Mazda Engine

FE and F2
GP/GLP/GDP20-35RK/TK [B871];
GP/GLP/GDP15-20AK [C812]
 INTRODUCTION

GENERAL sure a correct identification is made of the wire

before it is connected.
This section has the repair instructions for the engine. • Make sure a battery is the correct voltage and
Removal, disassembly, repair, assembly, installation, polarity before it is connected.
checks and adjustments and troubleshooting are
• Do not check for current flow by making a
included. The specifications are given at the end of the
spark because the transistors can be damaged.
section.
DESCRIPTION
Additional information on engine components are in
The Mazda FE and F2 engines are four cylinder engines
the sections for THE GASOLINE FUEL SYSTEM,
that have a displacement of 1998 cm3 for FE and 2184
THE LPG FUEL SYSTEM and THE ELECTRICAL
cm3 for F2. They are available with either a gasoline or
SYSTEM.
an LPG fuel system. The firing order is 1-3-4-2. The
number one cylinder is toward the end of the engine
CAUTION
with the cooling fan.
Disconnect the battery cables before doing any
disassembly and repair to the engine or parts of the The overhead camshaft is driven by a cog belt. The
electrical system. camshaft operates the rocker arms that actuate the
valves. The rocker arms are offset against the exhaust
The diodes and resistors in the electrical system can valve stem to rotate the exhaust valve to prevent carbon
be damaged if the following cautions are not followed: damage and irregular wear.
• Do not disconnect the battery when the engine The crankshaft has five main bearings. The main
is running. The voltage surge can damage the bearing in the center of the crankshaft is also the thrust
diodes and resistors. bearing.
• Do not disconnect an electric wire before the The pistons are aluminum alloy and have three piston
engine is stopped and the key switch is “OFF”. rings. Each of the two compression rings have a special
• Do not cause a short circuit by connection of shape designed for its position on the piston. The third
the electric wires to the wrong terminals. Make piston ring is the oil control ring.

REPAIRS

REMOVAL AND INSTALLATION OF THE CYLINDER HEAD, CAMSHAFT AND

ENGINE VALVE MECHANISM

Removal
NOTE: The removal and installation procedures for the
1. Disconnect the connections at the battery.
engine are not included in this section. See the section
for THE FRAME for more information. 2. Drain the cooling system.

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3. Remove the air cleaner, the carburetor linkage, the
inlet and exhaust manifolds.

4. Remove the coolant hoses.

5. Remove the cooling fan, belt, alternator and the

alternator bracket.

6. Remove the bracket for the cooling fan.

FIGURE 2. REMOVE THE CAMSHAFT GEAR

7. Remove the upper and lower timing belt covers. See 12. Remove the nuts and capscrews for the front
FIGURE 26. housing, then remove the housing. See FIGURE 22.

13. Remove the cylinder head cover.

8. Loosen the capscrews for the timing belt tensioner 14. Loosen the capscrews for the rocker shaft supports
and remove the spring. Remove the capscrews and the in steps. See FIGURE 3. Remove the rocker shaft
timing belt tensioner. assembly and the camshaft.

9. Use chalk to mark the direction of rotation of the

timing belt. Remove the timing belt. See FIGURE 1.

FIGURE 3. SEQUENCE FOR REMOVAL OF THE

ROCKER ASSEMBLY

FIGURE 1. TIMING BELT

15. Remove the capscrews for the cylinder head in
steps. Remove the capscrews in the sequence shown in
10. Disconnect the wires at the distributor. Remove the
FIGURE 4.
capscrew for the distributor mount and pull the
distributor from the front housing. 16. Lift the cylinder head from the block.

11. See FIGURE 2. Remove the camshaft pulley.

Prevent rotation of the pulley and loosen the capscrew.
Remove the capscrew and the pulley.

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 Inspection And Repairs
CYLINDER HEAD

Check the bottom surface of the cylinder head for

distortion. Use a straight edge and a thickness gauge.
Do the measurements at the positions shown in
FIGURE 6. The maximum amount of distortion is 0.15
mm. When grinding the cylinder head, the maximum
amount of correction is 0.2 mm.

FIGURE 4. SEQUENCE FOR REMOVAL OF THE

CYLINDER HEAD

17. Use a valve spring compressor and remove the

valve retainers, springs and valves from the head. See
FIGURE 5.

FIGURE 6. CYLINDER HEAD INSPECTION

ROCKER SHAFT ASSEMBLY

Disassemble the rocker shaft assembly. Put marks on

the rocker arms so that they can be installed on the same
shafts. Clean the oil passages in the rocker shafts and
rocker arms. Check the clearance between the rocker
FIGURE 5. REMOVE THE VALVES arms and the rocker shafts. The maximum clearance is
0.10 mm. The correct dimension for the inside diameter
of a rocker arm is 16.000 to 16.027 mm. The correct
Cleaning dimension for the outside diameter of a rocker shaft is
15.966 to 15.984 mm. If the parts do not meet
WARNING
specification, replace the rocker arm(s) or the rocker
Cleaning solvents can be flammable and toxic and can shaft(s).
cause skin irritation. When using cleaning solvents,
CAMSHAFT
a l w a y s fo l l ow t h e s o l ve n t m a n u f a c t u re r ' s
recommended safety procedures. Check the camshaft for cracks or damage.

Clean all of the parts in solvent. Make sure that all oil Check the movement of the camshaft in the cylinder
passages are clean. Make sure all machined surfaces head. Use a dial indicator on the end of the camshaft as
are smooth. shown in FIGURE 7. The maximum movement is 0.20
mm.

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 Center Journals (Nos. 2, 3 and 4) - 31.910 to 31.935
mm
Front Oil Seal Surface - 33.961 to 34.000 mm
Fuel Pump Lobe - 37.1 mm
Check the camshaft for being straight. Put the front and
rear journals in V blocks and rotate the camshaft one
complete turn. See FIGURE 9. The maximum amount
that the dial indicator can indicate is 0.03 mm.

FIGURE 7. CHECK THE CAMSHAFT

Measure the height of the camshaft lobes. See FIGURE

8. The minimum height of the intake and exhaust lobes
are 36.902 mm.
FIGURE 9. CHECK THE CAMSHAFT
Measure the clearance between the camshaft and the
bore in the cylinder head. Install the camshaft in the
cylinder head. Put a plastic gauge material between the
camshaft and the cap. Tighten the capscrews for the
caps to 18 to 27 N.m (180 to 270 kgf·cm). See FIG-
URE 10. The correct clearance for journals Nos. 1 and
5 is 0.035 to 0.085 mm. The correct clearance for jour-
nals Nos. 2, 3 and 4 is 0.065 to 0.115 mm. If any of the
clearances are greater than 0.15 mm, replace the cylin-
der head assembly.

Replace the camshaft if there is any damage or it does

not meet specifications.

1. FRONT OIL SEAL

SURFACE
2. FRONT JOURNAL (NO. 1)
3. CENTER JOURNALS (NOS. 2, 3 AND 4)
4. REAR JOURNAL (NO. 5)
5. FUEL PUMP LOBE

FIGURE 8. CAMSHAFT INSPECTION

Measure the camshaft journals at four points A-D as

shown in FIGURE 8. The minimum dimensions for the
journals are as follows: 1. PLASTIC GAUGE
2. SCALE
Front and Rear Journals (Nos. 1 and 5) - 31.940 to
31.965 mm FIGURE 10. MEASURE THE CLEARANCE FOR
THE CAMSHAFT

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VALVE GUIDES contact pattern of the valve and the valve seat. Use a
valve seat grinder to make sure the valve seats are with
Measure the clearance between the valve stems and the
the specifications shown in FIGURE 12. Use a valve
valve guides. Normal clearance is 0.025 to 0.060 mm.
compound to make sure the valves fit the seats.
Replace the valve or valve guide when the clearance is
more than 0.20 mm. Check the depth of the valve seat. Insert the valve(s)
from the combustion chamber and measure the height
from the cylinder head by using a caliper shown in
FIGURE 13. Replace the cylinder head assembly when
the height is more than 48.0 mm.

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

FIGURE 11. VALVE GUIDE

If replacement is necessary, use a tool to remove the

valve guide(s). Remove the seal from the valve guide,
FIGURE 13. MEASURE THE VALVE SEAT DEPTH
then remove the valve guide.

To install a valve guide, install the retaining ring on the 1. DIAMETER

2. THICKNESS,
valve guide. Use the tool and install the valve guide
VALVE HEAD
until the retaining ring contacts the cylinder head. See
FIGURE 11. The correct height of the valve guide
above the valve spring seat is 19.1 to 19.6 mm.

VALVE SEATS

Inspect the condition of the valve seats. If the valve

seats have cracks, the cylinder head must be replaced.
If the condition of the valve seats is good, check the

FIGURE 14. INSPECT THE VALVES

1. VALVE SEAT WIDTH VALVES

2. EXHAUST VALVE SEAT
3. INTAKE VALVE SEAT 1. See FIGURE 14. Inspect the stem of each valve for
FIGURE 12. VALVE SEAT SPECIFICATIONS wear. Use a micrometer to measure the outside diameter

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of the stem. The minimum dimension for an intake valve
is 7.980 mm. The minimum dimension for an exhaust
valve is 7.975 mm.

2. Inspect the valves for cracks, burned faces and

distortion. Inspect the seat face of the valves for wear
and damage. Measure the thickness of the valve head.
See FIGURE 14. The minimum thickness for an intake
valve is 0.5 mm. The minimum thickness for an exhaust
valve is 1.0 mm.

3. If the valves need grinding the correct surface angle

is 45° for both intake and exhaust valves.

VALVE SPRINGS

Check the valve springs for damage. See FIGURE 15.

Measure the free length of both inner and outer valve
springs. The minimum length of the inner spring is 46.3
mm. The minimum length of the outer spring is 50.6
FIGURE 16. INSPECT THE TIMING BELT
mm. Check the valve springs for being square. See
FIGURE 15. If the measurement is more tham 1.81
mm, replace the valve spring(s). Cylinder Head, Installation
1. Use a valve spring compressor and install the valves
retainers, springs and valves on the head. Tap the valve
end so that the valves and springs are settled down.

CAUTION
Make sure the shape of the valve cotters of the intake
and exhaust valves to avoid wrong usage. See
FIGURE 17.

FIGURE 15. INSPECT THE VALVE SPRINGS

FIGURE 17. VALVE COTTERS
TIMING BELT
2. Clean the surface of the cylinder head and the surface
CAUTION
of the block.
Do not allow any oil or water to contaminate the tim-
ing belt. Do not twist, turn inside out or bend the tim- 3. Install a new cylinder head gasket to the block. Install
ing belt. the cylinder head.

Check the timing belt for damage, wear, peeling, or 4. Install the capscrews and washers for the cylinder
hardening. See FIGURE 16. If there is any oil, water or head. Tighten the capscrews to 80 to 86 N.m (820 to
there is even a slight fault on the timing belt, replace 880 kgf·cm) as shown in FIGURE 18.
the timing belt.

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 FIGURE 18. INSTALLATION OF THE
FIGURE 20. ASSEMBLE THE ROCKER SHAFT
CYLINDER HEAD
7. Tighten the capscrews for the rocker shaft supports
5. See FIGURE 19. Apply a gasket sealer to the areas to 18 to 26 N.m (180 to 270 kgf·cm) in the sequence
shown by the arrows. Lubricate the camshaft with clean shown in FIGURE 21.
engine oil, then install the camshaft. Make sure the
dowel pin is at the top of the camshaft.

FIGURE 21. INSTALLATION OF THE ROCKER

1. DOWEL PIN SHAFT ASSEMBLY
2. APPLY SEALANT
HERE 8. If necessary, install the oil seal in the front housing.
See FIGURE 22. Install the front housing and a new
gasket on the cylinder head. Tighten the capscrews for
the front housing to 19 to 25 N.m (190 to 260 kgf·cm).

1. FRONT HOUSING
2. GASKET
3. OIL SEAL

FIGURE 19. INSTALL THE CAMSHAFT

6. Assemble the rocker shaft assembly. See FIGURE
20. Lubricate the rocker arms and shafts with engine
oil. Rocker arms Nos. 1 and 3 are the same and Nos. 2
and 4 are the same. Put the capscrews in the rocker
shaft supports, then install the assembly on the cylinder
head.
FIGURE 22. FRONT HOUSING

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9. With the dowel pin at the top of the camshaft, install 12. Install the timing belt tensioner and spring. Move
the camshaft pulley. Check that the letter “A” for FE or the tensioner fully toward the intake side of the engine
the letter “1” for F2 on the pulley is aligned with the and temporarily tighten the lock bolt. On F2 engine,
timing mark on the front husing. See FIGURE 23. install the idler and tighten the capscrew to 37 to 52
N.m (380 to 530 kgf·cm).

13. Clean any oil or grease from the pulleys. Install the
timing belt. Install the belt so that it goes in the same
direction as the mark made during removal. See
FIGURE 1.
1. TIMING
MARKS
2. CAMSHAFT
PULLEY

FIGURE 23. INSTALL THE CAMSHAFT PULLEY

10. Install the capscrew and washer for the camshaft

1. TENSIONER
pulley. See FIGURE 23. Keep the pulley from turning 2. SPRING
and tighten the capscrew to 47 to 65 N.m (480 to 660 3. LOCK BOLT
4. TENSION SIDE
kgf·cm). 5. IDLER
11. Align the timing marks for the timing pulley. See
FIGURE 24. Install the crankshaft pulley, tapered ring FIGURE 25. INSTALL THE TIMING BELT
and the capscrew. Tighten the capscrew to 177 to 196
N.m (1800 to 2000 kgf·cm). 14. See FIGURE 25. Loosen the lock bolt and apply
spring tension on the belt. Rotate the crankshaft pulley
1. TIMING PULLEY
2. TIMING MARK two complete turns clockwise and check the timing
marks. If the timing marks are correct, tighten the lock
bolt for the tensioner to 20 to 34 N.m (200 to 350
kgf·cm) for FE, to 37 to 52 N.m (380 to 530 kgf·cm)
for F2 engine. Check the movement on the tension side
of the timing belt. When the tension is correct the belt
will move 12 to 14 mm for FE, 9 to 10 mm for F2
engine with 98 N (10 kgf) of force.

15. See FIGURE 26. Install the lower timing belt cover
and gasket. Tighten the capscrews to 6.9 to 7.8 N.m
(70 to 80 kgf·cm) for FE, to 6.9 to 9.8 N.m (70 to 100
FIGURE 24. INSTALL THE TIMING PULLEY
kgf·cm) for F2 engine. Install the upper timing belt

-8-
 the capscrews to 19 to 30 N.m (190 to 310 kgf·cm).

20. Install the air cleaner and the carburetor linkage.

Tighten the capscrews for the air cleaner to 19 to 25
N.m (190 to 260 kgf·cm).

21. Install the alternator bracket. Tighten the capscrews

to 37 to 52 N.m (380 to 530 kgf·cm).

CRANKSHAFT AND MAIN BEARINGS

Removal
1. Remove the bracket for the cooling fan.

2. Prevent rotation of the crankshaft pulley. Remove

the six capscrews and plate from the crankshaft pulley.
Remove the six capscrews that hold the crankshaft
pulley to the timing pulley.

3. Remove the capscrew from the timing pulley. Install

the special tool on the crankshaft to remove the timing
pulley. Rotate the tool until it touches the front of the
crankshaft. Hit the tool with a hammer to loosen the
1. LOWER TIMING BELT COVER
2. UPPER TIMING BELT COVER timing pulley. Remove the pulley, dowel pin and the
tapered ring. Remove the tool.
FIGURE 26. TIMING BELT COVERS
4. Remove the oil pan. For F2 engine, remove the baffle
cover and gasket. Tighten the capscrews to 8 to 12 N.m plate. Remove the oil strainer.
(80 to 120 kgf·cm) for FE, to 6.9 to 9.8 N.m (70 to 100
5. Remove the rear cover. Remove the front cover with
kgf·cm) for F2 engine.
the oil pump.
16. Install the distributor as described in the procedures
6. Remove the caps for the connecting rods. Put a mark
for the DISTRIBUTOR.
of identification on each cap so that they will be installed
17. See FIGURE 27. Apply a gasket sealer to the areas to the same location.
shown by the arrows. Install the cylinder head covr and
the gasket. Tighten the capscrews to 3.9 to 5.9 N.m (40
1. CENTER MAIN
to 60 kgf·cm). BEARING

FIGURE 27. INSTALL THE CYLINDER HEAD

COVER
18. Install the exhaust manifold and the gasket. Tighten
the capscrews to 22 to 28 N·m (220 to 290 kgf·cm).
FIGURE 28. MEASURE THE CRANKSHAFT
19. Install the inlet manifold and the gasket. Tighten CLEARANCE

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7. Before removing the crankshaft, measure the Main Journal Diameter – 59.937 to 59.955 mm
clearance between the crankshaft and the flange of the
Connecting Rod Journals – 50.940 to 50.955 mm
center main bearing. See FIGURE 28. Push the
crankshaft fully forward before making the Rear Oil Seal Surface – 89.946 to 90.000 mm
measurement. The maximum clearance is 0.30 mm. If
Front Oil Seal Surface – 33.961 to 34.000 mm
the clearance is greater than the specification, replace
the center main bearing or the crankshaft. 3. Check the crankshaft for being straight. See
FIGURE 29. Put the front and rear journals in V blocks
8. Put marks for identification on the bearing caps.
and rotate the crankshaft one complete turn. The
Loosen the capscrews for the main bearing caps in
maximum amount that the dial indicator can indicate is
steps, then remove the capscrews and the caps. Remove
0.03 mm.
the crankshaft.
4. Check the passages for oil in the crankshaft. Make
Inspection And Repairs
sure the passages are clean, with no restrictions.
CRANKSHAFT
MAIN BEARINGS
1. Visually inspect the crankshaft for wear, cracks or
1. Visually inspect the main bearings for wear and
other damage. Replace the crankshaft if it has cracks.
damage. Replace the bearings as necessary.
2. Use a micrometer to measure the diameter of the
2. Measure the clearance between the main bearings
journals for the crankshaft. See FIGURE 29. Make the
and the crankshaft. Install the crankshaft in the block.
measurement at several locations for each journal. If
Put a plastic gauge material on the journals and install
the measurements are less than specifications, grind the
the main bearing caps. Tighten the capscrews for the
crankshaft and install undersize bearings. The correct
main bearing caps to 82 to 88 N.m (840 to 900 kgf·cm).
dimensions for the journals are as follows:
Remove the bearing caps. See FIGURE 30. The correct
clearance is 0.031 to 0.049 mm. 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 30. CHECK THE CLEARANCE FOR THE

MAIN BEARINGS

Installation
1. Clean the main bearings and the areas at the block
for the main bearings. Install the main bearings and
lubricate them with oil.

2. Install the crankshaft on the bearings. Install the main

FIGURE 29. CRANKSHAFT INSPECTION bearings in the caps and lubricate them with oil. Use

- 10 -
the identification marks and install the main bearing 9. Install the crankshaft pulley. Align the tip of timing
caps. Tighten the capscrews for the main bearing caps indicator plate with the top mark, left one of two. See
to 82 to 88 N.m (840 to 900 kgf·cm). FIGURE 32. Prevent rotation of the crankshaft pulley.
Put the plain washers on the capscrews for the
3. Install the pistons and the connecting rods as
crankshaft pulley and tighten the capscrews to 29 to 32
described in PISTONS AND THE CONNECTING
N.m (300 to 330 kgf·cm) for FE, to 32 to 37 N.m (330
RODS, Installation.
to 380 kgf·cm) for F2 engine.
4. Install the oil pump housing. Make sure the O-ring
is in the housing. Lubricate the oil seal with engine oil.
Use an adhesive sealant and install the housing to the
block. Make sure there is no sealant in the oil port.
Tighten the M10 capscrews to 37 to 52 N.m (380 to
530 kgf·cm). Tighten the M8 capscrews to 19 to 25 N.m
(190 to 260 kgf·cm).

5. Install the oil seal in the rear cover. Lubricate the

surfaces of the oil seal with engine oil and use a press
to install the seal. Install the alignment pin in the
cylinder block.
FIGURE 32. CRANKSHAFT PULLEY
6. Install the rear cover and the gasket. See FIGURE 31. ALIGNMENT
Make sure the dowel pin is installed. Tighten the
10. Install the drive plate on the crankshaft pulley end.
capscrews to 8 to 12 N.m (80 to 120 kgf·cm). Cut the
Tighten the capscrews to 24 to 26 N.m (240 to 270
part of the gasket that extends past the bottom of the
kgf·cm).
cylinder block.

PISTONS AND CONNECTING RODS

Removal And Disassembly
1. Remove the cylinder head as described in
CYLINDER HEAD, Removal.

2. Remove the oil pan, baffle plate (F2) and oil strainer.

3. Put a mark for identification on the top of each piston.

4. Clean the carbon from the top of each cylinder bore.

5. Remove the caps and bearings from each connecting

1. REAR COVER
2. OIL SEAL
rod. Keep the caps and bearings with the correct piston
3. CRANKSHAFT assemblies.
FIGURE 31. REAR COVER 6. Push the connecting rod and piston from the block.

7. Carefully remove the piston rings from the pistons.

7. Install the oil strainer. Tighten the M6 capscrews to
Use a tool to push the piston pin from the connecting
8 to 12 N.m (80 to 120 kgf·cm). Tighten the M8
rod.
capscrews to 16 to 23 N.m (160 to 230 kgf·cm).

8. For M4-2.2G engine, install the baffle plate and

tighten the capscrews to 8 to 11 N.m (80 to 110 kgf·cm).
Install the oil pan and the gasket. Tighten the capscrews
to 7 to 12 N.m (70 to 120 kgf·cm).

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Cleaning 2nd Piston Ring - 0.03 to 0.07 mm
Maximum clearance is 0.15 mm
WARNING
Cleaning solvents can be flammable and toxic and can
cause skin irritation. When using cleaning solvents,
a l w a y s fo l l ow t h e s o l ve n t m a n u f a c t u re r ’s 1. PISTON RING END
CLEARANCE
recommended safety procedures.
2. PISTON RING
GROOVE
Clean all of the parts in solvent. Make sure that all oil CLEARANCE
passages and grooves are clean. Make sure all machined
surfaces are smooth.

Inspection And Repairs

PISTONS

1. Inspect the pistons for wear and cracks. Replace a

piston that has damage.

FIGURE 34. MEASURING THE PISTON RINGS

CONNECTING RODS AND BEARINGS

1. Use an alignment tool to check the connecting rods
for being straight. The maximum amount of distortion
per 100 mm is 0.04 mm. If the amount of distortion is
greater than the specification, install a new rod or use a
press to straighten the connecting rod.
FIGURE 33. MEASURING THE PISTON
2. Check the clearance between the rod bearings and
2. Measure the outside diameter of the piston as shown the journals of the crankshaft. Clean the rod bearings
in FIGURE 33. The correct dimension is 85.944 to and journals. Use a plastic gauge material between the
85.964 mm. The maximum clearance between the journal and the bearing. Tighten the capscrews for the
piston and the cylinder bore is 0.15 mm. rod caps to 50 to 55 N.m (510 to 560 kgf·cm) for FE, to
PISTON RINGS 65 to 69 N.m (660 to 700 kgf·cm) for F2 engine. Do
not rotate the connecting rod. See FIGURE 35. The
1. Measure the end clearance of each piston ring as correct clearance is 0.027 to 0.067 mm. If the clearance
shown in FIGURE 34. Install the piston ring into the is greater than the specifications, replace the bearings.
cylinder bore where it will be used. Use a thickness
gauge to measure the amount of end clearance. The
correct dimensions are as follows:

Top Piston Ring - 0.20 to 0.35 mm

2nd Piston Ring - 0.15 to 0.30 mm
Oil Ring - 0.30 to 0.90 mm
Maximum clearance is 1.0 mm

2. Measure the clearance between the piston ring and

1. PLASTIC GAUGE
the groove in the piston as shown in FIGURE 34. The 2. SCALE
correct dimensions are as follows:
FIGURE 35. CHECK THE CLEARANCE OF THE
Top Piston Ring - 0.03 to 0.07 mm
CONNECTING ROD BEARINGS

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Assembly And Installation
PISTONS AND CONNECTING RODS

1. Align the oil port on the large end of the connecting

rod with the “F” mark on the piston. See FIGURE 36.
Lubricate the piston pin and bore in the piston with
engine oil. Use a press to install the piston pin. The
force to push the pin into the piston must be 5 to 15 kN
1. EXPANDER RING
(500 to 1500 kg). If the force is not correct, replace the 2. OIL RING (UPPER)
piston pin and/or connecting rod. Use the special tool 3. OIL RING (LOWER)
to make sure the piston pin is installed to the correct 4. TOP RING
5. SECOND RING
depth. After installation, check that the piston moves
freely on the piston pin.

FIGURE 37. PISTON RINGS

1. “F” MARK
2. OIL PORT
1. “F” MARK

FIGURE 36. CONNECTING ROD AND PISTON

2. Install the piston rings on the pistons. During

installation, the writing on each piston ring must be
toward the top of the piston. Check that the rings rotate
freely, then put the ends of the rings in the positions
shown in FIGURE 37. Make sure the ends of the upper
and lower oil control rings are each 30° from the piston
pin. Also make sure that the top and second rings are
each 30° from the piston pin. Lubricate the rings with FIGURE 38. INSTALL THE PISTON
engine oil.
4. Apply clean engine oil to the bearing then install the
3. Apply clean engine oil to the piston assembly. Install cap to the correct connecting rod. During installation
the bearings for the connecting rods. Install the piston of the caps, make sure to align the identification marks
into the correct cylinder making sure the “F” is toward that were made during disassembly. Tighten the nuts
the front (timing belt end) of the engine. See FIGURE for the caps to 50 to 55 N.m (510 to 560 kgf·cm) for
38. FE, to 65 to 69 N.m (660 to 700 kgf·cm) for F2 engine.

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CYLINDER BLOCK and remove the spring. Remove the capscrews and the
timing belt tensioner.
Repairs
4. Use chalk to mark the direction of rotation of the
1. After the engine block is cleaned, check its surface
timing belt. Remove the timing belt.
for distortion. See FIGURE 39. If the amount of
distortion is greater than 0.15 mm, grind the surface of 5. Prevent rotation of the crankshaft pulley. Remove
the engine block. The maximum amount of correction the six capscrews and plate from the crankshaft pulley.
that is permitted is 0.20 mm. Remove the six capscrews that hold the crankshaft shaft
pulley to the timing pulley.

6. Remove the capscrew from the timing pulley. Install

the special tool on the crankshaft to remove the timing
pulley. Rotate the tool until it touches the front of the
crankshaft. Hit the tool with a hammer to loosen the
timing pulley. Remove the pulley, dowel pin and the
tapered ring. Remove the tool.

7. Remove the capscrews that hold the oil pan to the

block and remove the oil pan. For F2 engine, remove
the baffle plate. Remove the oil strainer.

8. Remove the capscrews that hold the front cover

(pump housing) to the block. Remove the front cover
and oil pump assembly.

Disassembly (See FIGURE 40.)

1. SCREW
2. COVER
FIGURE 39. INSPECT THE CYLINDER BLOCK 3. OUTER GEAR
4. INNER GEAR

2. Check the cylinder bores for wear and damage.

Measure each bore. The correct dimension is 86.000 to
86.019 mm. The wear limit above this dimension is 0.15
mm. Repair the cylinder block or use bigger pistons as
necessary.

OIL PUMP
Before removing the oil pump, check the oil pressure. 5. FRONT COVER
Replace the sending unit with a gauge. The minimum (HOUSING)
6. OIL SEAL
oil pressure at governed rpm is approximately 0.29 MPa 7. PLUNGER
(3.0kgf/cm 2). If the pressure is less than the 8. SNAP RING
specification, the oil pump or the engine bearings need
FIGURE 40. OIL PUMP
repair.
1. Remove the screws and the pump cover.
Removal
2. Remove the outer gear and the inner gear from the
1. Remove the bracket for the cooling fan.
pump body.
2. Remove the upper and lower timing belt covers.
3. Remove the snap ring to remove the plunger
3. Loosen the capscrews for the timing belt tensioner assembly from the housing.

- 14 -
Cleaning b. For FE engine, measure the clearance between
the crescent and the teeth of the inner gear. The
WARNING correct clearance is 0.267 to 0.380 mm. If the
Cleaning solvents can be flammable and toxic and can clearance is more than 0.40 mm, repair as
cause skin irritation. When using cleaning solvents, necessary.
a l w a y s fo l l ow t h e s o l ve n t m a n u f a c t u re r ' s
c. For F2 engine, measure the clearance between
recommended safety procedures.
the teeth of the outer gear and the teeth of the
Clean all of the parts in solvent. Make sure all machined inner gear. If the clearance is more than 0.18
surfaces are smooth. mm, repair as necessary.

Inspection d. Use a straight edge and measure the side

clearance of the gears. The correct clearance is
1. Check the front cover (pump housing) and the pump
0.03 to 0.63 mm. If the clearance is more than
cover for wear or damage. Check the plunger spring
0.10 mm, repair as necessary.
for damage.
e. Measure the clearance between the body and the
2. See FIGURE 41. Measure the parts of the oil pump
outer gear. The correct clearance is 0.090 to 0.184
as follows:
mm. If the clearance is more than 0.20 mm, repair
a. For FE engine, measure the clearance between as necessary.
the teeth of the outer gear and the crescent. The
correct clearance is 0.20 to 0.32 mm. If the
clearance is more than 0.35 mm, repair as
necessary.

1. CLEARANCE BETWEEN CRESCENT AND INNER GEAR

2. CLEARANCE BETWEEN CRESCENT AND OUTER GEAR
3. CLEARANCE BETWEEN INNER GEAR AND OUTER GEAR
4. CLEARANCE BETWEEN HOUSING AND OUTER GEAR
5. SIDE CLEARANCE OF GEARS IN THE HOUSING

FIGURE 41. MEASURE THE OIL PUMP

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Assembly (See FIGURE 40.) 3. Test the operation of the thermostat. The thermostat
must begin to open at 82 ± 1.5°C. The thermostat must
1. Install the oil seal in the oil pump housing. Make
be completely open at 95°C.
sure the front edge of the oil seal is even with the outer
edge of the housing. 1. CYLINDER BLOCK
2. GASKET
2. Lubricate the gears with engine oil, then install them 3. THERMOSTAT
in the housing. 4. HOUSING

3. Install the pump cover. Use a thread locking

compound on the screws for the pump cover, then
install the screws.

4. Install the plunger assembly and the snap ring.

Installation (See FIGURE 42.)

1. O-RING

FIGURE 43. THERMOSTAT

4. Install the thermostat and new gasket. Make sure the

print side of the gasket is toward thermostat. Install the
thermostat housing and tighten the capscrews to 19 to
30 N.m (190 to 310 kgf·cm).

5. Connect the hose and fill the cooling system. Start

FIGURE 42. OIL PUMP the engine and check for leaks.

1. Install the O-ring on the oil pump housing. Use Fan Assembly
grease to hold the O-ring in position. Lubricate the oil
REMOVAL
seal with engine oil.
1. Loosen the alternator and remove the fan belt.
2. Use an adhesive sealant and install the oil pump
housing to the block. Make sure there is no sealant in 2. Remove the capscrews for the fan. Remove the fan
the oil port. Tighten the M10 capscrews to 37 to 52 and pulley from the hub.
N.m (380 to 530 kgf·cm). Tighten the M8 capscrews to
3. Remove the capscrews that hold the fan bracket to
19 to 25 N.m (190 to 260 kgf·cm).
the engine. Remove the fan bracket.
3. Install the suction tube assembly. Install the gasket
DISASSEMBLY AND REPAIR (See FIGURE 44.)
and the oil pan.
1. Use a press to remove the fan hub from the shaft.
COOLING SYSTEM Remove the snap ring and push the bearing and shaft
from the bracket.
Thermostat
2. Use a press to install the shaft and bearing in the
bracket. Push the bearing in until it touches the bracket.
REPLACEMENT (See FIGURE 43.)
Install the snap ring. Install the hub on the shaft. When
1. Drain the cooling system to the level of the installed, the shaft must extend 2.1 mm past the hub.
thermostat.

2. Disconnect the hose and remove the thermostat

housing. Remove the thermostat.

- 16 -
INSTALLATION (See FIGURE 44.) 4. Remove the capscrews that hold the fan bracket to
the engine. Remove the fan bracket.
1. Install the bracket assembly on the cylinder block.
For FE engine, tighten the M8 capscrews to 19 to 30 5. Remove the upper and lower timing belt covers. See
N.m (190 to 310 kgf·cm). Tighten the M10 capscrews FIGURE 26. Loosen the capscrews for the timing belt
to 37 to 52 N.m (380 to 530 kgf·cm). For F2 engine, tensioner and remove the spring. Remove the
tighten the capscrews to 64 to 89 N.m (650 to 910 capscrews and the timing belt tensioner.
kgf·cm).
6. Use chalk to mark the direction of rotation of the
2. Install the pulley and fan on the hub. Tighten the timing belt. See FIGURE 1. Align the timing marks,
capscrews to 8 to 11 N.m (80 to 110 kgf·cm). then remove the timing belt.

CAUTION
Do not rotate the camshaft gear or the crankshaft
gear while the timing belt is removed. If either of the
gears is moved, it will be necessary to align the timing
marks.

7. Disconnect the hose at the water pump. Remove the

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

DISASSEMBLY AND REPAIR FOR FE ENGINE

(See FIGURE 45.)

NOTE: For F2 engine, the water pump assembly can

1. FAN 5. SHAFT not be disassembled.
2. PULLEY 6. SUPPORT
3. HUB BRACKET
4. SNAP RING 7. BRACKET

FIGURE 44. FAN ASSEMBLY

3. Install the fan belt. Adjust the tension of the fan belt.
Check the movement of the fan belt between the fan
and the alternator. When the tension is correct a NEW
belt will move 7 to 8 mm with 98 N (10 kg) of force.
The tension for an OLD belt is correct when it moves
10 to 12 mm with 98 N (10 kg) of force. Tighten the
alternator when the tension is correct.

Water Pump 1. PULLEY 3. WASHER

2. SHAFT AND BEARING 4. HOUSING
NOTE: If either the shaft or impeller is damaged, the ASSEMBLY 5. SEAL
6. IMPELLER
complete water pump must be replaced.
FIGURE 45. WATER PUMP
REMOVAL

1. Drain the cooling system.

1. Use a puller to remove the pulley from the shaft.
2. Loosen the alternator and remove the fan belt.
2. Use a press to remove the impeller from the shaft
3. Remove the capscrews for the fan. Remove the fan and the bearing assembly from the housing. Remove
and pulley from the hub. the water seal from the housing.

- 17 -
ASSEMBLY FOR FE ENGINE Removal (See FIGURE 46.)
(See FIGURE 45.)
1. Rotate the crankshaft until the number one piston is
1. Install the water seal in the housing. Put anti-freeze
at TDC on the compression stroke. Make a note of the
on the lip of the seal.
position of the distributor rotor.
2. Use a press to install the shaft and bearing in the
2. Disconnect the wires at the spark plugs.
pump body. Make sure the shaft turns smoothly.
3. Remove the capscrew from the flange of the
3. Use a press to install the pulley. Use a press to install
distributor shaft housing.
the impeller. Make sure the surface of the impeller is
even with the end of the shaft. 4. Lift the distributor assembly from the engine.

Installation (See FIGURE 46.)

INSTALLATION
1. Rotate the crankshaft until the number one piston is
1. Install the water pump with a new gasket. Tighten at TDC on the compression stroke. Put the rotor in the
the capscrews to 19 to 25 N.m (190 to 260 kgf·cm). correct position.

2. Install the timing belt and the covers as described in 2. Lubricate the O-ring and the gear on the distributor
the procedures for Cylinder Head, Installation. with engine oil. Install the distributor, aligning the
marks on the distributor housing, distributor gear and
3. Install the fan assembly as described in the
engine.
procedures for Fan Assembly, Installation.
3. Connect the wires at the spark plugs.
4. Install the coolant hoses.

5. Fill the coolant system with coolant.

6. Start the engine and check the cooling system for

leaks.

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. DO NOT remove the cover for the
radiator when the engine is running.

7. After the engine has been operated, stop the engine.

If the coolant is hot, give the engine time to cool. Check
the coolant level.

DISTRIBUTOR

NOTE: This section has only the removal and

installation procedures for the distributor. The service
procedures for the ignition system are found in THE
ELECTRICAL SYSTEM. FIGURE 46. INSTALLATION OF THE
DISTRIBUTOR

- 18 -
FLYWHEEL FOR POWERSHIFT Installation (See FIGURE 47.)
TRANSMISSION
1. If the engine end plate was removed, install it on the
engine. Tighten the M14 capscrews to 114 to 136 N.m
Removal (See FIGURE 47.) (1160 to 1390 kgf·cm). Tighten the M8 capscrews to
21 to 25 N.m (210 to 250 kgf·cm).

2. Install the flange and the flywheel on the crankshaft.

1. Remove the capscrews for the flywheel, then remove
Apply an adhesive sealant on the threads of the
the flywheel and the flange.
capscrews. Then install the capscrews, washers and the
2. If necessary, remove the engine end plate. backplate. Tighten the capscrews to 96 to 103 N.m (980
to 1050 kgf·cm).

1. ENGINE END PLATE

2. M14 CAPSCREW
3. M8 CAPSCREW
4. COVER PLATE
5. FLYWHEEL
6. FLANGE
7. CAPSCREW
8. BACK PLATE
9. TORQUE CONVERTER

FIGURE 47. END PLATE, FLYWHEEL AND TORQUE CONVERTER

- 19 -
 CHECKS AND ADJUSTMENTS

ADJUST THE VALVES (See FIGURE 50.) CHECK THE COMPRESSION PRESSURE
(See FIGURE 51.)
1. Rotate the crankshaft until the number one piston is
at TDC on the compression stroke (intake and exhaust 1. Remove the spark plugs from the cylinder head.
valves closed). Now adjust the clearance of the intake Disconnect the high tension wire at the ignition coil.
valves for the No. 1 and No. 2 cylinders and the exhaust 2. Install a compression gauge in the number 1 cylinder.
valves for the No. 1 and No. 3 cylinders. The correct Make sure the gauge has a minimum range of 2 MPa
clearance for all the valves when the engine is hot is (20 kgf/cm2).
0.3 mm. To adjust the clearance, loosen the lock nut 3. Use the starter to crank the engine at least six (6)
and turn the adjustment screw. Tighten the lock nut to revolutions. Check the pressure reading and release the
16 to 21 N.m (160 to 210 kgf·cm). pressure. Repeat the test again and make a note of the
highest pressure. Do this test for each cylinder.
NOTE: During adjustment of the valves, check the
4. The standard pressure reading is 1.13 MPa (11.5
position of the balls that are in the ends of the rocker
kgf/cm2). The minimum reading is 0.79 MPa (8.1 kgf/
arms. The flat surface of the ball must be in contact
cm2). The maximum variation between cylinders is 0.20
with the stem of the valve. MPa (2 kgf/cm2).
2. Rotate the crankshaft clockwise one complete turn 5. If the readings are lower than the minimum reading,
(360 degrees). Now adjust the remaining valves. there is a problem with the valves, piston rings or
3. If the valves are adjusted when the engine is cold, cylinder head gasket. Do the following tests to find the
problem:
check the adjustments again after the engine is warm.
a. Add approximately 30 ml of engine oil to each
cylinder at the spark plug hole.
b. Crank the engine approximately ten revolutions
to distribute the oil.
c. Install the compression gauge and do the same
tests as described in step 3.
d. If the compression pressure increases to a
normal 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.

1. ADAPTER

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

FIGURE 50. ADJUST THE VALVES FIGURE 51. CHECK THE COMPRESSION
PRESSURE

- 20 -
 ENGINE SPECIFICATIONS
Model
FE F2
Item
Numbers and arrangement of cylinders In-line four cylinders
Bore x Stroke mm 86.0 x 86.0 86.0 x 94.0
Displacement cc 1998 2184
Compression ratio 8.6
Valve opening/closing timing
Open (BTDC) 3°
Intake
Close (ABDC) 37°
Open (BBDC) 37°
Exhaust
Close (ATDC) 3°
Standard 1.13 (11.5) – 270
Compression pressure
Limit 0.79 (8.1) –270
MPa (kgf/cm2) – rpm
Variation between cylinders 0.20 (2.0) or less
Valve clearance
Intake 0.30
Valve side mm
Exhaust 0.30
Intake 0.20
Cam side mm
Exhaust 0.20
Numbers of teeth of timing belt 109 110
Height 91.95 ~ 92.05
Cylinder head mm Distortion limit 0.15
Grinding limit 0.20
Valve seat
Standard 46.5
Intake
Depth amount mm Limit 48.0
(Length) Standard 46.5
Exhaust
Limit 48.0
Intake 45°
Valve seat angle
Exhaust 45°
Intake 1.2 ~ 1.6
Valve seat width mm
Exhaust 1.2 ~ 1.6
Valve guide, valve, and valve spring
Intake 0.025 ~ 0.060
Gap between the valve Standard
Exhaust 0.025 ~ 0.060
stem and guide mm
Limit 0.20
Valve guide inside diameter mm 8.07 ~ 8.09
Standard 8.030 ~ 8.045
Intake
Limit 7.980
Valve stem diameter mm
Standard 8.025 ~ 8.040
Exhaust
Limit 7.975

- 21 -
 ENGINE SPECIFICATIONS
Model
FE F2
Item
Intake 0.5
Valve head thickness mm
Exhaust 1.0
Intake 45°
Valve face angle
Exhaust 45°
Valve spring outer free Standard 52.2
length mm Limit 50.6
Valve spring inner free Standard 47.7
length mm Limit 46.3
Valve spring squareness mm 1.81 or less
Rocker arm and shaft
Gap between the arm and Standard 0.016 ~ 0.061
shaft mm Limit 0.10
Rocker arm shaft diameter mm 15.966 ~ 15.984
Rocker arm inside diameter mm 16.000 ~ 16.027
Cam shaft
Cam shaft deflection limit mm 0.03
Standard 0.08 ~ 0.16
Cam shaft end play mm
Limit 0.20
No. 1 0.035 ~ 0.085
No. 2 0.065 ~ 0.115
Journal oil clearance mm No. 3 0.065 ~ 0.115
No. 4 0.065 ~ 0.115
No. 5 0.035 ~ 0.085
Oil clearance limit mm 0.15
No. 1 31.940 ~ 31.965
No. 2 31.910 ~ 31.935
Standard journal diameter
No. 3 31.910 ~ 31.935
mm
No. 4 31.910 ~ 31.935
No. 5 31.940 ~ 31.965
Journal wear limit mm 0.05
Standard 37.102
Intake
Limit 36.902
Cam height mm
Standard 37.102
Exhaust
Limit 36.902
Connecting rod and bearing
Length (distance between the holes) mm 135.95 ~ 136.05 158.45 ~ 158.55
Bending limit (for every 100mm) mm 0.04
Small end diameter mm 21.943 ~ 21.961
Clearance between the small end and piston pin mm 0.015 ~ 0.010

- 22 -
 ENGINE SPECIFICATIONS
Model
FE F2
Item
Standard 0.110 ~ 0.262
Large end play
Limit 0.30
Oil clearance on large end Standard 0.027 ~ 0.067
mm Limit 0.10
Bearing under-size mm 0.025, 0.50, 0.75
Crank shaft and bearing
Standard 50.940 ~ 50.955
Crank pin diameter mm Wearing limit 0.05
Grinding limit 0.75
Standard 59.937 ~ 59.955
Main journal diameter
Wearing limit 0.05
mm
Grinding limit 0.75
Main journal oil clearance Standard 0.031 ~ 0.049
mm Limit 0.08
Main bearing under-size mm 0.25, 0.50, 0.75
Crank shaft deflection limit mm 0.03
Standard 0.08 ~ 0.18
End play mm
Limit 0.30
Thrust bearing over-size mm 0.25, 0.50, 0.75
Cylinder block, piston, and piston pin
Block surface distortion limit mm 0.15
Cylinder bore diameter Standard 86.000 ~ 86.019
mm Wearing limit 0.15
Cylinder boring amount mm 0.25, 0.50
Piston diameter mm 85.944 ~ 85.964
Gap between piston and Standard 0.036 ~ 0.075
cylinder mm Limit 0.15
Piston over-size mm 0.25, 0.50
Top compression ring 0.03 ~ 0.07
Gap between piston ring
Second compression ring 0.03 ~ 0.07
and ring groove mm
Limit 0.15
Top compression ring 1.520 ~ 1.540
Piston ring groove width
Second compression ring 1.520 ~ 1.540
mm
Oil control ring 4.020 ~ 4.040
Top compression ring 0.20 ~ 0.35
Piston ring end clearance Second compression ring 0.15 ~ 0.30
mm Oil control ring 0.3 ~ 0.9
Limit 1.0
Piston ring over-size mm 0.25, 0.50
Diameter mm 21.947 ~ 21.980
Piston pin
Installation pressure kN (kg) 5 ~ 15 (500 ~ 1500)

- 23 -
 TORQUE SPECIFICATIONS
Unit : N·m (kgf·cm)
Model
FE F2
Item
Cylinder head cover 3.9~ 5.9 (40~ 60)
Rocker shaft assy 18~ 26 (180~ 270)
Cold 80~ 86 (820~ 880)
Cylinder head
Hot 93~ 98 (950~ 1000)
Upper 8~ 12 (80~ 120) 6.9~ 9.8 (70~ 100)
Timing belt cover
Lower 6.9~ 7.8 (70~ 80) 6.9~ 9.8 (70~ 100)
Cam shaft pulley lock bolt 47~ 65 (480~ 660)
Timing tensioner lock bolt 20~ 34 (200~ 350) 37~ 52 (380~ 530)
Drive plate 24~ 26 (240~ 270)
Crank shaft pulley 29~ 32 (300~ 330) 32~ 37 (330~ 380)
Timing belt crank pulley bolt 177~196 (1800~ 2000)
Front housing assy 19~ 25 (190~ 260)
Rear cover assy 8~ 12 (80~ 120)
Oil pan 7~ 12 (70~ 120)
M6 8~ 12 (80~ 120)
Oil strainer
M8 16~ 23 (160~ 230)
M8 19~ 25 (190~ 260)
Oil pump
M10 37~ 52 (380~ 530)
Oil pressure switch 12~ 18 (120~ 180)
Main bearing cap 82~ 88 (840~ 900)
Connecting rod cap 50~ 55 (510~ 560) 65~ 69 (660~ 700)
Intake manifold 19~ 30 (190~ 310)
Exhaust manifold 22~ 28 (220~ 290)
Spark plug 15~ 23 (150~ 230)
Cooling fan 8~ 11 (80~ 110)
M8 19~ 30 (190~ 310)
Cooling fan bearing
M10 37~ 52 (380~ 530)
Cooling fan bracket — 64~ 89 (650~ 910)
Water pump 19~ 25 (190~ 260)
Thermostat cover 19~ 30 (190~ 310)
Alternator bracket 37~ 52 (380~ 530)
Alternator strap 19~ 25 (190~ 260)
Alternator flange bolt 19~ 30 (190~ 310)
Air cleaner bracket 19~ 25 (190~ 260)
Carburetor 12~ 17 (120~ 170)
Fuel pump 16~ 22 (160~ 220)

- 24 -
 TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
The engine will not start. The fuel tank is empty. Fill fuel tank.
The battery is not fully charged. Charge battery.
The connections at the battery are Check and tighten battery
loose or they have corrosion. connections.
The starter system has a problem. Check electrical circuit for starter.
There are damaged parts in the Repair engine.
engine.
The valves are worn or damaged. Install new valves.
The piston rings are worn or have Install new piston rings.
damage.
The fuel system has a problem. Check and repair fuel system.
Ignition timing is not correct. Adjust timing.
Fuel line has a restriction. Clean or use new fuel lines.
Fuel filter has a restriction. Install a new fuel filter.
Ignition system does not operate Check and repair ignition system.
correctly.
The engine does not run smoothly. The valve mechanism does not Check and repair valve mechan-
operate correctly. ism.
The cylinder head has cracks. Install a new cylinder head.
The head gasket has a leak. Install a new gasket.
There is a leak in the intake system. Check and repair intake system.
Engine is too hot. Check cooling system.
Fuel lines or fuel filter has a Clean or use new fuel lines.
restriction.
The ignition timing is not correct. Adjust timing.

The engine does not have enough The fuel is the wrong type. Fill tank with correct fuel.
power. The air filter is dirty. Install a new air filter.
The ignition timing is not correct. Adjust timing.
The valve mechanism does not Check and repair valve mechan-
work correctly. ism.
The piston assemblies are worn or Install new pistons.
damaged.
The exhaust system has Clean parts or install new muffler
restrictions. or pipes.
Fuel lines or fuel filter has a restric- Clean or use new fuel lines and
tion. filter.
Engine is too hot or too cold. Check cooling system.
Cylinder head gasket leaks. Install a new gasket.

- 25 -
 TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
There is noise inside the engine. The main bearings are worn or Install new main bearings.
damaged.
Engine is too hot. Check and repair cooling system.
Valves are not adjusted correctly. Adjust valves.
The bearings for the connecting Install new bearings.
rods are worn or damaged.
The pistons are worn or damaged. Install new pistons.
Valve spring is broken. Install new valve springs.
There is not enough oil in the Fill engine with correct oil.
engine.
The flywheel is loose. Tighten capscrews for flywheel.
A connecting rod is bent. Repair engine.
There is a leak in the exhaust Repair exhaust system.
system.
The valve mechanism does not Check and repair valve mechan-
operate correctly. ism.
Spark plugs are dirty. Install new spark plugs.
The engine gets too hot. There is not enough coolant in the Fill cooling system.
cooling system.
The air filter has a restriction. Install a new air filter.
The water pump has damage. Install a new water pump.
The radiator is dirty. Clean or repair the radiator.
The cooling system has restric- Check radiator and hoses.
tions.
The belt for the water pump is worn Check and adjust the belt.
or not adjusted correctly.
The thermostat has damage. Install a new thermostat.
The exhaust system has restric- Check and repair exhaust system.
tions.
Ignition timing is not correct. Adjust timing.
Cylinder head gasket leaks. Install a new head gasket.
Engine compression is not correct. Check and repair engine.

- 26 -