Cleaning and Inspection Procedure - Required
Clean the 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 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.
- CAUTION:
Do not use a caustic solution to clean the aluminum engine block.
Dirt or debris will cause premature wear of the rebuilt engine. When internal engine components are serviced, care and cleanliness is important. An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in millimeters or thousandths of an inch. These surfaces should be covered or protected to avoid component damage. A liberal coating of clean engine oil should be applied to friction areas during engine assembly to provide lubrication during initial engine operation.
- Clean all the following areas with solvent:
- Sealing surfaces
- Cooling passages
- Oil passages
- Bearing journals
- Clean all threaded and through holes with solvent.
- Dry the engine block (1) with compressed air.
- Inspect the crankshaft bearing journals for damage or spun bearings. The crankshaft bearing journals are not repairable, if the crankshaft bearing journals are damaged the engine block assembly must be replaced.
- Inspect all sealing and mating surfaces for damage, repair or replace the engine block assembly if necessary.
- Inspect all threaded and through holes for damage or excessive debris.
- Inspect all bolts for damage, if damaged replace with NEW bolts only.
- Inspect the cylinder walls for cracks or damage. The cylinder sleeves are not serviced separately, if the cylinders are damaged the cylinder block assembly must be replaced.
- Inspect the engine block (1) for cracks. Do not repair any cracks. If cracks are found, the cylinder block assembly must be replaced.
Inspect the engine block for flatness and distortion along the diagonal. Use a straightedge (1) and a feeler gauge (2). If the deck surface is out of specification, replace the block. DO NOT machine the block. Engine Mechanical Specifications
Inspect the engine block for flatness and deflection along the length and width. Use a straightedge (1) and a feeler gauge (2). If the deck surface is out of specification, replace the block. DO NOT machine the block. Engine Mechanical Specifications
- NOTE:
If the cylinder sleeve measurements are not within the recommended limits, ream the cylinder bores with the recommended oversize.
Using the EN-8087 Cylinder Bore Gauge (1), inspect the cylinder bores for the following items. Engine Mechanical Specifications
- Wear of cylinder sleeve
- Cylinder sleeve diameter
- Tapering of cylinder sleeve
- Oval status of cylinder sleeve
Using the EN-8087 Cylinder Bore Gauge, measure the cylinder bores at the following points. Engine Mechanical Specifications
- Dimension a: 10 mm (0.394 in)
- Dimension b: 42 mm (1.654 in)
- Dimension c: 140 mm (5.512 in)
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 high pressure diesel fuel pump (1) mating surfaces.
- Inspect the high pressure diesel fuel pump (1) for damage.
- Replace fuel injection pump (1) if any damage is found.
- Inspect the high pressure diesel fuel pump shaft notch (2) for damage.
Inspect the keyway (1) on the sprocket for damage.
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.
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.
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 (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 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 timing chain tensioner (1) surfaces.
- Inspect the timing chain tensioner (1) for wear.
- Replace the timing chain tensioner (1) if damaged.
Clean the timing chain tensioner (1) surfaces.
- Inspect the timing chain tensioner (1) for wear.
- Replace the timing chain tensioner (1) if damaged.
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).
- 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.