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 components in solvent.
- Dry the components with compressed air.
- Inspect the camshaft bearing journals (1) for scoring or excessive wear.
- Inspect the camshaft valve lifter lobes (2) for scoring or excessive wear.
- Inspect the camshaft position (CMP) actuator oil passages (3) for restrictions.
- Inspect the threaded bolt hole (4) in the front of the camshaft for damaged threads or debris.
- Inspect the camshaft sprocket pin (5) for damage.
- Inspect the camshaft retainer plate for wear or a damaged sealing gasket.
- If the camshaft retainer plate sealing gasket is not cut or damaged, it may be used again.
Using a micrometer (1), measure the camshaft journals for wear and out-of-round. Engine Mechanical Specifications (L84)
- If the camshaft bearing journals are out-of-round, replace the camshaft.
- If the camshaft bearing journal diameter is not within specification, replace the camshaft.
Using a micrometer (1), measure the camshaft lobes for wear. Engine Mechanical Specifications (L84)
Measure the camshaft runout.
- Mount the camshaft in wooden V-blocks or between centers on a fixture.
- Using the J-7872 Magnetic Base Dial Indicator Set (1), measure the runout of the intermediate camshaft bearing journals.
- If camshaft runout is not within specification, the camshaft is bent and should be replaced. Engine Mechanical Specifications (L84)
Inspect the camshaft bearings (1) for the following:
- Excessive wear, evidence of galling, pitting, scoring, or embedded debris. The appearance of the bearing material being different shades of gray are considered normal, and are not guideline for camshaft bearing (1) replacement. Measure the camshaft bearing inside diameter (ID) as required for an over-sized condition. Engine Mechanical Specifications (L84)
- Proper fit in the engine block (2), camshaft bearings (1) have an interference fit to the engine block and should not be loose in the engine block bearing bores.
- The oil lubrication feed hole in the camshaft bearing (1) must be in alignment with the drilled out passage in the engine block (2).
- The oil lubrication feed hole is not plugged by debris.
- Camshaft bearings (1) with excessive wear or scoring must be replaced.
- Camshaft bearings (1) with excessive wear, galling, pitting, scoring, or embedded debris must be replaced.
Clean the CMP actuator with cleaning solvent.
- Dry the components with compressed air.
- Inspect the CMP actuator for a broken spring (1).
Inspect the CMP actuator for the following conditions:
- Improper positioning of the CMP reluctor wheel (2). The CMP actuator return spring should reposition the CMP reluctor wheel to the PARK position. Inspect for proper alignment of the mark on the face of the CMP sprocket (1) with the flat edge of the reluctor wheel. If the CMP reluctor wheel is not properly positioned, the internal components of the actuator are sticking or the return spring is broken and the CMP actuator should be replaced as an assembly.
- Nicked or damaged edges on the CMP reluctor wheel (2)
- Damaged timing CMP sprocket teeth
- NOTE:
- The inspection procedure is provided for diagnostic purposes only.
- Do not use the camshaft position actuator solenoid valve again. Install a NEW valve during assembly.
Inspect the camshaft position actuator for dirt, debris, or restrictions within the oil passages (1, 2).
Inspect the camshaft position actuator solenoid valve for the following conditions:
- Dirt, debris, or restrictions within the oil passages (1)
- Damaged threads (2)
If the threads of the valve are damaged, also inspect the threads in the front of the camshaft for damage.
- Dirt, debris, or restrictions within the oil inlet (3)
If debris is detected, the engine assembly should be inspected to determine the source of contamination.
Inspect for a sticking valve spool or broken valve spool spring.
- Depress the valve spool into the housing. The valve should move freely with no binding or sticking and minimal resistance inward. When released, the valve spring should return the spool to the proper extended position (1) of 6.52 - 6.92 mm (0.257 - 0.272 in).
Clean the components with cleaning solvent.
- Dry the components with compressed air.
- Inspect the timing chain (1) for binding or wear.
- Inspect the crankshaft sprocket (2) for worn, damaged, or chipped teeth.
- Inspect for a damaged keyway.
- Inspect for worn oil pump drive splines.
Inspect the timing chain tensioner for the following conditions:
- Damaged or broken tension spring (1).
- Excessive wear or scoring on the chain guide surfaces (2, 3).
Clean the crankshaft balancer (1) in solvent.
- Clean the belt grooves of all dirt or debris with a wire brush.
- Dry the crankshaft balancer (1) with compressed air.
- Inspect the crankshaft balancer (1) for the following conditions:
- Worn, grooved, or damaged hub seal surface.
- A crankshaft balancer (1) hub seal surface with excessive scoring, grooves, rust or other damage must be replaced.
- Minor imperfections on the crankshaft balancer (1) hub seal surface may be removed with polishing compound or fine grade emery cloth.
- Dirty or damaged belt grooves:
The crankshaft balancer (1) belt grooves should be free of any nicks, gouges, or other damage that may not allow the belt to track properly.
- Minor imperfections may be removed with a fine file.
- Worn, chunking, or deteriorated rubber between the hub and pulley.
NOTE:In order for the belt to track properly, the belt grooves should be free of all dirt or debris.
Inspect the intake manifold cylinder head deck for warpage.
- Place a straight edge (1) across the intake manifold cylinder head deck surface.
Position the straight edge (1) across a minimum of two runner port openings and check for warpage using a feeler gage (2). Engine Mechanical Specifications (L84)
- Clean the valve rocker arm cover and inspect for the following:
- Inspect the valve rocker arm cover for cracks or other signs of damage.
- Inspect the valve rocker arm cover mating surfaces for damage.
- Inspect the ventilation system passages for restrictions.
- NOTE:
Parts that are to be used again must be marked, sorted or organized for assembly.
Mark, sort, or organize the components for assembly.
- Clean the components with cleaning solvent.
- Dry the components with compressed air.
- Inspect the valve rocker arms bearings (2) for binding or roughness.
- Inspect the valve rocker arm pushrod sockets (3) and valve stem mating surfaces (1). These surfaces should be smooth with no scoring or exceptional wear.
- Inspect the pushrods for worn or scored ends. These surfaces should be smooth with no scoring or exceptional wear.
- Inspect the pushrods for bends. Roll the pushrod on a flat surface to determine if the pushrod is bent.
- Inspect the pushrod oil passages for restrictions.
- Inspect the rocker arm pivot supports for cracks, wear, or other damage.
- NOTE:
Components that are to be used again must be marked, sorted or organized for assembly.
Clean the components in cleaning solvent.
- Dry the components with compressed air.
- Inspect the valve lifters for the following conditions:
- Broken or collapsed spring (1)
- Worn pushrod socket (2)
- Plugged lubrication hole (3)
- Plugged lifter oil switching hole (4)
- Flat spots on the roller (5)
- Worn or damaged roller bearing (6)
The roller should rotate freely with no binding or roughness.
- Scuffed or worn sides (7)
Inspect the valve lifter guides for the following conditions:
- Cracks or damage (1)
- Excessive wear in the lifter mounting bores (2)
- WARNING:
Refer to Safety Glasses Warning .
NOTE:- When cleaning a cylinder head in a thermal type oven, do not exceed 204°C (400°F).
- Be careful not to scuff the chamber.
Clean the following components:
- Use the J-8089 Carbon Removal Brush (1) in order to remove the carbon from the combustion chambers.
- Gasket surfaces
- Valve stems and heads on a buffing wheel
- Bolt hole threads
- Remove all dirt, debris, or threadlocking material from the bolt holes.
Inspect the fuel rail injector bores and clean with EN-47909 Injector Bore and Sleeve Cleaning Kit (1), if required.
- Inspect the cylinder head for the following conditions:
- Cracks in the exhaust ports and combustion chambers
- External cracks in the water chambers
- Gasket surfaces for excessive scratches or gouging
- Bolt hole threads for debris or damaged threads
Inspect the cylinder head for warpage. Engine Mechanical Specifications (L84)
Using the J-9666 Valve Spring Tester (1), measure the valve spring tension. Engine Mechanical Specifications (L84) .
- NOTE:
Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
Clean the cover in solvent. Remove the sealant from the front cover to the oil pan surface.
- Dry the cover with compressed air.
- Inspect the gasket sealing surfaces (1) for excessive scratches or gouging.
- Inspect the threaded bolt holes (2, 3, 5) for damaged threads or debris.
- Inspect the camshaft position sensor pass-thru hole and sealing surface (4) for excessive scratches or gouging.
- Inspect the oil flow control valve connector pass-thru hole and sealing surface (6) for excessive scratches or gouging.
Clean the exhaust manifold (1) and heat shield (2) in solvent.
- Dry the exhaust manifold (1) with compressed air.
- Inspect the exhaust manifold (1) to the cylinder head exhaust manifold gasket surface for excessive scratches or gouging.
- Inspect for a loose, damaged, or cracked heat shield (2).
- Inspect the heat shield bolts (3) for damaged threads.
- Inspection the spark plug wire for the following conditions:
- Correct routing of the spark plug wires. Incorrect routing may cause cross-firing.
- Inspect for any signs of cracks or splits in the wires.
- Inspect each boot for the following conditions:
- Tearing
- Piercing
- Arcing
- Carbon tracking
- Corroded terminals
- If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or on a terminal, replace the wire and the component connected to the wire.
Refer to Safety Glasses and Compressed Air Warning .
Refer to Safety Glasses and Compressed Air Warning .
Refer to Safety Glasses and Compressed Air Warning .
Refer to Safety Glasses and Compressed Air Warning .
Refer to Safety Glasses and Compressed Air Warning .
Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be necessary to accurately identify conditions that may affect engine operation.