Cleaning and Inspection Procedure - Required
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 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.
Clean the automatic transmission flex plate (3) in solvent.
- Dry the flex plate (3) with compressed air.
- Inspect the flex plate (3) for the following conditions:
- Stress cracks around the flex plate to torque converter mounting bolt hole locations (1) and flex plate to crankshaft (2, 4)
- Cracks at welded areas that retain the ring gear onto the flex plate (3)
- Damaged or missing ring gear teeth (5)
NOTE:Do not attempt to repair the welded areas that retain the ring gear to the flex plate. Install a NEW flex plate.
Clean the crankshaft pulley (1).
- Inspect the crankshaft pulley (1) for damage to belt drive surface and to crankshaft pulley hub.
- Inspect the crankshaft pulley (1) hub groove for damage or wear.
- Replace the crankshaft pulley (1) if any damage is found.
Clean the camshaft sprocket (1) surfaces.
- Inspect the camshaft sprocket (1) for grooves, excessive wear, chipping, or embedded bearing material.
- Replace the camshaft sprocket (1) if damaged.
- If the cylinder head (1) or ladder frame (2) is cracked or damaged, they must be replaced. No welding or patching of the is allowed.
- NOTE:
DO NOT soak or submerge the fuel rail or injectors in solvent.
Clean the exterior of the high pressure diesel fuel injection rail (4) and high pressure diesel fuel injectors in solvent.
- Inspect the high pressure diesel fuel injection rail (4) and components for the following conditions:
- Damage, debris, or restrictions to the high pressure diesel fuel injection rail (4)
- Damage, debris, or restrictions to the fuel ports (2) at the high pressure diesel fuel injection rail (4)
- Damage to the mounting area or threads on the high pressure diesel fuel injection rail (4)
- Damage to the holes of the high pressure diesel fuel sensor (1) and fuel pressure regulator (3)
- 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 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 the secondary timing chain (1) surfaces.
- Inspect the timing chain (1) for signs of excessive wear, chipping, or seizure of the timing chain links.
- Replace the timing chain (1) if damaged.
Clean the secondary timing chain guide (1) surfaces.
- Inspect the timing chain guide (1) for signs of cracking or wear.
- Replace the timing chain guides if wear exceeds 1.12 mm (0.045 in) of depth on the chain guide surface.
Clean the timing chain lower cover (1).
- Clean the timing chain lower cover mating surfaces.
- Inspect the timing chain lower cover mating surfaces for damage.
- Inspect the crankshaft rear oil seal bore for damage.
- Inspect the fuel pump access hole cover (2) for damage.
- Replace the timing chain lower cover (1) if damaged.
Clean the secondary timing chain tensioner (1) surfaces.
- Inspect the timing chain tensioner (1) for wear.
- Replace the timing chain tensioner (1) if damaged.