Cleaning and Inspection Procedure - Conditional
The following cleaning and inspection and/or overhaul steps are ONLY to be performed as determined necessary based on the condition of the part being removed with the intention of reinstallation. The labor time to perform any of these steps is not included in the base labor time and if required would need to be documented and submitted as Other Labor Hours for warranty claim reimbursement. A description of the repairs performed must be documented in the technician correction comments.
Remove any old thread sealant, gasket material or sealant from the cylinder head (1).
- Clean all cylinder head surfaces with non-corrosive cleaning solvent.
- Clean the oil galleries until all debris is removed.
- Remove any carbon deposits from the combustion chamber.
- Dry the cylinder head with compressed air.
- Inspect the cylinder head for the following:
- Cracks, damage or pitting in the combustion chambers
- Coolant leaks or damage to the deck face sealing surface
- Damage to any gasket surfaces
- Burnt or eroded areas in the combustion chamber
- Cracks in the exhaust ports and combustion chambers
- External cracks in the water passages
- Restrictions in the intake or exhaust passages
- Restrictions in the cooling system passages
- Rusted, damaged or leaking core plugs
- Inspect all the threaded holes for damage. Threads may be reconditioned with thread inserts.
- Inspect the sealing surfaces.
Inspect the cylinder head sealing surface for flatness. Use a straightedge (1). If the cylinder head sealing surface is uneven, replace the cylinder head. DO NOT machine the cylinder head.
- If the cylinder head is cracked or damaged, it must be replaced. No welding or patching of the cylinder head is allowed.
Clean the camshaft housing (1) in solvent.
- Dry the camshaft housing with compressed air.
- Inspect the camshaft housing for dents or damage to the exterior. A dented or damaged camshaft housing may:
- Leak engine oil
- Affect crankcase ventilation
- Interfere with the camshafts
- Inspect the exterior of the camshaft housing for the following conditions:
- Damage to the component mounting holes (2)
- Damage to the bolt holes (3)
- Damage to the sealing surfaces (4)
- Grooves, cracks, scratches and any other damage to the bearing bores (5)
NOTE:Only inspect the bearing bores if the camshafts have been removed.
Inspect the interior of the camshaft housing (1) for the following conditions:
- Cracks, casting imperfections or damage
- Cracks or damage to the sealing surfaces (3)
- Grooves, cracks, scratches and any other damage to the bearing bores (2)
NOTE:Only inspect the bearing bores if the camshafts have been removed.
- If any of the above conditions exist, replace the camshaft housing.
- NOTE:
Do not soak or submerge the camshaft position actuator magnet in solvent.
Clean the camshaft position actuator magnet electrical connector and mounting surface of dirt, debris or contamination.
- Dry the camshaft position actuator magnet with compressed air.
- Inspect the camshaft position actuator magnet for the following conditions:
- Damage to the sealing surface (1)
- Damage to the electrical connector (2)
- Damage to the mounting holes (3)
- Depress the valve (4) into the housing. The valve should move freely with no binding or sticking and minimal resistance inward.
- If any of the above conditions exist, replace the camshaft position actuator magnet.
- CAUTION:
If a turbocharger has failed, clean any turbocharger debris or excessive oil from the charge air cooler system before installing the new turbocharger. Failure to clean debris from the charge air cooler system will cause severe turbocharger and engine damage upon startup.
Completely inspect the compressor air intake turbocharger and all other engine components that may cause similar conditions before replacing the turbocharger. Symptoms - Engine Mechanical
- Clean all mating surfaces.
- Inspect all threaded holes for damage.
- Inspect the compressor and turbine blades for bent or broken conditions, and foreign material. PCV fluids and combustion product buildup are common and not a sign of failure.
- Using a straightedge and a feeler gauge, measure the cylinder head mating surface for warpage. A mating surface with warpage in excess of 0.2 mm (0.008 in) may cause an exhaust leak and may affect diagnostics and system performance.
- If any of the above conditions exist, replace the compressor air intake turbocharger.
- Check the turbocharger oil feed pipe for restrictions.
- Check the turbocharger coolant feed and return pipe for restrictions.
- If any of the above conditions exist, replace the turbocharger oil feed pipe, turbocharger coolant feed pipe, or turbocharger return pipe.
- NOTE:
Do not soak or submerge the engine coolant flow control valve in solvent.
Clean the engine coolant flow control valve (1) electrical connector, coolant passages, and mounting holes of dirt, debris or blockage.
- Dry the engine coolant flow control valve with compressed air.
- Inspect the engine coolant flow control valve for the following conditions:
- Damage to the mounting holes (2)
- Damage to the electrical connectors (3)
- Damage to the coolant passages and connection ports (4)
- If any of the above conditions exist, replace the engine coolant flow control valve.
Remove any remaining gasket or seal material from the intake manifold.
- Clean these intake manifold areas in solvent:
- Intake manifold gasket sealing areas
- Intake manifold passages
- Dry the intake manifold with compressed air.
- Inspect the intake manifold for the following conditions:
- Damage to the evaporative emission canister purge pump bolt holes (1)
- Damage to the intake manifold cover bolt holes (2)
- Damage to the intake manifold sealing surface (3 and 4)
- Damage to the throttle body sealing surface (5)
- Inspect the intake manifold sealing surface for warpage:
- Locate a straight edge across the lower intake manifold sealing surface.
- Insert a feeler gauge between the lower intake manifold and the straight edge. An intake manifold with warpage in excess of 0.50 mm (0.020 in) must be replaced.
- If any of the above conditions exist, replace the intake manifold.
Clean the positive crankcase ventilation oil separator (1) with solvent.
- Dry the positive crankcase ventilation oil separator with compressed air.
- Inspect the positive crankcase ventilation oil separator for the following conditions:
- Damage to the housing (1)
- Damage to the sealing surface (2)
- Damage to the mounting holes (3)
- If any of the above conditions exist, replace the positive crankcase ventilation oil separator.
Refer to Safety Glasses and Compressed Air Warning .