Cleaning and Inspection Procedure - Required

WARNING: This page is about a different variant/trim than selected.

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Clean the flex plate (3) in solvent.

WARNING:

Refer to Safety Glasses and Compressed Air Warning

Dry the flex plate (3) with compressed air.
Inspect the flex plate (3) for the following conditions:
1. Stress cracks around the flex plate to torque converter mounting bolt hole locations (1) and flex plate to crankshaft (2, 4)
2. Cracks at welded areas that retain the ring gear onto the flex plate (3)
3. Damaged or missing ring gear teeth (5)
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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.
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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.
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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.
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Inspect the timing belt (1) for grooves, pitting, fraying, or missing teeth.
Replace the timing belt (1) if damaged.
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Clean the oil pump sprocket (1) surfaces.
Inspect the oil pump sprocket (1) for grooves, scoring, scratches, pitting, or embedded bearing material.
Replace the oil pump sprocket (1) if damaged.
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Clean the 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.
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Clean the timing chain guide (1) surfaces.
Inspect the timing chain guide (1) for signs of cracking or wear.
Replace the timing chain guides (3, 7, 8, 10) if wear exceeds 1.12 mm (0.045 in) of depth on the chain guide surface.
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Clean the timing chain tensioner (1) surfaces.
Inspect the timing chain tensioner (1) for wear.
Replace the timing chain tensioner (1) if damaged.
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Clean the timing chain tensioner (1) surfaces.
Inspect the timing chain tensioner (1) for wear.
Replace the timing chain tensioner (1) if damaged.
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Clean the fuel injection pump driven sprocket (1) surfaces.
Inspect the fuel injection pump driven sprocket (1) for grooves, excessive wear, chipping, or embedded bearing material.
Replace the fuel injection pump driven sprocket (1) if damaged.
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Clean the crankshaft sprocket (1) surfaces.
Inspect the crankshaft sprocket (1) for grooves, excessive wear, chipping, or embedded bearing material.
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Clean the 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.
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Clean the timing chain guide (1) surfaces.
Inspect the timing chain guide (1) for signs of cracking or wear.
Replace the timing chain guides (3, 7, 8, 10) if wear exceeds 1.12 mm (0.045 in) of depth on the chain guide surface.
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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.
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Clean the camshaft housing (1) in solvent.
Inspect the camshaft housing (1) for damage or cracking. A cracked or damaged camshaft housing may:
1. Leak engine oil
2. Affect crankcase ventilation
3. Interfere with the camshafts
4. Allow water or condensation to enter the engine
Inspect the exterior of the camshaft housing (1) for the following conditions:
1. Damage to the camshaft housing bolt holes (2)
2. Damage to the camshaft housing injector bracket bolt holes (3)
3. Damage to the positive crankcase ventilation valve (4).
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Inspect the interior of the camshaft housing for the following conditions:
1. Inspect the camshaft housing for cracks, casting imperfections, or damage.
2. Inspect the camshaft housing seal locations (2) for cracks or damage.
3. Inspect the crankcase ventilation oil separator cover (1) for cracks or damage.
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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.
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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.