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 castiron 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
FIGURE 1. PERKINS 4.2482 ENGINE
without a flange. Both Perkins engines made for Hyster
Company normally have a flange on the cylinder liner.
The cylinder head is castiron 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.
9494
1
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.
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-
2
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 1970s, 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
manufacturers 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.
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 linesthe 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
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.
9467
FIGURE 2. CYLINDER HEAD TIGHTENING
SEQUENCE
1
2
8105
1. OIL SUPPLY CONNECTION
2. SEAL
FIGURE 3. OIL FEED CONNECTION
4. Install the push rods in the same positions from
which they were removed. Put a new Oring 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.
3
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
4.44 mm (0.175 in) MAX
WIDTH
0.08 mm (0.003 in)
CLEARANCE STRAIGHT EDGE
FIGURE 4. CYLINDER HEAD DIMENSIONS
4
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.
0.30 mm (0.012 in) MAX
LENGTH
8102
0.15 mm (0.006 in)
CLEARANCE
 A 169 to 187 N
30
45
9481
A: 2.39 to 2.51 mm
(0.094 to 0.099 in)
FIGURE 5. VALVE SEAT ANGLES
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
(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 8106
FIGURE 7. VALVE SPRINGS
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.
5
 mm (0.005 in) the bushings must be replaced. The cor-
1 rect clearance between the rocker arm bushings and the
shaft is 0.025 to 0.075 mm (0.001 to 0.003 in).

Assembly
2
If new bushings are needed, make sure the oil holes are
aligned. Slide the oil tube fitting on the shaft. Align the
3 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.

5 OIL PUMP

Removal
1. Remove the sump. Remove the screen assembly and
inlet tube.
4 2. Remove the tube between the pump and the relief
valve.

3. Remove the crankshaft pulley, timing gear cover,

6 timing gears and timing gear case.

Disassembly
7 1. Remove the snap ring for the drive gear for the
pump. Remove the Woodruff key from the drive shaft.
1. RETAINERS 2. Remove the end plate. Remove the drive and driven
2. RETAINER CAP
3. SEAL rotors from the pump body. Remove the Oring.
4. INNER SPRING
5. OUTER SPRING Inspection (See FIGURE 11. and FIGURE 12.)
6. SPRING SEAT
7. VALVE 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 8. VALVE ASSEMBLY

ROCKER ARM SHAFT

Disassembly
8107
Remove the rocker arms from the shaft by removing
the snap rings on the ends of the shaft. Remove the 1
washers, rocker arms, springs and support brackets. 2 1. ROCKER ARM
Remove the screw from the oil tube fitting and slide the 3 2. BUSHING
fitting from the shaft. If the clearance between the 3. OIL HOLE
rocker arm bushings and the shaft is more than 0.127 FIGURE 9. ROCKER ARM

6
 7

10048

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

FIGURE 10. ARRANGEMENT OF THE ROCKER ARM SHAFT

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.
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).

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 Oring and the end plate. 9472

2. Install the Woodruff key on the shaft. Install the

drive gear with the boss toward the snap ring groove. CLEARANCE
Install the snap ring.
OUTER ROTOR HAS 4 LOBES:
3. Put the inlet tube in a container of clean engine oil. 0.025 to 0.076 mm (0.001 to 0.003 in)
Turn the drive gear until oil flows from the oil pump. OUTER ROTOR HAS 5 LOBES:
0.025 to 0.152 mm (0.001 to 0.006 in)
Installation FIGURE 11. CHECK THE CLEARANCE
BETWEEN ROTORS
1. Install the oil pump on the main bearing cap.

7
 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)
FIGURE 12. CHECK THE CLEARANCE
BETWEEN ROTOR AND BODY
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.
8
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)
FIGURE 13. CHECK END CLEARANCE OF THE
ROTORS
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.
2. Remove the capscrews that hold the cover to the tim- 6. Remove the fuel injection pump. Remove the nine
ing gear case. Remove the cover. Do not damage the oil capscrews and washers that hold the timing gear case to
seal. the crankcase. Remove the four capscrews and washers
NOTE: Each drive gear for the crankshaft, camshaft that hold the timing gear case to the sump. Remove the
and fuel injection pump has timing marks that must be timing gear case.
aligned with the idler gear so that the engine will oper- Installation
ate. See FIGURE 13. See also that each drive gear and
1. Install a new gasket and install the timing gear case
shaft has marks that must be correctly aligned during as-
on the crankcase. Make sure the thrust washer is on the
sembly.
camshaft. Install the capscrews to the crankcase and
sump.
3. Rotate the crankshaft until the timing marks on the
timing marks on the timing gears are aligned. See 2. If the crankshaft gear was removed, install it on the
FIGURE 14. Remove the nuts for the retainer for the crankshaft.
idler gear. Remove the idler gear and hub assembly.
3. Install the Woodruff key and camshaft gear with the
mark away from the engine. Install the retainer plate,
CAUTION
lock plate, lock washer and capscrew. Tighten the caps-
Do not rotate the crankshaft or camshaft when the
crew to 68 N.m (50 lbf ft). Bend the lock plate over the
idler gear is removed. You will damage the pistons
nut.
and/or the valves.
4. Install the fuel injection pump on the timing gear
4. Remove the capscrew, lock washer and lock plate for case. Make sure the mark on the fuel injector pump
the camshaft gear. Use a puller to remove the camshaft aligns with the mark on the timing gear case. Install the
gear. gear for the fuel injection pump. Install the three caps-
crews and lock washers. Make sure the mark on the
5. Remove the three capscrews for the gear for the fuel gear is toward the idler gear.
injection pump. Remove the 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
10051 ft).
6. Check the clearance between the thrust washer and
the idler gear. The correct clearance is 0.25 to 0.41 mm
1. CRANK SHAFT (0.010 to 0.016 in).
2. IDLER GEAR
3. INJECTION PUMP GEAR 7. Check the clearance between the teeth of the gears.
4. CAMSHAFT GEAR The minimum is 0.08 mm (0.003 in). There is no maxi-
5. TIMING MARKS
mum clearance, but the gears can be replaced if they
6. HYDRAULIC PUMP DRIVE
are worn and make too much noise. The maximum
FIGURE 14. TIMING GEARS clearance on new engines is 0.24 mm (0.009 in).

9
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 8455

and washer to 406 N.m (300 lbf ft).
FIGURE 16. CONNECTING ROD
PISTONS AND CONNECTING RODS
CAUTION
Removal If the cylinder liners are worn, use a ridge reamer to
cut the ridges before removing the pistons.
1. Remove the cylinder head. See Cylinder Head Re-
moval. NOTE: The 4.236 engine has five piston rings on each
piston. See FIGURE 19.
2. Drain the oil and remove the sump.
NOTE: The 4.2482 engine has three piston rings on
3. Remove the nuts for the connecting rod caps. Re- each piston. See FIGURE 20.
move the caps and bearings. Make sure the caps have a
number on them before removal. See FIGURE 16. Disassembly
Each connecting rod cap and connecting rod are a ma-
1. Remove the rings from the pistons.
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.

6.35 mm 1
(0.25 in)

8119
1. TIMING GEAR CASE 2
2. SEAL 8454
FIGURE 15. CRANKSHAFT SEAL FOR TIMING FIGURE 17. REMOVING THE PISTON AND
GEAR CASE CONNECTING ROD

10
2. Remove the snap rings from the piston. 1
3. Push out the piston pin. If necessary, heat the piston
2
in warm water 40C (120F) to remove the pin.

Inspection 3

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- 4
place the piston.

2. Check the fit of the piston pin in the connecting rod 5

6
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
7
(0.0007 to 0.0017 in). If the bushing is replaced, use a 8
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.
11
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). 9
4. Check the pistons for wear or scratches on the sides
of the pistons. Clean the carbon from the top of the pis-
12
tons. 10 10050
NOTE: The pistons for the Perkins 4.2482 are special.
Do not remove any metal from the top of the piston. 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

0.25 mm
0.25 mm 9. CONNECTING ROD BEARINGS
(0.010 in) 127 mm 127 mm (0.010 in) 10. CONNECTING ROD CAP
(5.0 in) (5.0 in) 11. BOLT
12. NUT

FIGURE 19. PISTON AND CONNECTING ROD

8136 ASSEMBLY

FIGURE 18. ALIGNMENT OF CONNECTING

ROD BORES WITH BUSHING REMOVED

11

8137
FIGURE 20. CHECKING THE CLEARANCE AT
THE ENDS OF THE PISTON RINGS
5. Check the bore for the crankshaft in the connecting
rod to make sure it is round.
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).

6. Check the clearance of the ends of the rings in the 2. Install an iron compression ring in the second and
cylinder bore. See FIGURE 20. See SPECIFI- third grooves. These rings have a step on the inside di-
CATIONS in this section for correct dimensions. ameter. This step must be towards the top of the piston.
3. Install the top compression ring. This ring normally
has a chrome finish.
1
BOTH ENGINES
2
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-
3
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.
1. TOP COMPRESSION RING
2. SECOND COMPRESSION RING Installation
8442
3. OIL RING
1. Lubricate the piston, rings and bearings with engine
FIGURE 21. PISTON RINGS (4.2482 ENGINE) oil. Install the piston in their cylinders with the letter

12
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.
TOWARD FRONT OF THE ENGINE
8135
FIGURE 22. IDENTIFICATION OF THE PISTON
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.
13
 E C D C E F

B B

A A R A R R A
R A

R R B B R R
R 9469

E E

1. CRANKSHAFT 5. OIL SEAL

2. MAIN BEARING CAP 6. CRANKSHAFT PULLEY
3. THRUST WASHER 7. THRUST RING
4. CRANKSHAFT GEAR
FIGURE 23. CRANKSHAFT SPECIFICATIONS

3. Check the surface for the rear seal on the crankshaft. Assembly
If the surface has a groove, the new seal must be
installed in a different position. The surface for the seal 1. Install the new main bearings in the crankcase and
can be machined when the surface has too many groov- main bearing caps. Lubricate all the main bearings with
es. The diameter of the flange must not be less than oil. Install and lubricate the thrust washers.
133.17 mm (5.234 in).
2. Put the crankshaft in the crankcase. Install the main
4. The surfaces for the bearings can be ground to diam- bearing caps in the correct positions. The number 1
eters that are 0.25, 0.51 or 0.76 mm (0.010, 0.020 or main bearing cap is toward the timing gears.
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-
9475
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 FIGURE 24. MAKE SURE SUPPORT IS EVEN
WITH CRANKCASE
standard thrust washers on the other side.

14
3. Install and tighten the capscrews to 44 N.m (180 lbf CAMSHAFT AND CAM FOLLOWERS
ft).
Removal

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.
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.

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.
3.2 mm
(0.125 in)
CAUTION 6.4 mm
Do not damage the seal when installing the seal hous- (0.250 in)
ing.

8. Install the flywheel housing and flywheel. Tighten

the place bolts in the flywheel 122 N.m (90 lbf ft).

8131
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. FIGURE 25. REAR OIL SEAL AND HOUSING

15
 9476

8122 FIGURE 27. REMOVING THE CAM

FOLLOWERS
CAMSHAFT

3. Install the thrust washer. Check that the thrust wash-

er extends beyond the front face of the cylinder block
FIGURE 26. REMOVING THE CAMSHAFT surface by 0.66 to 0.79 mm (0.026 to 0.031 in).

4. Install the timing gear case. Check that the clearance

Inspection between the thrust washer and the camshaft is 0.10 to
1. Inspect the cams of the camshaft for wear or damage. 0.41 mm (0.004 to 0.016 in).
The cam lift must be 7.62 to 7.70 mm (0.300 to 0.303 5. Install the timing gears as described in TIMING
in). GEAR CASE AND TIMING GEARS, Installation.
2. Check the thrust surfaces for wear or damage. Install the cover for the timing gears and the crankshaft
pulley.
3. Inspect the bearing surface for wear or damage.
Measure the bearing surfaces of the camshaft. The di- 6. Install the push rods and rocker arm assembly. Ad-
ameter of the bearing surface next to the camshaft gear just the valve clearances to 0.030 mm (0.012 in) (cold).
must be 50.71 to 50.74 mm (1.9965 to 1.9975 in). The 7. Install the cover for the rocker arms.
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 8123

1. Lubricate the cam followers with oil. Install the cam

followers in their bores. CAMSHAFT THRUST RING
2. Lubricate and install the camshaft. Install the sump. FIGURE 28. CAMSHAFT THRUST RING

16
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.
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).

Repairs STEERING PUMP DRIVE

(See FIGURE 29.)
1. Replace the ring gear on the flywheel as follows:
Removal
a. During removal or installation, do not heat the
gear to more than 230C (450F). 1. Removing the steering pump (5)
b. During installation, push the ring gear fully 2. Remove the four adapter mount nuts and the adapter
against the shoulder of the flywheel. (4).

4
5
1

3
12099

6 7

1. IDLER GEAR 4. ADAPTER 6. GASKET

2. PUMP DRIVE GEAR 5. STEERING PUMP 7. GASKET
3. TIMING GEAR COVER (REFERENCE) 8. NUT
FIGURE 29. STEERING PUMP DRIVE

17
 1 EARLY UNITS
1. PCV VALVE
2. DRAFT TUBE
FIGURE 30. CRANKCASE VENTILATION
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).
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.
18
2
LATER UNITS
12099
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.
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.
 4

6
5

3 8465
8144
FIGURE 32. FUEL INJECTION PUMP
5. Remove the fuel pump gear as described in TIMING
1. DIAPHRAGM 4. COVER GEAR CASE AND TIMING GEARS, Removal.
2. SPRING 5. SPRING
3. LEVER 6. HOUSING 6. Remove the nuts that hold the pump on the timing
FIGURE 31. FUEL PUMP gear case.
7. Remove the fuel injection pump.
Installation
Repairs
1. Use a new gasket and install the fuel pump on the en-
gine. Tighten the capscrews to 27 N.m (20 lbf ft). Repairs to the fuel injection pump cannot be made
Tighten the capscrews again after the engine is hot. without special tools. Any necessary repairs must be
made by a dealer.
2. Connect the inlet and outlet fuel lines. Remove air
from the fuel system as described in Checks and Ad- Installation
justments. 1. Check the timing for the fuel injection pump as de-
scribed in CHECKS AND ADJUSTMENTS. Install
FUEL INJECTION PUMP the fuel injection pump to the timing gear case. Tighten
the nuts.
Removal
2. Connect the throttle cable and the engine stop cable.
1. Clean the outside of the fuel injection pump and the
fuel lines. 3. Connect all the fuel lines to the fuel injection pump.

2. Disconnect and remove all the fuel lines to the fuel CAUTION
injection pump. Remove the lines carefully. Do not Do not bend the fuel lines.
bend the fuel lines. When removing the fuel lines make
4. Remove the air from the system as described in
sure to disconnect the lines at each end. Put caps on the
Checks and Adjustments.
lines that are disconnected.
3. Remove the throttle cable and the engine stop cable.
FUEL INJECTORS

4. Remove the inspection plate for the fuel pump on the Removal
timing case cover. 1. Clean the outside of the fuel injectors.

19
2. Disconnect and remove the fuel lines.
3 4
CAUTION 1 2
Do not bend the fuel lines

3. Remove the capscrews and brackets from the fuel in-

jectors. Remove the fuel injectors and gaskets.

Repairs 8460

Unless special equipment is available, do not repair the

fuel injectors. 1. IGNITER 5 6
2. SHIELD
3. HEATER COIL
Installation 4. BALL VALVE
5. VALVE SYSTEM
1. Clean the fuel injectors. Clean the seals for the fuel 6. TUBULAR BODY
injectors in the cylinder head. Make sure the old copper
FIGURE 33. COLD START AID
washers are removed.
Removal
2. Install new copper washers on the fuel injectors. The
correct thickness is 2.13 mm (0.084 in). Use only one 1. Disconnect the fuel line to the cold start aid. Put a
washer for each injector. Install the injector into the cap on the fuel line.
cylinder head. 2. Disconnect the wire at the cold start aid.

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.
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
COLD START AID (See FIGURE 33.) Do not operate the button for the cold start aid until
all the air is removed from the fuel line to the cold
Description start aid.

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.
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.

20
 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 78C (167 to 173F). The thermostat must be
fully open at 92C (198F). 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 bypass 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.
CHECKS AND ADJUSTMENTS
CHECKING THE INJECTORS
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.
Injector nozzles that are damaged will cause black
smoke in the exhaust, a decrease in engine output, and
an increase in engine noise.
21
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:
22
C
A
B
8463
FIGURE 34. REMOVING THE AIR FROM THE
FUEL SYSTEM
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
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.
3698
FIGURE 35. DEVICE FOR TESTING THE FUEL
INJECTORS
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.
8464
FIGURE 36. TIMING OF THE FUEL INJECTION
PUMP
23
 8466

FIGURE 38. ADAPTER FOR CHECKING

TIMING MARK ON CASE
9477
FIGURE 37. ALIGNING THE TIMING MARKS Method B
1. Repeat steps 5. to 8. as described in Method A for
timing.

5. Rotate the crankshaft until the number 1 piston is at 2. Remove the inspection plate on the timing cover for
TDC on the compression stroke. the fuel pump. Remove the fuel pump.

3. Install the adapter. See FIGURE 38. to the rear of the

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.
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.

8. Turn the crankshaft in the opposite direction of nor- 5. Install the alignment bar (3) with the slot at the front
mal rotation approximately one eighth of a revolution. of the tool. Make sure the washer behind the screw (4)
Rotate the crankshaft in the normal direction until the holds the bar in position.
dial indicator indicates 3.17 mm (0.125 in). This posi-
tion is the static timing position of 16 BTDC on the 3 4 5 6 1 2
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.

1. SCREW
10. If the timing marks in the inspection opening do not
2. SHAFT 8439
align, loosen the nuts for the fuel injection pump. Ro- 3. ALIGNMENT BAR
tate the body of the fuel injection pump until the adjust- 4. SCREW
ment is correct. Make a mark on the fuel injection 5. BRACKET
6. SCREW
pump near the mark on timing gear case for future ref-
erence for installation. FIGURE 39. TIMING TOOL

24
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.
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.

8. If the pointer is 180 from the timing mark, the en- 7. Turn the pump in the direction of normal rotation un-
gine is on the wrong stroke. Remove the tool and rotate til it stops. Move the alignment bar in position at the
the crankshaft one revolution. fuel injection pump. See FIGURE 41.
8. If the marks to not align, make a new mark on the
9. Move the alignment bar so that it just touches the
fuel injection pump at the slot of the alignment bar.
face of the timing gear case.
9. Install the fuel injection pump with the new mark
10. Rotate the timing tool by hand in the opposite direc- aligned with the mark on the timing gear case. Install
tion to pump rotation. (See the nameplate on the fuel the fuel lines.
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 8467

with the chamfer aligns with the 289 (4.2482) or 292 FIGURE 40. INSTALLATION OF THE TIMING
(4.236) mark for the timing of the fuel injection pump. TOOL

25
 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.
8151
c. When the number 3 cylinder is in position, adjust
FIGURE 41. TIMING TOOL INSTALLED ON the clearance of the valves on cylinder number 2.
FUEL INJECTION PUMP

4. Install the rocker arm cover.

VALVE CLEARANCE ADJUSTMENT

(See FIGURE 42.)
ADJUSTING THE THROTTLE LINKAGE
(See FIGURE 43.)
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:
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.

8152 4. Adjust the pedal stop. The pedal and the throttle le-
ver on the injection pump must reach the full return
FIGURE 42. ADJUSTING THE CLEARANCE OF
positions at the same time. Turn the pedal stop to adjust
THE VALVES
the return position of the pedal.

26
 5

2 3

4 7
1
1. FUEL INJECTION PUMP
2. STOP LEVER
3. THROTTLE LEVER
4. CLAMP
5. THROTTLE PEDAL
6. MONOTROL PEDAL
7. PEDAL STOP
4 9482

FIGURE 43. ADJUSTING THE THROTTLE LINKAGE

27

PROBLEM
The starter rotates the engine slowly
The engine will not start
The engine is difficult to start
The engine does not have enough
power
The engine has low compression
The engine uses too much fuel
There is black exhaust smoke
There is blue/white exhaust smoke
The engine has low oil pressure
The engine has high oil pressure
The engine gets too hot
There is too much vibration
The engine makes too much noise
The engine does not run correctly
The engine stops and starts
There is too much pressure inside the
sump
TROUBLESHOOTING
POSSIBLE CAUSE
1, 2, 3, 4
5, 6, 7, 8, 9, 10, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 31, 32, 33
5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 24, 29, 31, 32,
33
8, 9, 10, 11, 12, 13, 14, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 31, 32,
33, 58
11,19, 25, 28, 29, 31, 32, 33, 34, 45, 57
11, 13, 14, 16, 18, 19, 20, 22, 23, 24, 25, 27, 28, 29, 31, 32, 33, 58
11, 13, 14, 16, 18, 19, 20, 22, 24, 25, 27, 28, 29, 31, 32, 42
4, 16, 18, 19, 20, 25, 27, 31, 33, 34, 44
4, 35, 36, 37, 38, 39, 41, 42, 43, 56
4, 37, 40
11, 13, 14, 16, 18, 19, 24, 25, 44, 49, 50, 51, 52, 53, 55
13, 14, 20, 23, 25, 26, 29, 30, 33, 44, 46, 47, 48
9, 14, 20, 23, 25, 26, 29, 30, 33, 44, 46, 47, 48
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
2, 11, 12
25, 31, 33, 34, 44, 54

List of Possible Causes for engine problems: 29. Valve movement is not free
30. Fuel lines for high pressure are not correct
1. The battery is weak 31. Cylinder bores have wear
2. Bad electrical connections 32. Valves and seats have corrosion
3. Starter is damaged 33. Piston rings are worn or have damage
4. Wrong oil 34. Valve stems and guides have wear
5. Starter rotates engine slowly 35. Crankshaft bearings have wear or damage
6. Fuel tank is empty 36. Not enough oil in the sump
7. Stop control operation is not correct 37. Fuel gauge reading is not correct
8. Fuel inlet line has a restriction 38. Oil pump has wear
9. Fuel pump is damaged 39. Relief valve for oil pressure will not close
10. Fuel filter(s) are not clean 40. Relief valve for oil pressure will not open
11. Air inlet system has a restriction 41. Spring for the relief valve is damaged
12. There is air in fuel system 42. Oil suction pipe is not clean
13. Fuel injection pump is damaged 43. Oil filter has a restriction
14. Fuel injectors are damaged or are not correct type 44. Piston does not move freely
15. Cold start aid is not used correctly 45. Piston height is not correct
16. Cold start aid is damaged 46. Fan has damage
17. The drive for the fuel injection pump has damage 47. Engine mounts are loose or damaged
18. The timing for the fuel injection pump is not correct 48. Flywheel or housing is not in alignment
19. The valve timing is not correct 49. Thermostat(s) are damaged
20. The compression is low 50. Water passages have a restriction
21. Vent for the fuel tank is not clean 51. Drive belts are loose or damaged
22. Fuel type is not correct 52. Radiator passages are not open
23. Throttle linkage has a restriction 53. Water pump is damaged
24. Exhaust pipe has a restriction 54. Breather pipe has a restriction
25. Cylinder head gasket has a leak 55. Not enough coolant in the engine
26. Engine runs too hot 56. Suction filter for the sump has a restriction
27. Engine runs too cold 57. Valve spring(s) has damage
28. Valve clearance is not correct 58. Air inlet system has leaks

28
 SPECIFICATIONS
ITEM DIMENSIONS
GENERAL 4.236 4.2482
Type 4stroke, Direct Injection 4stroke, Direct Injection
Firing Order 1342 1342
Capacity 3.86 litres (236 in3) 4.06 litres (248 in3)
Bore 98.48 to 98.50 mm 101.05 to 101.08 mm
(3.877 to 3.878 in) (3.9785 to 3.9795 in)
Stroke 127 mm (5 in) 127 mm (5 in)
Compression Ratio 16:1 18:1
Static Timing 22 BTDC 16 BTDC
Piston Movement 5.8 mm (0.230 in) 3.18 mm (0.125 in)
Engine Checking Angle 281 280.5
Fuel Injection Pump Marking Angle 292 289
COOLING SYSTEM
Thermostat 77 to 83C (170180F) 75 to 78C (167 to 173F)
CYLINDER HEAD
Surface Machining Maximum 0.30 mm (0.012 in) 3.765 in) 0.30 mm (0.012 in)
Injector Extension (Maximum) 4.44 mm (0.175 in) 4.44 mm (0.175 in)
Clearance from Straight Edge
Length 0.15 mm (0.006 in) 0.15 mm (0.006 in)
Width 0.08 mm (0.003 in) 0.08 mm (0.003 in)
VALVE MECHANISM
Valve Clearance 0.3 mm (0.012 in) Cold 0.3 mm (0.012 in) Cold
Valve Seat Angle 45 45
INLET VALVE
Stem Diameter 9.46 to 9.48 mm 9.46 to 9.48 mm
(0.3725 to 0.3735 in) (0.3725 to 0.3735 in)
Stem to Bore Clearance 0.02 to 0.07 mm 0.02 to 0.07 mm
(0.0007 to 0.0027 in (0.0007 to 0.0027 in)
Wear Limit 0.13 mm (0.005 in) 0.13 mm (0.005 in)
Valve Head Depth Below Cylinder 0.89 to 1.14 mm 0.89 to 1.14 mm
(0.035 to 0.045 in) (0.035 to 0.045 in)
Wear Limit 1.55 mm (0.06 in) 1.55 mm (0.06 in)
Length of Valve 122.71 to 123.11 mm 122.71 to 123.11 mm
(4.831 to 4.847 in) (4.831 to 4.847 in)
Available Oversize Valves 0.08, 0.38, 0.76 mm 0.08, 0.38, 0.76 mm
(0.003, 0.015, 0.030 in) (0.003, 0.015, 0.030 in)

29
 ITEM
EXHAUST VALVE 4.236
Stem Diameter 9.45 to 9.47 mm
(0.372 to 0.3728 in)
Stem to Bore Clearance 0.04 to 0.08 mm
(0.0015 to 0.0031 in)
Wear Limit 0.15mm (0.006 in)
Valve Head Depth Below Cylinder 1.07 to 1.32 mm
(0.042 to 0.052 in)
Wear Limit 1.40 mm (0.055 in)
Length of Valve 123.11 to 123.52 mm
(4.847 to 4.863 in)
Available Oversize Valves 0.08, 0.038, 0.076 mm
(0.003, 0.015, 0.030 in)
INNER VALVE SPRINGS
Installed Length 39.7 mm (1.5625 in)
Load at Installed Length 68 to 69 N (15.3 to 15.5 lb)
Installed Position Damper Coils to Cylinder Head
OUTER VALVE SPRINGS
Installed Length 45.2 mm (1.780 in)
Load at Installed Length 169 to 187 N (38 to 42 lb)
Installed Position Damper Coils to Cylinder Head
Cam Lift 7.2 to 7.7mm
(0.300 to 0.303 in)
PISTONS
Piston Pin Bore Diameter 34.92 to 34.93 mm
(1.3748 to 1.3751 in)
Ring Grove Width
Top Groove 2.43 to 2.46 mm
(0.0957 to 0.0967 in)
Second Groove 2.43 to 2.46 mm
(0.0957 to 0.0967 in)
Third Groove 2.43 to 2.46 mm
(0.0957 to 0.0967 in)
First Oil Groove 6.41 to 6.44 mm (0.2525 to
0.2535 in)
Second Oil Groove 6.41 to 6.44 mm (0.2525 to
0.2535 in)
30
DIMENSIONS
4.2482
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)
39.7 mm (1.5625 in)
68 to 69 N (15.3 to 15.5 lb)
Damper Coils to Cylinder Head
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)
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)
 ITEM DIMENSIONS
PISTON RINGS 4.236
Clearance in Groove Rings 1, 2 and 3:
Top Ring 0.05 to 0.10 mm
(0.0019 to 0.0039 in)
Second Ring Rings 4 and 5:
Oil Ring 0.06 to 0.11 mm
(0.0025 to 0.0045 in)
End Clearance When in Cylinder Top Ring:
0.41 to 0.86 mm (0.0160.034 in)
All Other Rings:
0.30 to 0.76 mm
(0.012 to 0.030 in)
PISTON PINS
Outside Diameter 34.92 to 34.93 mm
(1.3748 to 1.3750 in)
Clearance in Connecting Rod 0.02 to 0.04 mm
Bushing (0.00075 to 0.0017 in)
Clearance In Piston 0.002 to 0.006 mm
(0.0001 to 0.0002 in)
Length 83.74 to 84.12 mm
(3.297 to 3.312)
CONNECTING RODS
Piston Pin Bushing
O.D. 38.99 to 39.03 mm
(1.5350 to 1.5365 in)
I.D. (Machined) 34.94 to 34.96 mm
(1.3756 to 1.3764 in)
Bore for Piston Pin 38.90 to 38.92 mm
(1.5315 to 1.5322 in)
Bore For Crankshaft 67.21 to 67.22 mm
(2.6460 to 2.6465 in)
End Clearance on Crankshaft 0.21 to 0.37 mm
(0.0085 to 0.0145 in)
Alignment of Bores
With Bushing Parallel to 0.06 mm (0.0025 in)
Without Bushing Parallel to 0.25 mm (0.010 in)
4.2482
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)
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)
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)
31
 ITEM DIMENSIONS
CRANKSHAFT 4.236 4.2482
Diameter of Main Bearing Surface 76.16 to 76.18 mm 76.16 to 76.18 mm
(2.9984 to 2.9992 in) (2.9984 to 2.9992 in)
Diameter of Connecting Rod 63.47 to 63.49 mm 63.47 to 63.49 mm
Surface (2.4988 to 2.4996 in) (2.4988 to 2.4996 in)
Clearance of Crankshaft to 0.04 to 0.08 mm 0.04 to 0.08 mm
Connecting Rod Bearings (0.0015 to 0.0030 in) (0.0015 to 0.0030 in)
Clearance of Crankshaft to Main 0.06 to 0.12 mm 0.06 to 0.12 mm
Bearings (0.0023 to 0.0046 in) (0.0023 to 0.0046 in)
Clearance between Thrust Bearing 0.10 to 0.38 (0.004 to 0.015 in)
and Crankshaft
Wear Limit 0.35 mm (0.14 in) 0.46 mm (0.018 in)
CYLINDERS LINERS
With Flange
O.D. of Liner 103.24 to 103.26 mm 104.254 to 104.280 mm
(4.0645 to 4.0655 in) (4.104 to 1.55 in)
I.D of Liner 98.48 to 98.50 mm 101.05 to 101.08 mm
(3.877 to 3.878 in) (3.9785 to 3.9795 in)
Wear Limit 0.2 mm (0.008 in) 0.2 mm (0.008 in)

TORQUE SPECIFICATIONS
ITEM TORQUE SPECIFICATION
Cylinder Head 136 N.m (100 lbf ft)
Connecting Rod Nuts * 102 N.m (75 lbf ft) Silver / 129 N.m (95 lbf ft) Black
Main Bearings Capscrews 244 N.m (180 lbf ft)
Camshaft Gear Capscrew 68 N.m (50 lbf ft)
Crankshaft Capscrew 406 N.m (300 lbf ft)
Idler Gear Capscrews 41 N.m (30 lbf ft)
Flywheel Place Bolts 122 N.m (90 lbf ft)
Fuel Injector Capscrews 15 N.m (12 lbf ft)
Fuel Tube Nuts 20 N.m (15 lbf ft)
Cold Start Aid 13 N.m (10 lbf ft)

* The silver nuts are cadmium plated.

The black nuts are phosphated.

32