Cleaning and Inspection Procedure - Required
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 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.
Clean the crankshaft (1) with solvent.
- Thoroughly clean all oil passages and inspect for restrictions or burrs.
- Dry the crankshaft (1) with compressed air.
- Inspect the 7 crankshaft bearing journals (2) and 6 connecting rod bearing journals (3) for wear:
- Grooves or scoring
- Scratches
- Pitting or embedded bearing material
- Inspect for grooves, scoring, scratches, pitting, or embedded bearing material in the following components:
- Oil pump drive belt sprocket teeth
- Crankshaft sensor sprocket teeth
- Timing chain sprocket teeth
- Damaged or missing crankshaft gear teeth (4)
Inspect crankshaft bearings (1) for craters or pockets. Flattened sections on the bearing halves also indicate fatigue.
Inspect the crankshaft bearings (1) for excessive scoring or discoloration.
- Inspect the crankshaft bearings (1) for dirt or debris embedded into the bearing material.
Inspect the crankshaft bearings (1) for improper seating indicated by bright, polished sections of the bearing.
- NOTE:
- The crankshaft main bearings are a precision insert type. Main bearing caps are machined with the engine block, for proper clearance, and cannot be shimmed or filed for bearing fit. If the clearances are found to be excessive, new bearings and/or engine block and cap repair or replacement may be required.
- Do not rotate the crankshaft while gaging plastic is between the crankshaft journal and the bearing surface.
- The crankshaft bearing clearances are critical. Excessive bearing clearance may affect crankshaft position sensor signals and may affect diagnostics and system operation.
- Remove the bearing cap side bolts prior to cap removal.
Remove the bearing caps, bearing half, and bolts.
- Install gaging plastic (1) onto the crankshaft journal. Install the gaging plastic the full width of the crankshaft bearing journal.
- Install and tighten the bearing caps, bearing half, and bolts. Engine Mechanical Specifications
- Remove the bearing caps, bearing half, and bolts.
Using the scale supplied with the plastic gaging kit, measure the gaging plastic (1) at its widest area.
- If the gaging plastic (1) shows irregularity in the journal, exceeding 0.025 mm (0.001 in), remove the crankshaft and measure the journal with a micrometer.
- If clearance cannot be brought to specifications, replace the crankshaft or engine block as required. Engine Mechanical Specifications
- Crankshaft bearing clearance is calculated by using:
- Crankshaft bearing bore diameter
- Crankshaft bearing journal diameter
- Crankshaft bearing thickness
- Measure the crankshaft bearing play:
- Compare the width of the flattened plastic thread to the measuring scale.
- For the permissible crankshaft bearing clearance. Engine Mechanical Specifications
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 crankshaft sprocket (1) surfaces.
- Inspect the crankshaft sprocket (1) for grooves, excessive wear, chipping, or embedded bearing material.
- Replace the crankshaft sprocket (1) if damaged.
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.
- 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)
Clean the valve rocker arms (1) and hydraulic valve lash adjusters (2) with solvent.
- Inspect the valve rocker arms (1).
- Inspect the hydraulic valve lash adjusters (2).
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.
Inspect the timing belt (1) for grooves, pitting, fraying, or missing teeth.
- Replace the timing belt (1) if damaged.
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.
Clean the 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 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 primary timing chain tensioner (1) surfaces.
- Inspect the timing chain tensioner (1) for wear.
- Replace the timing chain tensioner (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.
- CAUTION:
The glow plug bore MUST be cleaned prior to glow plug installation. If the glow plug bore is not cleaned of carbon buildup prior to glow plug installation, it may cause severe damage to the glow plug. If the glow plug is damaged, the glow plug bore and combustion chamber must be cleaned of all debris, and the glow plug must be replaced.
Using the EN-52074 Glow Plug Bore Reamer (1), clean the glow plug bore. Hole must be free of lubricant and grease.
Different classes of bearing can be used for a crankshaft bearing to reduce bearing clearance. The stronger of the two bearing must be inserted in the crankshaft bearing cap.