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.
Clean the engine coolant flow control valve (1).
- Inspect the engine coolant flow control valve (1).
- Replace the engine coolant flow control valve (1) if any damage is found.
Clean the exhaust gas recirculation valve (1).
- Inspect the exhaust gas recirculation valve (1).
- Replace the exhaust gas recirculation valve (1) if any damage is found.
Clean the exhaust manifold (1) in solvent.
- Dry the exhaust manifold (1) with compressed air.
- Inspect the exhaust manifold (1) for damage.
Using a straightedge (2) and a feeler gauge, measure the exhaust manifold mounting face (3) for warpage. An exhaust manifold face with warpage in excess of 0.2 mm (0.008 in) may cause an exhaust leak and may effect diagnostics and system performance.
- An exhaust manifold (1) which does not fall within the specifications must be replaced.
Clean the intake manifold mating surfaces.
- Inspect the intake manifold (1) for damage.
- Inspect the intake manifold (1) for cracks and fractures.
- Inspect all 12 intake runner valves (5) for damage.
- Clean the throttle body sealing surface (3).
- Clean the exhaust gas recirculation cooler outlet pipe sealing surface (2).
- Clean the intake manifold to cylinder head sealing surface (4).
- Replace the intake manifold (1) as necessary.
Visually inspect the intake manifold mounting face (1) for cracks, warpage, or damage. If any damage is found replace the intake manifold. An intake manifold face with cracks warpage or damage may cause an intake leak and may effect diagnostics and system performance.
Clean all threads on the compressor air intake turbocharger, if necessary.
- Clean all sealing surfaces.
- Inspect the wastegate regulator mechanism (1) for functionality.
- Inspect the turbine blades for damage or foreign material.
- Inspect the turbine blade shaft for excessive radial and axial end play.
- Inspect the compressor air intake turbocharger for cracks or other damage.
- Inspect the compressor air intake turbocharger mating surface for flatness.