Camshaft, and Valve Mechanism Repair ............................................................................... 2
Remove ........................................................................................................................................................... 2
Clean .............................................................................................................................................................. 3
Inspect and Repair......................................................................................................................................... 4
Cylinder Head............................................................................................................................................ 4
Rocker Shaft Assembly ............................................................................................................................. 4
Camshaft.................................................................................................................................................... 4
Valve Guides .............................................................................................................................................. 5
Valve Seats................................................................................................................................................. 6
Valves ......................................................................................................................................................... 6
Valve Springs ............................................................................................................................................. 7
Install ............................................................................................................................................................. 7
Crankshaft and Main Bearings Repair ............................................................................................................ 10
Remove ........................................................................................................................................................... 10
Inspect and Repair......................................................................................................................................... 10
Crankshaft ................................................................................................................................................. 10
Main Bearings ........................................................................................................................................... 10
Install ............................................................................................................................................................. 11
Pistons and Connecting Rods Repair................................................................................................................ 12
Remove and Disassemble .............................................................................................................................. 12
Clean .............................................................................................................................................................. 12
Inspect and Repair......................................................................................................................................... 12
Pistons........................................................................................................................................................ 12
Piston Rings............................................................................................................................................... 12
Connecting Rods and Bearings................................................................................................................. 13
Assemble and Install ..................................................................................................................................... 13
Cylinder Block Repair........................................................................................................................................ 15
Oil Pump Repair ................................................................................................................................................ 15
Remove ........................................................................................................................................................... 15
Disassemble ................................................................................................................................................... 16
Clean .............................................................................................................................................................. 16
Inspect ............................................................................................................................................................ 17
Assemble ........................................................................................................................................................ 17
Install ............................................................................................................................................................. 18
Cooling System Repair ...................................................................................................................................... 18
Thermostat..................................................................................................................................................... 18
Replace ....................................................................................................................................................... 18
Fan Assembly................................................................................................................................................. 18
Remove and Disassemble.......................................................................................................................... 18
Assemble and Install................................................................................................................................. 19
Water Pump ................................................................................................................................................... 19
Remove and Disassemble.......................................................................................................................... 19
Assemble and Install................................................................................................................................. 20
Distributor Repair.............................................................................................................................................. 21
Remove ........................................................................................................................................................... 21
Install ............................................................................................................................................................. 21
Flywheel and Ring Gear Repair S/H2.00-3.20XM (S/H40-65XM)................................................................... 22
Remove ........................................................................................................................................................... 22

©2002 HYSTER COMPANY i

Table of Contents Mazda Engine

TABLE OF CONTENTS (Continued)

Ring Gear, Replace ........................................................................................................................................ 22
Install ............................................................................................................................................................. 22
Flywheel Repair H1.50-175XM, H2.00XMS (S/H25-35XM, S/H40XMS)........................................................ 23
Remove ........................................................................................................................................................... 23
Install ............................................................................................................................................................. 23
Valve Adjustment............................................................................................................................................... 24
Compression Pressure Check ............................................................................................................................ 25
Engine Timing Adjustment ............................................................................................................................... 25
Throttle Linkage Adjustment............................................................................................................................ 26
Gasoline Engines ........................................................................................................................................... 26
LPG Engines (IMPCO) .................................................................................................................................. 26
LPG Engines (AISAN)................................................................................................................................... 26
Engine Specifications......................................................................................................................................... 26
Engine Data ................................................................................................................................................... 26
Thermostat..................................................................................................................................................... 26
Cylinder Head ................................................................................................................................................ 26
Valve Mechanism........................................................................................................................................... 27
Camshaft ........................................................................................................................................................ 27
Crankshaft ..................................................................................................................................................... 27
Connecting Rods ............................................................................................................................................ 28
Cylinder Block ............................................................................................................................................... 28
Pistons ............................................................................................................................................................ 28
Oil Pump ........................................................................................................................................................ 28
Torque Specifications ......................................................................................................................................... 29
Troubleshooting.................................................................................................................................................. 30

This section is for the following models:

H1.50-1.75XM (S/H25-35XM) [C010, D001, D010, E001];

H2.00XMS (S/H40XMS) [C010, D001, D010, E001];
S/H2.00-3.20XM (S/H40-65XM) [D177, D187, H177]

ii
600 SRM 496 Engine Removal and Installation

General
This section has the instructions for removal, disas- Additional information on engine components can be
sembly, repair, assembly, installation, checks, adjust- found in the sections for Gasoline Fuel System,
ments, and troubleshooting for the Mazda M4-2.0G LPG Fuel System, and Electrical System.
and M4-2.2G engines. The engine specifications are
given at the end of the section.

Description
WARNING
Some gaskets used in this engine can contain
dangerous fibers. Breathing dust from these
fibers is a cancer or lung disease hazard. Do
not create dust! Use vacuum equipment for
asbestos or follow the cleaning procedure de-
scribed below.
• Make sure the gasket material is wet with wa-
ter or oil to prevent particles in the air.
• Use a hand scraper to remove old gasket ma-
terial. Do not use a power tool or compressed
air.
• Discard all asbestos material in a closed con-
tainer while it is still wet.
• Put a DANGEROUS FIBERS warning label on
the container. Discard dangerous fiber mate-
rial safely.
CAUTION
Disconnect the battery cables before doing any
disassembly and repair to the engine or parts
of the electrical system.
The diodes and resistors in the electrical sys-
tem can be damaged if the following cautions
are not followed:
• Do not disconnect the battery when the en-
gine is running. The voltage surge can dam-
age the diodes and resistors.
• Do not disconnect an electric wire before the
engine is stopped and the key switch is OFF.
• Do not cause a short circuit by connection
of the electric wires to the wrong terminals.
Make sure a correct identification of the wire
is made wire before it is connected.
• Make sure a battery is the correct voltage and
polarity before it is connected.
• Do not check for current flow by making a
spark because the transistors can be dam-
aged.
The Mazda M4-2.0G and M4-2.2G engines have
four cylinders. The displacement of the M4-2.0G
is 1998 cm 3 (121.9 in. 3 ). The displacement of the
M4-2.2G is 2184 cm 3 (133.2 in. 3 ). The firing order is
1 – 3 – 4 – 2. They are both available with either a
gasoline or LPG fuel system. The No. 1 cylinder is
toward the end of the engine with the cooling fan.
The overhead camshaft is driven by a cog belt. The
camshaft operates the rocker arms that actuate the
valves.
The crankshaft has five main bearings. The main
bearing in the center of the crankshaft is also the
thrust bearing.
The pistons are aluminum alloy and have three pis-
ton rings. Each of the two compression rings have a
special shape designed for its position on the piston.
The third piston ring is the oil control ring.

Engine Removal and Installation

The removal and installation procedures for the engine are not included in this section. For model
units H1.50-1.75 (S/H25-35XM) and H2.00 (S/H40XMS), see the section Frame 100 SRM 545. For model
units S/H2.00-3.20 (S/H40-65XM), see the section Frame 100 SRM 505.

1
Cylinder Head, Camshaft, and Valve Mechanism Repair 600 SRM 496

Cylinder Head, Camshaft, and Valve Mechanism Repair

REMOVE 8. Use chalk to mark direction of timing belt rota-
tion. See Figure 2. Remove timing belt.
1. Disconnect connections at battery.

2. Drain cooling system.

3. Remove air cleaner, carburetor linkage, inlet,

and exhaust manifolds.

4. Remove coolant hoses.

5. Remove bracket for cooling fan.

6. Remove upper and lower timing belt covers. See

Figure 1.

Figure 2. Timing Belt

9. Put labels on wires to aid in correct installation.

Disconnect wires at distributor. Remove cap-
screw for distributor mount and pull distributor
from front housing.

10. Remove camshaft pulley. Keep pulley from rotat-

ing and loosen capscrew. Remove capscrew and
pulley. See Figure 3.

1. LOWER TIMING BELT COVER

2. UPPER TIMING BELT COVER
Figure 3. Camshaft Gear Removal
Figure 1. Timing Belt Covers
11. Remove nuts and capscrews for front housing.
7. Loosen capscrews for timing belt tensioner and Then remove housing. See Figure 4.
remove spring. Remove capscrews and timing
belt tensioner.

2
600 SRM 496 Cylinder Head, Camshaft, and Valve Mechanism Repair

1. FRONT HOUSING 3. OIL SEAL Figure 6. Cylinder Head Removal Sequence

2. GASKET
16. Use valve spring compressor to remove valve re-
Figure 4. Front Housing
tainers, springs, and valves from head. See Fig-
12. Remove valve cover. ure 7.

13. Loosen capscrews for rocker shaft supports in

proper sequence. See Figure 5. Remove rocker
shaft assembly and camshaft.

Figure 7. Valve Removal

CLEAN

Figure 5. Rocker Assembly Removal Sequence
14. Remove capscrews for cylinder head in proper se-
quence. See Figure 6.
15. Lift cylinder head from the block.
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.

Clean all parts in solvent. Make sure all oil passages

are clean and all machined surfaces are smooth.

3
Cylinder Head, Camshaft, and Valve Mechanism Repair
INSPECT AND REPAIR
Cylinder Head
Use straight edge and thickness gauge to check bot-
tom surface of cylinder head for distortion. Do the
measurements at the positions shown in Figure 8.
Maximum amount of distortion is 0.15 mm
(0.0059 in.). If grinding of cylinder head is nec-
essary, maximum amount of correction is 0.2 mm
(0.008 in.).
Figure 8. Cylinder Head Inspection
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
(0.004 in.).
Correct dimension for inside diameter of rocker
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
4
600 SRM 496
0.6293 in.). If components do not meet specifica-
tions, replace rocker arm(s) or rocker shaft(s) as
necessary.
Camshaft
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 9. Maximum movement is 0.20 mm
(0.008 in.).
Figure 9. Camshaft Check
3. Measure height of camshaft lobes. See Figure 10.
Minimum height of intake and exhaust lobes is
36.902 mm (1.4528 in.).
4. Measure camshaft journals at four points (A-D)
as shown in Figure 10. Minimum dimensions for
the journals are as follows:
Front and Rear Journals (Nos. 1 and 5) -
31.940 to 31.965 mm (1.2575 to 1.2585 in.)
Center Journals (Nos. 2, 3 and 4) - 31.910 to
31.935 mm (1.2563 to 1.2573 in.)
Front Oil Seal Surface - 33.961 to 34.000 mm
(1.3371 to 1.3386 in.)
Fuel Pump Lobe - 37.1 mm (1.46 in.)
5. Check camshaft for straightness. Put front and
rear journals in V blocks and rotate camshaft one
complete turn. See Figure 11. Maximum amount
that the dial indicator should indicate is 0.03 mm
(0.0012 in.).
600 SRM 496 Cylinder Head, Camshaft, and Valve Mechanism Repair

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.

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

(13 to 20 lbf ft). See Figure 12.

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 Figure 11. Camshaft Check
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.

1. PLASTIC GAUGE 2. SCALE

Figure 12. Camshaft Clearance Measurement

Valve Guides
1. Measure clearance between valve stems and
valve guides. Normal clearance is 0.025 to
0.060 mm (0.001 to 0.002 in.).

If clearance is more than 0.20 mm (0.008 in.),

replace valve or valve guide.

2. If replacement is necessary, remove seal from

1. FRONT OIL SEAL SURFACE valve guide(s). Then use tool to remove valve
2. FRONT JOURNAL (NO. 1) guide(s).
3. CENTER JOURNALS (NOS. 2, 3, AND 4)
4. REAR JOURNAL (NO. 5) 3. To install valve guide, install retaining ring on
5. FUEL PUMP LOBE valve guide. Use tool to install valve guide so
that retaining ring contacts cylinder head. See
Figure 10. Camshaft Inspection
Figure 13.

Correct height of valve guide above valve spring

seat is 19.1 to 19.6 mm (0.75 to 0.77 in.).

5
Cylinder Head, Camshaft, and Valve Mechanism Repair 600 SRM 496

Valves
1. Inspect stem of each valve for wear. Use microm-
eter to measure outside diameter of stem. See
Figure 15.

Minimum dimension for intake valve is

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

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

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

3. 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
1. CYLINDER HEAD 3. VALVE GUIDE (0.040 in.).
2. RETAINING RING
If valves need grinding, correct surface angle is
Figure 13. Valve Guide Inspection
30 for both intake and exhaust valves.
Valve Seats
1. Inspect condition of valve seats. If valve seats
have cracks, cylinder head must be replaced.

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 14. Use valve com-
pound to make sure valves fit seats.

A. EXHAUST B. INTAKE
1. DIAMETER 2. THICKNESS,
1. VALVE SEAT 3. INTAKE VALVE VALVE HEAD
WIDTH SEAT
2. EXHAUST VALVE Figure 15. Valve Inspection
SEAT

Figure 14. Valve Seat Specifications

6
600 SRM 496 Cylinder Head, Camshaft, and Valve Mechanism Repair

Valve Springs
1. Check valve springs for damage.

2. Measure free length of outer valve springs. See

Figure 16.

Minimum length of intake spring is 44.3 mm

(1.74 in.). Minimum length of exhaust spring is
50.8 mm (2.00 in.).

3. Check outer valve springs for squareness. See

Figure 16.

If measurement is more than 1.81 mm (0.071 in.),

replace valve spring(s).

Figure 17. Cylinder Head Installation

A. MEASURE HERE

Figure 16. Valve Springs Inspection

INSTALL
1. Clean surface of cylinder head and surface of en-
gine block.

2. Install new gasket and cylinder head on engine

block.
1. DOWEL PIN 2. APPLY SEALANT
3. Install capscrews and washers for cylinder HERE
head. Tighten capscrews to 82 to 88 N•m (60 to
65 lbf ft) in proper sequence. See Figure 17. Figure 18. Camshaft Installation

4. Apply gasket sealer to areas shown by arrows. 5. Assemble rocker shaft assembly. See Figure 19.
Lubricate camshaft with clean engine oil. Then Lubricate rocker arms and shafts engine oil. Put
install camshaft. Make sure dowel pin is at top capscrews in rocker shaft supports. Then install
of camshaft. See Figure 18. assembly on cylinder head.

7
Cylinder Head, Camshaft, and Valve Mechanism Repair 600 SRM 496

9. Install capscrew and washer for camshaft pulley.

See Figure 22. 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 19. Rocker Shaft Assembly 1. FRONT HOUSING 3. OIL SEAL

2. GASKET
6. Tighten capscrews for rocker shaft supports to 18
to 27 N•m (13 to 20 lbf ft) in proper sequence. See Figure 21. Front Housing
Figure 20.

Figure 20. Rocker Shaft Assembly Installation

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

Figure 21. Use new gasket and install front hous-
ing on cylinder head. Tighten capscrews for front
housing to 19 to 26 N•m (14 to 19 lbf ft).

8. With dowel pin at top of camshaft, install

camshaft pulley. Check that letter A on pulley is
aligned with timing mark on front housing. See 1. TIMING MARKS 2. CAMSHAFT
Figure 22. PULLEY

Figure 22. Camshaft Pulley Installation

8
600 SRM 496 Cylinder Head, Camshaft, and Valve Mechanism Repair

10. Align timing marks for crankshaft pulley. See

Figure 23. Install crankshaft pulley, tapered
ring, and capscrew. Tighten capscrew to 160 to
170 N•m (118 to 125 lbf ft).

1. TENSIONER 3. LOCK BOLT

2. SPRING 4. TENSION SIDE

Figure 24. Timing Belt Installation

1. CRANKSHAFT 2. TIMING MARK
PULLEY

Figure 23. Timing Belt Installation

11. Install timing belt tensioner and spring. Move

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

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

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

13. 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). Check
movement on tension side of timing belt. If ten-
sion is correct, belt will move 12 to 14 mm (0.47
to 0.55 in.) with 10 kg (20 lb) of force. See Fig-
ure 24.

14. Install lower timing belt cover and gasket.

Tighten capscrews to 7 to 8 N•m (5 to 6 lbf ft).
Install upper timing belt cover and gasket.
Tighten capscrews to 8 to 12 N•m (6 to 9 lbf ft).
See Figure 25.

15. Install distributor. See Distributor Repair for

procedures. 1. LOWER TIMING BELT COVER
2. UPPER TIMING BELT COVER

Figure 25. Timing Belt Covers

9
Crankshaft and Main Bearings Repair
Crankshaft and Main Bearings Repair
REMOVE
1. Remove bracket for cooling fan.
2. Remove six capscrews and plate from crankshaft
pulley. Remove six capscrews that hold crank-
shaft pulley to timing pulley.
3. Remove capscrew from timing pulley. Install spe-
cial tool on crankshaft to remove timing pulley.
Rotate tool until it touches front of crankshaft.
Hit tool with hammer to loosen timing pulley. Re-
move pulley, dowel pin, and tapered ring. Re-
move tool.
4. Remove oil pan and oil strainer.
5. Remove rear cover. Remove front cover with oil
pump.
6. Remove caps for connecting rods. Put identifica-
tion mark on each cap so they will be installed in
correct location.
7. Before removing crankshaft, measure clearance
between crankshaft and flange of center main
bearing. See Figure 26. 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 crankshaft.
1. CENTER MAIN BEARING
Figure 26. Crankshaft Clearance Measurement
10
600 SRM 496
8. 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
for crankshaft. See Figure 27. 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 undersize bearings.
3. Check crankshaft for straightness. See Fig-
ure 27. Put front and rear journals in V blocks
and rotate crankshaft one complete turn. Maxi-
mum amount that dial indicator should indicate
is 0.03 mm (0.0012 in.).
4. Check oil passages crankshaft. Make sure pas-
sages are clean and have no restrictions.
Main Bearings
NOTE: Do not clean main bearings. If any bearings
are too dirty, replace all main bearings.
1. Inspect main bearings for damage. If any main
bearing is damaged, all main bearings must be
replaced.
2. To inspect main bearings for wear, measure
clearance between main bearings and crank-
shaft. See Figure 28.
a. Install crankshaft in cylinder block.
600 SRM 496
1. REAR OIL SEAL 3. MAIN BEARING
SURFACE JOURNALS
2. CONNECTING 4. FRONT OIL SEAL
ROD JOURNALS SURFACE
Figure 27. Crankshaft Inspection
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 is 0.031 to 0.049 mm
(0.0012 to 0.0019 in.). If any clearance is
greater than specification, replace all main
bearings.
Crankshaft and Main Bearings Repair
1. PLASTIC GAUGE 2. SCALE
MATERIAL
Figure 28. Main Bearings Clearance Check
INSTALL
1. Clean areas of cylinder block around main bear-
ings. Carefully install bottom half of new main
bearings if necessary. Lubricate bearings with
clean engine oil.
2. Install crankshaft.
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-
ment pin in cylinder block.
7. Install gasket and rear cover. See Figure 29.
Make sure dowel pin is installed. Tighten cap-
screws to 8 to 12 N•m (6 to 9 lbf ft). Cut off
part of gasket that extends past bottom of cylin-
der block.
11
Pistons and Connecting Rods Repair 600 SRM 496

8. Install oil strainer. Tighten M6 capscrews to 8 to

12 N•m (6 to 9 lbf ft). Tighten M8 capscrews to
16 to 23 N•m (12 to 17 lbf ft).

9. Install gasket and oil pan. Tighten capscrews to

7 to 12 N•m (5 to 9 lbf ft).

1. REAR COVER 3. CRANKSHAFT

2. OIL SEAL

Figure 29. Rear Cover

Pistons and Connecting Rods Repair

REMOVE AND DISASSEMBLE INSPECT AND REPAIR
1. Remove cylinder head as described in Cylinder Pistons
Head, Camshaft, and Valve Mechanism Repair.
1. Inspect pistons for wear and cracks. Replace any
2. Remove oil pan and oil strainer. piston that is damaged.
3. Put identification mark on top of each piston. 2. Measure outside diameter of piston. See
Figure 30. Correct dimension is 85.944 to
4. Clean carbon from top of each cylinder bore.
85.964 mm (3.3836 to 3.3844 in.). Maximum
5. Remove caps and bearings from each connecting clearance between piston and cylinder bore is
rod. Keep caps and bearings with correct piston 0.15 mm (0.0059 in.).
assemblies.

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. Figure 30. Piston Measurement

Clean all parts in solvent. Make sure all oil passages Piston Rings
and grooves are clean. Make sure all machined sur-
faces are smooth. 1. Install piston ring into cylinder bore where it will
be used. Use thickness gauge to measure amount

12
600 SRM 496
of end clearance of each piston ring. See Fig-
ure 31. 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 - 0.30 to 0.90 mm (0.012 to 0.035 in.)
Maximum clearance is 1.0 mm (0.039 in.)
2. Measure clearance between piston ring and
groove in piston. See Figure 31. Correct dimen-
sions are as follows:
Top Piston Ring - 0.03 to 0.07 mm (0.0012 to
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.)
1. PISTON RING END CLEARANCE
2. PISTON RING GROOVE CLEARANCE
Figure 31. Piston Rings Measurement
Connecting Rods and Bearings
1. Use alignment tool to check connecting rods for
straightness. Maximum amount of distortion per
100 mm (4.0 in.) is 0.04 mm (0.0016 in.).
If amount of distortion is greater than specifica-
tion, install new rod or use press to straighten
connecting rod.
Pistons and Connecting Rods Repair
2. Clean rod bearings and crankshaft journals. To
check bearings for wear, measure clearance be-
tween rod bearings and journals. See Figure 32.
a. Put plastic gauge material on crankshaft
journals and install rod caps. Tighten cap-
screws for rod caps to 51 to 56 N•m (38 to
41 lbf ft). Do not rotate connecting rod.
b. Remove rod caps. Plastic gauge material will
adhere to journals or rod caps.
c. Use graduations on scale to measure width
of plastic gauge material at its widest point.
Correct clearance is 0.027 to 0.067 mm
(0.0011 to 0.0026 in.). If any clearance is
greater than specification, replace all rod
bearings.
1. BEARING 2. PLASTIC GAUGE
Figure 32. Connecting Rod Bearings Clearance
Check
ASSEMBLE AND INSTALL
1. Align oil port on large end of connecting rod with
F mark on piston. See Figure 33. 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.
Use special tool to make sure piston pin is in-
stalled to correct depth. After installation, check
that piston moves freely on piston pin.
13
Pistons and Connecting Rods Repair 600 SRM 496

1. F MARK 2. OIL PORT

Figure 33. Connecting Rod and Piston

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 34. 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.
A. OIL CONTROL RING
B. TOP AND SECOND RINGS
4. Apply clean engine oil to piston assembly. Install
bearings for connecting rods. Install piston into 1. EXPANDER RING 4. TOP RING
correct cylinder, making sure F is toward front 2. OIL RING (UPPER) 5. SECOND RING
(timing belt end) of engine. See Figure 35. 3. OIL RING (LOWER)

5. Apply clean engine oil to bearing. Then install Figure 34. Piston Rings
each cap to correct connecting rod. During in-
stallation of caps, make sure to align identifi-
cation marks that were made during disassem-
bly. Tighten nuts for caps to 51 to 56 N•m (38 to
41 lbf ft).

1. F MARK

Figure 35. Piston Installation

14
600 SRM 496 Oil Pump Repair

Cylinder Block Repair

1. After cylinder block is cleaned, check its surface
for distortion. See Figure 36.

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 0.015 mm (0.001 in.).

Repair cylinder block or use bigger pistons as

necessary.

Figure 36. Cylinder Block Insepction

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 bracket for cooling fan.
6. Remove capscrew from timing pulley. Install spe-
cial tool on crankshaft to remove timing pulley.
Rotate tool until it touches the front of crank-
shaft. Hit tool with hammer to loosen timing pul-
ley. Remove pulley, dowel pin, and tapered ring.
Remove tool.
7. Remove capscrews that hold oil pan to cylinder
block. Remove oil pan.

2. Remove upper and lower timing belt covers. See 8. Remove capscrews that hold front cover (pump
Figure 37. housing) to cylinder block. Remove front cover
and oil pump assembly.
3. Loosen capscrews for timing belt tensioner and
remove spring. Remove capscrews and timing
belt tensioner.
1. UPPER TIMING BELT COVER
4. Use chalk to mark direction of rotation of timing 2. LOWER TIMING BELT COVER
belt. See Figure 38. Remove timing belt.
Figure 37. Timing Belt Covers
5. Remove six capscrews and plate from crankshaft
pulley. Remove six capscrews that hold crank-
shaft shaft pulley to timing pulley. Figure 38. Timing Belt

15
Oil Pump Repair 600 SRM 496

DISASSEMBLE 2. Remove outer gear and inner gear from pump

body.
1. Remove screws and pump cover. See Figure 39.
3. Remove snap ring and plunger assembly from
housing.

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.

Clean all parts in solvent. Make sure all machined

surfaces are smooth.

1. SCREW 5. FRONT COVER

2. COVER (HOUSING)
3. OUTER GEAR 6. OIL SEAL
4. INNER GEAR 7. PLUNGER
8. SNAP RING

Figure 39. Oil Pump

16
600 SRM 496 Oil Pump Repair

INSPECT d. Measure clearance between body and outer

gear. Correct clearance is 0.090 to 0.184 mm
1. Check front cover (pump housing) and pump (0.0035 to 0.0072 in.). If clearance is more
cover for wear or damage. Check plunger spring than 0.20 mm (0.008 in.), repair as necessary.
for damage.
ASSEMBLE
2. Measure parts of oil pump. See Figure 40.
1. Install oil seal in oil pump housing. Make sure
a. Measure clearance between gears and cres-
front edge of oil seal is even with outer edge of
cent. Correct clearance is 0.20 to 0.32 mm
housing. See Figure 39.
(0.008 to 0.013 in.). If clearance is more than
0.35 mm (0.014 in.), repair as necessary. 2. Lubricate gears with engine oil. Then install
gears in housing.
b. Measure clearance between crescent and
teeth of inner gear. Correct clearance is 3. Install pump cover. Apply thread-locking com-
0.267 to 0.380 mm (0.0105 to 0.0150 in.). If pound on screws for pump cover. Then install
clearance is more than 0.40 mm (0.0157 in.), screws.
repair as necessary.
4. Install plunger assembly and snap ring.
c. Use straight edge to measure side clearance
of gears. Correct clearance is 0.03 to 0.63 mm
(0.0012 to 0.0248 in.). If clearance is more
than 0.10 mm (0.004 in.), repair as necessary.

1. CLEARANCE BETWEEN CRESCENT AND 3. SIDE CLEARANCE OF GEARS IN HOUSING

INNER GEAR 4. CLEARANCE BETWEEN HOUSING AND OUTER
2. CLEARANCE BETWEEN CRESCENT AND GEAR
GEARS

Figure 40. Oil Pump Measurement

17
Cooling System Repair 600 SRM 496

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 41.

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
to 19 to 26 N•m (14 to 19 lbf ft).

3. Install suction tube assembly. Install gasket and

oil pan.
1. O-RING

Figure 41. Oil Pump

Cooling System Repair

THERMOSTAT
Replace
1. Drain cooling system to level of thermostat.
2. Disconnect hose and remove thermostat housing.
Remove thermostat. See Figure 42.
3. Test operation of thermostat. See Cooling Sys-
tem 700 SRM 626.
Thermostat must begin to open at 82 ±1.5 C (180
±3 F). Thermostat must be completely open at
95 C (203 F).
4. Install thermostat and new gasket. Make sure
print side of gasket is toward thermostat.

5. Install thermostat housing and tighten cap-

screws to 12 to 18 N•m (9 to 13 lbf ft).

6. Connect hose and fill cooling system. Start en-

gine and check for leaks.

FAN ASSEMBLY
Remove and Disassemble
1. Loosen alternator and remove fan belt.

2. Remove capscrews for fan. Remove fan and pul-

ley from hub.

3. Remove capscrews that hold fan bracket to en-

gine. Remove fan bracket.
1. CYLINDER BLOCK 3. THERMOSTAT
2. GASKET 4. HOUSING 4. Use press to remove fan hub from shaft. Re-
Figure 42. Thermostat move snap ring, and push bearing and shaft from
bracket. See Figure 43.

18
600 SRM 496 Cooling System Repair

WATER PUMP
Remove and Disassemble
NOTE: If either the shaft or impeller is damaged, the
complete water pump must be replaced.

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.

1. FAN 5. SHAFT 5. Remove upper and lower timing belt covers. See
2. PULLEY 6. SUPPORT Figure 44.
3. HUB BRACKET
4. SNAP RING 7. BRACKET

Figure 43. Fan Assembly 1. UPPER TIMING BELT COVER

2. LOWER TIMING BELT COVER
Assemble and Install
Figure 44. Timing Belt Covers
1. Use press to install shaft and bearing in bracket.
See Figure 43. Push bearing in until it touches
bracket. Install snap ring. Install hub on shaft.
When installed, shaft must extend 2.1 mm
(0.083 in.) past hub.

2. Install bracket assembly on cylinder block.

Tighten M8 capscrews to 32 to 47 N•m (24
to 35 lbf ft). Tighten M10 capscrews to 38 to
64 N•m (28 to 47 lbf ft).

3. Install pulley and fan on hub. Tighten capscrews

to 8 to 11 N•m (6 to 8 lbf ft).

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

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

Tension for NEW belt is correct when it moves 8

to 10 mm (0.32 to 0.39 in.) with 10 kg (22 lb) of
force. Tension for USED belt is correct when it
moves 10 to 12 mm (0.39 to 0.47 in.) with 10 kg
(22 lb) of force. Tighten alternator when tension
is correct.

19
Cooling System Repair
6. Loosen capscrews for timing belt tensioner and
remove spring. Remove capscrews and timing
belt tensioner.
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.
7. Use chalk to mark direction of rotation of timing
belt. See Figure 45. Align timing marks. Then
remove timing belt.
Figure 45. Timing Belt
8. Disconnect hose at water pump. Remove cap-
screws for water pump. Then remove water
pump from cylinder block.
9. Use puller to remove pulley from shaft. See Fig-
ure 46.
10. Use press to remove impeller from shaft and
bearing assembly from housing. Remove water
seal from housing.
Assemble and Install
1. Install water seal in housing. Put antifreeze on
lip of the seal. See Figure 46.
2. Use press to install shaft and bearing in pump
body. Make sure shaft turns smoothly.
3. Use a press to install the shaft and bearing in the
pump body. Make sure the shaft turns smoothly.
20
600 SRM 496
1. PULLEY 3. WASHER
2. SHAFT AND 4. HOUSING
BEARING 5. SEAL
ASSEMBLY 6. IMPELLER
Figure 46. Water Pump
4. Install water pump with a new gasket. Tighten
capscrews to 19 to 26 N•m (14 to 19 lbf ft).
5. Clean any oil or grease from pulleys. Install tim-
ing belt so that it goes in same direction as mark
made during removal.
6. 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). Check
movement on tension side of timing belt. If ten-
sion is correct, belt will move 12 to 14 mm (0.47
to 0.55 in.) with 10 kg (22 lb) of force. See Fig-
ure 47.
7. Install lower timing belt cover and gasket.
Tighten capscrews to 7 to 8 N•m (5 to 6 lbf ft).
Install upper timing belt cover and gasket.
Tighten capscrews to 8 to 12 N•m (6 to 9 lbf ft).
See Figure 44.
8. Install fan assembly as described in the proce-
dure for Fan Assembly, Assemble and Install.
9. Install coolant hoses. Fill cooling system with
coolant.
10. Start engine and check cooling system for leaks.
600 SRM 496 Distributor Repair

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.

11. After engine has been operated, stop engine. If

coolant is hot, give engine time to cool. Check
coolant level and add coolant if necessary.

1. TENSIONER 3. LOCK BOLT

2. SPRING 4. TENSION SIDE

Figure 47. Timing Belt Installation

Distributor Repair
NOTE: This section only has the removal and instal-
lation procedures for the distributor. Service proce-
dures for the ignition system are found in the Elec-
trical System section.

REMOVE
1. Rotate crankshaft until No. 1 piston is at TDC
on compression stroke. Make note of position of
distributor rotor. See Figure 48.

2. Disconnect wires at spark plugs.

3. Remove capscrew from flange of distributor shaft

housing. Lift distributor assembly from engine.

INSTALL
1. Rotate crankshaft until No. 1 piston is at TDC on
compression stroke. Put rotor in correct position.
See Figure 48.

2. Lubricate O-ring and gear on distributor engine

oil. Install distributor, making sure to align
marks on distributor housing, distributor gear,
and engine.

3. Connect wires at spark plugs.

Figure 48. Distributor Replacement

21
Flywheel and Ring Gear Repair S/H2.00-3.20XM (S/H40-65XM) 600 SRM 496

Flywheel and Ring Gear Repair S/H2.00-3.20XM (S/H40-65XM)

REMOVE 1. Use hammer and chisel to break ring gear. See
Figure 50. Be careful to not damage flywheel.
1. Remove capscrews for flywheel. Then remove fly-
wheel and drive plate. See Figure 49.

2. If necessary, remove flywheel housing.

Figure 50. Ring Gear Removal

WARNING
Parts are hot. Wear protective clothing and
gloves to prevent burns.

2. Heat ring gear before installation on flywheel.

Make sure ring gear is not heated to more than
200 C (392 F).

3. Install ring gear on flywheel. Make sure chamfer

A. TIGHTENING SEQUENCE on teeth is in correct direction toward starter.

1. COVER PLATE 4. DRIVE PLATE INSTALL

2. FLYWHEEL 5. SUPPORT PLATE
HOUSING 6. CAPSCREW 1. If flywheel housing was removed, install it on en-
3. FLYWHEEL gine. Tighten M14 capscrews to 114 to 136 N•m
Figure 49. Flywheel Arrangement (84 to 100 lbf ft). Tighten M8 capscrews to 21 to
25 N•m (15 to 18 lbf ft).
RING GEAR, REPLACE 2. Install flywheel on crankshaft. Install drive
plate and support plate.
WARNING
Wear eye protection for this operation to pre- 3. Apply adhesive sealant on threads of capscrews.
vent eye injury from metal chips. You will be Then install capscrews for flywheel. Tighten cap-
using a hammer and chisel to break the ring screws to 96 to 103 N•m (71 to 76 lbf ft) in proper
gear. sequence. See Figure 49.

NOTE: Before ring gear is removed, note position of

chamfer on teeth.

22
600 SRM 496 Flywheel Repair H1.50-175XM, H2.00XMS (S/H25-35XM, S/H40XMS)

Flywheel Repair H1.50-175XM, H2.00XMS (S/H25-35XM, S/H40XMS)

REMOVE 2. Install flange and flywheel on crankshaft.

1. Remove capscrews for flywheel. Then remove fly- 3. Apply thread-locking adhesive on threads of cap-
wheel and flange. See Figure 51. screws. Then install capscrews and lockwash-
ers. Tighten capscrews to 96 to 103 N•m (71 to
2. If necessary, remove adapter plate. 76 lbf ft).

INSTALL
1. If adapter plate for the torque converter hous-
ing was removed, install it on engine. See Fig-
ure 51. Tighten capscrews to 43 to 51 N•m (32 to
38 lbf ft).

NOTE: EARLIER MODEL TORQUE CONVERTER HOUSING IS SHOWN. LATER MODEL IS SIMILAR.
1. FLANGE 4. TORQUE CONVERTER
2. FLYWHEEL 5. ACCESS COVER
3. DRIVE PLATE 6. TORQUE CONVERTER HOUSING

Figure 51. Flywheel and Torque Converter

23
Valve Adjustment 600 SRM 496

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 52. Correct clear-
ance for all valves when engine is hot is 0.3 mm
(0.012 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.

4. If valves are adjusted when engine is cold, check

adjustments again after engine is warm.

A. INTAKE VALVES B. EXHAUST VALVES

1. CAMSHAFT 3. BALL
2. ROCKER ARM 4. VALVE STEM

Figure 52. Valve Adjustment

24
600 SRM 496 Engine Timing Adjustment

Compression Pressure Check

1. Remove spark plugs from cylinder head. Discon-
nect high tension wire at ignition coil. See Fig-
ure 53.
2. Install compression gauge in No. 1 cylin-
der. Make sure gauge has minimum range of
1725 kPa (250 psi).
3. Use starter to crank engine at least six revolu-
tions. Check pressure reading and release pres-
sure. Repeat test again and make note of highest
pressure. Do this test for each cylinder.
• If pressure reading increases to normal
reading, low pressure was caused by worn
or damaged piston rings. Cylinder bore
may also be damaged.
• If pressure reading does not increase, low
pressure was caused by worn valves, valve
seats, or valve guides.
• If low pressure readings are in two cylin-
ders next to each other, cylinder head may
be leaking.

Standard pressure reading is 1130 kPa (164 psi).

Minimum reading is 793 kPa (115 psi).

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. 1. ADAPTER
c. Install compression gauge and do same tests Figure 53. Compression Pressure Check
as described in Step 3.

Engine Timing Adjustment

See Ignition System Check and Adjustment in the
section Mazda M4-2.0G And M4-2.2G Gasoline/
LPG Engines 2200 SRM 524 for the adjustment pro-
cedure for engine timing.
The correct timing for the H1.50-1.75XM, H2.00XMS
(S/H25-35XM, S/H40XMS) units is as follows:
• Gasoline Engine = 0 BTDC @ 725 ±25 rpm
(white mark)
• LPG Engine = 8 BTDC @ 725 ±25 rpm
The correct timing for the S/H2.00-3.20XM (SH40-
65XM) units is as follows:
• Gasoline Engine = 0 BTDC @ 725 ±25 rpm
(white mark)
• LPG Engine = 9 BTDC @ 725 ±25 rpm (red mark)

25
Engine Specifications 600 SRM 496

Throttle Linkage Adjustment

Whenever the throttle linkage is disassembled, the LPG ENGINES (IMPCO)
throttle cable must be adjusted after installation.
For earlier units, see LPG Fuel System 900 SRM
GASOLINE ENGINES 523 for the correct adjustment procedure.

For the H1.50-1.75XM, 2.00XMS (S/H25-35XM, LPG ENGINES (AISAN)

40XMS) units, see Gasoline Fuel System 900 SRM
547 for the correct adjustment procedure. For the
S/H2.00-3.20XM(S/H40-65XM) units, see Gasoline
Fuel System 900 SRM 502 for the correct adjust-
ment procedure.
For later units, see LPG Fuel System, Aisan
Open-Loop 900 SRM 925 or LPG Fuel System,
Aisan Closed-Loop 900 SRM 948 for the correct
adjustment procedure.

Engine Specifications
ENGINE DATA – Gasoline....................... 1980 ±50 rpm
– LPG.............................. 1930 ±50 rpm
Engine Type........................ In-line, Four Cylinders
Stall Speed (M4-2.0G Engine With 30 Hours or
Bore × Stroke (M4-2.0G).... 86 mm (3.39 in.) × More):
86 mm (3.39 in.)
– Gasoline....................... 2100 ±50 rpm
Bore × Stroke (M4-2.2G).... 86 mm (3.39 in.) × – LPG.............................. 2050 ±50 rpm
94 mm (3.70 in.)
Stall Speed (New M4-2.2G Engine):
Displacement (M4-2.0G) .... 1998 cm 3 (121.9 in. 3 )
– Gasoline....................... 2150 ±50 rpm
Displacement (M4-2.2G) .... 2184 cm 3 (133.2 in. 3 ) – LPG.............................. 2100 ±50 rpm
Firing Order ....................... 1 - 3 - 4 - 2 Stall Speed (M4-2.2G Engine With 30 Hours or
More):
Compression Ratio ............. 8.6 : 1
– Gasoline....................... 2270 ±50 rpm
Compression Pressure ....... 1131 kPa (164 psi) @
– LPG.............................. 2220 ±50 rpm
270 rpm
Oil Pressure @ 2400 rpm ... 226 to 362 kPa
Engine Timing (No. 1 Cylinder):
(33 to 53 psi)
– Gasoline....................... 0 /TDC
– LPG, H1.50 -1.75XM,
THERMOSTAT
2.00 XMS (S/H25-35XM,
40XMS)........................... 8 BTDC Starts to Open .................... 82 ±1.5 C (180 ±3 F)
– LPG, S/H2.00 -3.20XM
(S/H40-65XM) ................ 9 BTDC Fully Open.......................... 95 ±1.5 C (203 ±3 F)

Engine Speed, M4-2.0G (IMPCO):

CYLINDER HEAD
– Idle Speed.................... 725 ± 25 rpm
– Governed Speed .......... 2650 ± 50 rpm Height ................................. 91.25 to 92.05 mm
(3.620 to 3.624 in.)
Engine Speed, M4-2.0G and M4-2.2G (AISAN):
Distortion Limit ................. 0.15 mm (0.006 in.)
– Idle Speed.................... 800 ±25 rpm
– Governed Speed .......... 2750 ±50 rpm Grinding Limit ................... 0.20 mm (0.008 in.)
Stall Speed (New M4-2.0G Engine):

26
600 SRM 496 Engine Specifications

VALVE MECHANISM Rocker Arm Shaft

Diameter............................. 15.966 to 15.984 mm
Inside Diameter of Valve (0.6286 to 0.6293 in.)
Guide................................... 8.07 to 8.09 mm
(0.3177 to 0.3185 in.) Rocker Arm Bore
Diameter............................. 16.000 to 16.027 mm
Clearance in Guide (0.6299 to 0.6311 in.)
(Exhaust) ............................ 0.025 to 0.060 mm
(0.001 to 0.0024 in.) Clearance Between
Rocker Arm and
Clearance in Guide
Shaft ................................... 0.016 to 0.061 mm
(Intake) ............................... 0.025 to 0.060 mm (0.0006 to 0.0024 in.)
(0.001 to 0.0024 in.)
– Service Limit CAMSHAFT
(Intake and Exhaust)..... 0.20 mm (0.008 in.)
Diameter of Valve Stem Cam Lobes to
(Intake) ............................... 8.03 to 8.045 mm Production Limit ................ 37.102 mm (1.4607 in.)
(0.3161 to 0.3167 in.) Cam Lobes to Service
– Service Limit............... 7.980 mm (0.3142 in.) Limit ................................... 36.902 mm (1.4528 in.)

Diameter of Valve Stem Bearing Journals

(Exhaust) ............................ 8.025 to 8.045 mm (Nos. 1 and 5) ..................... 31.940 to 31.965 mm
(0.3159 to 0.3167 in.) (1.2575 to 1.2585 in.)

– Service Limit............... 7.975 mm (0.3140 in.) Bearing Journals

(Nos. 2, 3, and 4) ................ 31.910 to 31.935 mm
Valve Head Thickness (1.2563 to 1.2573 in.)
(Intake) ............................... 0.5 mm (0.020 in.)
Bearing Journal Wear
Valve Head Thickness Limit ................................... 0.05 mm (0.002 in.)
(Exhaust) ............................ 1.0 mm (0.040 in.)
Clearance Between
Valve Face Angle Journals and Bore
(Intake and Exhaust) ......... 30 (Nos. 1 and 5) ..................... 0.035 to 0.085 mm
Spring Free Length (0.0014 to 0.0033 in.)
- Outer (M4-2.0G)............... 52.4 mm (2.063 in.) Clearance Between
– Service Limit Journals and Bore
(M4-2.0G) ....................... 50.8 mm (2.00 in.) (Nos. 2, 3, and 4) ................ 0.065 to 0.115 mm
(0.0026 to 0.0045 in.)
Spring Free Length
- Outer (M4-2.2G) ........... 52.2 mm (2.055 in.) End Clearance .................... 0.08 to 0.16 mm
(0.003 to 0.006 in.)
– Service Limit
(M4-2.2G) ....................... 50.6 mm (1.992 in.) – Service Limit............... 0.20 mm (0.008 in.)

Spring Free Length

- Inner (M4-2.0G) ............... 45.7 mm (1.799 in.)
CRANKSHAFT
– Service Limit Distortion (M4-2.0G).......... less than 0.03 mm
(M4-2.0G) ....................... 44.3 mm (1.744 in.) (0.0012 in.)

Spring Free Length Distortion (M4-2.2G).......... less than 0.04 mm

- Inner (M4-2.2G) ............... 47.7 mm (1.878 in.) (0.0016 in.)

– Service Limit Main Bearing Journal

(M4-2.2G) ....................... 46.3 mm (1.823 in.) Diameter............................. 59.937 to 59.955 mm
(2.3597 to 2.3604 in.)
– Service Limit............... 0.05 mm (0.002 in.)

27
Engine Specifications 600 SRM 496

– Grinding Limit ............ 0.75 mm (0.030 in.) – Service Limit............... 0.15 mm (0.0059 in.)
Clearance Between Piston Pin Diameter .......... 21.974 to 21.980 mm
Journals and Main (0.8651 to 0.8654 in.)
Bearings.............................. 0.031 to 0.049 mm
Groove Width for Piston
(0.0012 to 0.0019 in.)
Rings Nos. 1 and 2 ............. 1.520 to 1.540 mm
– Service Limit............... 0.08 mm (0.003 in.) (0.0598 to 0.0606 in.)
Connecting Rod Journal Groove Width for
Diameter............................. 50.940 to 50.955 mm Oil Ring............................... 4.020 to 4.040 mm
(2.0055 to 2.0061 in.) (0.1583 to 0.1591 in.)
– Service Limit............... 0.05 mm (0.002 in.) Piston Ring Clearance in
Groove (Nos. 1 and 2) ........ 0.03 to 0.07 mm
– Grinding Limit ............ 0.75 mm (0.030 in.)
(0.0012 to 0.0028 in.)
Thrust Bearing
– Service Limit............... 0.15 mm (0.0059 in.)
Clearance............................ 0.08 to 0.18 mm
(0.003 to 0.007 in.) Piston Ring End Clearance:
– Service Limit............... 0.30 mm (0.012 in.) – Top Ring ...................... 0.20 to 0.35 mm
(0.008 to 0.014 in.)
CONNECTING RODS – Second Ring................. 0.15 to 0.30 mm
(0.006 to 0.012 in.)
Small End Bore .................. 21.943 to 21.961 mm
(0.8639 to 0.8646 in.) – Oil Control Ring.......... 0.30 to 0.90 mm
(0.012 to 0.035 in.)
Clearance Between
Piston Pin and – Service Limit
Bore..................................... 0.015 to 0.040 mm (All Rings) ...................... 1.0 mm (0.039 in.)
(0.0006 to 0.0016 in.)
Clearance Between OIL PUMP
Crankshaft Journals
Clearance Between
and Rod Bearings ............... 0.027 to 0.067 mm
Inner Gear and Crescent ... 0.267 to 0.380 mm
(0.0011 to 0.0026 in.)
(0.0105 to 0.0150 in.)
– Service Limit............... 0.10 mm (0.004 in.)
– Service Limit............... 0.40 mm (0.0157 in.)
Clearance Between
CYLINDER BLOCK
Crescent and Outer Gear... 0.20 to 0.32 mm
Distortion at Top Surface... 0.15 mm (0.0059 in.) (0.008 to 0.013 in.)

Bore Diameter .................... 86.00 to 86.019 mm – Service Limit............... 0.35 mm (0.014 in.)
(3.3858 to 3.3866 in.) Clearance Between Outer
– Wear Limit .................. 0.15 mm (0.0059 in.) Gear and Housing .............. 0.090 to 0.184 mm
(0.0035 to 0.0072 in.)

PISTONS – Service Limit............... 0.20 mm (0.008 in.)

Side Clearance Between
Diameter............................. 85.944 to 85.964 mm
Gears and Housing ............ 0.03 to 0.063 mm
(3.3836 to 3.3844 in.)
(0.0012 to 0.0025 in.)
Clearance Between
– Service Limit............... 0.10 mm (0.004 in.)
Piston and Bore .................. 0.036 to 0.075 mm
(0.0014 to 0.0030 in.)

28
600 SRM 496 Torque Specifications

Torque Specifications
Camshaft Pulley Lock Bolt Oil Pan
48 to 66 N•m (35 to 49 lbf ft) 7 to 12 N•m (62 to 106 lbf in)

Cooling Fan Oil Pump

8 to 11 N•m (71 to 97 lbf in)
Connecting Rod Cap
M4-2.0G 51 to 56 N•m (38 to 41 lbf ft)
M4-2.2G 66 to 70 N•m (49 to 52 lbf ft)
Crankshaft Pulley
30 to 33 N•m (22 to 24 lbf ft)
Cylinder Head
Cold 81 to 88 N•m (60 to 65 lbf ft)
Hot 95 to 100 N•m (70 to 74 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)
Rocker Cover
M4-2.0G 30 to 40 N•m (22 to 30 lbf ft)
M4-2.2G 40 to 60 N•m (30 to 44 lbf ft)
Rocker Shaft Assembly
18 to 27 N•m (13 to 20 lbf ft)
Spark Plugs
15 to 23 N•m (133 to 204 lbf in)

Engine Mount to Engine Starter

55 N•m (41 lbf ft) 66 to 79 N•m (49 to 58 lbf ft)

Engine Mount Capscrew Thermostat Cover

66 N•m (49 lbf ft) M4-2.0G 12 to 18 N•m (107 to 159 lbf in)
M4-2.2G 19 to 31 N•m (14 to 23 lbf ft)
Exhaust Manifold
22 to 29 N•m (195 to 257 lbf in) Timing Belt Cover
M4-2.0G Upper Capscrews 8 to 12 N•m
Flywheel Housing (71 to 106 lbf in)
M10 Capscrews 41 to 49 N•m (30 to 36 lbf ft) M4-2.0G Lower Capscrews 7 to 8 N•m
M14 Capscrews 114 to 136 N•m (84 to 100 lbf ft) (62 to 71 lbf in)
M4-2.2G Capscrews 7 to 10 N•m (62 to 89 lbf in)
Fuel Pump
16 to 22 N•m (142 to 195 lbf in) Timing Belt Tension Lock Bolt
M4-2.0G 20 to 35 N•m (15 to 26 lbf ft)
Intake Manifold
M4-2.2G 38 to 53 N•m (28 to 39 lbf ft)
19 to 31 N•m (14 to 23 lbf ft)
Water Pump
Main Bearing Cap
19 to 26 N•m (168 to 230 lbf in)
84 to 90 N•m (62 to 66 lbf ft)

29
Troubleshooting 600 SRM 496

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

The engine will not start. The fuel tank is empty. Fill fuel tank.

The battery is not fully charged. Charge battery.

The connections at the battery are Check and tighten battery connec-
loose or they have corrosion. tions.

The starter system has a problem. Check electrical circuit for starter.

There are damaged parts in the en- Repair engine.

gine.

The valves are worn or damaged. Install new valves.

The piston rings are worn or dam- Install new piston rings.
aged.

The fuel system has a problem. Check and repair fuel system.

Ignition timing is not correct. Adjust timing.

Fuel line has a restriction. Clean or use new fuel lines.

Fuel filter has a restriction. Install new fuel filter.

Ignition system does not operate cor- Check and repair ignition system.
rectly.

The engine does not run The valve mechanism does not oper- Check and repair valve mechanism.
smoothly. ate correctly.

The cylinder head has cracks. Install new cylinder head.

The head gasket has a leak. Install new gasket.

There is a leak in the intake system. Check and repair intake system.

Engine is too hot. Check cooling system.

Fuel lines or fuel filter has a restric- Clean or use new fuel lines.
tion.

The ignition timing is not correct. Adjust timing.

30
600 SRM 496 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

The engine does not have The fuel is the wrong type. Fill tank with correct fuel.
enough power.

The air filter is dirty. Install new air filter.

The ignition timing is not correct. Adjust timing.

The valve mechanism does not work Check and repair valve mechanism.
correctly.

The piston assemblies are worn or Install new pistons.

damaged.

The exhaust system has restrictions. Clean parts or install new muffler or
pipes.

Fuel lines or fuel filter has a restric- Clean or use new fuel lines and filter.
tion.

Engine is too hot or too cold. Check cooling system.

Cylinder head gasket leaks. Install new gasket.

There is noise inside the en- The main bearings are worn or dam- Install new main bearings.
gine. aged.

Engine is too hot. Check and repair cooling system.

Valves are not adjusted correctly. Adjust valves.

The bearings for the connecting rods Install new bearings.

are worn or damaged.

The pistons are worn or damaged. Install new pistons.

Valve spring is broken. Install new valve springs.

There is not enough oil in the engine. Fill engine with correct oil.

The flywheel is loose. Tighten capscrews for flywheel.

A connecting rod is bent. Repair engine.

There is a leak in the exhaust sys- Repair exhaust system.

tem.

The valve mechanism does not oper- Check and repair valve mechanism.
ate correctly.

Spark plugs are dirty. Install new spark plugs.

31
Troubleshooting 600 SRM 496

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

The engine gets too hot. There is not enough coolant in the Fill cooling system.
cooling system.

The air filter has a restriction. Install new air filter.

The water pump has damage. Install new water pump.

The radiator is dirty. Clean or repair the radiator.

The cooling system has restrictions. Check radiator and hoses.

The belt for the water pump is worn Check and adjust the belt.
or not adjusted correctly.

The thermostat has damage. Install new thermostat.

The exhaust system has restrictions. Check and repair exhaust system.

Ignition timing is not correct. Adjust timing.

Cylinder head gasket leaks. Install new head gasket.

Engine compression is not correct. Check and repair engine.

32
 TECHNICAL PUBLICATIONS

600 SRM 496 2/01 (4/96)(1/96)(1/95)(9/93)(4/93) Printed in U.S.A.