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.
- WARNING:
Clean the connecting rods (1) in solvent and dry with compressed air.
- Inspect the connecting rod (1) for the following:
- Signs of being twisted, bent, nicked or cracked
- Scratches or abrasion on the connecting rod (1) bearing seating surfaces
- If the connecting rod bores (2) contain minor scratches or abrasions, clean the bores in a circular direction with a light emery paper. DO NOT scrape the connecting rod (1) or connecting rod cap.
- If the beam of the connecting rod (1) is scratched or has other damage replace the connecting rod.
Clean the piston with a cleaning solvent. Do NOT wire brush any parts of the piston.
- Clean the piston ring grooves.
- Inspect the piston on the following:
- Cracked ring lands, skirts or pin bosses
- Ring grooves for nicks
- Eroded areas on the top of the piston (1)
- Scored or damaged skirts (2)
- Worn piston pin bores (3)
- If there is any excessive wear, replace the piston.
Measure the clearance between the piston pin (1) and the piston bore. Use the following procedure:
- Measure the piston pin outside diameter (a).
- Measure the piston bore diameter (b).
- Substract the piston pin outside diameter (a) from the piston bore diameter (b) to calculate the clearance.
- For the correct value of the clearance piston pin (1) in the piston (2). Engine Mechanical Specifications
Inspect the connecting rod piston pin bore for any signs of pitting or erosion. If any pitting or erosion is present replace the connecting rod.
- Measure the clearance between the piston pin (1) and the connecting rod bore. Use the following procedure:
- Measure the piston pin outside diameter (a).
- Measure the connecting rod bore diameter (b).
- Substract the piston pin outside diameter (a) from the connecting rod diameter (b) to calculate the clearance.
- For the correct value of the clearance piston pin (1) in the connecting rod (2). Engine Mechanical Specifications
- If there is excessive clearance, replace the piston pin (1) and repeat the measurements.
- If there is still excessive clearance, replace the connecting rod (2).
- If there is excessive clearance, replace the piston pin (1) and repeat the measurements.
- If there is still excessive clearance, replace the piston.
Install each piston ring to the cylinder (1) and measure the piston ring end gap at the points mentioned in the step below.
Measure piston ring end gap at point a:
- The piston compression upper ring end gap. Place the piston ring in the area of the bore where the piston ring will travel, approximately 10 mm (0.394 in) down from the deck surface. Engine Mechanical Specifications
- The piston compression lower ring end gap. Place the piston ring in the area of the bore where the piston ring will travel, approximately 10 mm (0.394 in) down from the deck surface. Engine Mechanical Specifications
- The piston oil ring rail end gap. Place the piston ring in the area of the bore where the piston ring will travel, approximately 10 mm (0.394 in) down from the deck surface. Engine Mechanical Specifications
- Measure piston ring end gap at point b:
- The piston compression upper ring end gap. Place the piston ring in the area of the bore where the piston ring will travel, approximately 42 mm (1.654 in) down from the deck surface. Engine Mechanical Specifications
- The piston compression lower ring end gap. Place the piston ring in the area of the bore where the piston ring will travel, approximately 42 mm (1.654 in) down from the deck surface. Engine Mechanical Specifications
- The piston oil ring rail end gap. Place the piston ring in the area of the bore where the piston ring will travel, approximately 42 mm (1.654 in) down from the deck surface. Engine Mechanical Specifications
- Measure piston ring end gap at point c:
- The piston compression upper ring end gap. Place the piston ring in the area of the bore where the piston ring will travel, approximately 140 mm (5.512 in) down from the deck surface. Engine Mechanical Specifications
- The piston compression lower ring end gap. Place the piston ring in the area of the bore where the piston ring will travel, approximately 140 mm (5.512 in) down from the deck surface. Engine Mechanical Specifications
- The piston oil ring rail end gap. Place the piston ring in the area of the bore where the piston ring will travel, approximately 140 mm (5.512 in) down from the deck surface. Engine Mechanical Specifications
- If the clearance is greater than the provided specifications, the piston rings must be replaced.
Measure the piston ring axial clearance (1). Compare the measurements with those provided below:
- The piston compression upper ring clearance. For the correct value of the clearance. Engine Mechanical Specifications
- The piston compression lower ring clearance. For the correct value of the clearance. Engine Mechanical Specifications
- The piston oil ring rail clearance. For the correct value of the clearance. Engine Mechanical Specifications
- If the clearance is greater than the provided specifications, replace the piston rings and repeat the measurements.
- If the clearance is still greater than the provided specifications, replace the pistons.
- Measure the engine cylinder bore. Engine Block Overhaul
Using a micrometer (2) or caliper at a right angle to the piston, measure the width of the piston (1) at 3 different measuring points from the bottom of the skirt.
- First measure point 13 mm (0.512 in) from the bottom of the skirt.
- Second measure point 38 mm (1.496 in) from the bottom of the skirt.
- Third measure point 68.2 mm (2.685 in) from the bottom of the skirt.
- Subtract the piston (1) diameter from the cylinder bore diameter in order to calculate the piston-to-bore clearance.
- For the correct value of the clearance piston to bore. Engine Mechanical Specifications
- If the clearance obtained through measurement is greater than these specifications and the cylinder bores are within the specification, replace the piston (1).
- Install the connecting rod bearings and the connecting rod bearing caps.
- Connecting Rod Bolt - Install and tighten - Fastener Specifications
Using an internal measuring device, measure the connecting rod bearing diameters at 3 different measuring points (1).
- Calculate the average connecting rod inner diameter.
Formula: (1. result + 2. result + 3. result) / 3
Using a micrometer gauge, measure the connecting rod journal diameter at 2 different measuring points between (1) and (3) and between (2) and (4).
- Calculate the average connecting rod journal diameter.
Formula: (1. result + 2. result) / 2.
- Subtract the average connecting rod journal diameter from the average connecting rod bearing diameter in order to determine the connecting rod bearing clearance.
- For the correct value of the connecting rod bearing clearance. Engine Mechanical Specifications
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.
Remove any old sealant or gasket material from the cylinder head.
- Clean all cylinder head surfaces with non-corrosive cleaning solvent.
- Blow out all the oil galleries using compressed air.
- Remove any carbon deposits from the combustion chamber (2).
- Inspect the cylinder head sealing surface for flatness using a straightedge (1). If the cylinder head sealing surface is uneven, replace the cylinder head. Do NOT machine the cylinder head.
- Inspect all the threaded holes for damage. Threads may be reconditioned with thread inserts.
- Inspect the cylinder head camshaft bearing surfaces for the following conditions:
- Excessive scoring or pitting.
- Discoloration from overheating.
- Deformation from excessive wear.
- If any of the above conditions exist on the camshaft bearing surfaces, replace the cylinder head.
Inspect the cylinder head (1) for the following:
- Cracks, damage, or pitting in the combustion chambers.
- Debris in the oil galleries, continue to clean the galleries until all debris is removed.
- Coolant leaks or damage to the deck face sealing surface, if coolant leaks are present, measure the surface warpage as described under cylinder head measurement deck flatness inspection.
- Damage to any gasket surfaces.
- Burnt or eroded areas in the combustion chamber.
- Cracks in the exhaust ports (3) and combustion chambers.
- External cracks in the water passages.
- Restrictions in the intake or exhaust ports (3).
- Restrictions in the cooling system passages.
- Rusted, damaged or leaking core plugs.
- Inspect the exterior of the camshaft housing ladder frame (2) for the following conditions:
- Damage to the camshaft housing ladder frame (4) bolt holes.
- Damage to the injector bore holes.
- Damage to the oil passages.
- Inspect the interior of the camshaft housing ladder frame (2) for the following conditions:
- Inspect the camshaft housing ladder frame (2), casting imperfections, cracks or damage.
- Inspect the camshaft housing ladder frame (2) seal locations (1) for cracks or damage.
- 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.
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 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 primary 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 primary 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.
Refer to Fastener Caution .
Refer to Torque-to-Yield Fastener Caution .
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.