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 camshaft housing (1) in solvent.
- Inspect the camshaft housing (1) for damage or cracking. A cracked or damaged camshaft housing may:
- Leak engine oil
- Affect crankcase ventilation
- Interfere with the camshafts
- Allow water or condensation to enter the engine
- Inspect the exterior of the camshaft housing (1) for the following conditions:
- Damage to the camshaft housing bolt holes (2)
- Damage to the camshaft housing injector bracket bolt holes (3)
- Damage to the positive crankcase ventilation valve (4).
Inspect the interior of the camshaft housing for the following conditions:
- Inspect the camshaft housing for cracks, casting imperfections, or damage.
- Inspect the camshaft housing seal locations (2) for cracks or damage.
- Inspect the crankcase ventilation oil separator cover (1) for cracks or damage.
Clean the camshaft components in solvent.
- Dry the components with compressed air.
- Inspect the camshaft bearing journals (1) and camshaft lobes (3) for following conditions:
- Excessive scoring or pitting
- Discoloration from overheating
- Deformation from excessive wear, especially the camshaft lobes (3)
- Inspect the hexagon (2) for damage.
- Inspect the threaded hole (4) for damage.
- If any of the conditions above exist on the camshafts, replace the camshafts.
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 engine oil cooler (1, 2).
- Inspect the engine oil cooler (1, 2).
- Replace the engine oil cooler (1, 2) 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.
- CAUTION:
The fuel injector must be cleaned with the proper cleaning equipment. DO NOT use abrasive cleaning methods, such as a metallic brush, to remove deposits. Cleaning an injector with improper tools will damage the fuel injector.
Using a soft bristle non-metallic brush and top engine cleaner, remove any deposits from the high pressure diesel fuel injector nozzle tip (1) and the copper washer sealing area before installation.
- Inspect the high pressure diesel fuel injector nozzle tip (1) for cracks, dents, or other damage.
- Inspect the high pressure diesel fuel injector nozzle tip (1) for any signs of discoloration.
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 the lower crankcase extension (1) in solvent.
- Inspect all sealing and mating surfaces for damage, and repair or replace the lower crankcase extension (1) if necessary.
- Inspect all threaded and through holes for damage or excessive debris.
- Check for roughness or end play in the oil pump drive shaft bearing (1).
Clean the oil pump (1) sealing surfaces with solvent.
- Dry the oil pump (1) sealing surfaces.
- Inspect the oil pump (1) sealing surfaces.
- Rotate the oil pump drive shaft and check for roughness.
Clean the timing chain upper cover (1).
- Inspect the timing chain upper cover (1) mating surfaces for damage.
- Replace the timing chain upper cover (1) if damaged.
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.
Clean and inspect the water pump (1).
- Clean and inspect the water pump mating surfaces.
- Inspect the water pump impeller for damage.
- Inspect the water pump shaft for looseness.
- Replace the water pump (1) if damaged.
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Courtesy of GENERAL MOTORS COMPANY
NOTE:- Install the crankshaft bearing caps in the same position as removed.
- The arrow (2) on the crankshaft bearing cap must shown in the front direction of the engine.
Crankshaft Bearing Cap (3) - Install [7x]
- Crankshaft Bearing Cap Bolt (1) - Install and hand tighten [14x]
- Tighten the 14 crankshaft bearing cap bolts (1) in sequence. Fastener Specifications
Inspect the bearing bore diameter (1) in cylinder block using the EN-8087 Cylinder Bore Gauge. Refer to Engine Mechanical Specifications for the recommended limits.
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NOTE:Organize the crankshaft bearing caps in the order they are removed.
Crankshaft Bearing Cap Bolt (1) - Remove and DISCARD [14x]
- Crankshaft Bearing Cap (2) - Remove [7x]
- NOTE:
- Ensure that the guide lugs (3) are seated properly.
- When using the original crankshaft bearing, ensure it is installed in the same position as removed.
Lubricate the crankshaft upper bearings with engine oil. Adhesives, Fluids, Lubricants, and Sealers
- Crankshaft Upper Bearing (1) - Install [7x]
When using NEW bearings, select the correct bearing based on the following procedure:
Measure the crankshaft bearing journal diameter with a micrometer gauge at the measuring points (1, 3) and (2, 4).
- Calculate the average crankshaft bearing journal diameter. Formula: (1. result + 2. result) / 2.
Refer to Engine Mechanical Specifications for the recommended limits.
- Clean and inspect all components for damage. Replace as needed.
Refer to Fastener Caution .
Refer to Torque-to-Yield Fastener Caution .