Crankshaft and main bearing repair anchors this 38-page Utilev Mazda 2.2L engine service manual (OEM ID 76001980), which follows the engine job across ten UT forklift variants, UT15P through UT35P and UT20C through UT32C. This Utilev UT series service manual PDF also pulls the engine and puts it back, then works through the cylinder head, camshaft and valves, block distortion and bore checks, the oil pump, and the flywheel and ring gear. A compression check closes the book, with engine data and speeds split for 2007 and later emission compliant engines versus earlier ones, plus a torque table. Set intake valve clearance to 0.15 ±0.05 mm cold; oil pan capscrews take 8 to 12 N·m (70 to 106 lb. in) on a new gasket. Late shift, engine apart, nobody to ask. Bookmarks and a searchable text layer find any spec fast, and measuring your journals against factory limits first means the bearings you order fit the first time.
What's Inside This Utilev Mazda 2.2L Engine Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 5 | Serial Number |
| Engine Removal and Installation | 6-17 | Cylinder Head, Camshaft, And Valve Mechanism |
| Crankshaft and Main Bearings Repair | 18-22 | Crankshaft, Main Bearings, Oil Pan, Oil Strainer, Rear Cover, Front Cover |
| Cylinder Block Repair | 23 | Cylinder Block, Surface Distortion, Cylinder Bores, Pistons |
| Oil Pump Repair | 24-29 | Oil Pump Housing, Pump Cover, Outer Gear, Inner Gear, Plunger, Oil Seal |
| Flywheel and Ring Gear Repair | 30-31 | Flywheel, Flywheel Housing, Adapter Plate, Pin |
| Compression Pressure Check | 32-38 | Engine Specifications, Engine Data, Engine Speeds, 2007, And Later, Emission Compliant Engines, All Engines Except 2007 |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| CAM angle sensor mounting bolt torque | 19 to 25 N·m (14 to 18 lb. ft.) | p. 9 |
| CAM angle sensor output signal | 1 pulse (5 V)/rev | p. 10 |
| Oil strainer assembly capscrew torque | 8 to 12 N•m (70 to 106 lb. in) | p. 26 |
| Oil pan capscrew torque | 8 to 12 N•m (70 to 106 lb. in) | p. 26 |
| Valve Clearance (Intake, Engine Cold) | 0.15 ±0.05 mm | p. 33 |
| Valve Clearance (Exhaust, Engine Cold) | 0.35 ±0.05 mm | p. 33 |
| Compression Pressure (Gasoline) | 1130 kPa @ 270 rpm | p. 33 |
| Compression Pressure (LPG) | 1130 kPa @ 270 rpm | p. 33 |
| Thermostat Starts to Open | 82 ±1.5°C | p. 33 |
| Camshaft Cap Torque | 18 to 27 N•m | p. 36 |
| UT15P, UT18P, UT20P, UT25P | ||
| Idle Speed (1.5 to 2 Ton Lift Trucks) | 720 ±25 rpm | p. 33 |
| UT20P, UT25P, UT30P, UT35P, UT20C, UT25C, UT30C, UT32C | ||
| Idle Speed (2.0 to 3.5 Ton Lift Trucks) | 720 ±25 rpm | p. 33 |
Utilev Mazda 2.2L Engine Common Problems This Manual Covers
Utilev UT25P Mazda 2.2L engine CAM angle sensor not producing the specified output signal on voltage check
Verify ignition is OFF and disconnect the fuel injector connector first; page 10 warns the injector actuates if left connected at key ON. Tag and unplug the ignition coil connectors, turn ignition ON, measure across terminals A and D, and hand-rotate the drive for 1 pulse (5 V)/rev. If the signal is wrong, check the harness for open or short; if it tests good, replace the sensor and torque the bolt to 19 to 25 N·m per page 9.
Manual Section: CAM Angle Sensor p. 10Gas or LPG engine compression pressure low when checked at cranking speed
Remove the spark plugs carefully from the aluminum cylinder head, using penetrating oil if they bind, as the caution on page 32 directs, and disconnect the high tension wire at the ignition coil. Measure each cylinder against 1130 kPa at 270 rpm from page 33. Before refitting, apply a couple of drops of engine oil to the plugs and torque them to 15 to 23 N·m (page 37).
Manual Section: Compression Pressure Check p. 32Intake or exhaust valve clearance out of specification when measured on a cold engine
Measure valve clearance with the engine cold and adjust following the Valve Adjustment procedure. Set intake valves to 0.15 ±0.05 mm and exhaust valves to 0.35 ±0.05 mm, per the engine specifications on page 33. Recheck every valve after adjusting and before you refit the valve cover.
Manual Section: Valve AdjustmentCylinder head bottom surface warped when checked with a straight edge during head removal
Clean the head in solvent, following the solvent maker's safety procedures as page 11 warns, without damaging machined surfaces. Check the bottom surface and manifold faces with a straight edge and thickness gauge at the positions shown; maximum distortion is 0.15 mm, and grinding can remove no more than 0.2 mm. Fit a new gasket and torque head capscrews to 82 to 88 N·m in sequence (page 14).
Manual Section: Cylinder Head, Camshaft, and Valve Mechanism Repair p. 11Camshaft journal clearance in cylinder head beyond limit on plastic gauge check
Measure clearance with the camshaft installed: lay plastic gauge between each journal and cap, keep the camshaft from rotating, and torque cap capscrews to 18 to 27 N·m per page 12. Journals 1 and 5 should read 0.035 to 0.085 mm; journals 2, 3, and 4 read 0.065 to 0.115 mm. Over 0.15 mm, replace the cylinder head assembly.
Manual Section: Cylinder Head, Camshaft, and Valve Mechanism Repair p. 12Engine thermostat not starting to open at the specified temperature on the 2.2L engine
Replace the thermostat following the cooling system repair starting on page 28; it should start to open at 82 ±1.5°C (page 33). Never remove the radiator cap with the engine hot, since page 30 warns of burns from steam and boiling coolant. Fill with the specified coolant only, contact your dealer before using additives, then start the engine and check for leaks.
Manual Section: Cooling System Repair p. 28Frequently Asked Questions
What are the torque specifications for a Utilev UT25P, UT30P, UT25C, or UT30C?
The torque specifications for various components are listed in the manual. For example, the cylinder head capscrews must be tightened to 81 to 88 N•m (60 to 65 lb. ft.), and the camshaft cap bolts require 18 to 27 N•m (13 to 20 lb. ft.). p. 37
What is the correct intake valve clearance on the Mazda Mazda 2.2L Engine when the engine is cold?
The correct clearance for intake valves when the engine is cold is 0.15 ±0.05 mm (0.0059 ±0.002 in.). This adjustment is performed by loosening the lock nut and turning the adjustment screw. p. 31
What is the minimum oil pressure for the Mazda Mazda 2.2L Engine at governed rpm?
The minimum oil pressure at governed rpm is approximately 275 kPa (40 psi). If the pressure is less than this specification, the oil pump or engine bearings may need repair. p. 24
What is the correct torque for the connecting rod caps on the Mazda Mazda 2.2L Engine?
The connecting rod caps must be tightened to 66 to 70 N•m (49 to 52 lb. ft.). Ensure that identification marks made during disassembly are aligned before tightening. p. 36
What is the procedure for checking the thermostat operation?
The thermostat must begin to open at 82 ±1.5°C (180 ±3°F) and must be completely open at 95°C (203°F). Note that additives may damage the cooling system, so contact your dealer before using them (page 28). p. 28
Is this Utilev UT15P manual a download or a disc?
A single searchable PDF file of 38 pages, downloadable right after payment. Nothing ships, nothing waits in the mail.
Is printing allowed for this Utilev UT15P Service Manual?
Yes. Print the pages you need for the job in your own shop, and bin them when they get greasy.
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