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 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 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.
Lay the camshaft position sensor exciter wheel (1) facedown on a flat surface to check for the straightness and wear.
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 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.
- 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.
Clean the camshaft housing (1) in solvent.
- Inspect the camshaft housing (1) for damage or cracking. A cracked or damaged camshaft housing may:
- Leak engine oil
- Affect crankcase ventilation
- Interfere with the camshafts
- Allow water or condensation to enter the engine
- Inspect the exterior of the camshaft housing (1) for the following conditions:
- Damage to the camshaft housing bolt holes (2)
- Damage to the camshaft housing injector bracket bolt holes (3)
- Damage to the positive crankcase ventilation valve (4).
Inspect the interior of the camshaft housing for the following conditions:
- Inspect the camshaft housing for cracks, casting imperfections, or damage.
- Inspect the camshaft housing seal locations (2) for cracks or damage.
- Inspect the crankcase ventilation oil separator cover (1) for cracks or damage.
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.
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.