Hyster D001 (H40XMS) Forklift Service Repair Manual by 163114103

SERVICE REPAIR H25XM H30XM H35XM H40XMS [D001]

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INTRODUCTION • Do not disconnect the battery when the engine

DANGER

is running. The voltage surge can damage the diodes and resistors.

Some gaskets used in this engine can contain asbestos or other fibers. Breathing asbestos dust is a cancer or lung disease hazard. Do not create dust! Use vacuum equipment for asbestos or follow the cleaning procedure described below.

• 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

• Make sure the gasket material is wet with

the electric wires to the wrong terminals. Make sure a correct identification is made of the wire before it is connected.

water or oil to prevent particles in the air.

• Use a hand scraper to remove old gasket material. Do not use a power tool or compressed air.

• Make sure a battery is the correct voltage and

• Discard all asbestos material in a closed con-

polarity before it is connected.

tainer while it is still wet.

• Do not check for current flow by making a

Put an “ASBESTOS” warning label on the container. Discard asbestos material safely.

spark because the transistors can be damaged.

CAUTION

DESCRIPTION

Disconnect the battery cables before doing any disassembly and repair to the engine or parts of the electrical system.

The Mazda engine is a four cylinder engine that has a displacement of 1489 cm3 (90.8 in3). The firing order is 1–3–4–2. It is available with either a gasoline or an LPG fuel system. The number one cylinder is toward the end of the engine with the cooling fan.

The diodes and resistors in the electrical system can be damaged if the following cautions are not followed: 1

3 2

1. 2. 3. 4.

SPARK PLUG EXHAUST MANIFOLD DIPSTICK ALTERNATOR

FIGURE 1. M4–1.5G ENGINE

The overhead camshaft is driven by a chain. 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 bear-

ing. The pistons are aluminum alloy and have three piston 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.

REPAIRS CYLINDER HEAD, CAMSHAFT AND VALVE MECHANISM Removal

9. Remove the cylinder head capscrew that is below the front of the camshaft as shown in FIGURE 3. Loosen the remaining capscrews for the cylinder head in the sequence shown in FIGURE 4. Remove the capscrews.

1. Disconnect the connections at the battery. 2. Drain the cooling system. 3. Remove the air cleaner, the carburetor linkage, the intake and exhaust manifolds. 4. Remove the coolant hoses. 5. Remove the bracket for the cooling fan. 6. Disconnect the wires at the distributor. Remove the capscrew for the distributor mount and pull the distributor from the cylinder head.

FIGURE 3. CYLINDER HEAD CAPSCREW 10. Remove the rocker shaft assembly. See FIGURE 21. Remove the camshaft, leaving the sprocket and chain in the engine. Use a piece of wire or a tie strap to hold the sprocket in position on the timing chain. Make sure the polished chain link is aligned with the timing mark on the sprocket. See FIGURE 5. and FIGURE 18. 1

1. SPACER 2. GEAR 3. SEAL

FIGURE 2. REMOVE THE CAMSHAFT GEAR 7. Remove the valve cover. Remove the half round seals from the cylinder head. See FIGURE 2. 8. Hold the bolt on the crankshaft pulley and remove the nut on the camshaft. Remove the drive gear for the distributor and the spacer. See FIGURE 2. 2

FIGURE 4. SEQUENCE FOR REMOVAL OF THE CYLINDER HEAD

1. CAMSHAFT SPROCKET 2. TIMING CHAIN 3. CRANKSHAFT SPROCKET

c. Remove the sprockets and chain for the oil pump. Remove the timing chain and crankshaft sprocket. d. Remove the guides for the timing chain. Remove the timing chain tensioner. See FIGURE 17. Cleaning

WARNING 3

Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturerâ&#x20AC;&#x2122;s recommended safety procedures. Clean all of the parts in solvent. Make sure that all oil passages are clean. Make sure all machined surfaces are smooth. Inspection And Repairs CYLINDER HEAD

FIGURE 5. TIMING CHAIN AND SPROCKETS

11. Lift the cylinder head from the block. 12. Use a valve spring compressor and remove the valve retainers, springs and valves from the head. See FIGURE 6.

Check the bottom surface of the cylinder head for distortion. Use a straight edge and a thickness gauge. Do the measurements at the positions shown in FIGURE 7. The maximum amount of distortion is 0.15 mm (0.0059 in). When grinding the cylinder head, the maximum amount of correction is 0.2 mm (0.008 in).

FIGURE 6. REMOVE THE VALVES 13. Remove the timing chain as follows: a. Remove the crankshaft pulley. Remove the oil pan. b. Remove the front cover from the cylinder block.

FIGURE 7. CYLINDER HEAD INSPECTION ROCKER SHAFT ASSEMBLY (See FIGURE 21.)

Disassemble the rocker shaft assembly. Put marks on the rocker arms so that they can be installed on the same 3

shafts. Clean the oil passages in the rocker shafts and rocker arms. Check the clearance between the rocker arms and the rocker shafts. The maximum clearance is 0.10 mm (0.004 in). The correct dimension for the inside diameter of a rocker arm is 19.000 to 19.033 mm (0.748 to 0.749 in). The correct dimension for the outside diameter of a rocker shaft is 18.959 to 18.980 mm (0.746 to 0.747 in). If the parts do not meet specification, replace the rocker arm(s) or the rocker shaft(s).

A B C D 3 1

2 CAMSHAFT

Check the camshaft for cracks or damage.

1. FRONT JOURNAL 2. CENTER JOURNAL 3. REAR JOURNAL

FIGURE 9. CAMSHAFT INSPECTION Check the movement of the camshaft in the cylinder head. Install the supports for the rocker shafts. Install the camshaft and thrust plate. Tighten the nut for the camshaft to 69 to 79 N.m (51 to 58 lbf ft).Use a dial indicator on the end of the camshaft as shown in FIGURE 8. The maximum movement is 0.20 mm (0.008 in). Install a new thrust plate if the measurement is not correct.

Measure the camshaft journals at four points A–D as shown in FIGURE 9. The minimum dimensions for the journals are as follows: Front and Rear Journals – 41.949 to 41.965 mm (1.651 to 1.652 in) Center Journal – 41.919 to 41.935 mm (1.650 to 1.651 in) Check the camshaft for being straight. Put the front and rear journals in V blocks and rotate the camshaft one complete turn. See FIGURE 10. The maximum amount that the dial indicator can indicate is 0.05 mm (0.002 in).

FIGURE 8. CHECK THE CAMSHAFT

FIGURE 10. CHECK THE CAMSHAFT

Measure the height of the camshaft lobes. See FIGURE 9. The minimum height of the intake and exhaust lobes are 43.912 mm (1.729 in).

Measure the clearance between the camshaft and the bore in the cylinder head. Use a plastic gauge material as shown in FIGURE 11. Tighten the capscrews for the caps to 76 to 81 N.m (56 to 60 lbf ft). The correct clearance for the front and rear journals is 0.035 to 0.076 mm (0.0014 to 0.003 in). The correct clearance for the center journal is 0.065 to 0.106 mm (0.0026 to 0.0041 in). If

any of the clearances are greater than 0.15 mm (0.0059 in), replace the cylinder head assembly. Install a new camshaft when there is any damage or when it does not meet specifications. TIMING CHAIN AND SPROCKETS

Check the timing chain for loose or broken links. Check the sprockets and chain guides for wear or damage. Use new parts as necessary.

If replacement is necessary, use a tool to remove the valve guide(s). Remove the seal from the valve guide, then remove the valve guide. To install a valve guide, install the retaining ring on the valve guide. Use the tool and install the valve guide until the retaining ring contacts the cylinder head. See FIGURE 12. Install the seals on the valve guides. NOTE: The intake and exhaust valve guides are not the same. Make sure the valve guides are installed correctly. VALVE SEATS

Inspect the condition of the valve seats. If the valve seats have cracks, the cylinder head must be replaced. If the condition of the valve seats is good, check the contact pattern of the valve and the valve seat. Use a valve seat grinder to make sure the valve seats are with the specifications shown in FIGURE 13. Use a valve compound to make sure the valves fit the seats.

EXHAUST 75°

FIGURE 11. MEASURE THE CLEARANCE FOR THE CAMSHAFT

1.4 mm (0.055 in)

VALVE GUIDES 45°

Measure the clearance between the valve stems and the valve guides. Normal clearance is 0.018 to 0.055 mm (0.0007 to 0.002 in). Replace the valve or valve guide when the clearance is more than 0.20 mm (0.008 in).

45° INTAKE 75°

3 1

1.4 mm (0.055 in) 15°

45°

FIGURE 13. VALVE SEAT SPECIFICATIONS

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

FIGURE 12. VALVE GUIDE

Check the depth of the valve seats by measuring the length of the valve stem as shown in FIGURE 14. The standard dimension from the valve spring seat to the end of the valve stem is 39.5 mm (1.55 in). When the measurement is 0.5 to 1.5 mm (0.02 to 0.06 in) more than standard, use a spacer under the valve spring seat. When the measurement is more than 41.0 mm (1.61 in), the 5

valve seat is too deep and the cylinder head must be replaced.

2. Inspect the valves for cracks, burned faces and distortion. Inspect the seat face of the valves for wear and damage. Measure the thickness of the valve head. See The minimum thickness for an intake valve is 0.5 mm (0.020 in). The minimum thickness for an exhaust valve is 1.0 mm (0.040 in). 3. If the valves need grinding the correct surface angle is 45Â° for both intake and exhaust valves.

1 1. VALVE STEM

FIGURE 14. VALVE GUIDE

VALVE SPRINGS

Check the valve springs for damage. See FIGURE 16. Measure the free length of the valve springs. The minimum length is 42.0 mm (1.65 in). Check the valve springs for being square. See FIGURE 16. If the measurement is more than 1.52 mm (0.059 in), replace the valve spring(s).

VALVES

1. See FIGURE 15. Inspect the stem of each valve for wear. Use a micrometer to measure the outside diameter of the stem. The minimum dimension for an intake valve is 7.980 mm (0.3142 in). The minimum dimension for an exhaust valve is 7.975 mm (0.3140 in).

MEASURE HERE

1. DIAMETER 2. THICKNESS, VALVE HEAD

FIGURE 16. INSPECT THE VALVE SPRINGS

Installation 1

1. Clean the surface of the cylinder head and the surface of the block. 2

2. Install the valves and valve springs. 3. If the timing chain was removed, do the following:

FIGURE 15. INSPECT THE VALVES

a. Install the guides for the timing chain on the cylinder block. See FIGURE 17.

nut on the oil pump shaft to 30 to 34 N.m (22 to 25 lbf ft). Bend the lock washer on the nut.

e. Install the oil seal in the front cover. Install the baffle on the crankshaft. Install the front cover and gaskets on the cylinder block. See FIGURE 19. Tighten the capscrews for the front cover to 19 to 26 N.m (14 to 19 lbf ft). 1. 2. 3. 4.

CYLINDER BLOCK GASKET FRONT COVER OIL SEAL

1 2

1. CHAIN GUIDE

FIGURE 17. CHAIN GUIDES FOR TIMING CHAIN b. Install the key and sprocket for the timing chain on the crankshaft. Install the timing chain on the sprocket so that the polished link is aligned with the mark on the sprocket. Install the camshaft sprocket in the timing chain. Use a piece of wire or a tie strap to hold the sprocket in position on the timing chain. See FIGURE 18. Make sure the polished chain link is aligned with the timing mark on the sprocket.

1 2

1. TIMING MARK 2. POLISHED LINK

3 2

FIGURE 19. FRONT COVER f. Use a silicone sealant on the oil pan and install the oil pan. Tighten the capscrews to 7 to 9 N.m (5 to 7 lbf ft). 4. Use a gasket sealant at the joint between the cylinder block and the front cover. See FIGURE 20. Install a new cylinder head gasket to the block. Install the cylinder head on the gasket.

1 2

FIGURE 18. TIMING CHAIN c. Install the tensioner for the timing chain. d. Install the key on the oil pump shaft. Install the chain and sprockets for the oil pump. Tighten the

1. APPLY SEALANT HERE

FIGURE 20. INSTALL THE CYLINDER HEAD 7

1. 2. 3. 4. 5. 6. 7. 8.

CAMSHAFT TIMING CHAIN TENSIONER NUT DRIVE GEAR SPACER SPROCKET INTAKE VALVE

18 15 19 16

18 17

16 20

13 12

11 11 10 10

9 14

9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

8 6 5

4 3

VALVE STEM SEAL SPRING SEAT VALVE SPRING RETAINER KEEPERS EXHAUST VALVE ROCKER SHAFT SPRING ROCKER ARM SUPPORT LOCK NUT ADJUSTMENT SCREW

FIGURE 21. ROCKER ARM AND CAMSHAFT ASSEMBLY 5. Install the camshaft as follows: a. Install the key on the camshaft.

b. Remove the wire from the sprocket and chain. Hold the sprocket so that the chain is tight. c. Install the camshaft in the sprocket. Rotate the crankshaft so that the dowel pin is at the top. 6. Assemble the rocker shaft assembly as shown in FIGURE 21. 7. Lubricate the rocker shaft supports with oil, then install the rocker shaft assembly on the cylinder head. Install the capscrews and tighten in several steps to 85 to 91 N.m (63 to 67 lbf ft). Use the tightening sequence shown in FIGURE 22. Install the capscrews that hold the cylinder head to the front cover. Tighten the capscrews to 19 to 26 N.m (14 to 19 lbf ft). 8

FRONT OF ENGINE

FIGURE 22. CYLINDER HEAD TIGHTENING SEQUENCE

8. Install the spacer and distributor drive gear. Hold the capscrew on the crankshaft pulley and tighten the nut for the camshaft to 69 to 79 N.m (51 to 58 lbf ft). 9. Adjust the timing chain as follows: a. See FIGURE 23. Remove the two access plugs. Loosen the capscrew for the timing chain guide. b. Use a screwdriver and push on the chain guide with a force of approximately 1 kg (2.2 lb) and tighten the capscrew. c. Install the access plugs.

4. Remove the sprockets and chain for the oil pump. Remove the timing chain and crankshaft sprocket. 5. Remove the oil pump and strainer as an assembly. 6. Remove the caps for the connecting rods. Put a mark of identification on each cap so that they will be installed to the same location. 7. Before removing the crankshaft, measure the clearance between the crankshaft and the flange of the rear main bearing. See FIGURE 24. Push the crankshaft fully forward before making the measurement. Normal clearance is 0.08 to 0.242 mm (0.003 to 0.0095 in). The maximum clearance is 0.30 mm (0.012 in). If the clearance is greater than the specification, replace the thrust bearing. 1. REAR MAIN BEARING

1. ACCESS HOLE FOR CHAIN GUIDE CAPSCREW 2. ACCESS HOLE FOR CHAIN GUIDE 3. SCREWDRIVER

FIGURE 23. ADJUST THE TIMING CHAIN 10. Adjust the valve clearance. 11. Use a silicone sealant on the half round seals in the cylinder head. Install the seal in the cylinder head. Install the gasket and the valve cover. Tighten the capscrews for the valve cover to 19 to 30 N.m (14 to 22 lbf ft).

FIGURE 24. MEASURE THE CRANKSHAFT CLEARANCE 8. Put marks for identification on the bearing caps. Loosen the capscrews for the main bearing caps in steps, then remove the capscrews and the caps. Remove the crankshaft. Remove the oil seal from the crankshaft. Remove the main bearings from the engine. Inspection And Repair

12. Install the distributor.

CRANKSHAFT

CRANKSHAFT AND MAIN BEARINGS

1. Visually inspect the crankshaft for wear, cracks or other damage. Replace the crankshaft if it has cracks.

Removal

2. Use a micrometer to measure the diameter of the journals for the crankshaft. See FIGURE 25. Make the measurement at several locations for each journal. If the measurements are less than specifications, grind the crankshaft and install undersize bearings. The correct dimensions for the journals are as follows:

1. Remove the cylinder head. 2. Remove the crankshaft pulley. Remove the oil pan. 3. Remove the front cover from the cylinder block.

Main Journal Diameter – 49.938 to 49.956 mm (1.966 to 1.983 in)

4. Check the passages for oil in the crankshaft. Make sure the passages are clean, with no restrictions.

Connecting Rod Journals – 39.940 to 39.956 mm (1.586 to 1.573 in)

MAIN BEARINGS

1. Visually inspect the main bearings for wear and damage. Replace the bearings as necessary.

3. Check the crankshaft for being straight. See FIGURE 25. Put the front and rear journals in V blocks and rotate the crankshaft one complete turn. The maximum amount that the dial indicator can indicate is 0.04 mm (0.0016 in).

2 4

FIGURE 26. CHECK THE CLEARANCE FOR THE MAIN BEARINGS

3 1. 2. 3. 4.

REAR OIL SEAL SURFACE CONNECTING ROD JOURNALS MAIN BEARING JOURNALS FRONT OIL SEAL SURFACE

2. Measure the clearance between the main bearings and the crankshaft. Use a plastic gauge material as shown in FIGURE 26. Tighten the capscrews for the main bearing caps to 65 to 69 N.m (48 to 51 lbf ft). The correct clearance is 0.023 to 0.064 mm (0.0009 to 0.0025 in). The maximum clearance is 0.08 mm (0.003 in). Installation 1. Clean the main bearings and the areas at the block for the main bearings. Install the main bearings and lubricate them with oil.

FIGURE 25. CRANKSHAFT INSPECTION

2. Install the crankshaft on the bearings. Install the rear seal on the crankshaft. Install the main bearings in the caps and lubricate them with oil. Use the identification marks and install the main bearing caps. Install the thrust bearing at the rear main bearing cap. (The oil grooves on the thrust bearing must contact the crankshaft. Tighten the capscrews for the main bearing caps to 65 to 69 N.m (48 to 51 lbf ft). Install the oil seals in the grooves between the cylinder block and the cap for the rear main bearing as shown in FIGURE 27.

the cylinder block. Tighten the capscrews for the front cover to 19 to 26 N.m (14 to 19 lbf ft). 8. Use a silicone sealant on the oil pan and install the oil pan. Tighten the capscrews to 7 to 9 N.m (5 to 7 lbf ft). 9. Lubricate the oil seal, the install the pulley on the crankshaft. Tighten the capscrew for the pulley to 156 to 165 N.m (115 to 122 lbf ft). 10. Install the cylinder head as described in CYLINDER HEAD, Installation.

2 1. REAR SEAL 2. CRANKSHAFT

3. MAIN BEARING CAP 4. SEAL

PISTONS AND CONNECTING RODS Removal And Disassembly

1. Remove the cylinder head. 2. Remove the oil pan and oil strainer. 3. Put a mark for identification on the top of each piston. 4

FIGURE 27. REAR OIL SEAL

4. Clean the carbon from the top of each cylinder bore. 5. Remove the caps and bearings from each connecting rod. Keep the caps and bearings with the correct piston assemblies. 6. Push the connecting rod and piston from the block.

3. Install the pistons and the connecting rods. 4. Install the push rod for the fuel pump in the cylinder block. Install the oil pump assembly. Make sure the marks on the rotors in the oil pump are toward the engine block. Install the oil strainer. 5. Install the key and sprocket for the timing chain on the crankshaft. Install the timing chain on the sprocket so that the polished link is aligned with the mark on the sprocket. Install the camshaft sprocket in the timing chain. Use a piece of wire or a tie strap to hold the sprocket in position on the timing chain. Make sure the polished chain link is aligned with the timing mark on the sprocket.

7. Carefully remove the piston rings from the pistons. Use a tool to push the piston pin from the connecting rod. Cleaning

WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturerâ&#x20AC;&#x2122;s recommended safety procedures. Clean all of the parts in solvent. Make sure that all oil passages and grooves are clean. Make sure all machined surfaces are smooth.

6. Install the key on the oil pump shaft. Install the chain and sprockets for the oil pump. Tighten the nut on the oil pump shaft to 30 to 34 N.m (22 to 25 lbf ft). Bend the lock washer on the nut.

Inspection And Repair

7. Install the oil seal in the front cover. Install the baffle on the crankshaft. Install the front cover and gaskets on

1. Inspect the pistons for wear and cracks. Replace a piston that has damage.

PISTONS

Top Piston Ring – 0.20–0.40 mm (0.008–0.016 in) 2nd Piston Ring – 0.20–0.40 mm (0.006–0.016 in) Oil Ring – 0.30–0.90 mm (0.012–0.035 in) Maximum clearance is 1.0 mm (0.039 in) 2. Measure the clearance between the piston ring and the groove in the piston as shown in FIGURE 29. The correct dimensions are as follows:

16.5 mm (0.65 in)

Top Piston Ring – 0.030–0.065 mm (0.0012–0.0026 in) FIGURE 28. MEASURING THE PISTON

2nd Piston Ring – 0.030–0.065 mm (0.0012–0.0026 in) Maximum clearance is 0.15 mm (0.0059 in)

2. Measure the outside diameter of the piston as shown in FIGURE 28. The correct dimension is 76.954 to 76.974 mm (3.0297 to 3.0305 in). The maximum clearance between the piston and the cylinder bore is 0.15 mm (0.0059 in). PISTON RINGS

1. Measure the end clearance of each piston ring as shown in FIGURE 29. Install the piston ring into the cylinder bore where it will be used. Use a thickness gauge to measure the amount of end clearance. The correct clearance is as follows:

1. PISTON RING END CLEARANCE 2. PISTON RING GROOVE CLEARANCE

CONNECTING RODS AND BEARINGS

1. Use a special machine to check the connecting rods for being straight. The maximum amount of distortion per 100 mm (4.0 in) is 0.04 mm (0.0016 in). If the amount of distortion is greater than the specification, use a press to straighten the connecting rod. 2. Check the clearance between the rod bearings and the journals of the crankshaft. Clean the rod bearings and journals. Use a plastic gauge material as shown in FIGURE 30. Tighten the nuts for the rod caps to 30 to 34 N.m (22 to 25 lbf ft). The correct clearance is 0.023 to 0.064 mm (0.0009 to 0.0025 in). The maximum clearance is 0.10 mm (0.0039 in). If the clearance is greater than the specifications, replace the bearings.

1 2

FIGURE 30. CHECK THE CLEARANCE OF THE CONNECTING ROD BEARINGS

FIGURE 29. MEASURING THE PISTON RINGS

3. Check the clearance between the side of the connecting rod and the crankshaft. The maximum clearance is 0.30 mm (0.012 in). Install a new connecting rod or crankshaft if the clearance exceeds the limit.

Assembly And Installation °

PISTONS AND CONNECTING RODS

° 1

1. Align the oil port on the large end of the connecting rod with the “F” mark on the piston. See FIGURE 31. Lubricate the piston pin and bore in the piston with engine oil. Install the piston pin from the side of the piston with the “F” mark. Use a press to install the piston pin. The force to push the pin into the piston must be 500 to 1500 kg (1100 to 3300 lb). If the force is not correct, replace the piston pin and/or connecting rod. Use the special tool to make sure the piston pin is installed to the correct depth. After installation, check that the piston moves freely on the piston pin. 2. Install the piston rings on the pistons. During installation, the writing on each piston ring must be toward the top of the piston. Check that the rings rotate freely, then put the ends of the rings in the positions shown in FIGURE 32. Make sure the ends of the upper and lower oil control rings are each 30° from the piston pin. Also make sure that the top and second rings are each 30° from the piston pin. Lubricate the rings with engine oil.

PISTON PIN

3 1. EXPANDER RING 2. OIL RING (UPPER) 3. OIL RING (LOWER) OIL CONTROL RING °

PISTON PIN

TOP AND SECOND RINGS

FIGURE 32. PISTON RINGS 1

1. “F” MARK 1

1. “F” MARK 2. OIL PORT

FIGURE 33. INSTALL THE PISTON FIGURE 31. CONNECTING ROD AND PISTON 3. Apply clean engine oil to the piston assembly. Install the bearings for the connecting rods. Install the piston into the correct cylinder making sure the “F” is toward the front (timing belt end) of the engine.

4. Apply clean engine oil to the bearing then install the cap to the correct connecting rod. During installation of the caps, make sure to align the identification marks that were made during disassembly. Tighten the nuts for the rod caps to 30 to 34 N.m (22 to 25 lbf ft).

CYLINDER BLOCK Repairs 1. After the cylinder block is cleaned, check its surface for distortion. See FIGURE 34. If the amount of distortion is greater than 0.15 mm (0.0059 in), grind the surface of the cylinder block.

Ring Gear

WARNING Wear eye protection for this operation to prevent eye injury from metal chips. You will be using a hammer and chisel to break the ring gear. Before the ring gear is removed, check the position of the chamfer on the teeth. 1. See FIGURE 35. Use a hammer and chisel to break the ring gear. Make sure that you do not damage the flywheel.

FIGURE 35. RING GEAR REMOVAL 2. The ring gear must be heated before it can be installed on the flywheel. Make sure that the ring gear is not heated to more than 200Â°C (390Â°F). FIGURE 34. INSPECT THE CYLINDER BLOCK

WARNING 2. Check the cylinder bores for wear and damage. Measure each bore. The correct dimension is 77.000 to 77.019 mm (3.0315 to 3.0322 in). The wear limit above this dimension is 0.15 mm (0.0059 in). Repair the cylinder block or use bigger pistons as necessary.

FLYWHEEL AND RING GEAR Flywheel, Removal (See FIGURE 36.) 1. Remove the capscrews for the flywheel, then remove the flywheel and the drive plate. 2. If necessary, remove the adapter plate. 14

Hot parts. Wear protective clothing and gloves to prevent burns. 3. Install the ring gear on the flywheel. Make sure that the chamfer on the teeth is in the correct direction toward the starter. Flywheel, Installation (See FIGURE 36.) 1. If the adapter plate for the torque converter housing was removed, install it on the engine. Tighten the capscrews to 41 N.m (30 lbf ft). 2. Install the flywheel on the crankshaft. Apply a thread locking adhesive on the threads of the capscrews. then install the capscrews and lock washers. Tighten the capscrews to 71 N.m (52 lbf ft).

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