Maintenance

MAZDA XA AND HA
DIESEL ENGINES
2.5L AND 3.0L DIESEL ENGINES

PART NO. 524162461 600 YRM 1019

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed
the specifications of the original equipment manufacturer.

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

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

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

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

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

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

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

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

On the lift truck, the WARNING symbol and word are on orange background.
The CAUTION symbol and word are on yellow background.
Mazda XA and HA Diesel Engines Table of Contents

TABLE OF CONTENTS

General................................................................................................................................................................ 1
Description .......................................................................................................................................................... 1
Engine Removal and Installation ......................................................................................................................... 1
Cylinder Head and Valve Mechanism Repair ...................................................................................................... 3
Remove ........................................................................................................................................................... 3
Clean............................................................................................................................................................... 3
Inspect and Repair .......................................................................................................................................... 4
Cylinder Head ............................................................................................................................................. 4
Rocker Shaft Assembly............................................................................................................................... 4
Valve Guides............................................................................................................................................... 5
Valve Seats ................................................................................................................................................. 5
Valves ......................................................................................................................................................... 6
Valve Springs .............................................................................................................................................. 6
Push Rods .................................................................................................................................................. 7
Cylinder Head, Assemble................................................................................................................................ 7
Cylinder Head, Install ...................................................................................................................................... 8
Timing Gears Repair ........................................................................................................................................... 9
Remove ........................................................................................................................................................... 9
Clean and Inspect ........................................................................................................................................... 9
Install............................................................................................................................................................... 10
Camshaft Repair.................................................................................................................................................. 11
Remove ........................................................................................................................................................... 11
Inspect and Repair .......................................................................................................................................... 11
Install............................................................................................................................................................... 12
Crankshaft and Main Bearings Repair................................................................................................................. 12
Remove ........................................................................................................................................................... 12
Inspect and Repair .......................................................................................................................................... 12
Crankshaft................................................................................................................................................... 12
Main Bearings............................................................................................................................................. 13
Install .......................................................................................................................................................... 13
Piston and Connecting Rods Repair ................................................................................................................... 14
Remove and Disassemble .............................................................................................................................. 14
Clean............................................................................................................................................................... 14
Inspect and Repair .......................................................................................................................................... 14
Pistons ........................................................................................................................................................ 14
Piston Rings................................................................................................................................................ 15
Connecting Rods and Bearings .................................................................................................................. 15
Assemble and Install ....................................................................................................................................... 16
Cylinder Block and Liners Repair ........................................................................................................................ 17
Inspect and Repair .......................................................................................................................................... 17
Lubrication System Repair .................................................................................................................................. 19
Oil Pump ......................................................................................................................................................... 19
Remove....................................................................................................................................................... 19
Disassemble ............................................................................................................................................... 19
Clean .......................................................................................................................................................... 19
Inspect ........................................................................................................................................................ 19
Assemble .................................................................................................................................................... 20
Install .......................................................................................................................................................... 21
Oil Filter Mount................................................................................................................................................ 21
Remove....................................................................................................................................................... 21
Install .......................................................................................................................................................... 21

©2011 Yale Materials Handling Corp. i

Table of Contents Mazda XA and HA Diesel Engines

TABLE OF CONTENTS (Continued)

Oil Cooler ........................................................................................................................................................ 22
Remove....................................................................................................................................................... 22
Clean and Inspect ....................................................................................................................................... 22
Install .......................................................................................................................................................... 22
Cooling System Repair........................................................................................................................................ 22
Thermostat ...................................................................................................................................................... 22
Remove and Install ..................................................................................................................................... 22
Water Pump .................................................................................................................................................... 23
Remove....................................................................................................................................................... 23
Disassemble ............................................................................................................................................... 23
Inspect ........................................................................................................................................................ 24
Assemble .................................................................................................................................................... 24
Install .......................................................................................................................................................... 25
Fuel System Repair ............................................................................................................................................. 26
Description and Operation .............................................................................................................................. 26
Fuel Injection Pump ........................................................................................................................................ 26
Remove....................................................................................................................................................... 26
Install .......................................................................................................................................................... 27
Fuel Filter ........................................................................................................................................................ 28
Filter, Replace............................................................................................................................................. 28
Water Sensor Check ................................................................................................................................... 29
Fuel System Air Removal................................................................................................................................ 29
Fuel Injectors................................................................................................................................................... 30
Remove and Disassemble .......................................................................................................................... 30
Clean and Inspect ....................................................................................................................................... 30
Assemble .................................................................................................................................................... 30
Inspect and Adjust ...................................................................................................................................... 30
Install .......................................................................................................................................................... 31
Flywheel and Ring Gear Repair .......................................................................................................................... 31
Flywheel, Remove........................................................................................................................................... 31
Ring Gear, Replace......................................................................................................................................... 31
Flywheel, Install............................................................................................................................................... 32
Flywheel, Remove........................................................................................................................................... 32
Flywheel, Install............................................................................................................................................... 32
Alternator Repair ................................................................................................................................................. 33
Starting System Repair ....................................................................................................................................... 34
Cold Start Aid.................................................................................................................................................. 34
Description and Operation .......................................................................................................................... 34
Glow Plugs, Replace................................................................................................................................... 34
Glow Plugs, Check...................................................................................................................................... 35
Fuse ............................................................................................................................................................ 35
Relay and Controller ................................................................................................................................... 35
Checks and Adjustments..................................................................................................................................... 36
Valves, Adjust.................................................................................................................................................. 36
Compression Pressure Check ........................................................................................................................ 36
Throttle Linkage, Adjust .................................................................................................................................. 37
Fuel Injection Pump Timing Check ................................................................................................................. 38
Engine Specifications .......................................................................................................................................... 39
Engine Data .................................................................................................................................................... 39
Cylinder Head ................................................................................................................................................. 39
Camshaft......................................................................................................................................................... 40

ii
Mazda XA and HA Diesel Engines Table of Contents

TABLE OF CONTENTS (Continued)

Crankshaft....................................................................................................................................................... 41
Connecting Rods............................................................................................................................................. 42
Cylinder Block ................................................................................................................................................. 43
Pistons ............................................................................................................................................................ 43
Oil Pump ......................................................................................................................................................... 43
Torque Specifications .......................................................................................................................................... 44
Special Tools ....................................................................................................................................................... 45
Troubleshooting ................................................................................................................................................... 47

This section is for the following models:

2.5L and 3.0L Diesel Engines

iii
600 YRM 1019 Engine Removal and Installation

General
The diodes and resistors in the electrical system
WARNING can be damaged if the following cautions are not
The solvent for cleaning carburetors is very followed:
flammable. Carefully follow the instructions of • Do not disconnect the battery when the engine
the manufacturer. is running. The voltage surge can damage the
diodes and resistors.
Some gaskets used in this engine can contain as-
• Do not disconnect an electric wire before the en-
bestos or other fibers. Breathing asbestos dust is a
gine is stopped and the key switch is OFF.
cancer or lung disease hazard. Do not create dust!
• Do not cause a short circuit by connection of the
Use vacuum equipment for asbestos or follow the
electric wires to the wrong terminals. Make sure
cleaning procedure described below.
a correct identification is made of the wire before
• Make sure the gasket material is wet with water or
it is connected.
oil to prevent particles in the air.
• Make sure a battery is the correct voltage and po-
• Use a hand scraper to remove old gasket material.
larity before it is connected.
Do not use a power tool or compressed air.
• Do not check for current flow by making a spark
• Discard all asbestos material in a closed con-
because the transistors can be damaged.
tainer while it is still wet.
This section contains the description and repair proce-
Put a DANGEROUS FIBERS warning label on the
dures for the Mazda XA (2.5L) and HA (3.0L) diesel en-
container. Discard dangerous fiber material safely.
gines. Disassembly, cleaning, assembly, specifications,
and troubleshooting are also included in this section.
CAUTION
Disconnect the battery cables before doing any dis-
assembly and repair to the engine or parts of the
electrical system.

Description
The Mazda 2.5L (XA) and 3.0L (HA) engines are both The crankshaft has five main bearings. The thrust bear-
four-cylinder diesel engines. The XA engine has a dis- ing for the crankshaft is at the center main bearing cap.
placement of 2522 cm 3 (153.9 in. 3 ) and the HA has a
displacement of 2977 cm 3 (181.7 in. 3 ). The firing order The pistons are aluminum alloy and have three piston
for both engines is 1-3-4-2. The number one cylinder is rings. Each of the two compression rings have a special
toward the end of the engine with the cooling fan. shape designed for its position on the piston. The third
piston ring is the oil control ring. See Figure 1.
An arrangement of timing gears is driven by the crank-
shaft. These gears operate the camshaft and the fuel
injection pump. The camshaft operates the rocker arms
that actuate the valves.

Engine Removal and Installation

The removal and installation procedures for the engines and transmission are not covered in this section. See the
Frame section for your lift truck model for these procedures.

1
Engine Removal and Installation 600 YRM 1019

NOTE: THE MAZDA HA (3.0L) ENGINE IS SHOWN HERE. THE MAZDA XA (2.5L) ENGINE IS SIMILAR.
1. VALVE COVER 8. OIL FILTER
2. CYLINDER HEAD 9. OIL PAN
3. INTAKE MANIFOLD 10. OIL PAN UPPER BLOCK
4. EXHAUST MANIFOLD 11. INJECTION PUMP
5. GLOW PLUG 12. TIMING GEAR COVER
6. INJECTION NOZZLE 13. COOLING FAN
7. FUEL FILTER 14. ALTERNATOR

Figure 1. Mazda Diesel Engine

2
600 YRM 1019 Cylinder Head and Valve Mechanism Repair

Cylinder Head and Valve Mechanism Repair

REMOVE Clean all of the parts in solvent. Make sure that all oil
passages are clean. Make sure all machined surfaces
1. Disconnect the connections at the battery. are smooth.
2. Drain the cooling system.

3. Remove the coolant hoses.

4. Remove the air cleaner. Remove the intake and

exhaust manifolds. See Figure 1.

5. Remove the fuel lines between the fuel pump and

the fuel injectors.

6. Remove the valve cover. Remove the nuts for the

rocker arm assembly. Remove the rocker arm as-
sembly. Remove the push rods.

7. Loosen the capscrews for the cylinder head slowly

and evenly in the sequence shown in Figure 2.
Carefully remove the cylinder head.

8. Use a valve spring compressor and remove the

valve retainers, springs, and valves from the cylin- A. FRONT OF ENGINE
der head. See Figure 3. Also, see the Special Tools Figure 2. Cylinder Head Removal Sequence
section.

9. If necessary, remove the combustion chamber in-

serts. Use a soft drift through the hole for the glow
plug or the fuel injector. Hit the drift with a hammer
to remove the insert and retainer.

10. Remove the rocker arms, springs, and supports

from the rocker shaft.

CLEAN

WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufacturer’s Figure 3. Valves Removal
recommended safety procedures.

3
Cylinder Head and Valve Mechanism Repair 600 YRM 1019

INSPECT AND REPAIR

Cylinder Head
Check the bottom surface of the cylinder head for dis-
tortion. Use a straight edge and a thickness gauge. Do
the measurements at the positions shown in Figure 4.
The maximum amount of distortion across the width
of the cylinder head (along lines A and B) is 0.10 mm
(0.004 in.). The maximum amount of distortion along
the length of lines C, D, E, and F is 0.25 mm (0.010 in.).
If the distortion exceeds the specifications, use a new
cylinder head.

Check the combustion chamber inserts for cracks or

damage caused by heat. Check the retainer for the
insert. If the insert or retainer is loose or damaged, 1. COMBUSTION CHAMBER INSERT
install new parts. See Figure 5. 2. RETAINER

Figure 5. Combustion Chamber Insert

Rocker Shaft Assembly

Clean the oil passages in the rocker shafts and rocker
arms. Check the clearance between the rocker arms
and the rocker shafts. Normal clearance is 0.016 to
0.061 mm (0.0006 to 0.002 in.). The maximum clear-
ance is 0.07 mm (0.0028 in.). The correct dimension
for the inside diameter of a rocker arm is 15.876 to
15.896 mm (0.625 to 0.626 in.). The correct dimension
for the outside diameter of a rocker shaft is 15.835 to
15.860 mm (0.623 to 0.624 in.). If the parts do not meet
specification, install new bushings in the rocker arm(s)
or use a new rocker shaft. Use a reamer to get the
correct inside diameter of the rocker arm bushing. See
Figure 6.

Figure 4. Cylinder Head Inspection

Figure 6. Rocker Arm Bushing Reamer

4
600 YRM 1019 Cylinder Head and Valve Mechanism Repair

Valve Guides Valve Seats

Measure the clearance between the valve stems and Inspect the condition of the valve seats. If the valve
the valve guides. See Figure 7. Use a dial indicator to seats have cracks, the cylinder head must be replaced.
measure the side-to-side movement of the valve stem If the condition of the valve seats is good, check the
in the guide. The maximum clearance is 0.127 mm contact pattern of the valve and the valve seat. Use
(0.005 in.). Replace the valve or valve guide when the a valve seat grinder to make sure the valve seats are
clearance is more than specifications. within the specifications shown in Figure 9. Use a valve
compound to make sure the valves fit the seats.

Figure 7. Valve Stem Clearance Check

If replacement is necessary, remove the valve guide(s)

using a valve guide removal tool (see the Special Tools
section). During removal, push the valve guide toward
the combustion chamber. Install a valve guide from the
top of the cylinder head. The correct height of the valve
guide above the valve spring seat is 16.5 mm (0.65 in.). A. EXHAUST VALVE B. INTAKE VALVE
See Figure 8. Figure 9. Valve Seat Specifications

A. DIMENSION A = 16.5 mm (0.65 in.).

Figure 8. Valve Guide Installation

5
Cylinder Head and Valve Mechanism Repair 600 YRM 1019

Valves Valve Springs

1. Inspect the stem of each valve for wear. Use a mi- 1. Check the valve springs for damage. See Fig-
crometer to measure the outside diameter of the ure 11. Measure the free length of the outer valve
stem. See Figure 10. The standard dimension springs. The minimum length of an inner spring
for an intake valve is 8.955 to 8.980 mm (0.352 to is 43.6 mm (1.72 in.). The minimum length of an
0.353 in.). The minimum dimension for an intake outer spring is 52.9 mm (2.08 in.).
valve is 8.884 mm (0.350 in.). The standard di-
mension for an exhaust valve is 8.935 to 8.960 mm 2. Check the valve springs for squareness. See Fig-
(0.352 to 0.353 in.). The minimum dimension for an ure 11. The maximum dimension for an inner spring
exhaust valve is 8.864 mm (0.349 in.). is 1.25 mm (0.049 in.). The maximum dimension for
an outer spring is 1.37 mm (0.054 in.). Install new
2. Inspect the valves for cracks, burned faces, and dis- valve spring(s) if they exceed these dimensions.
tortion. Inspect the seat face of the valves for wear
and damage. Measure the thickness of the valve 3. Use a valve spring tester to check the tension of
head. See Figure 10. The minimum thickness for the valve springs. At a height of 37.8 mm (1.49 in.),
all valves is 1.0 mm (0.040 in.). the correct measurement for the inner valve spring
is 12.1 to 13.3 kg (26.7 to 29.3 lb). At a height of
3. If the valves need grinding, the correct surface an- 40.3 mm (1.59 in.), the correct measurement for the
gle is 45° for intake valves and 40° for the exhaust inner valve spring is 32.4 to 34.2 kg (71.4 to 75.4 lb).
valves. The standard width for all valve seats is Use new valve springs if their tension is less than
2.0 mm (0.079 in.). specifications.

A. MEASURE HERE

Figure 11. Valve Springs Inspection

1. DIAMETER
2. THICKNESS (VALVE HEAD)

Figure 10. Valves Inspection

6
600 YRM 1019 Cylinder Head and Valve Mechanism Repair

Push Rods Use a shim of the correct thickness to obtain

dimension A.
1. Put the push rod on a flat plate as shown in Fig-
ure 12. Roll the push rod on the flat plate and check d. If dimension A is 1.50 mm (0.059 in.) or longer
the variation with a spacer gauge. If a push rod is than the standard dimension, use a new valve.
more than 0.19 mm (0.007 in.) from straight, it must If dimension A is still too long, the valve seat is
be straightened or replaced. worn.

2. Check the push rod for wear or damage. Use new 2. Install the seals on the valve guides for the intake
push rods as necessary. valves. See Special Tools section. Install the valve
spring seats. Install the inner and outer valve
springs.

3. Install the valves. Use a valve spring compressor

and install the valve, spring caps, and retainers.
See Figure 3.

4. Assemble the parts of the rocker arm assembly.

See Figure 14.

Figure 12. Push Rods Check

CYLINDER HEAD, ASSEMBLE

1. Before installing the valves in the cylinder head, do
the following:

a. Install each valve and measure the distance

from the surface of the cylinder head to the end
of the valve stem. See Figure 13. The standard
dimension is 48.05 mm (1.892 in.).

b. If the measurement is 0 to 0.50 mm (0 to

0.020 in.) longer than dimension A, the valve
can be used. 1. VALVE SPRING SEAT
2. SHIM (WASHER)
3. A DIMENSION = 48.05 mm (1.892 in.)
c. If dimension A is 0.50 to 1.50 mm (0.020 to
0.059 in.) longer than standard, use a shim Figure 13. Valve Depth Measurement
under the valve spring seat. See Figure 13.

7
Cylinder Head and Valve Mechanism Repair 600 YRM 1019

1. SNAP RING 4. SPRING 7. BUSHING

2. WASHER 5. SHAFT 8. ADJUSTMENT SCREW
3. ROCKER ARM 6. SUPPORT 9. NUT

Figure 14. Rocker Arm Assembly

CYLINDER HEAD, INSTALL

1. Clean the surface of the cylinder head and the sur-
face of the cylinder block.

2. Install a new cylinder head gasket to the block. In-

stall the cylinder head.

3. Install the push rods, making sure they are fully in-
stalled in the tappets. Lubricate the rocker arms
and shaft with engine oil, then install the rocker arm
assembly on the cylinder head.

4. Install the capscrews and washers for the cylinder

head. Tighten the capscrews in several steps to
116 to 123 N•m (86 to 91 lbf ft) in the sequence
shown in Figure 15. Tighten the nuts for the rocker
shaft supports to 116 to 123 N•m (86 to 91 lbf ft).
A. FRONT OF ENGINE

Figure 15. Cylinder Head Installation Sequence

8
600 YRM 1019 Timing Gears Repair

5. Adjust the valves. See the Checks and Adjust- 6. Use a new gasket and install the valve cover.
ments section for the valve adjustment procedures. Tighten the capscrews to 30 to 45 N•m (22 to
33 lbf ft).

Timing Gears Repair

REMOVE 5. Remove the nut, washer, and friction gear for the
fuel injection pump. See Figure 18. Use a removal
1. Remove the timing gear cover. tool to remove the timing gear. See the section
Special Tools. Remove the mounting nuts for the
2. Remove the capscrews for the thrust plate and idler
fuel injection pump, then remove the fuel injection
gear and hub. Remove the parts from the engine.
pump.
3. Use a puller and remove the crankshaft timing gear.
6. If necessary, the timing gear case can be removed
See Figure 16.
from the engine block.
4. Remove the capscrew, washer, and lock plate for
the camshaft gear. Remove the friction gear. See
Figure 17. Use a puller and remove the camshaft
timing gear.

Figure 18. Injection Pump Timing Gear Removal

CLEAN AND INSPECT

WARNING
Cleaning solvents can be flammable and toxic and
Figure 16. Crankshaft Gear Removal can cause skin irritation. When using cleaning
solvents, always follow the solvent manufacturer’s
recommended safety procedures.

Clean all of the parts in solvent. Make sure that all

oil passages are clean. Check the gears for damaged
teeth, burned surfaces, or worn surfaces. Measure the
inner diameter of the idler gear and the outer diameter
of the idler hub. The standard clearance between the
two parts is 0.034 to 0.084 mm (0.0013 to 0.0033 in.).
Maximum clearance is 0.15 mm (0.0059 in.). If the
clearance exceeds the limits, install a new bushing in
the idler gear and use a new hub.

Figure 17. Camshaft Timing Gear Removal

9
Timing Gears Repair 600 YRM 1019

INSTALL to 0.0079 in.). The maximum movement is 0.30 mm

(0.0118 in.). See Figure 21.
1. Install the timing gear case on the engine block.
6. Install a new oil seal in the timing gear cover. Install
2. Install the idler gear hub and idler gear. Install the the timing gear cover and tighten the capscrews to
thrust plate and capscrews. Tighten the capscrews 19 to 26 N•m (168 to 230 lbf in).
to 23 to 31 N•m (204 to 274 lbf in). See Figure 19.
Check the clearance between the thrust plate and
the idler gear. The correct clearance is 0.15 to
0.30 mm (0.0059 to 0.0118 in.).

1. CAMSHAFT GEAR
2. IDLER GEAR
3. INJECTION PUMP GEAR
4. CRANKSHAFT GEAR

Figure 20. Timing Gears Alignment

Figure 19. Thrust Plate Clearance Check

3. Align the timing marks and install the crankshaft

timing gear and camshaft timing gear. Install the
friction gear, lock plate, washer, and capscrew.
Tighten the capscrew for the camshaft gear to 63
to 93 N•m (46 to 69 lbf ft).

4. Install the fuel injection pump on the timing gear

case. Align the timing marks and install the timing
gear for the fuel injection pump. Install the friction
gear, washer, and nut. Tighten the nut for the gear
to 65 to 70 N•m (48 to 52 lbf ft).

5. Make sure all of the timing marks are aligned. See

Figure 20. Use a dial indicator to check the move-
ment between the idler gear and the timing gears. Figure 21. Gear Clearance Check
The standard movement is 0.10 to 0.20 mm (0.0039

10
600 YRM 1019 Camshaft Repair

Camshaft Repair
REMOVE Table 1. Camshaft Journal Diameters

NOTE: The camshaft is normally removed during dis- Camshaft Journal Diameter Limit
assembly of the engine. Use the following procedures
to remove the camshaft while the engine is assembled. No. 1 51.910 to 51.940 mm 51.902 mm
(2.0437 to 2.0449 in.) (2.0434 in.)
1. Remove the valve cover. See Figure 1. Remove the
No. 2 51.660 to 51.690 mm 51.652 mm
rocker arm assembly and the push rods. Remove
(2.0339 to 2.0350 in.) (2.0335 in.)
the fuel pump from the engine block.
No. 3 51.410 to 51.440 mm 51.402 mm
2. Remove the oil pan and the oil pump. (2.0240 to 2.0252 in.) (2.0237 in.)
3. Remove the timing gear cover. See Figure 1. No. 4 51.160 to 51.190 mm 51.152 mm
(2.0142 to 2.0154 in.) (2.0139 in.)
4. Turn the engine upside down to keep the tappets
from falling out. 3. Check the camshaft to make sure it is straight. Put
5. Remove the capscrews for the camshaft timing the front and rear journals in V blocks and rotate
gear. Remove the capscrews and thrust plate for the camshaft one complete turn. See Figure 23.
the camshaft. Pull the camshaft from the engine. The maximum amount that the dial indicator can
indicate is 0.08 mm (0.0003 in.).
INSPECT AND REPAIR 4. Measure the clearance between the camshaft
1. Check the camshaft for cracks or damage. journals and the bore in the engine block. See
Figure 24. The correct clearance between a
2. Measure the height of the camshaft lobes. The min- journal and its corresponding bore is 0.145 mm
imum height of the intake and exhaust lobes are (0.0057 in.). If any of the clearances are greater
42.478 mm (1.6724 in.). Measure the camshaft than the specifications, replace the engine block or
journals at four points; A, B, C, and D. See Fig- camshaft as necessary.
ure 22. The minimum dimensions for the journals
are shown in Table 1.

Figure 23. Camshaft Check

Figure 22. Camshaft Inspection

11
Crankshaft and Main Bearings Repair 600 YRM 1019

4. Install a new oil seal in the timing gear cover. Install

the timing gear cover and tighten the capscrews to
19 to 26 N•m (168 to 230 lbf in). See Figure 1.

5. Install the oil pump and the oil pan. Tighten cap-
screws for oil pan to 19 to 26 N•m (168 to 230 lbf in).

6. Install the push rods and the rocker arm assembly.

Adjust the valves and install the valve cover. See
Figure 1.

Figure 24. Camshaft Clearance Measurement

5. Measure the clearance between the thrust plate

and the camshaft timing gear. Install the thrust
plate and timing gear on the camshaft. Tighten the
capscrew for the timing gear to 63 to 93 N•m (46
to 69 lbf ft). See Figure 25. The correct clearance
between the thrust plate and the side of the timing
gear is 0.30 mm (0.012 in.).

INSTALL
1. Clean the journals and the areas at the block for
the journals. Lubricate the camshaft and bores with 1. SPACER GAUGE 3. CAMSHAFT
clean engine oil and install the camshaft. 2. THRUST PLATE JOURNAL

2. Install the thrust plate for the camshaft. Tighten the Figure 25. Camshaft Thrust Plate Clearance
capscrews for the thrust plate to 19 to 26 N•m (168 Measurement
to 230 lbf in).

3. Align the timing marks and install the camshaft tim-

ing gear. Tighten the capscrew for the camshaft to
63 to 93 N•m (46 to 69 lbf ft).

Crankshaft and Main Bearings Repair

REMOVE 6. Remove the crankshaft and main bearings.

1. Remove the flywheel. Remove the rear oil seal. INSPECT AND REPAIR
2. Remove the timing gear cover, timing gears, and Crankshaft
the timing gear housing.
1. Visually inspect the crankshaft for wear, cracks, or
3. Remove the oil pan and the oil pump. other damage. Replace the crankshaft if it has
NOTE: Before removing the caps for the connecting cracks.
rods and main bearings, put a mark of identification on 2. Use a micrometer to measure the diameter of the
each cap so they will be installed in the same location. journals for the crankshaft. See Figure 26. Take the
4. Remove the caps for the connecting rods. measurement at several locations for each journal.
If the measurements are less than specifications,
5. Loosen the capscrews for the main bearing caps in grind the crankshaft and install undersize bearings.
steps, then remove the capscrews and the caps. The correct dimensions for the journals are shown
in Table 2.

12
600 YRM 1019 Crankshaft and Main Bearings Repair

V blocks and rotate the crankshaft one complete

turn. The maximum amount that the dial indicator
can indicate is 0.05 mm (0.002 in.).

4. Check the passages for oil in the crankshaft. Make

sure the passages are clean and contain no restric-
tions.

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

2. Measure the clearance between the main bearings

and the crankshaft. Use a plastic gauge material as
shown in Figure 27. Tighten the capscrews for the
main bearing caps to 98 to 105 N•m (72 to 77 lbf ft).
The correct clearance is 0.059 to 0.090 mm (0.0023
to 0.0035 in.). The maximum clearance is 0.12 mm
(0.0047 in.). If the clearance is greater than the
specifications, replace the main bearings.

1. REAR OIL SEAL SURFACE

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

Figure 26. Crankshaft Inspection

1. PLASTIC GAUGE 2. SCALE
Table 2. Crankshaft Journal Diameters
Figure 27. Main Bearings Clearance Check
Engine Main Journals Wear Limit
Install
HA 75.812 to 75.825 mm 0.05 mm
(2.9847 to 2.9852 in.) (0.002 in.) 1. Clean the main bearings and the areas at the block
for the main bearings. Lubricate the parts with
XA 69.812 to 69.825 mm 0.05 mm
clean engine oil and Install the main bearings.
(2.7485 to 2.7490 in.) (0.002 in.)
Engine Rod Journals Wear Limit 2. Install the crankshaft on the bearings. Install the
main bearings in the caps and lubricate them with
HA 61.112 to 61.125 mm 0.05 mm oil. Use the identification marks and install the main
(2.4060 to 2.4065 in.) (0.002 in.) bearing caps. Make sure the arrows on the caps
XA 57.112 to 57.125 mm 0.05 mm are toward the front of the engine. Install the thrust
(2.2485 to 2.2490 in.) (0.002 in.) bearings at the center main bearing cap. Tighten
the capscrews for the main bearing caps to 98 to
3. Check the crankshaft to make sure it is straight. 105 N•m (72 to 77 lbf ft).
See Figure 26. Put the front and rear journals in

13
Piston and Connecting Rods Repair 600 YRM 1019

3. Check the clearance between the crankshaft and 7. Install the timing gear housing, timing gears, and
the thrust bearings at the center main bearing cap. the timing gear cover. Tighten capscrews for timing
See Figure 28. Move the crankshaft fully forward gear cover to 19 to 26 N•m (168 to 230 lbf in).
before making the measurement. The standard
clearance is 0.14 to 0.39 mm (0.0055 to 0.0153 in.).
Use new thrust bearings if the clearance is not cor-
rect.

4. Install the connecting rods as described in Piston

and Connecting Rods Repair.

5. Install the oil pump and oil pan. Tighten capscrews

for oil pan to 19 to 26 N•m (168 to 230 lbf in).

6. Install the rear oil seal. Tighten capscrews for rear

oil seal to 19 to 26 N•m (168 to 230 lbf in). Install
the flywheel. Tighten capscrews to 206 to 226 N•m
(168 to 230 lbf ft).
Figure 28. Thrust Bearing Clearance Check

Piston and Connecting Rods Repair

REMOVE AND DISASSEMBLE Clean all of the parts in solvent. Make sure that all oil
passages and grooves are clean. Make sure all ma-
1. Remove the cylinder head. Put a mark for identifi- chined surfaces are smooth.
cation on the top of each piston.
INSPECT AND REPAIR
2. Remove the oil pan and the oil pump.

3. Clean the carbon from the top of each cylinder bore. Pistons

NOTE: Before removing the caps and bearings from 1. Inspect the pistons for wear and cracks. Replace a
connecting rod, tag the caps and bearings so they are piston that has damage.
assembled into the correct piston assembly. 2. Measure the outside diameter of the piston as
4. Remove the caps and bearings from each connect- shown in Figure 29. The correct dimensions for the
ing rod. pistons are shown in Table 3.

5. Push the connecting rod and piston from the block.

6. Carefully remove the piston rings from the pistons.

Use a tool to push the piston pin from the connect-
ing rod.

CLEAN

WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufacturer’s
recommended safety procedures.
Figure 29. Piston Measurement

14
600 YRM 1019 Piston and Connecting Rods Repair

Table 3. Piston Diameters Connecting Rods and Bearings

Engine Diameter 1. Use a special machine to check the connecting

rods to make sure they are straight. The maxi-
HA 94.967 to 94.993 mm mum amount of distortion per 100 mm (4.0 in.) is
(3.7389 to 3.7399 in.) 0.05 mm (0.0020 in.). If the amount of distortion is
XA 88.872 to 88.898 mm greater than the specification, replace the connect-
(3.499 to 3.500 in.) ing rod.

2. Check the clearance between the rod bearings and

The maximum clearance between the piston and the journals of the crankshaft. Clean the rod bear-
the cylinder bore is 0.044 to 0.070 mm (0.0017 to ings and journals. Use a plastic gauge material as
0.0028 in.). shown in Figure 31.
Piston Rings 3. Tighten the nuts for the rod caps to 80 to 88 N•m
(59 to 65 lbf ft). The correct clearance is 0.037 to
1. Measure the end clearance of each piston ring as 0.076 mm (0.0015 to 0.0030 in.). If the clearance is
shown in Figure 30. greater than the specifications, grind the crankshaft
2. Install the piston ring into the cylinder bore where it and use undersize bearings.
will be used. Use a thickness gauge to measure the 4. Check the clearance between the piston pin and
amount of end clearance. The correct dimension the connecting rod. The maximum clearance is
for all piston rings is 1.5 mm (0.059 in.). 0.05 mm (0.002 in.). If the clearance exceeds the
3. Measure the clearance between the piston ring and limit, install a new bushing in the connecting rod.
the groove in the piston as shown in Figure 30. Make sure the oil hole in the bushing is aligned with
The correct dimension for all pistons is 0.3 mm the hole in the connecting rod. If necessary, use
(0.012 in.). a reamer to finish the bushing. The correct clear-
ance for new parts is 0.012 to 0.039 mm (0.0005 to
0.0015 in.).

1. PLASTIC GAUGE 2. SCALE

Figure 31. Connecting Rod Bearings Clearance

Check

1. PISTON RING END CLEARANCE

2. PISTON RING GROOVE CLEARANCE

Figure 30. Piston Ring Measurement

15
Piston and Connecting Rods Repair 600 YRM 1019

ASSEMBLE AND INSTALL 4. Apply clean engine oil to the bearing, then install
the cap to the correct connecting rod. During in-
1. Use the identification marks and align the piston stallation of the caps, make sure to align the identi-
with the connecting rod. See Figure 32. Lubricate fication marks that were made during disassembly.
the piston pin and bore in the piston with engine oil. See Figure 34. Tighten the nuts for the caps to 80
Install the piston pin and snap rings in the piston. to 88 N•m (59 to 65 lbf ft).
See the Special Tools section for the piston pin in-
stallation tool. After installation, check that the pis-
ton moves freely on the piston pin.

A. FRONT
1. TOP RING
2. SECOND RING
3. OIL RING
4. OIL RING EXPANDER
A. FRONT
Figure 33. Piston Rings
1. COMBUSTION CHAMBER
2. NOTCH

Figure 32. Connecting Rod and Piston

2. Install the piston rings on the pistons. During in-

stallation, the marks on each piston ring must be
toward the top of the piston. Check that the rings
rotate freely, then put the ends of the rings in the po-
sitions as shown in Figure 33. Lubricate the rings
with engine oil.

3. Apply clean engine oil to the piston assembly. In-

stall the bearings for the connecting rods. Install
the piston into the correct cylinder, making sure the
front of the piston is toward the front of the engine.
See Figure 32. 1. F MARK

Figure 34. Piston Installation

16
600 YRM 1019 Cylinder Block and Liners Repair

Cylinder Block and Liners Repair

INSPECT AND REPAIR
1. After the engine block is cleaned, check the sur-
face for distortion. See Figure 35. The maximum
amount of distortion along lines A and B is 0.10 mm
(0.0039 in.). The maximum amount of distortion
along lines C, D, E, and F is 0.25 mm (0.0098 in.).
If the distortion exceeds the limits, have the block
machined or use a new one.

2. Check the cylinder liners for wear and damage.

Measure each liner at three positions and in two
different directions. See Figure 36. If the differ-
ence between the maximum measurement and the
minimum measurement of a liner exceeds 0.20 mm
(0.0079 in.), use a new liner.
Figure 36. Cylinder Liners Measurement
The correct dimension for a standard liner is shown in
Table 4. 3. Remove and install the cylinder liners as follows:
Table 4. Cylinder Liner Diameters a. Use a press and a removal tool to push the lin-
ers from the cylinder block. See Figure 37. If a
Engine Type Diameter liner is difficult to remove, use a boring machine
HA 95.025 to 95.050 mm to reduce the thickness of the liner. Decreasing
(3.7411 to 3.7421 in.) the thickness of the liner will reduce the tension
of the liner in the block.
XA 88.925 to 88.950 mm
(3.5010 to 3.5020 in.) b. After the liner is removed, check the inner sur-
face of the block for damage. Remove any
marks with a fine abrasive paper. Be careful
not to increase the size of the bore.

c. Use a press and an installation tool to install

a liner in the cylinder block (see the Special
Tools section). Lubricate the inner surface of
the block and the outer surface of the liner with
engine oil. Install the liner in the block. The
pressure required to install a liner is approxi-
mately 1000 to 3000 kg (2200 to 6600 lb). Af-
ter installation, check that the liner is even with
or below the surface of the cylinder block by
0.101 mm (0.004 in.). See Figure 38.

Figure 35. Cylinder Block Inspection

17
Cylinder Block and Liners Repair 600 YRM 1019

4. Check the tappets as follows:

a. Check the clearance between the tappet and

the bore in the block. The difference be-
tween the two measurements must not exceed
0.10 mm (0.0039 in.). See Figure 39.

1. REMOVAL TOOL 2. PRESS

Figure 37. Cylinder Liners Removal

Figure 39. Tappets Measurement

1. PRESS
2. INSTALLATION TOOL
3. LINER
4. BLOCK

Figure 38. Cylinder Liners Installation

18
600 YRM 1019 Lubrication System Repair

Lubrication System Repair

Before removing the oil pump, check the oil pressure. 3. Use a press to remove the gear from the shaft. Re-
Replace the sending unit with a gauge. Run the en- move the rotors from the pump housing.
gine until it is at operating temperature. The minimum
oil pressure at 2000 rpm is 250 kPa (36 psi). If the pres- 4. Remove the relief valve from the pump cover.
sure is less than the specification, the oil pump or the
engine bearings need repair. See Figure 40. Clean

WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufacturer’s
recommended safety procedures.

Clean all of the parts in solvent. Make sure all machined

surfaces are smooth.

Inspect
1. Check the pump housing and the pump cover for
wear or damage. Check the relief valve spring for
damage.

2. Measure the parts of the oil pump as follows:

a. Measure the clearance between the inner and

outer rotors. See Figure 41. The correct clear-
ance is 0.30 mm (0.012 in.). Use new rotors if
the clearance is more than specifications.

b. Measure the clearance between the outer ro-

tor and the housing. The correct clearance is
0.30 mm (0.012 in.). Use a new rotor and/or
housing if the clearance is more than specifica-
1. OIL PUMP 4. LOWER OIL PAN tions. See Figure 42.
2. GASKET 5. OIL JET
3. UPPER OIL PAN

Figure 40. Lubrication System

OIL PUMP
Remove
1. Remove the oil pan.

2. Remove the oil pump and the oil pipe from the en-
gine.

Disassemble
1. Remove the oil strainer from the pump cover.

2. Remove the screws and the pump cover. Remove Figure 41. Clearance Check Between the Rotors
the cover and the outer rotor.

19
Lubrication System Repair 600 YRM 1019

Figure 44. Shaft Clearance Measurement

Figure 42. Clearance Check Between the Rotor
and Housing e. Measure the free length of the relief spring. The
correct length is 40 mm (1.57 in.). Install a new
c. Use a straight edge on the housing and mea- spring if the length is less than the specifica-
sure the side clearance of the rotors. See tions.
Figure 43. The correct clearance is 0.15 mm
(0.006 in.). If the clearance exceeds the limits, Assemble
use a new pump.
1. Lubricate the parts with clean engine oil. Install
the shaft and outer rotor in the housing. Install the
drive gear on the shaft. See Figure 45. Make sure
the marks on the rotors are toward the pump cover.
Install the cover and tighten the capscrews to 8 to
12 N•m (71 to 106 lbf in). See Figure 46.

2. Install the relief valve in the cover. See Figure 46.

Figure 43. Gears Clearance Measurement

d. Use a dial indicator to measure the clearance

between the pump housing and the shaft. The
maximum clearance for the shaft is 0.10 mm
(0.0039 in.). See Figure 44.
Figure 45. Assembly Marks on Rotors

20
600 YRM 1019 Lubrication System Repair

OIL FILTER MOUNT

Remove
1. Drain cooling system so the engine block is empty
of coolant. There is a drain plug for the block next
to the oil filter mount.

2. Remove oil filter from housing. See Figure 47. Re-

move housing from block.

Install
1. Install a new gasket. Install housing on engine
block. See Figure 47.

2. Install oil filter.

WARNING
DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator cap is
removed, the pressure is released from the system.
If the system is hot, the steam and boiling coolant
can cause burns.

3. Operate engine and check for leaks. Check coolant

for signs of engine oil.

1. DRIVE GEAR 7. GASKET

2. HOUSING 8. SUPPLY TUBE
3. SHAFT 9. RELIEF VALVE
4. INNER ROTOR ASSEMBLY
5. OUTER ROTOR 10. SUCTION TUBE
6. COVER 11. STRAINER

Figure 46. Oil Pump Assembly

Install
1. Install the oil pump in the block, making sure the
drive gear engages with the camshaft. See Fig-
ure 40.

2. Connect the supply tube and gaskets between the

oil pump and block. Install the suction tube and 1. GASKET 4. PLUG
strainer. 2. HOUSING 5. SCREW
3. OIL FILTER
3. Install the gasket and bottom oil pan. Tighten the
Figure 47. Oil Filter Mount
capscrews to 19 to 26 N•m (168 to 230 lbf in).

21
Cooling System Repair 600 YRM 1019

OIL COOLER
Remove
NOTE: The oil cooler is used on the HA engine only.
See Figure 48.

1. Drain the cooling system so the engine block is

empty of coolant. There is a drain plug for the block
next to the oil cooler housing.

2. Remove the oil filter from the housing. Remove the

housing from the block.

Clean and Inspect

Check the oil cooler for restrictions or leaks. Check the
parts of the relief valves for damage. Check the housing
for cracks or damaged surfaces.

Install
1. OIL COOLER
1. Using new O-rings, install the oil cooler to the hous- 2. HOUSING
ing. See Figure 48. 3. O-RING
4. RELIEF VALVE ASSEMBLY
2. Install the relief valve assemblies in the housing. 5. RELIEF VALVE ASSEMBLY (HA ENGINE ONLY)
6. PLUG
3. Use a new gasket and install the housing on the
Figure 48. Oil Cooler
engine block.

4. Install the oil filter. Operate the engine and check

for leaks. Check the coolant for signs of engine oil.

Cooling System Repair

THERMOSTAT 3. Test the operation of the thermostat. The thermo-
stat must begin to open at 82 ±1.5°C (180 ±3°F).
NOTE: This section covers the removal and installation The thermostat must be completely open at 95°C
of the thermostat and the removal, disassembly, inspec- (203°F).
tion, assembly, and installation of the water pump. For
a description of how these parts operate, see the sec- 4. Install the thermostat and new gasket. Install the
tion Cooling System 700 YRM 626. thermostat housing and tighten the capscrews.

Remove and Install 5. Connect the hose and fill the cooling system. Start
the engine and check for leaks.
1. Drain the cooling system to the level of the thermo-
stat.

2. Disconnect the hose and remove the thermostat

housing. Remove the thermostat. See Figure 49.

22
600 YRM 1019 Cooling System Repair

1. PULLEY HUB 8. GASKET

2. SNAP RING 9. WATER SEAL
3. OUTER BEARING 10. SEAL PLATE
4. SHAFT AND 11. IMPELLER
SPACER 12. PUMP BODY
5. INNER SEAL 13. WATER PIPE
6. DUST SEAL
7. IMPELLER
HOUSING

Figure 50. Water Pump Parts

Disassemble
1. HOUSING
2. GASKET 1. Use a press to remove the hub for the pulley from
3. THERMOSTAT the shaft. See Figure 51.
4. THERMOSTAT HOUSING
5. CYLINDER HEAD 2. Remove the snap ring from the opening of the im-
6. WATER PUMP peller housing.
7. PULLEY

Figure 49. Cooling System Parts

WATER PUMP
Remove
1. Drain the cooling system.

2. Loosen the alternator and remove the fan belt.

3. Remove the capscrews for the fan. Remove the fan

and pulley from the hub.

4. Disconnect the hose at the water pump. Remove

the capscrews for the water pump, then remove the
water pump from the cylinder block. See Figure 50.

Figure 51. Hub for Pulley Removal

23
Cooling System Repair 600 YRM 1019

3. Use a press and a support block to remove the Use a new impeller if it does not have a tight fit with the
bearings and shaft from the impeller housing. See water seal.
the Special Tools section and Figure 52.

Figure 54. Bearings Removal

Assemble
Figure 52. Shaft and Bearing Removal 1. Install the inner snap ring on the shaft. Install the
inner bearing, spacer, outer bearing, and dust seal
4. Remove the water seal assembly from the impeller on the shaft. Lubricate the bearings with multipur-
housing. See Figure 53. pose grease. Fill the area between the bearings
approximately 1/3 full with grease. See Figure 55.
Use a press to install the bearings and shaft in the
housing.

Figure 53. Water Seal Removal

5. Use a press to remove the bearings from the shaft.

See Figure 54. Figure 55. Bearings Installation

Inspect 2. Install the snap ring in the end of the housing. See
Figure 56. Use a press to install the pulley hub on
Inspect all parts of the water pump for cracks, corrosion, the shaft. Check that the movement of the shaft is
or damaged surfaces. smooth and quiet.

24
600 YRM 1019 Cooling System Repair

5. Use a new gasket and install the impeller housing

onto the pump body.

Figure 56. Pulley Hub Installation

3. Install the water seal in the housing. Make sure Figure 58. Bearings Installation
the seal is not tilted or damaged during installation.
After installation, check that the seal moves freely Install
by pushing on it with your finger. See Figure 57.
1. Install the water pump with a new gasket. Tighten
the capscrews to 19 to 26 N•m (168 to 230 lbf in).

2. Install the coolant hoses.

3. Install the pulley on the hub. Install the drive belt,

then install the fan on the pulley. Tighten capscrews
for fan to 19 to 26 N•m (168 to 230 lbf in). See
Figure 50.

4. Fill the coolant system with coolant.

WARNING
DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator cap is
removed, the pressure is released from the system.
If the system is hot, the steam and boiling coolant
can cause burns.
Figure 57. Bearings Installation
5. Start the engine and check the cooling system for
4. Use a press to install the impeller. Make sure the leaks.
impeller is even with the end of the shaft. See Fig-
ure 58.

25
Fuel System Repair 600 YRM 1019

Fuel System Repair

DESCRIPTION AND OPERATION A control sleeve slides on the plunger and partially
opens a passage in the plunger to control the amount
NOTE: Special tools and training are needed to repair of fuel sent to the fuel injectors. This control sleeve is
the fuel injection pump. A fuel injection pump is nor- controlled by both the control lever and the mechanical
mally sent to an authorized repair station if repairs are governor. The control lever is connected to the accel-
necessary. Fuel injectors also require special equip- erator pedal for the lift truck.
ment and training for repair. Most users have a special
repair service do this work. The repair of the fuel in- FUEL INJECTION PUMP
jection pump and fuel injectors is not described in
this section. Remove
The parts of the fuel system include the fuel tank, in- 1. Disconnect the battery cables at the battery.
jection pump and governor, fuel filters, and injectors. A
basic diagram of the fuel system with the fuel injection 2. Remove clamps as necessary so that the fuel lines
pump is shown in Figure 59. are not bent. Remove the fuel line between the fuel
filter and the fuel injection pump.
A solenoid valve, installed on the injection pump, per-
mits the engine to be stopped quickly when the key 3. Remove the fuel lines from the fuel injection pump
switch is turned to OFF. The solenoid valve is controlled and the fuel injectors that returns fuel to the fuel
by the ignition switch. When the key switch is turned to tank.
ON, the coil in the solenoid valve is energized. The so-
lenoid valve opens to permit fuel to flow into the pres- 4. Disconnect the throttle cable from the control lever
sure chamber for the plunger. When the key switch is on the fuel injection pump
turned to OFF, the solenoid valve closes and stops the 5. Remove the access cover for the injection pump
flow of fuel. gear from the timing cover. Rotate the engine until
The drive shaft is turned by the gear train in the engine. the key slot in the injection pump shaft is in the
The fuel pump is a rotary vane pump that pulls fuel from top position. Put alignment marks on the injection
the fuel tank through the fuel filter/water separator. The pump and the timing gear housing. See Figure 60.
pressure of the fuel from the fuel pump increases as the
speed of the drive shaft increases. The regulator valve CAUTION
controls the pressure of the fuel oil to the specifications Do not rotate the engine or move the timing gears
set by the manufacturer. The fuel flows into the inlet while the injection pump is removed.
for the distributor head to the pressure chamber for the
plunger. The cam disk rotates the plunger and moves 6. Remove the nut and washer from the injection
the plunger in and out of the plunger barrel. The plunger pump shaft. Do not let the washer and nut drop
increases the pressure of the fuel oil. The rotation of into the timing case. Remove the friction gear. See
the plunger aligns the passages with the ports in the Figure 61. Use a puller to loosen the gear from the
distributor head. Each port in the distributor head has shaft.
a fuel line connected to a fuel injector. The fuel flows to
the fuel injector. 7. Remove the nuts that hold the fuel injection pump
to the timing gear housing. Move the fuel injec-
The overflow valve in the injection pump is a bypass tion pump away from the timing gear housing so
valve that permits some fuel to return to the fuel tank. the drive gear is disengaged from the timing gears.
The overflow valve keeps the fuel at a constant pres- Make sure the key does not fall from the pump shaft.
sure in the plunger chamber so the fuel flow to the fuel
injectors is even.

26
600 YRM 1019 Fuel System Repair

1. FUEL INJECTOR 6. SHAFT FOR GEAR, FUEL INJECTION PUMP

2. PLUNGER 7. FUEL FILTER/WATER SEPARATOR
3. FUEL TANK 8. OVERFLOW VALVE
4. FUEL PUMP (VIEW ROTATED FOR CLARITY) 9. SOLENOID VALVE
5. REGULATOR VALVE 10. CONTROL LEVER

Figure 59. Mazda Diesel Fuel System and Fuel Injection Pump

Install 3. Install the access cover and gasket on the timing

cover. Check the timing of the fuel injection pump.
NOTE: The timing gears must be correctly aligned and
installed in the engine before the fuel injection pump is 4. Install the fuel lines at the fuel injection pump and
installed. the fuel injectors.

1. Put the key in the pump shaft. Make sure the key is 5. Install the clamps as necessary so the fuel lines are
in the top position, then install the injection pump. not bent. Install the fuel line between the fuel filter
Make sure the shaft and key engage with the timing and the fuel injection pump.
gear.
6. Connect the throttle cable to the control lever on the
2. Install the nuts that fasten the fuel injection pump fuel injection pump.
to the timing gear housing. Align the marks and
tighten the nuts. Install the friction gear, washer, 7. Remove the air from the fuel system before starting
and nut on the pump shaft. Tighten the nut for the the engine.
injection pump gear to 65 to 70 N•m (48 to 52 lbf ft).

27
Fuel System Repair 600 YRM 1019

1. DISTRIBUTOR HEAD 6. CAM DISK 11. FLY WEIGHT

2. PLUNGER 7. ROLLER HOLDER 12. ADJUSTMENT SCREW, FULL
3. DELIVERY VALVE 8. SHAFT LOAD
4. PLUNGER SPRING 9. FLY WEIGHT 13. GOVERNOR LEVER
5. TIMER 10. CONTROL LEVER 14. SOLENOID VALVE

Figure 60. Fuel Injection Pump

FUEL FILTER
NOTE: There is a water separator in the bottom of the
fuel filter. A sensor in the bottom of the fuel filter illumi-
nates an indicator light on the instrument panel if there
is water in the water separator.

Filter, Replace
1. Disconnect the two sensor wires from the bottom of
the fuel filter. Drain the fuel from the filter. Remove
the parts that include the sensor from the bottom of
the fuel filter. Remove the filter. See Figure 62.

2. Lubricate the filter seal with diesel fuel and install

the new filter. Tighten the filter by hand.
Figure 61. Injection Pump Timing Gear Removal

28
600 YRM 1019 Fuel System Repair

Figure 63. Water Sensor Test

FUEL SYSTEM AIR REMOVAL

NOTE: The fuel injection pump will normally remove
small amounts of air from the fuel system when the en-
gine is started. If the fuel pump, fuel injection pump, or
the fuel filter is empty, it is necessary to remove air from
1. HAND PUMP 7. CAP the system as follows:
2. HOUSING 8. SENSOR AND
3. VENT SCREW FLOAT 1. Loosen the vent screw on the fuel filter housing.
4. INLET (FROM 9. O-RING Use the hand pump to pump fuel from the vent until
FUEL TANK) 10. WIRE there are no air bubbles in the fuel. Hold down
5. OUTLET (TO CONNECTOR on the hand pump and close the vent screw. See
INJECTION PUMP) 11. DRAIN VALVE AND
6. FUEL FILTER HOSE Figure 62.

Figure 62. Fuel Filter With Water Separator 2. Loosen the fitting for the return line on the injection
pump. Operate the hand pump until there is fuel at
3. Use a new O-ring between the fuel filter and the the injection pump. Rotate the engine until the fuel
cap. Lubricate the O-ring with diesel fuel during at the fitting is free of air bubbles. Tighten the fitting.
installation. Install the parts that include the sensor
in the new fuel filter. See Figure 62. 3. Loosen the supply line at each fuel injector. Rotate
the engine until the fuel at the fittings is free of air
4. Start the engine and check for leaks. bubbles. Tighten the fittings.

Water Sensor Check 4. Start the engine and check for leaks.

Check the operation of the water sensor for the fuel filter 5. Tighten the mounting nuts for the injection pump.
as follows: Repeat the timing procedure to make sure the tim-
1. Drain the fuel from the filter. Disconnect the wires at ing is correct.
the sensor. Remove the sensor and float assembly
6. Remove the dial indicator and install the capscrew
from the fuel filter. See Figure 62.
in the distributor head. Connect the fuel lines to the
2. Connect a continuity tester between the two wires
injection pump.
for the sensor. Lift on the float. There is continuity
when the float is raised. There is no continuity when 7. Remove the air from the fuel system.
the float is lowered. See Figure 63.

29
Fuel System Repair 600 YRM 1019

FUEL INJECTORS width of 4 degrees. If the spray pattern is not cor-

rect, clean or replace nozzle as necessary.
NOTE: The inspection and repair of fuel injectors re-
quire special tools and training. Many users have a
special repair service make repairs on fuel injectors. WARNING
Fuel injector nozzles that have damage or are dirty will Make sure that the nozzle of the injector is away
cause black smoke in the exhaust, a decrease in engine from the operator during a test. Fuel can be injected
power, and an increase in engine noise. into your body by the hydraulic pressure.

The engine will run roughly if a fuel injector is damaged 3. Use an injector tester to check the starting pressure
or dirty. To find which fuel injector has a problem, oper- at which the nozzle operates. The correct starting
ate the engine at approximately 1000 rpm. Loosen and pressure is 13.4 to 13.9 MPa (1940 to 2000 psi).
tighten the connection to the inlet of each fuel injector
in a sequence. When the connection to the fuel injector 4. To change the pressure at which the nozzle oper-
with a problem is loosened, there will not be a change ates, add or subtract shims. See Figure 64.
in the engine speed. Shims are available in ten different sizes for the HA
engine and nine different sizes for the XA engine.
Remove and Disassemble Each increase of 0.05 mm (0.002 in.) in shim thick-
ness will add approximately 0.49 MPa (70 psi) to
WARNING the starting pressure.
Do not put your hands on fuel lines under pressure.
Fuel can be injected into your body by the hydraulic
pressure.

1. Disconnect the fuel lines at the fuel injectors. Do

not bend the fuel lines.

2. Remove the nozzle holder. Remove the remaining

parts of the fuel injector. See Figure 64.

Clean and Inspect

Carefully clean the parts of the fuel injector in clean
diesel fuel. Check the sliding surfaces for wear or dam-
age. Replace any damaged parts.

Assemble
1. Assemble the parts in the body of the injector in
correct sequence. See Figure 64.

2. On the HA engine, tighten the nozzle holder to 80 to

100 N•m (59 to 74 lbf ft). On the XA engine, tighten
the nozzle holder to 60 to 80 N•m (44 to 59 lbf ft).

Inspect and Adjust

1. The operation of the fuel injectors must be checked
with an injection tester. See Figure 65. When do- 1. RETAINING NUT 5. PRESSURE PIN
ing the test, use diesel fuel at approximately 20°C 2. NOZZLE HOLDER 6. SPACER
3. ADJUSTMENT 7. NOZZLE
(68°F). SHIM 8. BODY
4. SPRING
2. Check the spray pattern of the nozzle. See Fig-
ure 65. The fuel should spray straight down at a Figure 64. Fuel Injector

30
600 YRM 1019 Flywheel and Ring Gear Repair

Legend for Figure 65

1. INJECTOR TESTER
2. FUEL INJECTOR (CORRECT PATTERN)
3. PATTERN NOT CORRECT

Install
1. Install the complete fuel injectors in the cylinder
head.

2. Install and connect the fuel lines to the injectors.

Install the line clamps if they were removed.

3. Remove the air from the fuel system. See Fuel

System Air Removal.

4. When the engine can be operated, check for fuel

leaks.

Figure 65. Fuel Injectors Check

Flywheel and Ring Gear Repair

FLYWHEEL, REMOVE RING GEAR, REPLACE
NOTE: The procedures to remove and install the fly-
wheel and replace the ring gear that follow, apply only WARNING
to model GDP2.00-3.00RF/TF (GDP040-060RF/TF). Wear eye protection for this operation to prevent
eye injury from metal chips. You will be using a
1. Remove the capscrews for the flywheel, then re- hammer and chisel to break the ring gear.
move the flywheel and the drive plate.
Before the ring gear is removed, check the position of
2. If necessary, remove the flywheel housing. the chamfer on the teeth.

1. Use a hammer and chisel to break the ring gear.

Make sure that you do not damage the flywheel.
See Figure 66.

31
Flywheel and Ring Gear Repair 600 YRM 1019

Legend for Figure 67

A. TIGHTENING SEQUENCE
1. COVER PLATE 4. DRIVE PLATE
2. FLYWHEEL 5. SUPPORT PLATE
HOUSING 6. CAPSCREW
3. FLYWHEEL

FLYWHEEL, INSTALL
1. If the flywheel housing was removed, install it on
the engine. Tighten the M14 capscrews to 114 to
136 N•m (84 to 100 lbf ft). Tighten the M10 cap-
screws to 41 to 49 N•m (30 to 36 lbf ft). Tighten the
Figure 66. Ring Gear, Remove nuts for the starter to 64 to 89 N•m (47 to 66 lbf ft).
2. The ring gear must be heated before it can be in- 2. Install the flywheel on the crankshaft. Install the
stalled on the flywheel. Make sure that the ring gear drive plate and support plate. Apply an adhesive
is not heated to more than 200°C (390°F). sealant on the threads of the capscrews. then in-
stall the capscrews for the flywheel. Tighten the
WARNING capscrews to 206 to 225 N•m (152 to 166 lbf ft) as
Be careful of hot parts. Wear protective clothing shown in the sequence in Figure 67.
and gloves to prevent burns.
FLYWHEEL, REMOVE
3. Install the ring gear on the flywheel. Make sure that
the chamfer on the teeth is in the correct direction NOTE: The procedures to remove and install the fly-
toward the starter. wheel that follow, apply only to model GDP16-20AF
(GDP030-040AF).

1. Remove the capscrews for the flywheel, then re-

move the flywheel and the flange.

2. If necessary, remove the adapter plate.

FLYWHEEL, INSTALL
1. If the adapter plate for the torque converter housing
was removed, install it on the engine. Tighten the
capscrews to 43 to 51 N•m (32 to 38 lbf ft). See
Figure 68.

2. Install the flange and flywheel on the crankshaft.

Apply a thread-locking adhesive on the threads of
the capscrews, then install the capscrews and lock-
washers. Tighten the capscrews to 206 to 225 N•m
(152 to 166 lbf ft). See Figure 68.

Figure 67. Flywheel Arrangement

32
600 YRM 1019 Alternator Repair

1. FLANGE 4. TORQUE CONVERTER

2. FLYWHEEL 5. ACCESS COVER
3. DRIVE PLATE 6. TORQUE CONVERTER HOUSING

Figure 68. Flywheel and Torque Converter

Alternator Repair
Repair service information for the alternator can be found in the service manual Electrical System, Mazda XA and
HA Diesel Engines 2200 YRM 550.

33
Starting System Repair 600 YRM 1019

Starting System Repair

Most of the repair procedures for the starting system
can be found in Electrical System, Mazda XA and HA
Diesel Engines 2200 YRM 550. Information on how to
replace the glow plugs and how to check the cold start
aid system are described as follows.

COLD START AID

Description and Operation
The cold start aid contains the following parts (see Fig-
ure 69):
• Glow plug for each cylinder
• Relay
• Controller
• Thermal switch
• Key switch
• Fuse
• Battery

The glow plugs for the cold start aid heat the fuel from
the injectors. Heating the fuel lowers the combustion
point of the fuel. The glow plugs are resistance heaters
that have parallel electrical connections. The glow
plugs are electrically in series with the relay, fuse, and
battery.

The relay is energized to complete the circuit to the glow

plugs when the following conditions are true:
• The key switch is in the IGN or START position
• There is a voltage signal to the controller from the
S terminal of the starter and the thermal switch is
1. GLOW PLUG 5. KEY SWITCH
closed. 2. RELAY 6. FUSE
3. CONTROLLER 7. BATTERY
The thermal switch is closed when the engine coolant 4. THERMAL SWITCH
is cold.
Figure 69. Cold Start Aid Circuit
The relay is de-energized for the following conditions:
• The key switch is in the OFF position Glow Plugs, Replace
• The controller has completed the time cycle or the en-
gine coolant has warmed enough so that the thermal The glow plugs for the cold start aid are directly below
switch contacts open. the injectors on the engine. They cannot be repaired
and must be replaced if bad. Disconnect the electrical
The glow plugs are de-energized when the relay is wire at the metal strip connected to all the glow plugs.
de-energized. Remove the nuts from all of the glow plugs and remove
the metal strip. Use a wrench to remove the glow plugs
and install the replacement glow plugs. Install the metal
strip and wire. See Figure 70.

34
600 YRM 1019 Starting System Repair

Fuse
Find the fuse for the cold start aid on the fuse panel.
The fuse panel is on the left-hand side of the cowl. Re-
move the fuse. Use an ohmmeter to check the fuse for
continuity. If there is no continuity, check the wires and
connections between the fuse and the relay for a short
circuit. Replace the fuse.

Relay and Controller

The relay is on a bracket at the battery tray. See Fig-
ure 72. Remove the wire connectors for the BU and BZ
wires. Use an ohmmeter set to a low scale to check for
continuity between the terminals. If there is a short cir-
cuit or infinity reading, the relay coil is bad. If there is a
very low resistance reading, the coil is good. Install the
wire connectors on the terminals.
1. NUT 3. POWER LEAD
2. CONNECTOR 4. GLOW PLUG Remove the wire connector for the BT and BR wires.
PLATE 5. CYLINDER HEAD Use an ohmmeter set to a low scale to check for con-
tinuity between the BT and BR terminals. If there is a
Figure 70. Glow Plug
short-circuit reading, the relay contacts are welded. Re-
place the relay. If there is an infinity reading, install the
Glow Plugs, Check
wire connectors on the terminals.
Use an ohmmeter to check the glow plugs of the cold
Check the wires and connectors for the controller at the
start aid. Check for 1.4 to 1.5 ohms between the posi-
controller. Also check the connectors and wires be-
tive wire at the glow plug and the cylinder head. If the
tween the controller, starter, key switch, relay, instru-
ohmmeter indicates zero or infinity, replace the glow
ment panel indicator, and thermal switch. If all connec-
plug.
tions and wires are good, replace the controller.

1. CYLINDER HEAD 2. POSITIVE WIRE

1. BRACKET 3. RELAY
Figure 71. Glow Plugs Check 2. CONTROLLER

Figure 72. Relay and Controller for Glow Plug

Circuit

35
Checks and Adjustments 600 YRM 1019

Checks and Adjustments

VALVES, ADJUST 4. The standard pressure reading is 3.0 MPa
(435 psi). The minimum reading is 2.7 MPa
1. Rotate the crankshaft until the number one piston (392 psi). The maximum variation between cylin-
is at TDC on the compression stroke (intake and ders is 0.3 MPa (43 psi).
exhaust valves closed). Adjust the clearance of the
intake valves for the No. 1 and No. 2 cylinders 5. If the readings are lower than the minimum reading,
and the exhaust valves for the No. 1 and No. 3 there is a problem with the valves, piston rings, or
cylinders. The correct clearance for all the valves cylinder head gasket. Do the following tests to find
when the engine is cold is 0.30 mm (0.012 in.). To the problem:
adjust the clearance, loosen the lock nut and turn
the adjustment screw. Tighten the lock nut when a. Add approximately 30 ml (1.0 oz) of engine oil
adjustments are complete. See Figure 73. to each cylinder at the fuel injector port.

2. Rotate the crankshaft clockwise one complete turn b. Crank the engine approximately ten revolutions
(360 degrees) so the number 4 piston is at TDC. to distribute the oil.
Adjust the remaining valves.
c. Install the compression gauge and do the same
test as described in Step 3.

d. If the compression pressure increases to a nor-

mal reading, the low pressure was caused by
worn or damaged piston rings. The cylinder
bore can also be damaged.

e. If the compression reading does not increase,

the low pressure was caused by worn valves,
valve seats, or valve guides.

f. If the low pressure readings are in two cylinders

next to each other, the cylinder head can be
leaking.

Figure 73. Valves Adjustment

COMPRESSION PRESSURE CHECK

1. Remove the fuel injectors from the cylinder head.
Disconnect the wire at the fuel shutoff solenoid on
the injection pump.

2. Install a compression gauge in the number 1 cylin-

der. See the Special Tools section. Make sure the 1. ADAPTER
gauge has a minimum range of 3.5 MPa (508 psi). 2. COMPRESSION GAUGE

3. Use the starter to crank the engine at least six rev- Figure 74. Compression Pressure Check
olutions. Check the pressure reading and release
the pressure. Repeat the test again and make a
note of the highest pressure. Do this test for each
cylinder.

36
600 YRM 1019 Checks and Adjustments

THROTTLE LINKAGE, ADJUST load, is 2600 to 2700 rpm. For lift truck models
GDP16-20AF (GDP030-040AF), the engine speed
NOTE: Each time the throttle linkage is disassembled, is 2100 to 2200 rpm.
it is important to adjust the throttle cable.

1. Loosen the cable housing at the bracket on the in-

take manifold. See Figure 75.

2. Adjust the idle speed of the engine. The idle adjust-

ment screw on the injection pump controls the idle
speed. The correct idle speed is 725 ±25 rpm. Be
sure to use a tachometer that will work for a diesel
engine.

3. Make sure the throttle linkage at the pedal assem-

bly is in the correct position. For the HA engine, the
throttle cable must be connected to the bottom hole
in the crank. For the XA engine, the throttle cable
must be connected to the top hole in the crank.

4. Adjust the length of the cable housing so the cable

is not loose. With the engine running at the correct
idle speed, change the position of the cable housing
with the nuts. See Figure 75.

5. Turn the pedal stop down until it is against the jam

nut. Depress the accelerator pedal until the con-
trol lever is in the wide open position. Turn the
pedal stop up until it touches the pedal. Turn the
pedal stop up another 1/4 turn. Tighten the jam nut.
Check that the height of the pedal stop is approxi- 1. ACCELERATOR PEDAL
mately: 2. LINK
• 46.7 mm (1.84 in.) for GDP2.00-3.00RF/TF 3. PEDAL STOP
(GDP040-060RG/TG/ZG) lift trucks with the HA 4. JAM NUT
5. CRANK
engine. 6. IDLE ADJUSTMENT SCREW
• 42.9 mm (1.69 in.) for GDP2.00-3.00RF/TF 7. MAXIMUM SPEED ADJUSTMENT SCREW
(GDP040-060RG/TG/ZG) lift trucks with the XA 8. THROTTLE CABLE
engine. 9. JAM NUTS
• 39.5 mm (1.55 in.) for GDP16-20AF (GDP030- 10. CABLE HOUSING
040AF) lift trucks with the XA engine. Figure 75. Throttle Linkage Adjustment
6. For lift truck models GDP2.00-3.00RF/TF
(GDP040-060RG/TG/ZG), check that the en-
gine speed, with the throttle wide open and no

37
Checks and Adjustments 600 YRM 1019

FUEL INJECTION PUMP TIMING CHECK in the opposite direction until the indication is
1.00 mm (0.0394 in.).
1. Remove the fuel lines at the fuel injection pump.
Remove the capscrew from the center of the dis-
tributor head. Use a dial indicator so the movement
of the plunger can be measured. The movement
of the plunger can be measured through the hole
in the distributor head where the capscrew was re-
moved. See Figure 76.

2. Rotate the engine by hand until the number 1 piston

is at approximately 30° BTDC on the compression
stroke. Move the crankshaft a small amount in both
directions to make sure the dial indicator does not
move. Set the dial indicator at zero. See Figure 77.
• For the HA engine, rotate the crankshaft clock-
wise to the 3° BTDC timing mark. At this point,
the timing is correct when the dial indicator indi- 1. DISTRIBUTOR HEAD
cates 1.00 mm (0.0394 in.) of movement. 2. PLUNGER
• For the XA engine, rotate the crankshaft clock- 3. DIAL INDICATOR
wise to the 0° or TDC timing mark. At this point,
the timing is correct when the dial indicator indi- Figure 76. Injection Pump Timing Check
cates 1.00 mm (0.0394 in.) of movement.

3. If the measurement is not 1.00 mm (0.0394 in.), the

timing is not correct. Adjust the timing as follows:

a. If the measurement is more than 1.00 mm

(0.0394 in.), move the injection pump in the
direction of the engine rotation as far as it will
move. Move the injection pump in the oppo-
site direction until the indication is 1.00 mm
(0.0394 in.)

b. If the measurement is less than 1.00 mm

(0.0394 in.), move the injection pump in the
direction opposite of the engine rotation as
far as it will move. Move the injection pump Figure 77. Timing Marks

38
600 YRM 1019 Engine Specifications

Engine Specifications
ENGINE DATA
Mazda 2.5 Liter (XA) Diesel Engine
Engine Type................................................................... In-Line, Four Cylinder
Bore × Stroke ................................................................ 88.9 × 101.6 mm (3.50 × 4.00 in.)
Firing Order ................................................................... 1-3-4-2
Displacement................................................................. 2522 cm 3 (153.9 in. 3 )
Compression Ratio ........................................................ 21:1
Compression Pressure .................................................. 2944 kPa (427 psi)@ 200 rpm
Governed Speed (No Load) .......................................... 2600 to 2700 rpm
Idle Speed ..................................................................... 725 ±25 rpm

Mazda 3.0 Liter (HA) Diesel Engine

Engine Type................................................................... In-Line, Four Cylinders
Bore × Stroke ................................................................ 95 × 105 mm (3.74 × 4.13 in.)
Firing Order ................................................................... 1-3-4-2
Displacement................................................................. 2977 cm 3 (181.7 in. 3 )
Compression Ratio ........................................................ 21:1
Compression Pressure .................................................. 2944 kPa (427 psi)@ 200 rpm
Governed Speed (No Load) .......................................... 2100 to 2200 rpm
Idle Speed ..................................................................... 725 ±25

CYLINDER HEAD
Mazda 2.5 Liter (XA) Diesel Engine
Inside Diameter of Valve Guide ..................................... 8.07 to 8.09 mm (0.3177 to 0.3185 in.)
Clearance in Guide (Exhaust) ....................................... 0.127 mm (0.005 in.)
Clearance in Guide (Intake)........................................... 0.127 mm (0.005 in.)
Diameter of Valve Stem (Intake).................................... 8.955 to 8.980 mm (0.353 to 0.354 in.)
Service Limit.................................................................. 8.904 mm (0.350 in.)
Diameter of Valve Stem (Exhaust) ................................ 8.935 to 8.960 mm (0.3518 to 0.3527 in.)
Service Limit.................................................................. 8.904 mm (0.350 in.)
Valve Head Thickness (Intake) ...................................... 1.7 mm (0.067 in.)
Valve Head Thickness (Exhaust)................................... 1.5 mm (0.059 in.)
Service Limit.................................................................. 1.0 mm (0.039 in.)
Valve Face Angle (Intake).............................................. 45°

39
Engine Specifications 600 YRM 1019

Mazda 2.5 Liter (XA) Diesel Engine

Valve Face Angle (Exhaust) .......................................... 40°
Spring Free Length (Inner) ............................................ 43.6 mm (1.717 in.)
Spring Free Length (Outer) ........................................... 52.9 mm (2.083 in.)
Clearance Between Rocker Arm
and Shaft ....................................................................... 0.16 to 0.61 mm (0.0006 to 0.0240 in.)
Service Limit.................................................................. 0.07 mm (0.0028 in.)

Mazda 3.0 Liter (HA) Diesel Engine

Inside Diameter of Valve Guide ..................................... 8.07 to 8.09 mm (0.3177 to 0.3185 in.)
Clearance in Guide (Exhaust) ....................................... 0.127 mm (0.005 in.)
Clearance in Guide (Intake)........................................... 0.127 mm (0.005 in.)
Diameter of Valve Stem (Intake).................................... 8.955 to 8.980 mm (0.353 to 0.354 in.)
Service Limit.................................................................. 8.904 mm (0.350 in.)
Diameter of Valve Stem (Exhaust) ................................ 8.935 to 8.960 mm (0.3518 to 0.3527 in.)
Service Limit.................................................................. 8.904 mm (0.350 in.)
Valve Head Thickness (Intake) ...................................... 1.5 mm (0.059 in.)
Valve Head Thickness (Exhaust)................................... 1.5 mm (0.059 in.)
Service Limit.................................................................. 1.0 mm (0.039 in.)
Valve Face Angle (Intake).............................................. 45°
Valve Face Angle (Exhaust) .......................................... 40°
Spring Free Length (Inner) ............................................ 43.6 mm (1.717 in.)
Spring Free Length (Outer) ........................................... 52.9 mm (2.083 in.)
Clearance Between Rocker Arm
and Shaft ....................................................................... 0.16 to 0.61 mm (0.0006 to 0.0240 in.)
Service Limit.................................................................. 0.07 mm (0.0028 in.)

CAMSHAFT
Mazda 2.5 Liter (XA) Diesel Engine
Cam Lobes - Minimum Height ....................................... 42.478 mm (1.6724 in.)
Bearing Journal No. 1 ................................................... 51.910 to 51.940 mm (2.0437 to 2.0449 in.)
Service Limit.................................................................. 51.902 mm (2.0434 in.)
Bearing Journal No. 2 ................................................... 51.660 to 51.690 mm (2.0339 to 2.0350 in.)
Service Limit.................................................................. 51.652 mm (2.0335 in.)
Bearing Journal No. 3 ................................................... 51.410 to 51.440 mm (2.0240 to 2.0252 in.)
Service Limit.................................................................. 51.402 mm (2.0237 in.)

40
600 YRM 1019 Engine Specifications

Mazda 2.5 Liter (XA) Diesel Engine

Bearing Journal No. 4 ................................................... 51.160 to 51.190 mm (2.0141 to 2.0154 in.)
Service Limit.................................................................. 51.152 mm (2.0139 in.)
Clearance Between Journals
and Bore ........................................................................ 0.145 mm (0.0057 in.)
End Clearance (Maximum)............................................ 0.30 mm (0.012 in.)

Mazda 3.0 Liter (HA) Diesel Engine

Cam Lobes - Minimum Height ....................................... 42.478 mm (1.6724 in.)
Bearing Journal No. 1 ................................................... 51.910 to 51.940 mm (2.0437 to 2.0449 in.)
Service Limit.................................................................. 51.902 mm (2.0434 in.)
Bearing Journal No. 2 ................................................... 51.660 to 51.690 mm (2.0339 to 2.0350 in.)
Service Limit.................................................................. 51.652 mm (2.0335 in.)
Bearing Journal No. 3 ................................................... 51.410 to 51.440 mm (2.0240 to 2.0252 in.)
Service Limit.................................................................. 51.402 mm (2.0237 in.)
Bearing Journal No. 4 ................................................... 51.160 to 51.190 mm (2.0141 to 2.0154 in.)
Service Limit.................................................................. 51.152 mm (2.0139 in.)
Clearance Between Journals
and Bore ........................................................................ 0.145 mm (0.0057 in.)
End Clearance (Maximum)............................................ 0.30 mm (0.012 in.)

CRANKSHAFT
Mazda 2.5 Liter (XA) Diesel Engine
Distortion ....................................................................... Less than 0.04 mm (0.0016 in.)
Main Bearing Journal Diameter..................................... 69.812 to 69.825 mm (2.7485 to 2.7490 in.)
Service Limit.................................................................. 0.05 mm (0.002 in.)
Grinding Limit ................................................................ 0.75 mm (0.030 in.)
Clearance Between Journals
and Main Bearings ........................................................ 0.059 to 0.090 mm (0.0023 to 0.0035 in.)
Service Limit.................................................................. 0.12 mm (0.0047 in.)
Connecting Rod Journal
Diameter ........................................................................ 57.112 to 57.125 mm (2.2485 to 2.2490 in.)
Service Limit.................................................................. 0.05 mm (0.002 in.)
Grinding Limit ................................................................ 0.75 mm (0.030 in.)
Thrust Bearing Clearance ............................................. 0.14 to 0.39 mm (0.0055 to 0.0153 in.)
Service Limit.................................................................. 0.40 mm (0.0157 in.)

41
Engine Specifications 600 YRM 1019

Mazda 3.0 Liter (HA) Diesel Engine

Distortion ....................................................................... Less than 0.03 mm (0.0012 in.)
Main Bearing Journal Diameter..................................... 75.812 to 75.825 mm (2.9847 to 2.9852 in.)
Service Limit.................................................................. 0.05 mm (0.002 in.)
Grinding Limit ................................................................ 0.75 mm (0.030 in.)
Clearance Between Journals
and Main Bearings ........................................................ 0.059 to 0.090 mm (0.0023 to 0.0035 in.)
Service Limit.................................................................. 0.12 mm (0.0047 in.)
Connecting Rod Journal
Diameter ........................................................................ 61.112 to 61.125 mm (2.4060 to 2.4065 in.)
Service Limit.................................................................. 0.05 mm (0.002 in.)
Grinding Limit ................................................................ 0.75 mm (0.030 in.)
Thrust Bearing Clearance ............................................. 0.14 to 0.39 mm (0.0055 to 0.0153 in.)
Service Limit.................................................................. 0.40 mm (0.0157 in.)

CONNECTING RODS
Mazda 2.5 Liter (XA) Diesel Engine
Small End Bore.............................................................. 21.943 to 21.961 mm (0.8639 to 0.8646 in.)
Clearance Between Piston
Pin and Bore.................................................................. 0.012 to 0.039 mm (0.0005 to 0.0015 in.)
Service Limit.................................................................. 0.05 mm (0.002 in.)
Clearance Between Crankshaft
Journals and Rod .......................................................... 0.037 to 0.076 mm (0.0015 to 0.0030 in.)
Service Limit.................................................................. 0.10 mm (0.004 in.)

Mazda 3.0 Liter (HA) Diesel Engine

Small End Bore.............................................................. 21.943 to 21.961 mm (0.8639 to 0.8646 in.)
Clearance Between Piston
Pin and Bore.................................................................. 0.012 to 0.039 mm (0.0005 to 0.0015 in.)
Service Limit.................................................................. 0.05 mm (0.002 in.)
Clearance Between Crankshaft
Journals and Rod Bearings ........................................... 0.037 to 0.076 mm (0.0015 to 0.0030 in.)
Service Limit.................................................................. 0.10 mm (0.004 in.)

42
600 YRM 1019 Engine Specifications

CYLINDER BLOCK
Mazda 2.5 Liter (XA) Diesel Engine
Bore (Liner) Diameter .................................................... 88.925 to 88.950 mm (3.5010 to 3.5020 in.)
Wear Limit ..................................................................... 0.20 mm (0.0079 in.)

Mazda 3.0 Liter (HA) Diesel Engine

Bore (Liner) Diameter .................................................... 95.025 to 95.050 mm (3.7411 to 3.7421 in.)
Wear Limit ..................................................................... 0.20 mm (0.0079 in.)

PISTONS
Mazda 2.5 Liter (XA) Diesel Engine
Diameter ........................................................................ 88.872 to 88.898 mm (3.3489 to 3.500 in.)
Clearance Between Piston
and Bore ........................................................................ 0.036 to 0.075 mm (0.0014 to 0.0030 in.)
Clearance in Groove for
Piston Rings .................................................................. 0.3 mm (0.012 in.)
Piston Ring End Clearance ........................................... 1.5 mm (0.059 in.)

Mazda 3.0 Liter (HA) Diesel Engine

Diameter ........................................................................ 94.967 to 94.993 mm (3.7389 to 3.7399 in.)
Clearance Between Piston
and Bore ........................................................................ 0.044 to 0.070 mm (0.0017 to 0.0028 in.)
Clearance in Groove for
Piston Rings .................................................................. 0.3 mm (0.012 in.)
Piston Ring End Clearance ........................................... 1.5 mm (0.059 in.)

OIL PUMP
Mazda 2.5 Liter (XA) Diesel Engine
Clearance Between Shaft and
Body (Maximum) ........................................................... 0.1 mm (0.0039 in.)
Clearance Between Inner and
Outer Rotors (Maximum) ............................................... 0.3 mm (0.012 in.)
Clearance Between Outer Rotor
and Housing (Maximum) ............................................... 0.3 mm (0.012 in.)
End Clearance Between Rotors
and Housing (Maximum) ............................................... 0.15 mm (0.006 in.)

43
Torque Specifications 600 YRM 1019

Mazda 3.0 Liter (HA) Diesel Engine

Clearance Between Shaft and
Body (Maximum) ........................................................... 0.1 mm (0.0039 in.)
Clearance Between Inner and
Outer Rotors (Maximum) ............................................... 0.3 mm (0.012 in.)
Clearance Between Outer Rotor
and Housing (Maximum) ............................................... 0.3 mm (0.012 in.)
End Clearance Between Rotors
and Housing (Maximum) ............................................... 0.15 mm (0.006 in.)

Torque Specifications
Camshaft Gear Injection Pump Drive Gear
63 to 93 N•m (46 to 69 lbf ft) 65 to 70 N•m (48 to 52 lbf ft)

Camshaft Thrust Plate Intake Manifold

19 to 26 N•m (168 to 230 lbf in) 19 to 25 N•m (168 to 221 lbf in)

Cooling Fan Main Bearing Cap

19 to 26 N•m (168 to 230 lbf in) 98 to 105 N•m (72 to 77 lbf ft)

Connecting Rod Cap Oil Pan

80 to 88 N•m (59 to 65 lbf ft) 19 to 26 N•m (168 to 230 lbf in)

Crankshaft Pulley Oil Pan Drain Plug

343 to 392 N•m (253 to 289 lbf ft) 34 N•m (25 lbf ft)

Cylinder Head Rear Oil Seal

116 to 123 N•m (86 to 91 lbf ft) 19 to 26 N•m (168 to 230 lbf in)

Engine Mount to Engine Rocker Cover

GDP16-20AF/BF (GDP030-040AF/BF) 37 19 to 26 N•m (168 to 230 lbf in)
to 52 N•m (28 to 38 lbf ft)
GDP2.00-3.00RF/TF (GDP040-060RG/TG/ZG) Rocker Shaft Assembly
55 N•m (41 lbf ft) 116 to 123 N•m (86 to 91 lbf ft)

Exhaust Manifold Starter

19 to 26 N•m (168 to 230 lbf in) 64 to 89 N•m (47 to 66 lbf ft)

Flywheel Timing Gear Cover

206 to 225 N•m (152 to 166 lbf ft) 19 to 26 N•m (168 to 230 lbf in)

Flywheel Housing, Torque Converter Housing Adapter

GDP2.00-3.00RF/TF (GDP040-060RG/TG/ZG) GDP16-20AF/BF (GDP030-040AF/BF)
M10 Capscrews 41 to 49 N•m (30 to 36 lbf ft) 43 to 51 N•m (32 to 38 lbf ft)
M14 Capscrews 114 to 136 N•m (84 to 100 lbf ft)
Torque Converter Housing
Glow Plug GDP16-20AF/BF (GDP030-040AF/BF)
15 to 20 N•m (133 to 170 lbf in) 69 to 88 N•m (51 to 65 lbf ft)

Water Pump
19 to 26 N•m (168 to 230 lbf in)

44
600 YRM 1019 Special Tools

Special Tools
9125483-05
Engine Stand

9125483-07
Engine Hanger

9125483-01
Valve Spring Compressor

9125483-02
Pivot for Valve Spring Lifter

9125483-35
Valve Guide Removal and Installation Tool

9125483-43
Cylinder Liner Removal and Installation

9125483-44
Ring Gear Holder

9125483-45
Collar for Ring Gear Holder

9125483-34
Piston Pin Installation Tool

45
Special Tools 600 YRM 1019

9125483-46
Oil Seal Installation (Timing Cover)

9125483-40
Oil Pressure Gauge

9125483-47
Adapter for Compression Gauge

9125483-48
Valve Seal Installation Tool

9125483-51
Fuel Injection Pump Timing Tool

9125483-33
Removal Tool

9125483-16
Water Pump Pulley Remover

46
600 YRM 1019 Troubleshooting

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Engine will not start. Fuel tank is empty. Fill tank with correct fuel.

Battery is not fully charged. Charge battery or install a new battery.

Connections at battery are loose or Clean and tighten battery connections.

corroded.

Starter system has a problem. Check starter, starter relay, and wiring.
Repair or replace as needed.

Damaged parts in engine. Repair or replace parts as needed.

Valves are worn or damaged. Grind valves or install new valves.

Piston rings are worn or damaged. Install new piston rings. Overhaul en-
gine if needed.

Fuel system has a problem. Check fuel delivery system (fuel pump,
lines, etc.). Install new parts as
needed.

Engine stop solenoid has a problem. Install new solenoid.

Fuel line has restriction. Repair fuel line.

Air in fuel system. See Fuel System Air Removal in the

Fuel System Repair section.

Cold start aid does not operate cor- Repair or install new parts as needed.
rectly.

Engine does not run smoothly. Valve mechanism does not operate Repair or install new parts as needed.
correctly.

Head gasket has a leak. Install new gasket

Cylinder head has cracks. Install new cylinder head.

Intake system has leak. Repair leak.

Engine is too hot. Check cooling system.

Fuel lines or fuel filter has restriction. Repair fuel line or install new filter.

Air in fuel system. See Fuel System Air Removal in the

Fuel System Repair section.

47
Troubleshooting 600 YRM 1019

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Engine does not have enough Air filter is dirty. Clean or install new filter element.
power.

Fuel is wrong type. Drain fuel tank. Fill with correct fuel.

Fuel injection pump timing is not cor- See Fuel Injection Pump Timing Check
rect. in the Checks and Adjustments sec-
tion.

Valve mechanism does not operate Repair or install new parts as needed.
correctly.

Piston assemblies are worn or dam- Install new pistons and rings. Overhaul
aged. engine if needed.

Valve timing is not correct. Adjust valve timing.

Exhaust system has restriction. Remove restriction. Install new parts

as needed.

Fuel line or fuel filter has restriction. Repair fuel line or install new filter.

Air in fuel system. See Fuel System Air Removal in the

Fuel System Repair section.

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

Cylinder head gasket leaks. Install new gasket.

There is noise inside engine. Main bearings are worn or damaged. Install new bearings. Overhaul engine
if needed.

Engine is too hot. Check the thermostat. Check cooling

system (radiator, fan, drive belt, etc.).
Clean and repair as needed.

Valves are not adjusted correctly. See Valves, Adjust in the Checks and
Adjustments section.

Bearings for connecting rods are worn Install new bearings. Overhaul engine
or damaged. if needed.

Pistons are worn or damaged. Install new pistons and rings. Overhaul
engine if needed.

Valve spring is broken. Install new valve spring.

Fuel injection pump timing is not cor- See Fuel Injection Pump Timing Check
rect. in the Checks and Adjustments sec-
tion.

48
600 YRM 1019 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

There is noise inside engine. There is not enough oil in engine. Check oil level. Add oil up to ADD mark
(Cont.) on dipstick.

Flywheel is loose. Tighten flywheel mounting bolts.

Connecting rod is bent. Install new connecting rod.

Exhaust system has leak. Repair leak.

Valve mechanism does not operate Repair or install new parts as needed.
correctly.

Engine gets too hot. There is not enough coolant in cooling Check coolant level in radiator and aux-
system. iliary coolant reservoir. Add coolant if
needed.

Air filter has restriction. Install new filter element.

Water pump has damage. Repair or install new pump as needed.

Radiator is dirty. See the section Cooling System 700

YRM 626 for cleaning procedure.

Cooling system has restrictions. See the section Cooling System 700
YRM 626 for cleaning procedure.

Belt for water pump is worn or not ad- Adjust belt or install new belt.
justed correctly.

Thermostat is damaged. Install new thermostat.

Exhaust system has restriction. Remove restriction. Install new parts

as needed.

Fuel injection pump timing is not cor- See Fuel Injection Pump Timing Check
rect. in the Checks and Adjustments sec-
tion.

Cylinder head gasket leaks. Install new gasket.

49
Troubleshooting 600 YRM 1019

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Coolant leaks. Radiator is damaged. Repair or replace as needed.

Radiator, hose, or tubes for coolant are Install new parts as needed.
damaged.

Water pump is damaged. Repair or replace water pump as

needed.

Cylinder head is loose or gasket is Tighten cylinder head or install new

damaged. gasket.

Engine block or cylinder head has Replace with new parts as needed.
cracks.

Oil leaks. Drain plug is loose. Tighten drain plug or replace if needed.

Seal between oil pan and engine block Install new seal.
is damaged.

Oil filter is loose. Tighten oil filter.

Oil filter mount is loose. Repair or replace as needed.

Oil pressure is low. Oil leaks. Check drain plug, hose connections,
and oil filter.

Oil level is low. Add oil to correct level.

Oil pump gears are worn or damaged. Replace gears.

Drive gear for oil pump is damaged. Install new drive gear.

Oil strainer has restriction. Clean oil strainer or replace if needed.

Bearings for crankshaft or connecting Install new bearings as needed.

rods are worn.

50
600 YRM 1019 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

There is black exhaust smoke. Air filter has restriction. Install new filter element.

Cold start aid does not operate cor- Check and repair as needed.
rectly.

Fuel injection pump timing is not cor- See Fuel Injection Pump Timing Check
rect. in the Checks and Adjustments sec-
tion.

Fuel injection pump is damaged. Repair or install new pump as needed.

Valve timing is not correct. Adjust valve timing.

Exhaust system has restriction. Remove restriction. Install new parts

as needed.

Valves are not adjusted correctly or do See Valves, Adjust in the Checks and
not operate smoothly. Adjustments section.

Piston rings are damaged. Install new rings. Overhaul engine if

needed.

Cylinder head gasket leaks. Install new gasket.

Fuel is not correct type. Drain fuel tank. Fill with correct fuel.

There is blue or white exhaust Engine oil is not correct type. Drain oil. Fill with correct oil to FULL
smoke. mark on dipstick.

Cold start aid does not operate cor- Check and repair as needed.
rectly.

Fuel injection pump timing is not cor- See Fuel Injection Pump Timing Check
rect. in the Checks and Adjustments sec-
tion.

Fuel injection pump is damaged. Install new pump.

Valve timing is not correct. Adjust valve timing.

Engine operating temperature is too Check cooling system.

cold.

Valves or valve guides are worn. Install new parts as needed.

Piston rings are damaged. Install new rings. Overhaul engine if

needed.

Cylinder head gasket leaks. Install new gasket.

Engine compression is not correct. See Compression Pressure Check in

the Checks and Adjustments section.

51
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52
 Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011

600 YRM 1019 1/11 (5/02)(3/02) Printed in U.S.A.