1

INTRODUCTION

GENERAL

This section has descriptions and repair instructions for
the Perkins 4.236 and the Perkins 4.2482 diesel en-
gines. Checks and Adjustments and Troubleshooting
procedures are included in this section.

DESCRIPTION

The 4.2482 engine is a modification of the 4.236 design
to give decreased exhaust emissions and smoke. Some
parts are not common to the two engines, but the repair
procedures are similar. When the procedures or parts
are different, a description is given for each engine.

The cylinder block is cast–iron and has cylinder liners
that can be replaced. The 4.236 engine is available with
two types of cylinder liners: either with a flange or

without a flange. Both Perkins engines made for Hyster
Company normally have a flange on the cylinder liner.

The cylinder head is cast–iron and has an intake valve
and an exhaust valve for each cylinder. The injectors
are in the cylinder head. The overhead valve assembly
is actuated by the camshaft found on the right side of
the cylinder block.

The crankshaft has five main bearings. Number three
main bearing is the thrust bearing and has thrust wash-
ers on each side of the main bearing.

The pistons are aluminum alloy castings. The piston for
the 4.236 engine has five piston rings and a combustion
chamber in the top of the piston. The piston for the
4.2482 engine has three piston rings. The combustion
chamber in the 4.2482 engine is a modification of the
4.236 engine and is called a “squish lip” by the
manufacturer.

FIGURE 1. PERKINS 4.2482 ENGINE

9494

2

The timing and quantity of fuel sent to the injectors is

controlled by a throttle and governor in the fuel injec-

tion pump. The static timing is set by the position of the

injection pump when it is installed. The throttle linkage

must be correctly adjusted to control the quantity of

fuel sent to the injectors.

Special tools are needed to repair the injection pump.

The injection pump must be sent to an authorized deal-

er if repairs are necessary.

ENGINE SERIAL NUMBER CODES

Serial numbers before 1974 were as follows:

236 U 470028 A
1 2 3 4

1 Type of engine 4.236

2 Manufactured in the United Kingdom

3 Serial number

4 The letter “A” after the serial number indi-

cates the engine has 0.5 in diameter cylinder
head studs. The letter “C” after the serial
number indicates the engine has chrome
cylinder liners.

This serial number is found above the tappet
cover on the blocks of early engines. The serial
number is found above the generator of later en-
gines.

During the middle 1970’s, the introduction of a
new serial number system was made in the dif-
ferent Perkins plants.

Serial number beginning in 1974 are as follows:

LD 21498 U 510256 D
1 2 3 4 5

1 Type of engine LD = 4.236, LF = 4.248,

LG = 4.2482

2 Parts list number

3 Country of manufacture

4 Serial number

5 Year of manufacture. The letter indicates

the year of manufacture starting with “A”
in 1974 (D = 1977). The letters I, O, Q, R
and Z will not be used. Not all of the
manufacturer’s plants started the newer
serial number sequence in 1974. Some en-
gines made after 1974 can have the earlier
serial number sequence.

REMOVAL AND INSTALLATION

See the section for THE FRAME for the specific mod-
el of interest for the procedure for removing and instal-
ling the engine and transmission. See the sections for
THE TRANSMISSION to separate the transmission
from the engine.

ENGINE

WARNING

Always disconnect the connections at the battery be-
fore making repairs to the engine. (Disconnect the
negative cable first.)

CYLINDER HEAD

Removal

1. Disconnect the negative battery cable at the battery.
Remove the brackets for the wires to the alternator. Re-

move the wire to the cold start aid. Clean the cylinder
head so that dirt cannot enter the cylinder head or fuel
system.

2. Drain the cooling system. Remove the hoses.

3. Disconnect and remove the air cleaner, hose bracket
and hose. Disconnect the lines–the secondary filter and
remove the air cleaner bracket. Remove the inlet and
exhaust manifolds.

4. Make sure the area around the fittings is clean. Re-
move the fuel line to the cold start aid. Disconnect the

3

high pressure and drain lines at the fuel injectors and at
the fuel injection pump. Remove the injectors. Remove
the brackets and tubes.

CAUTION

DO NOT bend the tubes.

5. Remove the hose for the crankcase ventilation valve.
Remove the rocker arm cover. Remove the rocker arm
assembly. Remove the push rods.

NOTE: Keep the push rods in order so that they can be
installed in the same positions.

6. Remove the cylinder head nuts and capscrews in op-
posite order of the tightening sequence shown in
FIGURE 2. Remove the cylinder head.

Installation

1. Clean the threads of all the studs and capscrews. Use
a tap to clean threads of the holes in the block. Put a
small amount of oil on the threads.

2. Make sure the surfaces of the engine block and cylin-
der head are clean. Install the cylinder head gasket with
the words “TOP FRONT” in view on the fan end of the
engine block. Use only the HYSTER APPROVED cyl-
inder head gasket. Do not use sealant on the gasket.

3. Put the cylinder head on the engine block. See
FIGURE 2. for the correct location of studs and caps-
crews. Tighten the nuts and capscrews to 27 N.m (20
lbf ft) in the sequence shown in FIGURE 2. Tighten the
nuts and capscrews again the same sequence to 102
N.m (75 lbf ft). Tighten the nuts and capscrews in the
same sequence to a final torque of 136 N.m (100 lbf ft).
Repeat the final tightening procedure.

FIGURE 2. CYLINDER HEAD TIGHTENING

SEQUENCE

9467

FIGURE 3. OIL FEED CONNECTION

8105

1. OIL SUPPLY CONNECTION
2. SEAL

1

2

4. Install the push rods in the same positions from
which they were removed. Put a new O–ring for the oil
tube in the correct hole in the cylinder head.

5. Install the rocker arm assembly on the cylinder head.
Make sure each push rod is in position in the rocker
arm before tightening the capscrews. Tighten the caps-
crews to 43 N.m (32 lbf ft).

6. Adjust the clearance between the valves and the
rocker arm as described in CHECKS AND ADJUST-
MENTS in this section.

7. Install new copper washers on the injectors. Install
the injectors and brackets. Connect the lines to the in-
jectors and to the fuel injection pump. Tighten the caps-
crews for the injector bracket 16 N.m (12 lbf ft).

8. Install a new gasket for the rocker arm cover. Put a
steel washer and a rubber washer on each rocker arm
capscrew. Install the cover, rubber washers, steel wash-
ers and capscrews.

9. Make sure the surfaces of the inlet and exhaust man-
ifolds are clean and smooth. Install new gaskets and
install the manifolds. Connect the hose for the crank-
case ventilation valve.

10. Connect the fuel line and wire to the cold start aid.
Connect the wire to the temperature sender. Connect
the hose to the radiator. Install the bracket for the air
cleaner. Connect the lines to the secondary filter. Install
the air cleaner, hose and clamp.

4

11. Fill the cooling system with coolant. Check for
leaks. Connect the negative battery terminal.

12. Remove the air from the fuel system as described in
CHECKS AND ADJUSTMENTS in this section. Re-
move the air from the cold start aid before starting the
engine.

13. Run the engine until the normal operating tempera-
ture is reached. The cylinder head nuts and bolts must
be tightened to the final torque again when the engine
has reached operating temperature. After the engine
has been run for 25 to 50 hours, the nuts and capscrews
must be tightened again. Use the sequence shown in
FIGURE 2. and tighten to 136 N.m (100 lbf ft). If the
nut or capscrews does not turn when tightened to the
final torque, loosen it 30

°

to 60

°

. Tighten it to 136 N.m

(100 lbf ft). After all the capscrews or nuts have been
tightened, again tighten the first ten capscrews or nuts
to the final torque.

CAUTION

It is very important that the nuts and capscrews for

the cylinder head be tightened after the engine has
been operated for 25 to 50 hours.

Cylinder Head Repairs

The maximum clearance along the length of the surface
of the cylinder head is 0.15 mm (0.006 in). The maxi-
mum clearance across the width of the surface of the
cylinder head is 0.08 mm (0.003 in). See FIGURE 4.

The surface of the cylinder head can be machined to a
maximum of 0.030 mm (0.012 in). The nozzles of the
injectors must not extend more than 4.44 mm (0.175 in)
below the surface of the cylinder head. Use only one
washer for each injector. The correct thickness for the
washers is 2.13 mm (0.084 in).

VALVE SEATS

NOTE: Perkins 4.236 and 4.2482 engines made for
Hyster Company do not have separate valve guides nor
valve seats. Valves are available with oversize valve
stems of 0.08, 0.038 and 0.76 mm (0.003, 0.015 and
0.030 in) valve seats can be installed if necessary when a
cylinder head is repaired.

FIGURE 4. CYLINDER HEAD DIMENSIONS

8102

4.44 mm (0.175 in) MAX

0.30 mm (0.012 in) MAX

WIDTH

LENGTH

0.08 mm (0.003 in)
CLEARANCE

STRAIGHT EDGE

0.15 mm (0.006 in)
CLEARANCE

5

FIGURE 5. VALVE SEAT ANGLES

9481

A: 2.39 to 2.51 mm
(0.094 to 0.099 in)

A

45

°

30

°

1. If the surface of the valve seat is not smooth, the seat
must be cut or ground. The seat must ground at two
angles so that the surface for the valve is not too wide.
Grind the seat with the 45

°

stone until the surface is

smooth. Use the 30

°

stone to make the seat narrow. See

FIGURE 5.

2. Check the depth of a new valve head below the sur-
face of the cylinder head after the seat is machined. See
FIGURE 6. The exhaust valve head must not be more
than 1.4 mm (0.055 in) below the surface of the cylin-
der head. The inlet valve head must not be more than
1.5 mm (0.061 in) below the surface of the cylinder
head. If the depth of the valve head is more than the
specification, the valve seat or valve must be replaced.

FIGURE 6. CHECKING THE DEPTH OF THE

VALVE HEAD

FIGURE 7. VALVE SPRINGS

8106

169 to 187 N
(38 to 42 lb)

45.2 mm
(1.78 in)

OUTER VALVE SPRING

63.6 to 69.4 N
(14.3 to 15.6 lb)

39.7 mm
(1.56 in)

INNER VALVE SPRING

3. Do not lubricate the valve seats before installation.
Grind or cut the valve seats after installation as de-
scribed above.

VALVE SPRINGS

Check the pressure of the valve springs when the cylin-
der head is disassembled. The springs must be square.
The height of an inner spring that is compressed by a
load of 63.6 to 69.4 N (14.3 to 15.6 lb) must be 39.7
mm (1.56 in). A load of 169 to 187 N (38 to 42 lb) is
needed to compress the outside spring to a height of
45.2 mm (1.78 in). If the springs are not at the correct
height when the specified load is applied, they must be
replaced. See FIGURE 7.

The correct height for the inner springs when they are
installed is 39.7 mm (1.56 in). The correct height for
the outer springs is 45.2 mm (1.78 in).

The spring coils that are together must be installed to-
ward the cylinder head.

VALVES

The valves must be checked for wear on the stems. The
valve head must not be bent or have cracks. The valve
face must be ground to a 45

°

angle. Do not grind too

much metal from the valve or the valve head will be too
far below the surface of the cylinder head.

Lubricate the valve with engine oil before installing the
valve in the valve guide. Use new valve seals when as-
sembling the valve mechanism.

6

FIGURE 8. VALVE ASSEMBLY

1. RETAINERS
2. RETAINER CAP
3. SEAL
4. INNER SPRING
5. OUTER SPRING
6. SPRING SEAT
7. VALVE

1

2

3

4

5

6

7

ROCKER ARM SHAFT

Disassembly

Remove the rocker arms from the shaft by removing
the snap rings on the ends of the shaft. Remove the
washers, rocker arms, springs and support brackets.
Remove the screw from the oil tube fitting and slide the
fitting from the shaft. If the clearance between the
rocker arm bushings and the shaft is more than 0.127

mm (0.005 in) the bushings must be replaced. The cor-
rect clearance between the rocker arm bushings and the
shaft is 0.025 to 0.075 mm (0.001 to 0.003 in).

Assembly

If new bushings are needed, make sure the oil holes are
aligned. Slide the oil tube fitting on the shaft. Align the
hole for the screw in the shaft with the hole in the fit-
ting. Install the screw. Install the support brackets,
springs and rocker arms in the correct order. Install the
washers and snap rings on the shaft.

OIL PUMP

Removal

1. Remove the sump. Remove the screen assembly and
inlet tube.

2. Remove the tube between the pump and the relief
valve.

3. Remove the crankshaft pulley, timing gear cover,
timing gears and timing gear case.

Disassembly

1. Remove the snap ring for the drive gear for the
pump. Remove the Woodruff key from the drive shaft.

2. Remove the end plate. Remove the drive and driven
rotors from the pump body. Remove the O–ring.

Inspection (See FIGURE 11. and FIGURE 12.)

1. Check the rotors and plate and body for grooves or
cracks.

2. Check the clearance between the inner rotor and the
outer rotor. See FIGURE 11.

FIGURE 9. ROCKER ARM

8107

1. ROCKER ARM
2. BUSHING
3. OIL HOLE

1

2

3

7

FIGURE 10. ARRANGEMENT OF THE ROCKER ARM SHAFT

10048

1. SNAP RING
2. WASHER
3. ROCKER ARM
4. SUPPORT BRACKET
5. SPRING
6. OIL SUPPLY CONNECTION
7. ROCKER ARM SHAFT
8. PLUG

7

8

1

2

3

4

3

5

5

6

3. Check the clearance between the outer rotor and the
pump body. See FIGURE 12.

4. Check the clearance between a straight edge across
the pump body and the driven rotor. See FIGURE 13.

5. Check the clearance between a straight edge and the
inner rotor. See FIGURE 13.

If any parts of the pump are damaged or worn, the oil
pump must be replaced. The parts are not available sep-
arately.

Assembly

1. Install the inner and outer rotors into the oil pump
body. The ends of the rotors with the chamfer must be
installed first. Install a new O–ring and the end plate.

2. Install the Woodruff key on the shaft. Install the
drive gear with the boss toward the snap ring groove.
Install the snap ring.

3. Put the inlet tube in a container of clean engine oil.
Turn the drive gear until oil flows from the oil pump.

Installation

1. Install the oil pump on the main bearing cap.

2. Install the idler gear with the boss toward the oil
pump. Install the snap ring. The clearance between the
idler gear and the mount flange must be 0.05 to 0.41
mm (0.002 to 0.016 in). The clearance between the
idler gear and the oil pump gear must be 0.15 to 0.23
mm (0.006 to 0.009 in).

FIGURE 11. CHECK THE CLEARANCE

BETWEEN ROTORS

9472

CLEARANCE

OUTER ROTOR HAS 4 LOBES:

0.025 to 0.076 mm (0.001 to 0.003 in)

OUTER ROTOR HAS 5 LOBES:

0.025 to 0.152 mm (0.001 to 0.006 in)

8

FIGURE 12. CHECK THE CLEARANCE

BETWEEN ROTOR AND BODY

9471

CLEARANCE

OUTER ROTOR HAS 4 LOBES:

0.28 to 0.033 mm (0.011 to 0.013 in)

OUTER ROTOR HAS 5 LOBES:

0.139 to 0.254 mm (0.0055 to 0.010 in)

3. Install the timing case, timing gears, timing case
cover, and crankshaft pulley.

4. Install the oil tube between the oil pump and relief
valve.

5. Install the inlet tube and screen. Install the sump.

6. Before starting the engine fill the sump with oil to
the correct level. Run the starter with the stop cable
pulled until the warning light for oil pressure does not
illuminate.

RELIEF VALVE

1. Remove the sump. Remove the tube to the oil pump.

2. Remove the capscrew and remove the relief valve
body from the crankcase.

3. Remove the cotter pin from the body.

WARNING

The cotter pin holds a compressed spring in the relief
valve body.

FIGURE 13. CHECK END CLEARANCE OF THE

ROTORS

9470

CLEARANCE

3 LOBE INNER ROTOR:

0.008 to 0.076 mm (0.0015 to 0.003 in)

4 LOBE INNER ROTOR:

0.025 to 0.127 mm (0.001 to 0.005 in)

4 LOBE OUTER ROTOR:

0.013 to 0.063 mm (0.0005 to 0.0025 in)

5 LOBE OUTER ROTOR:

0.025 to 0.127 mm (0.001 to 0.005 in)

Remove the cap, spring and plunger.

4. Clean all the parts. Inspect the spring for damage.
The length of the spring must be 32.51 mm (1.28 in)
with a 34.5 to 36.7 N (7.76 to 8.24 lb) load. Inspect the
bore and plunger for scratches or wear. There must be
0.03 to 0.10 mm (0.001 to 0.004 in) clearance between
plunger and bore.

5. Lubricate the parts with engine oil. Install the plung-
er and spring in the bore. Install the cap and cotter pin.

6. Install the relief valve body on the crankcase. Install
the capscrew and lock washer.

7. Connect the tube to the oil pump. Install the sump.
Make sure there is oil in the sump before starting the
engine.

8. The relief valve must open at 345 to 415 kPa (50 to
60 psi).

TIMING GEAR CASE AND TIMING GEARS

Removal

1. Remove the crankshaft pulley.

9

2. Remove the capscrews that hold the cover to the tim-
ing gear case. Remove the cover. Do not damage the oil
seal.

NOTE: Each drive gear for the crankshaft, camshaft
and fuel injection pump has timing marks that must be
aligned with the idler gear so that the engine will oper-
ate. See FIGURE 13. See also that each drive gear and
shaft has marks that must be correctly aligned during as-
sembly.

3. Rotate the crankshaft until the timing marks on the
timing marks on the timing gears are aligned. See
FIGURE 14. Remove the nuts for the retainer for the
idler gear. Remove the idler gear and hub assembly.

CAUTION

Do not rotate the crankshaft or camshaft when the
idler gear is removed. You will damage the pistons
and/or the valves.

4. Remove the capscrew, lock washer and lock plate for
the camshaft gear. Use a puller to remove the camshaft
gear.

5. Remove the three capscrews for the gear for the fuel
injection pump. Remove the gear.

FIGURE 14. TIMING GEARS

10051

1. CRANK SHAFT
2. IDLER GEAR
3. INJECTION PUMP GEAR
4. CAMSHAFT GEAR
5. TIMING MARKS
6. HYDRAULIC PUMP DRIVE

6. Remove the fuel injection pump. Remove the nine
capscrews and washers that hold the timing gear case to
the crankcase. Remove the four capscrews and washers
that hold the timing gear case to the sump. Remove the
timing gear case.

Installation

1. Install a new gasket and install the timing gear case
on the crankcase. Make sure the thrust washer is on the
camshaft. Install the capscrews to the crankcase and
sump.

2. If the crankshaft gear was removed, install it on the
crankshaft.

3. Install the Woodruff key and camshaft gear with the
mark away from the engine. Install the retainer plate,
lock plate, lock washer and capscrew. Tighten the caps-
crew to 68 N.m (50 lbf ft). Bend the lock plate over the
nut.

4. Install the fuel injection pump on the timing gear
case. Make sure the mark on the fuel injector pump
aligns with the mark on the timing gear case. Install the
gear for the fuel injection pump. Install the three caps-
crews and lock washers. Make sure the mark on the
gear is toward the idler gear.

5. Lubricate the thrust washers and bushing for the
idler gear. Install the hub and thrust washer. Put the
idler gear on the hub with the marks for the camshaft,
crankshaft and fuel injection pump gears aligned. If the
marks are not aligned within three teeth, remove the
idler gear and turn the gear that is not aligned. If the
gears are not aligned more than three teeth, the rocker
arm assembly must be removed. This action prevents
damage to the valve mechanism when the camshaft or
crankshaft is rotated. Install the idler gear so that the
marks are in alignment. Install the other thrust washer,
the plate and nuts. Tighten the nuts to 41 N.m (30 lbf
ft).

6. Check the clearance between the thrust washer and
the idler gear. The correct clearance is 0.25 to 0.41 mm
(0.010 to 0.016 in).

7. Check the clearance between the teeth of the gears.
The minimum is 0.08 mm (0.003 in). There is no maxi-
mum clearance, but the gears can be replaced if they
are worn and make too much noise. The maximum
clearance on new engines is 0.24 mm (0.009 in).

10

8. Install a new seal in the cover for the timing gear
case. Press the seal in from the front until the seal is
9.73 to 9.97 mm (0.38 to 0.39 in) from the front face of
the cover. See FIGURE 15.

9. Put the spacer on the crankshaft. Install the cover for
the timing gear case. The three capscrews for the bot-
tom of the cover must have aluminum washers on
them.

CAUTION

The cover must be installed so that the crankshaft is
exactly in the center of the bore for the seal.

10. Install the crankshaft pulley. Tighten the capscrew
and washer to 406 N.m (300 lbf ft).

PISTONS AND CONNECTING RODS

Removal

1. Remove the cylinder head. See Cylinder Head Re-
moval.

2. Drain the oil and remove the sump.

3. Remove the nuts for the connecting rod caps. Re-
move the caps and bearings. Make sure the caps have a
number on them before removal. See FIGURE 16.
Each connecting rod cap and connecting rod are a ma-
chined assembly and must not be mixed with another
assembly.

4. Push the piston and connecting rod away from the
crankshaft. See FIGURE 17. Be careful so that the
bolts for the connecting rods do not touch the crank-
shaft and damage the bearing surface.

FIGURE 15. CRANKSHAFT SEAL FOR TIMING

GEAR CASE

8119

6.35 mm
(0.25 in)

1. TIMING GEAR CASE
2. SEAL

2

1

FIGURE 16. CONNECTING ROD

8455

CAUTION

If the cylinder liners are worn, use a ridge reamer to
cut the ridges before removing the pistons.

NOTE: The 4.236 engine has five piston rings on each
piston. See FIGURE 19.

NOTE: The 4.2482 engine has three piston rings on
each piston. See FIGURE 20.

Disassembly

1. Remove the rings from the pistons.

FIGURE 17. REMOVING THE PISTON AND

CONNECTING ROD

8454

11

2. Remove the snap rings from the piston.

3. Push out the piston pin. If necessary, heat the piston
in warm water 40

°

C (120

°

F) to remove the pin.

Inspection

1. Clean the carbon from the grooves for the piston
rings. Check the clearance of a new ring in its groove.
If the clearance is more than 0.20 mm (0.008 in) re-
place the piston.

2. Check the fit of the piston pin in the connecting rod
and piston. Measure the piston pin. Measure the diame-
ter of the holes in the piston and connecting rod. The
piston pin diameter must be 34.92 to 34.93 mm 1.3748
to 1.3750 in). The inside diameter of the bushing in the
connecting rod must be 34.94 to 34.96 mm (1.3757 to
1.3765 in). The clearance between the piston pin and
the connecting rod bushing must be 0.02 to 0.04 mm
(0.0007 to 0.0017 in). If the bushing is replaced, use a
reamer to make the bushing the correct size. The diam-
eter of the bores in the piston must be 34.92 to 34.93
mm (1.3748 to 1.3750 in).

3. Check the alignment of the connecting rod bores.
The bores must be parallel to within 0.06 mm (0.0025
in) with the bushing installed when measured at 127
mm (5 in) from the center of the connecting rod. See
FIGURE 16. When the bushing is removed the bores
must be parallel to 0.25 mm (0.010 in).

4. Check the pistons for wear or scratches on the sides
of the pistons. Clean the carbon from the top of the pis-
tons.

NOTE: The pistons for the Perkins 4.2482 are special.
Do not remove any metal from the top of the piston.

FIGURE 18. ALIGNMENT OF CONNECTING

ROD BORES WITH BUSHING REMOVED

8136

0.25 mm

(0.010 in)

0.25 mm

(0.010 in)

127 mm
(5.0 in)

127 mm
(5.0 in)

FIGURE 19. PISTON AND CONNECTING ROD

ASSEMBLY

10050

2

4

3

1

5

6

7

8

1. TOP COMPRESSION RING
2. COMPRESSION RING
3. OIL CONTROL RING
4. PISTON (4.236)
5. PISTON PIN
6. SNAP RING
7. BUSHING
8. CONNECTING ROD
9. CONNECTING ROD BEARINGS

10. CONNECTING ROD CAP

11. BOLT

12. NUT

9

10

12

11

12

FIGURE 20. CHECKING THE CLEARANCE AT

THE ENDS OF THE PISTON RINGS

8137

5. Check the bore for the crankshaft in the connecting
rod to make sure it is round.

6. Check the clearance of the ends of the rings in the
cylinder bore. See FIGURE 20. See SPECIFI-
CATIONS in this section for correct dimensions.

FIGURE 21. PISTON RINGS (4.2482 ENGINE)

8442

1

2

3

1. TOP COMPRESSION RING
2. SECOND COMPRESSION RING
3. OIL RING

Assembly

4.2482 ENGINE (See FIGURE 21.)

1. Install the oil control ring on the the number “1” pis-
ton. Install the spring so that both ends of the spring are
in the pin. Install the oil control ring so that the space is
opposite the pin. Make sure the spring is in the inner
groove of the oil control ring.

2. Install the second ring into the groove with the step
toward the top of the piston. The ring for the second
groove has a tapered face. Move the second ring so that
the space does not align with the space of the oil control
ring. See FIGURE 21.

3. Install the top compression ring in the top groove
with the step toward the top of the piston. The gap for
the top ring must not be aligned with the gap of the sec-
ond ring. See FIGURE 21.

4.236 ENGINE (See FIGURE 19.)

1. Install an oil control ring below the bore for the pis-
ton pin (number five groove). Install an oil control ring
above the bore for the piston pin (number four groove).

2. Install an iron compression ring in the second and
third grooves. These rings have a step on the inside di-
ameter. This step must be towards the top of the piston.

3. Install the top compression ring. This ring normally
has a chrome finish.

BOTH ENGINES

4. Lubricate the bores with oil for the piston pin in the
connecting rod and piston. Put the connecting rod in
between the piston bores. The letter “F” on the piston
must be toward the fan end of the engine when the
number on the connecting rod is away from the cam-
shaft. See FIGURE 22. Push the piston pin into the pis-
ton and connecting rod. Heat the piston in warm water
if the piston pin will not enter the piston. Install the
snap rings.

5. Install the connecting rod bearings in the connecting
rods and caps. Do not touch the bearing surface with
your fingers.

Installation

1. Lubricate the piston, rings and bearings with engine
oil. Install the piston in their cylinders with the letter

13

“F” toward the fan end of the engine. Use a ring com-
pressor so that the pistons will fit in the cylinders. Use a
wood handle to push the pistons into the cylinders.
Make sure the bolts of the connecting rod do not touch
the crankshaft.

2. Install the caps for the connecting rods. Install the
nuts. Tighten the nuts to 102 N.m (75 lbf ft). Bend the
lock plates over the nuts (4.2482 engines). 4.236 en-
gines do not have lock plates. Use new nuts on the bolts
for the connecting rods on the 4.236 engine.

NOTE: If new pistons are installed in a 4.236 engine,
check the piston height. Measure the difference between
the top face of the cylinder block and the top of a piston
installed in the engine. The piston will normally extend
0.08 to 0.25 mm (0.003 to 0.010 in) above the top face of
the cylinder block. A maximum limit is 0.41 to 0.61 mm
(0.016 to 0.024 in) for the piston to extend above the top
face of the cylinder block. Remove metal from the top of
the piston if necessary to make the correct clearance.

FIGURE 22. IDENTIFICATION OF THE PISTON

8135

TOWARD FRONT OF THE ENGINE

NOTE: DO NOT remove the metal from the tops of the
pistons for the 4.2482 engine. This action will change
the special combustion chamber and decrease the per-
formance of the engine.

3. Install the oil sump. Install the cylinder head as de-
scribed in Cylinder Head Installation in this section.

CRANKSHAFT AND MAIN BEARINGS

Removal

1. Remove the sump, the screen for the oil pump, the
relief valve and the oil pump.

2. Remove the timing gears and case. See TIMING
GEAR CASE AND TIMING GEARS, Removal for
the procedures.

3. Remove the flywheel and flywheel housing. See Fly-
wheel and Flywheel Housing.

4. Remove the connecting rod caps.

5. Remove the housing for the rear oil seal. Remove the
support from the rear main bearing.

6. Remove the capscrews from the main bearings. Re-
move the caps for the main bearings.

7. Remove the crankshaft. Remove the bearings and
thrust washers.

Inspection

1. Inspect the bearing surfaces of the crankshaft for
grooves or damage.

2. Measure the bearing surfaces of the crankshaft. Each
bearing surface must be measured four times. Measure
at each end of the bearing surface and then measure at
positions 90

°

from the first positions. The bearing sur-

faces must not be worn more than 0.04 mm (0.0015 in).
See FIGURE 23. for the specifications.

14

FIGURE 23. CRANKSHAFT SPECIFICATIONS

9469

1. CRANKSHAFT
2. MAIN BEARING CAP
3. THRUST WASHER
4. CRANKSHAFT GEAR

R

R

E

B

R

A

R

B

E

C

A

D

R

B

E

A

R

C

E

A

R

F

R

B

R

A

5. OIL SEAL
6. CRANKSHAFT PULLEY
7. THRUST RING

3. Check the surface for the rear seal on the crankshaft.
If the surface has a groove, the new seal must be
installed in a different position. The surface for the seal
can be machined when the surface has too many groov-
es. The diameter of the flange must not be less than
133.17 mm (5.234 in).

4. The surfaces for the bearings can be ground to diam-
eters that are 0.25, 0.51 or 0.76 mm (0.010, 0.020 or
0.030 in) smaller than the original size. The crankshaft
must be replaced if the surface must be ground more
than 0.76 mm (0.030 in).

5. Clean the oil passages in the crankshaft. Clean the
bearing caps.

6. Check the capscrews for the main bearings for dam-
age. Use only capscrews for the main bearings that are
HYSTER APPROVED.

7. The thrust washers are found in the support for the
center main bearing. Check the thrust surfaces of the
crankshaft for wear. The correct total clearance be-
tween the crankshaft and the thrust washers is 0.10 to
0.38 mm (0.004 to 0.015 in). Thrust washers are avail-
able that are 0.19 mm (0.0075 in) thicker than the stan-
dard thrust bearings. A pair of thick thrust washers can
be used on one side of the main bearing with a pair of
standard thrust washers on the other side.

Assembly

1. Install the new main bearings in the crankcase and
main bearing caps. Lubricate all the main bearings with
oil. Install and lubricate the thrust washers.

2. Put the crankshaft in the crankcase. Install the main
bearing caps in the correct positions. The number “1”
main bearing cap is toward the timing gears.

FIGURE 24. MAKE SURE SUPPORT IS EVEN

WITH CRANKCASE

9475

15

3. Install and tighten the capscrews to 44 N.m (180 lbf
ft).

4. Check the clearance between the crankshaft and the
thrust washers. The clearance must be 0.010 to 0.38
mm (0.004 to 0.015 in). Install thicker thrust washers if
the clearance is more than 0.38 mm (0.015 in).

5. Install the connecting rod bearings in the connecting
rods and caps. Lubricate the bearings and install the
caps on the connecting rods. Tighten the nuts to 102
N.m (75 lbf ft).

6. Install the support for the rear main bearing. Use new
seals when installing the support. Make sure the rear
surface of the support is even with the rear surface of
the crankcase. See FIGURE 24.

7. Install the new seal in the seal housing as shown in
FIGURE 25. The seal must be installed so that the lip
does not touch a groove in the crankshaft flange. Install
a new gasket with sealant. Lubricate the seal and install
the seal housing. Make sure the flange of the crankshaft
is in the center of the seal.

CAUTION

Do not damage the seal when installing the seal hous-
ing.

8. Install the flywheel housing and flywheel. Tighten
the place bolts in the flywheel 122 N.m (90 lbf ft).

9. Install the oil pump and relief valve. Install the tim-
ing gear case and timing gears. Install the crankshaft
pulley.

10. Install the oil pump screen and tube. Install the
sump.

CAMSHAFT AND CAM FOLLOWERS

Removal

The engine must be on an engine stand to remove the
camshaft and cam followers.

1. Remove the crankshaft pulley, timing case cover,
timing gears and timing case. See TIMING GEAR
CASE AND TIMING GEARS, Removal.

2. Rotate the engine so that the cylinder head is toward
the floor.

3. Remove the sump. Remove the fuel pump.

4. Remove the thrust ring for the camshaft. Remove the
camshaft.

5. Remove the cam followers as shown in FIGURE 27.

FIGURE 25. REAR OIL SEAL AND HOUSING

8131

6.4 mm
(0.250 in)

3.2 mm
(0.125 in)

16

FIGURE 26. REMOVING THE CAMSHAFT

8122

CAMSHAFT

Inspection

1. Inspect the cams of the camshaft for wear or damage.
The cam lift must be 7.62 to 7.70 mm (0.300 to 0.303
in).

2. Check the thrust surfaces for wear or damage.

3. Inspect the bearing surface for wear or damage.
Measure the bearing surfaces of the camshaft. The di-
ameter of the bearing surface next to the camshaft gear
must be 50.71 to 50.74 mm (1.9965 to 1.9975 in). The
diameter of the middle bearing surface must be 50.46
to 50.48 mm (1.9865 to 1.9875 in). The diameter of the
rear bearing surface must be 49.95 to 49.98 mm
(1.9665 to 1.9675 in). The clearance between the front
bearing surface and the bore must be 0.06 to 0.11 mm
(0.0025 to 0.0045 in). The clearance for the other two
bearing surfaces must be 0.06 to 0.14 mm (0.0025 to
0.0053 in).

4. Check the cam followers for wear or damage. The
clearance between the cam followers and the bores
must be 0.04 to 0.10 mm (0.0015 to 0.0038 in).

Assembly

1. Lubricate the cam followers with oil. Install the cam
followers in their bores.

2. Lubricate and install the camshaft. Install the sump.

FIGURE 27. REMOVING THE CAM

FOLLOWERS

9476

3. Install the thrust washer. Check that the thrust wash-
er extends beyond the front face of the cylinder block
surface by 0.66 to 0.79 mm (0.026 to 0.031 in).

4. Install the timing gear case. Check that the clearance
between the thrust washer and the camshaft is 0.10 to
0.41 mm (0.004 to 0.016 in).

5. Install the timing gears as described in TIMING
GEAR CASE AND TIMING GEARS, Installation.
Install the cover for the timing gears and the crankshaft
pulley.

6. Install the push rods and rocker arm assembly. Ad-
just the valve clearances to 0.030 mm (0.012 in) (cold).

7. Install the cover for the rocker arms.

FIGURE 28. CAMSHAFT THRUST RING

8123

CAMSHAFT THRUST RING

17

FLYWHEEL AND FLYWHEEL HOUSING

Removal

1. Remove all but two of the place bolts that hold the
flywheel to the crankshaft. Install two long studs into
the crankshaft with your fingers. Remove the two place
bolts.

2. Pull the flywheel away from the crankshaft. If the
engine has a hydraulic chain drive, remove the gear,
chain and shims as described in the HYDRAULIC
PUMP DRIVE ASSEMBLY, 1900 SRM 64. Remove
the flywheel housing and the two studs.

Repairs

1. Replace the ring gear on the flywheel as follows:

a. During removal or installation, do not heat the

gear to more than 230

°

C (450

°

F).

b. During installation, push the ring gear fully

against the shoulder of the flywheel.

2. The pilot bearing in the flywheel can be replaced.
Push out the old bearing and push in a new bearing.
Apply the force only on the outer bearing.

Installation

1. Install a new seal in the flywheel housing. If
equipped, install the flywheel housing and pump drive
assembly as described in the HYDRAULIC PUMP
DRIVE ASSEMBLY for the model of interest.

2. Install to studs into the flywheel. Slide the flywheel
on the studs. Install the place bolts and tighten the caps-
crews to 122 N.m (90 lbf ft). Remove the studs and
install the place bolts. Tighten the place bolts to 122
N.m (90 lbf ft).

STEERING PUMP DRIVE
(See FIGURE 29.)

Removal

1. Removing the steering pump (5)

2. Remove the four adapter mount nuts and the adapter
(4).

FIGURE 29. STEERING PUMP DRIVE

12099

1. IDLER GEAR
2. PUMP DRIVE GEAR
3. TIMING GEAR COVER

6. GASKET
7. GASKET
8. NUT

4. ADAPTER
5. STEERING PUMP

(REFERENCE)

1

4

5

8

2

3

6

7

18

FIGURE 30. CRANKCASE VENTILATION

12099

1. PCV VALVE
2. DRAFT TUBE

EARLY UNITS

LATER UNITS

1

2

Installation

1. Install the adapter gasket (6) and adapter 4. Tighten
the adapter mount nuts to 20 Nm (15 lbf ft).

2. If the steering pump gear (2) was removed, reinstall
the gear and tighten the nut (8) to 45 Nm (33 lbf ft).

3. Install the steering pump (5).

PCV VALVE (See FIGURE 30.)

Early units used a PCV valve for crankcase ventilation.
Later units use an open draft tube. See the Periodic
Maintenance Section for the maintenance procedures.

FUEL SYSTEM

FUEL PUMP (See Figure 31)

Removal

1. Disconnect and remove the fuel lines at the fuel
pump.

2. Remove the nuts and washers that hold the fuel
pump to the engine. Remove the fuel pump.

Disassembly

1. Clean the outside of the fuel pump. Make a mark be-
tween the flanges of the fuel pump.

2. Remove the cover on the top of the fuel pump. Re-
move the screws on the housing and separate the parts.

3. Remove the diaphragm assembly by rotating it 90

°

in either direction.

4. Remove all other parts as necessary.

Assembly

1. Install the lever and spring into the lower half of the
fuel pump body.

2. Install the spring and diaphragm. Push on the dia-
phragm and rotate it 90

°

in either direction. This action

engages the diaphragm and the lever.

3. Align the marks and assemble the housings of the
fuel pump. Tighten the screws evenly.

4. Install the cover on top of the fuel pump.

19

FIGURE 31. FUEL PUMP

8144

1

2

3

4

5

6

4. COVER
5. SPRING
6. HOUSING

1. DIAPHRAGM
2. SPRING
3. LEVER

Installation

1. Use a new gasket and install the fuel pump on the en-
gine. Tighten the capscrews to 27 N.m (20 lbf ft).
Tighten the capscrews again after the engine is hot.

2. Connect the inlet and outlet fuel lines. Remove air
from the fuel system as described in Checks and Ad-
justments.

FUEL INJECTION PUMP

Removal

1. Clean the outside of the fuel injection pump and the
fuel lines.

2. Disconnect and remove all the fuel lines to the fuel
injection pump. Remove the lines carefully. Do not
bend the fuel lines. When removing the fuel lines make
sure to disconnect the lines at each end. Put caps on the
lines that are disconnected.

3. Remove the throttle cable and the engine stop cable.

4. Remove the inspection plate for the fuel pump on the
timing case cover.

FIGURE 32. FUEL INJECTION PUMP

8465

5. Remove the fuel pump gear as described in TIMING
GEAR CASE AND TIMING GEARS, Removal.

6. Remove the nuts that hold the pump on the timing
gear case.

7. Remove the fuel injection pump.

Repairs

Repairs to the fuel injection pump cannot be made
without special tools. Any necessary repairs must be
made by a dealer.

Installation

1. Check the timing for the fuel injection pump as de-
scribed in CHECKS AND ADJUSTMENTS. Install
the fuel injection pump to the timing gear case. Tighten
the nuts.

2. Connect the throttle cable and the engine stop cable.

3. Connect all the fuel lines to the fuel injection pump.

CAUTION

Do not bend the fuel lines.

4. Remove the air from the system as described in
Checks and Adjustments.

FUEL INJECTORS

Removal

1. Clean the outside of the fuel injectors.

20

2. Disconnect and remove the fuel lines.

CAUTION

Do not bend the fuel lines

3. Remove the capscrews and brackets from the fuel in-
jectors. Remove the fuel injectors and gaskets.

Repairs

Unless special equipment is available, do not repair the
fuel injectors.

Installation

1. Clean the fuel injectors. Clean the seals for the fuel
injectors in the cylinder head. Make sure the old copper
washers are removed.

2. Install new copper washers on the fuel injectors. The
correct thickness is 2.13 mm (0.084 in). Use only one
washer for each injector. Install the injector into the
cylinder head.

3. Install the brackets for the fuel injectors. Install the
capscrews and tighten them to 16 N.m (12 lbf ft).

4. Connect the fuel lines to the fuel injectors. Tighten
the fittings on the fuel lines to 20 N.m (15 lbf ft).

5. Remove the air from the fuel system as described in
CHECKS AND ADJUSTMENTS.

COLD START AID (See FIGURE 33.)

Description

The cold start aid is used to help start a cold diesel en-
gine. A fuel line goes from the fuel filter to the cold
start aid. The heater coil installed in the intake man-
ifold heats the fuel when the control button is pushed.
The fuel burns and the hot gas is pulled into the cylin-
ders as the starter rotates the engine. The hot gas heats
the cylinders and increases the compression tempera-
ture in the cylinders. The increased temperature helps
start the cold engine.

FIGURE 33. COLD START AID

8460

1

2

3

1. IGNITER
2. SHIELD
3. HEATER COIL
4. BALL VALVE
5. VALVE SYSTEM
6. TUBULAR BODY

4

5

6

Removal

1. Disconnect the fuel line to the cold start aid. Put a
cap on the fuel line.

2. Disconnect the wire at the cold start aid.

3. Remove the cold start aid.

Installation

1. Install the cold start aid in the inlet manifold.

2. Connect the fuel line for the cold start aid. Do not
tighten the fitting. Connect the wire to the cold start
aid.

CAUTION

Do not operate the button for the cold start aid until
all the air is removed from the fuel line to the cold
start aid.

3. Remove the air from the fuel line to the cold start aid
as follows:

a. Rotate the engine until fuel flows from the fuel

line.

b. Tighten the fitting for the fuel line to the cold start

aid.

4. Start the engine and check for leaks and correct op-
eration.

21

COOLING SYSTEM

THERMOSTAT

Removal

1. Drain the cooling system.

2. Disconnect and remove the top radiator hose.

3. Remove the nuts and the washers at the thermostat
housing. Remove the housing and the thermostat.

Inspection

Put the thermostat into a container of water. Heat the
water slowly. The thermostat valve must begin to open
at 75 to 78

°

C (167 to 173

°

F). The thermostat must be

fully open at 92

°

C (198

°

F). Replace the thermostat if it

does not open according to the specifications.

Installation

1. Put the thermostat into the housing.

2. Use a new gasket and install the housing.

3. Connect the top radiator hose.

4. Fill the cooling system.

5. Run the engine and check for leaks.

WATER PUMP

Removal

1. Drain the cooling system.

2. Disconnect and remove the radiator hose at the water
pump.

3. Remove the belt.

4. Remove the water pump and the by–pass connector
as a unit.

Disassembly

1. Use a puller to remove the water pump pulley.

2. Push the shaft and impeller out of the housing.

3. Remove the snap ring for the front bearing.

4. Remove the bearings, spacers and seals.

Assembly

1. Install the felt seal,seal hosing, and seal retainer plate
into the housing. Make sure the seal retainer plate is
installed so that the center will not come in contact with
the rear bearing.

2. Lubricate the bearings and fill half the space be-
tween them with high temperature grease.

3. Push the bearings and spacer into the pump body as a
unit. Install the snap rings.

4. Push the rear seal on the end of the shaft. Install the
ceramic seal so that the face of the seal makes contact
with the carbon face.

5. Push the shaft into the pump body.

6. Push the impeller on the shaft until the clearance be-
tween the blades and the body is 0.38 to 0.64 mm
(0.015 to 0.025 in).

7. Push the pulley on the shaft making sure the shaft
does not move to the rear.

Installation

1. Apply sealant to new gaskets for the water pump and
bypass connector. Install the water pump with the by-
pass connector to the engine.

2. Tighten the nut for the water pump pulley to 82 N.m
(60 lbf ft).

3. Install the belt. Adjust the belt so that there is a 10
mm (0.375 in) movement along the longest length of
the belt.

4. Connect the coolant hose to the water pump.

5. Fill the cooling system.

6. Start the engine and check for leaks.

CHECKS AND ADJUSTMENTS

CHECKING THE INJECTORS

Injector nozzles that are damaged will cause black
smoke in the exhaust, a decrease in engine output, and
an increase in engine noise.

22

1. Start the engine and run it at half speed.

2. Loosen the fitting for the high pressure fuel line at
the injector. If the engine speed does not change, the in-
jector is damaged.

3. Use an injector tester to check the pressure at which
the nozzle operates. See FIGURE 35. The setting pres-
sure is as follows:

4.236

17.8 MPa (2575 psi)

. . . . . . . . . . . . .

4.2482 (new injector)

26.4 MPa (3822 psi)

4.2482 (previously installed

injector)

22.3 MPa (3234 psi)

. . . . . .

4. To change the pressure at which the nozzle operates,
remove cap, loosen lock nut and turn adjusting screw.

5. Check the spray pattern of the nozzle. If the spray
pattern is not correct, the needle valve is not seated cor-
rectly against the valve seat. Remove carbon deposits
or replace parts as required.

Repairs

Unless special equipment is available, do not repair the
fuel injector.

Installation

1. Clean the fuel injector. Clean the seal for the fuel in-
jector in the cylinder head. Make sure the old copper
washer is removed.

2. Install a new copper washer on the fuel injector. The
correct thickness is 0.76 mm (0.030 in). Install the in-
jector into the cylinder head.

3. Tighten the fuel injector nuts evenly to 15 N.m (12
lbf ft).

4. Connect the fuel lines to the fuel injectors. Tighten
the fittings on the high pressure fuel lines to 20 N.m (15
lbf ft).

5. Remove the air from the fuel system as described in
CHECKS AND ADJUSTMENTS.

REMOVING AIR FROM THE FUEL
SYSTEM

Air must be removed from the fuel system if the engine
has run out of fuel, or a fuel line was disconnected. Re-
move air from the fuel system as follows:

FIGURE 34. REMOVING THE AIR FROM THE

FUEL SYSTEM

8463

A

B

C

CAUTION

Do not start the engine until air is removed from the
fuel system. Do not push the button for the cold start
aid until air is removed from the fuel line to the cold
start aid.

1. Loosen vent screw A at the fuel injection pump. See
FIGURE 34.

2. Loosen vent screw B at the pump.

3. Manually operate the lever under the fuel pump. If
necessary, rotate the engine so that the fuel pump lever
inside of the engine is not on top of the camshaft lobe.
When fuel, without air bubbles, comes from each
screw, close the vent screws in the following sequence:

a. Vent screw B.

b. Vent screw A.

4. Loosen the top nut C for the fuel tube at the fuel in-
jector pump.

5. Operate the lever under the fuel pump until fuel, free
from air bubbles, comes out of the threads. Tighten the
nut.

6. Loosen the nuts for the high pressure fuel lines at
two fuel injectors.

7. Set the accelerator to the fully open position. Make
sure the engine stop cable is in the Start position. Ro-
tate the engine until fuel, without air bubbles, comes

23

out of the threads. Tighten the nuts to 20 N.m (15 lbf
ft).

8. Loosen the nut at the cold start aid. Rotate the engine
until fuel, without air bubbles, flows from the threads.
Tighten the nut.

CAUTION

Do not push the button for the cold start aid until
there is fuel at the cold start aid. The cold start aid
will be damaged if there is not fuel to cool it.

CHECKING THE TIMING MARKS

Two methods of checking the timing of the fuel injec-
tion pump are given. Method A is for fuel injection
pumps that are removed for service or replacement fuel
injection pumps. Method B is a procedure that uses a
special timing tool. This method checks the timing
mark on the fuel injection pump and timing gear case.

FIGURE 35. DEVICE FOR TESTING THE FUEL

INJECTORS

3698

There is a rotor inside the fuel injection pump that has
marks on it. A snap ring, also inside the pump, must be
set to align with one of the marks.

Method A

1. Remove the fuel injection pump from the engine.
Remove the inspection cover from the fuel injection
pump.

2. Connect the fitting on the fuel injection pump for the
number 1 cylinder (“W”) to a pump for testing fuel in-
jectors. See FIGURE 35. Add pressure until it reaches
3 MPa (440 psi).

CAUTION

Fuel pressure must be used. Do not use air pressure
and do not go above the specified pressure.

3. Rotate the fuel injection pump by hand in the direc-
tion of the arrow until it stops. Adjust the position of
the snap ring. The straight edge of the snap ring must
align with letter “C” on the rotor. Move the snap ring to
align it with the line for letter “C”. See FIGURE 36. If
the fuel
injector pump has a hydraulic governor, the correct let-
ter is “A”.

4. Install the fuel injection pump. Make sure the timing
mark on the fuel
injection pump aligns with the mark on the timing gear
case. See FIGURE 37.

FIGURE 36. TIMING OF THE FUEL INJECTION

PUMP

8464

C

24

FIGURE 37. ALIGNING THE TIMING MARKS

9477

5. Rotate the crankshaft until the number 1 piston is at
TDC on the compression stroke.

6. Remove the rocker arm cover. Remove the springs
for the number 1 inlet valve. Let the valve stop on top
of the piston.

7. Install a dial indicator to measure the movement of
the valve. Set the dial indicator to zero at TDC.

8. Turn the crankshaft in the opposite direction of nor-
mal rotation approximately one eighth of a revolution.
Rotate the crankshaft in the normal direction until the
dial indicator indicates 3.17 mm (0.125 in). This posi-
tion is the static timing position of 16

°

BTDC on the

4.2482 engine. Rotate the crankshaft on the 4.2482 en-
gine until the dial indicator indicates 5.8 mm (0.230
in). This position is 22

°

BTDC on the 4.236 engine.

9. If the timing is correct, the snap ring in the fuel injec-
tion pump and the line for the letter “C” will align. See
FIGURE 36.

10. If the timing marks in the inspection opening do not
align, loosen the nuts for the fuel injection pump. Ro-
tate the body of the fuel injection pump until the adjust-
ment is correct. Make a mark on the fuel injection
pump near the mark on timing gear case for future ref-
erence for installation.

FIGURE 38. ADAPTER FOR CHECKING

TIMING MARK ON CASE

8466

Method B

1. Repeat steps 5. to 8. as described in Method A for
timing.

2. Remove the inspection plate on the timing cover for
the fuel pump. Remove the fuel pump.

3. Install the adapter. See FIGURE 38. to the rear of the
gear for the fuel injection pump. Make sure the slot on
the adapter aligns with the dowel of the gear for the fuel
injection pump.

4. Loosen screw (1) on the timing tool. See
FIGURE 37. Remove the shaft that has splines.

5. Install the alignment bar (3) with the slot at the front
of the tool. Make sure the washer behind the screw (4)
holds the bar in position.

FIGURE 39. TIMING TOOL

8439

1

2

3

4 5

6

1. SCREW
2. SHAFT
3. ALIGNMENT BAR
4. SCREW
5. BRACKET
6. SCREW

25

6. Loosen the screw (6). Set the bracket (5) so that the
edge with the chamfer aligns with the correct mark.
The 4.2482 is 280.5

°

, 4.236 is 281

°

.

7. Install the timing tool in the position of the fuel in-
jection pump. See FIGURE 37. Make sure the timing
tool is in the seat for the fuel injection pump. Tighten
screw (1) to hold the shaft to the tool.

8. If the pointer is 180

°

from the timing mark, the en-

gine is on the wrong stroke. Remove the tool and rotate
the crankshaft one revolution.

9. Move the alignment bar so that it just touches the
face of the timing gear case.

10. Rotate the timing tool by hand in the opposite direc-
tion to pump rotation. (See the nameplate on the fuel
injection pump.) This procedure will remove the clear-
ance between the gears. Check that the timing mark on
the timing gear case aligns with the slot in the align-
ment bar.

CHECKING THE TIMING ANGLE OF THE
FUEL INJECTION PUMP WITH THE
SPECIAL TOOL

1. Remove the fuel injection pump from the engine.

2. Loosen screw (1) on the timing tool. Move the shaft
with splines to the rear. See FIGURE 36.

3. Loosen screw (4) on the timing tool. Move the slot of
the alignment bar o the rear. Make sure the washer for
the screw (4) is in position to hold the alignment bar in
position.

4. Loosen screw (6). Set the bracket so that the edge
with the chamfer aligns with the 289

°

(4.2482) or 292

°

(4.236) mark for the timing of the fuel injection pump.

5. Connect the number 1 outlet (W) of the fuel injection
pump to a pump for testing fuel injectors. Operate the
test pump until the pressure of the fuel pressure is 3.0
MPa (440 psi).

6. Install the timing tool on the drive shaft of the fuel
injection pump. Tighten screw (1) of the timing tool to
hold the shaft in position.

7. Turn the pump in the direction of normal rotation un-
til it stops. Move the alignment bar in position at the
fuel injection pump. See FIGURE 41.

8. If the marks to not align, make a new mark on the
fuel injection pump at the slot of the alignment bar.

9. Install the fuel injection pump with the new mark
aligned with the mark on the timing gear case. Install
the fuel lines.

FIGURE 40. INSTALLATION OF THE TIMING

TOOL

8467

26

FIGURE 41. TIMING TOOL INSTALLED ON

FUEL INJECTION PUMP

8151

VALVE CLEARANCE ADJUSTMENT
(See FIGURE 42.)

The correct valve clearance is 0.30 mm (0.012 in) for
both the inlet and exhaust valves when the engine is
cold. Adjust the clearance as follows:

FIGURE 42. ADJUSTING THE CLEARANCE OF

THE VALVES

8152

1. Remove the rocker arm cover. Pull engine stop cable
to the stop position.

2. Rotate the crankshaft so that the number 4 exhaust
valve is almost closed and the number 4 inlet valve is
beginning to open. Adjust the valves on the number 1
cylinder.

3. Use the same procedure as described in step 2. and
adjust the clearance of the other valves as follows:

a. When the number 2 cylinder is in position, adjust

the clearance of the valves on cylinder number 3.

b. When the number 1 cylinder is in position, adjust

the clearance of the valves on cylinder number 4.

c. When the number 3 cylinder is in position, adjust

the clearance of the valves on cylinder number 2.

4. Install the rocker arm cover.

ADJUSTING THE THROTTLE LINKAGE
(See FIGURE 43.)

1. Disconnect the throttle cable at the lever on the fuel
injection pump. Set the idle speed to 700 to 750 RPM.
Use the adjustment screw on the fuel injection pump to
set the RPM at idle.

2. Loosen the clamp to adjust the length of the cable.
The ball joint must align with the throttle lever on the
fuel injection pump. Tighten the clamp.

3. Adjust the clamp at the throttle or Monotrol pedal.
The pedal must just touch the floor plate as the throttle
lever on the pump reaches the fully open position.
Tighten the clamp when the adjustment is correct.

4. Adjust the pedal stop. The pedal and the throttle le-
ver on the injection pump must reach the full return
positions at the same time. Turn the pedal stop to adjust
the return position of the pedal.

27

FIGURE 43. ADJUSTING THE THROTTLE LINKAGE

9482

1. FUEL INJECTION PUMP
2. STOP LEVER
3. THROTTLE LEVER
4. CLAMP
5. THROTTLE PEDAL
6. MONOTROL PEDAL
7. PEDAL STOP

1

2

3

4

7

4

6

5

7

4

28

TROUBLESHOOTING

PROBLEM

POSSIBLE CAUSE

The starter rotates the engine slowly

1, 2, 3, 4

The engine will not start

5, 6, 7, 8, 9, 10, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 31, 32, 33

The engine is difficult to start

5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 24, 29, 31, 32,

33

The engine does not have enough

power

8, 9, 10, 11, 12, 13, 14, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 31, 32,

33, 58

The engine has low compression

11,19, 25, 28, 29, 31, 32, 33, 34, 45, 57

The engine uses too much fuel

11, 13, 14, 16, 18, 19, 20, 22, 23, 24, 25, 27, 28, 29, 31, 32, 33, 58

There is black exhaust smoke

11, 13, 14, 16, 18, 19, 20, 22, 24, 25, 27, 28, 29, 31, 32, 42

There is blue/white exhaust smoke

4, 16, 18, 19, 20, 25, 27, 31, 33, 34, 44

The engine has low oil pressure

4, 35, 36, 37, 38, 39, 41, 42, 43, 56

The engine has high oil pressure

4, 37, 40

The engine gets too hot

11, 13, 14, 16, 18, 19, 24, 25, 44, 49, 50, 51, 52, 53, 55

There is too much vibration

13, 14, 20, 23, 25, 26, 29, 30, 33, 44, 46, 47, 48

The engine makes too much noise

9, 14, 20, 23, 25, 26, 29, 30, 33, 44, 46, 47, 48

The engine does not run correctly

7, 8, 9, 10, 11, 12, 13, 14, 16, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28,

29, 30, 32, 33, 44, 57

The engine stops and starts

2, 11, 12

There is too much pressure inside the
sump

25, 31, 33, 34, 44, 54

List of Possible Causes for engine problems:

1. The battery is weak
2. Bad electrical connections
3. Starter is damaged
4. Wrong oil
5. Starter rotates engine slowly
6. Fuel tank is empty
7. Stop control operation is not correct
8. Fuel inlet line has a restriction
9. Fuel pump is damaged

10. Fuel filter(s) are not clean

11. Air inlet system has a restriction

12. There is air in fuel system
13. Fuel injection pump is damaged
14. Fuel injectors are damaged or are not correct type
15. Cold start aid is not used correctly
16. Cold start aid is damaged
17. The drive for the fuel injection pump has damage
18. The timing for the fuel injection pump is not correct
19. The valve timing is not correct
20. The compression is low
21. Vent for the fuel tank is not clean
22. Fuel type is not correct
23. Throttle linkage has a restriction
24. Exhaust pipe has a restriction
25. Cylinder head gasket has a leak
26. Engine runs too hot
27. Engine runs too cold
28. Valve clearance is not correct

29. Valve movement is not free
30. Fuel lines for high pressure are not correct
31. Cylinder bores have wear
32. Valves and seats have corrosion
33. Piston rings are worn or have damage
34. Valve stems and guides have wear
35. Crankshaft bearings have wear or damage
36. Not enough oil in the sump
37. Fuel gauge reading is not correct
38. Oil pump has wear
39. Relief valve for oil pressure will not close
40. Relief valve for oil pressure will not open
41. Spring for the relief valve is damaged
42. Oil suction pipe is not clean
43. Oil filter has a restriction
44. Piston does not move freely
45. Piston height is not correct
46. Fan has damage
47. Engine mounts are loose or damaged
48. Flywheel or housing is not in alignment
49. Thermostat(s) are damaged
50. Water passages have a restriction
51. Drive belts are loose or damaged
52. Radiator passages are not open
53. Water pump is damaged
54. Breather pipe has a restriction
55. Not enough coolant in the engine
56. Suction filter for the sump has a restriction
57. Valve spring(s) has damage
58. Air inlet system has leaks

29

SPECIFICATIONS

ITEM

DIMENSIONS

GENERAL

4.236

4.2482

Type

Firing Order

Capacity

Bore

Stroke

Compression Ratio

Static Timing

Piston Movement

Engine Checking Angle

Fuel Injection Pump Marking Angle

4–stroke, Direct Injection

1–3–4–2

3.86 litres (236 in

3

)

98.48 to 98.50 mm

(3.877 to 3.878 in)

127 mm (5 in)

16:1

22

°

BTDC

5.8 mm (0.230 in)

281

°

292

°

4–stroke, Direct Injection

1–3–4–2

4.06 litres (248 in

3

)

101.05 to 101.08 mm

(3.9785 to 3.9795 in)

127 mm (5 in)

18:1

16

°

BTDC

3.18 mm (0.125 in)

280.5

°

289

°

COOLING SYSTEM

Thermostat

77 to 83

°

C (170–180

°

F)

75 to 78

°

C (167 to 173

°

F)

CYLINDER HEAD

Surface Machining Maximum

Injector Extension (Maximum)

Clearance from Straight Edge

Length

Width

0.30 mm (0.012 in) 3.765 in)

4.44 mm (0.175 in)

0.15 mm (0.006 in)

0.08 mm (0.003 in)

0.30 mm (0.012 in)

4.44 mm (0.175 in)

0.15 mm (0.006 in)

0.08 mm (0.003 in)

VALVE MECHANISM

Valve Clearance

Valve Seat Angle

0.3 mm (0.012 in) Cold

45

°

0.3 mm (0.012 in) Cold

45

°

INLET VALVE

Stem Diameter

Stem to Bore Clearance

Wear Limit

Valve Head Depth Below Cylinder

Wear Limit

Length of Valve

Available Oversize Valves

9.46 to 9.48 mm

(0.3725 to 0.3735 in)

0.02 to 0.07 mm

(0.0007 to 0.0027 in

0.13 mm (0.005 in)

0.89 to 1.14 mm

(0.035 to 0.045 in)

1.55 mm (0.06 in)

122.71 to 123.11 mm

(4.831 to 4.847 in)

0.08, 0.38, 0.76 mm

(0.003, 0.015, 0.030 in)

9.46 to 9.48 mm

(0.3725 to 0.3735 in)

0.02 to 0.07 mm

(0.0007 to 0.0027 in)

0.13 mm (0.005 in)

0.89 to 1.14 mm

(0.035 to 0.045 in)

1.55 mm (0.06 in)

122.71 to 123.11 mm

(4.831 to 4.847 in)

0.08, 0.38, 0.76 mm

(0.003, 0.015, 0.030 in)

30

ITEM

DIMENSIONS

EXHAUST VALVE

4.236

4.2482

Stem Diameter

Stem to Bore Clearance

Wear Limit

Valve Head Depth Below Cylinder

Wear Limit

Length of Valve

Available Oversize Valves

9.45 to 9.47 mm

(0.372 to 0.3728 in)

0.04 to 0.08 mm

(0.0015 to 0.0031 in)

0.15mm (0.006 in)

1.07 to 1.32 mm

(0.042 to 0.052 in)

1.40 mm (0.055 in)

123.11 to 123.52 mm

(4.847 to 4.863 in)

0.08, 0.038, 0.076 mm

(0.003, 0.015, 0.030 in)

9.45 to 9.47 mm

(0.372 to 0.3728 in)

0.04 to 0.08 mm

(0.0015 to 0.0031 in)

0.15mm (0.006 in)

1.07 to 1.32 mm

(0.042 to 0.052 in)

1.40 mm (0.055 in)

123.11 to 123.52 mm

(4.847 to 4.863 in)

0.08, 0.38, 0.76 mm

(0.003, 0.015, 0.030 in)

INNER VALVE SPRINGS

Installed Length

Load at Installed Length

Installed Position

39.7 mm (1.5625 in)

68 to 69 N (15.3 to 15.5 lb)

Damper Coils to Cylinder Head

39.7 mm (1.5625 in)

68 to 69 N (15.3 to 15.5 lb)

Damper Coils to Cylinder Head

OUTER VALVE SPRINGS

Installed Length

Load at Installed Length

Installed Position

Cam Lift

45.2 mm (1.780 in)

169 to 187 N (38 to 42 lb)

Damper Coils to Cylinder Head

7.2 to 7.7mm

(0.300 to 0.303 in)

45.2 mm (1.780 in)

169 to 187 N (38 to 42 lb)

Damper Coils to Cylinder Head

7.62 to 7.70 mm

(0.300 to 0.303 in)

PISTONS

Piston Pin Bore Diameter

Ring Grove Width

Top Groove

Second Groove

Third Groove

First Oil Groove

Second Oil Groove

34.92 to 34.93 mm

(1.3748 to 1.3751 in)

2.43 to 2.46 mm

(0.0957 to 0.0967 in)

2.43 to 2.46 mm

(0.0957 to 0.0967 in)

2.43 to 2.46 mm

(0.0957 to 0.0967 in)

6.41 to 6.44 mm (0.2525 to

0.2535 in)

6.41 to 6.44 mm (0.2525 to

0.2535 in)

34.92 to 34.93 mm

(1.3748 to 1.3751 in)

2.58 to 2.60 mm

(0.1016 to 0.1024 in)

2.56 to 2.58 mm (0.1008 to

0.1016 in)

–––

5.04 to 5.06 mm (0.1986 to

0.1994 in)

–––

31

ITEM

DIMENSIONS

PISTON RINGS

4.236

4.2482

Clearance in Groove

Top Ring

Second Ring

Oil Ring

End Clearance When in Cylinder

Rings 1, 2 and 3:

0.05 to 0.10 mm

(0.0019 to 0.0039 in)

Rings 4 and 5:

0.06 to 0.11 mm

(0.0025 to 0.0045 in)

Top Ring:

0.41 to 0.86 mm (0.016–0.034 in)

All Other Rings:

0.30 to 0.76 mm

(0.012 to 0.030 in)

0.009 to 0.135 mm

(0.0035 to 0.0053 in)

0.070 to 0.115 mm

(0.0027 to 0.0045 in)

0.05 to 0.095 mm

(0.0020 to 0.0037 in)

All Rings:

0.41 to 0.66 mm

(0.016 to 0.026 in)

PISTON PINS

Outside Diameter

Clearance in Connecting Rod
Bushing

Clearance In Piston

Length

34.92 to 34.93 mm

(1.3748 to 1.3750 in)

0.02 to 0.04 mm

(0.00075 to 0.0017 in)

0.002 to 0.006 mm

(0.0001 to 0.0002 in)

83.74 to 84.12 mm

(3.297 to 3.312)

34.92 to 34.93 mm

(1.3748 to 1.3750 in)

0.01 to 0.04 mm

(0.00075 to 0.00170 in)

0.002 to 0.006 mm

(0.0001 to 0.0002 in)

83.74 to 84.12 mm

(3.297 to 3.312)

CONNECTING RODS

Piston Pin Bushing

O.D.

I.D. (Machined)

Bore for Piston Pin

Bore For Crankshaft

End Clearance on Crankshaft

Alignment of Bores

With Bushing

Without Bushing

38.99 to 39.03 mm

(1.5350 to 1.5365 in)

34.94 to 34.96 mm

(1.3756 to 1.3764 in)

38.90 to 38.92 mm

(1.5315 to 1.5322 in)

67.21 to 67.22 mm

(2.6460 to 2.6465 in)

0.21 to 0.37 mm

(0.0085 to 0.0145 in)

Parallel to 0.06 mm (0.0025 in)

Parallel to 0.25 mm (0.010 in)

38.99 to 39.03 mm

(1.5350 to 1.5365 in)

34.94 to 34.96 mm

(1.3756 to 1.3764 in)

38.90 to 38.92 mm

(1.5315 to 1.5322 in)

67.21 to 67.22 mm

(2.6460 to 2.6465 in)

0.21 to 0.37 mm

(0.0085 to 0.0145 in)

Parallel to 0.06 mm (0.0025 in)

Parallel to 0.25 mm (0.010 in)

32

ITEM

DIMENSIONS

CRANKSHAFT

4.236

4.2482

Diameter of Main Bearing Surface

Diameter of Connecting Rod
Surface

Clearance of Crankshaft to
Connecting Rod Bearings

Clearance of Crankshaft to Main
Bearings

Clearance between Thrust Bearing
and Crankshaft

Wear Limit

76.16 to 76.18 mm

(2.9984 to 2.9992 in)

63.47 to 63.49 mm

(2.4988 to 2.4996 in)

0.04 to 0.08 mm

(0.0015 to 0.0030 in)

0.06 to 0.12 mm

(0.0023 to 0.0046 in)

0.10 to 0.38 (0.004 to 0.015 in)

0.35 mm (0.14 in)

76.16 to 76.18 mm

(2.9984 to 2.9992 in)

63.47 to 63.49 mm

(2.4988 to 2.4996 in)

0.04 to 0.08 mm

(0.0015 to 0.0030 in)

0.06 to 0.12 mm

(0.0023 to 0.0046 in)

–––

0.46 mm (0.018 in)

CYLINDERS LINERS

With Flange

O.D. of Liner

I.D of Liner

Wear Limit

103.24 to 103.26 mm

(4.0645 to 4.0655 in)

98.48 to 98.50 mm

(3.877 to 3.878 in)

0.2 mm (0.008 in)

104.254 to 104.280 mm

(4.104 to 1.55 in)

101.05 to 101.08 mm

(3.9785 to 3.9795 in)

0.2 mm (0.008 in)

TORQUE SPECIFICATIONS

ITEM

TORQUE SPECIFICATION

Cylinder Head

Connecting Rod Nuts *

Main Bearings Capscrews

Camshaft Gear Capscrew

Crankshaft Capscrew

Idler Gear Capscrews

Flywheel Place Bolts

Fuel Injector Capscrews

Fuel Tube Nuts

Cold Start Aid

136 N.m (100 lbf ft)

102 N.m (75 lbf ft) Silver / 129 N.m (95 lbf ft) Black

244 N.m (180 lbf ft)

68 N.m (50 lbf ft)

406 N.m (300 lbf ft)

41 N.m (30 lbf ft)

122 N.m (90 lbf ft)

15 N.m (12 lbf ft)

20 N.m (15 lbf ft)

13 N.m (10 lbf ft)

* The silver nuts are cadmium plated.
The black nuts are phosphated.