Cleaning and Inspection Procedure - Required
Clean the crankshaft balancer in solvent.
- Clean the belt grooves of all dirt or debris with a wire brush.
- Dry the crankshaft balancer with compressed air.
- Inspect the crankshaft balancer for the following conditions:
- Worn, grooved, or damaged hub seal surface
- A crankshaft balancer hub seal surface (2) with excessive scoring, grooves, rust or other damage must be replaced.
- Minor imperfections on the hub seal surface (2) may be removed with polishing compound or fine grade emery cloth.
- Dirty or damaged belt grooves (1)
- The balancer belt grooves (1) should be free of any nicks, gouges, or other damage that may not allow the belt to track properly.
- Minor imperfections may be removed with a fine file.
- Worn, chunking, or deteriorated rubber between the hub and pulley
NOTE:In order for the belt to track properly, the belt grooves should be free of all dirt or debris.
- Clean the valve rocker arm cover and inspect for the following:
- Inspect the valve rocker arm cover for cracks or other signs of damage.
- Inspect the valve rocker arm cover mating surfaces for damage.
- Inspect the ventilation system passages for restrictions.
- CAUTION:
When cleaning the sealing surfaces of engine components, DO NOT use bristle discs, abrasive pads, wire wheels or surface conditioning discs. These types of devices should not be used because they produce a very fine grit that is abrasive and known to cause internal engine damage. The bristle discs and pads are embedded with abrasive material and wear down as they clean, continually exposing fresh abrasive to the surface of the component.
NOTE:- Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
- Care must be used to avoid gouging or scraping the sealing surfaces.
- Do not use any other method or technique to remove sealant or gasket material from a part.
- Do not use abrasive pads, sand paper, or power tools to clean the gasket surfaces. Abrasive pads also produce a fine grit that the oil filter cannot remove from the oil. This grit is abrasive and has been known to cause internal engine damage. These methods of cleaning can cause damage to the component sealing surfaces.
Remove all gasket and sealing material using the EN-28410 Remover or equivalent.
- Clean the gasket sealing surfaces.
- Dry the cover with compressed air.
- Clean the threaded bolt holes (1).
- Clean the camshaft position sensor pass-thru hole and sealing surface (2).
- Clean the crankshaft sealing surfaces (4).
- Clean the camshaft position actuator magnet sealing surface (3)
- Clean the oil Pump flow control solenoid valve wire pass-thru hole and sealing surface (5).
Inspect the engine front cover for the following conditions:
- Damage to the engine front sealing surface (1)
- Damage to the engine front cover bolt holes (2)
- Damage to the camshaft position actuator magnet sealing surface (3)
- Damage to the camshaft position sensor sealing surfaces, bores and mounting hole threads (4)
- Damage to the crankshaft front oil seal bore (5)
- Repair or replace the engine front cover as necessary.
Clean the oil pump (1) sealing surfaces with solvent.
- Dry the oil pump sealing surfaces.
- Inspect the oil pump sealing surfaces.
- Remove all gasket and sealing material using the EN-28410 Remover or equivalent.
- NOTE:
- Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
- Care must be used to avoid gouging or scraping the sealing surfaces.
- Do not use any other method or technique to remove sealant or gasket material from a part.
- Do not use abrasive pads, sand paper, or power tools to clean the gasket surfaces. Abrasive pads also produce a fine grit that the oil filter cannot remove from the oil. This grit is abrasive and has been known to cause internal engine damage. These methods of cleaning can cause damage to the component sealing surfaces.
Clean the oil pan and oil pan components in solvent.
- Clean out debris from the bolt holes.
- Dry the oil pan and oil pan components with compressed air.
- Inspect the oil pan for the following conditions:
- Damage to the oil pan mounting holes (1)
- Damage to the oil pan cover threads (2)
- Damage to the oil pan cover surface and bores (3)
- Damage to the engine oil filter fitting threads (4)
- Damage to the oil pan drain plug threads (5)
- Damage to the oil pan high pressure port sealing surfaces (6)
- Gouges or damage to the oil pan sealing surfaces (7)
- Damage to the oil pan gasket area (8)
- Damage to the oil pan deflector mounting holes (9)
- Damage to the oil level indicator mounting threads (10)
- Damage to the oil level indicator sensor bore (11)
- Damage to the transmission case mounting holes (12)
Clean all sealing surfaces.
- Inspect the cylinder head (1) for warpage using a straight edge (2) and a feeler gauge (3). Engine Mechanical Specifications (L84) , or Engine Mechanical Specifications (L87)
- Inspect for loose threaded inserts or studs.
- Inspect for damaged or broken vacuum fitting.
- Inspect the intake manifold assembly for cracks or other damage.
- inspect for damaged intake manifold gasket sealing surfaces.
- Inspect for debris or restrictions within the passages of the manifold.
Clean all sealing surfaces.
- Dry the intake manifold with compressed air.
- Inspect the intake manifold cylinder head deck for warpage.
- Place a straight edge (1) across the intake manifold cylinder head deck surface.
- Inspect the intake manifold for the following conditions:
- Position the straight edge (1) across a minimum of two runner port openings and check for warpage using a feeler gage. Engine Mechanical Specifications (L84) , or Engine Mechanical Specifications (L87)
- Inspect the ventilation system passages for restrictions.
- Perform the following cleaning and inspection or overhaul steps, as necessary. ONLY perform steps when components are removed with the intention of reinstallation.
- Be careful not to scuff the chamber.
- Clean the following components of the combustion chamber:
- Use EN-8089 Carbon Removal Brush to remove the carbon from the combustion chambers.
- Gasket surfaces
- Clean the valve stems and heads on a buffing wheel
- Remove all dirt, debris, or adhesive patch material from the bolt holes.
- Inspect the cylinder head for the following conditions:
- Cracks in the exhaust ports and combustion chambers
- External cracks in the water chambers
- Gasket surfaces for excessive scratches or gouging
- Inspect the valve rocker arm cover mating surfaces for damage.
- Bolt hole threads for debris or damaged threads
Clean the flex plate in solvent.
- Dry the flex plate with compressed air.
- Inspect the flex plate for the following conditions:
- Damaged ring gear teeth (1)
- Stress cracks around the flex plate-to-crankshaft bolt hole locations (2)
- Welded areas (3) that retain the ring gear onto the flex plate for cracking
- 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.
- Remove any old thread sealant, gasket material or sealant using appropriate tools.
- 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 with compressed air.
Inspect the crankshaft bearings journals for damage or spun bearings. The crankshaft bearing journals are not repairable, if the crankshaft bearing journals are damaged the engine block must be replaced.
- Inspect the primary camshaft drive chain tensioner mounting surface on the engine block for burrs or any defects that would degrade the sealing of the NEW primary camshaft drive chain tensioner gasket.
- Inspect all sealing and mating surfaces for damage, repair or replace the engine block 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.
- Check the cylinder condition. Some light vertical marks may be visible on the cylinder wall. In these areas, check that the honing marks are still visible in this marked area. If they are, the cylinder surface has not been compromised and the engine block can be used.
- Inspect the cylinder walls for cracks or damage. The cylinder sleeves are not serviced separately, if the cylinders are damaged the engine block must be replaced.
- Inspect the engine block for cracks. Do not repair any cracks. If cracks are found, the engine block must be replaced.
- Repair any damaged threaded holes.
Inspect the camshaft bearings (1) for the following:
- Excessive wear, evidence of galling, pitting, scoring, or embedded debris. The appearance of the bearing material being different shades of gray are considered normal, and are not guideline for bearing replacement. Measure the bearing inside diameter (ID) as required for an over-sized condition. Engine Mechanical Specifications (L84) , or Engine Mechanical Specifications (L87)
- Proper fit in the engine block. Camshaft bearings have an interference fit to the engine block and should not be loose in the engine block bearing bores.
- The oil lubrication feed hole in the bearing must be in alignment with the drilled out passage in the block.
- The oil lubrication feed hole is not plugged by debris.
- Bearings with excessive wear or scoring must be replaced.
- Bearings with excessive wear, galling, pitting, scoring, or embedded debris must be replaced.
- NOTE:
If checking the operating range of the camshaft position magnet pintle, DO NOT energize the magnet with a 12V power supply. Use steps 2 thru 5 below to check pintle operating range.
Inspect the camshaft position magnet (1) for the following conditions:
- A damaged electrical connector
- An accumulation of dirt or debris in the recessed area around the pintle
- A build-up of burnt engine oil on the shaft of the pintle which may cause the pintle to stick and not move freely within the proper range of travel
- Holding the camshaft position magnet with the pintle facing upward, measure the pintle retracted position (a). Record the dimension.
Holding the camshaft position magnet (1) with the pintle facing downward, measure the pintle extended position (b). Record the dimension.
- Subtract the retracted dimension (a) from the extended dimension (b) to determine pintle travel. A properly moving pintle will travel 3.0 - 5.5 mm (0.12 - 0.22 in).
- If the pintle of the camshaft position magnet is binding or does not move within the proper range of travel, replace the camshaft position magnet as an assembly.
Clean the camshaft position actuator with cleaning solvent.
- Dry the components with compressed air.
- Inspect the camshaft position actuator for a broken spring (1).
Inspect the camshaft position actuator for the following conditions:
- Improper positioning of the camshaft position reluctor wheel. The actuator return spring should reposition the reluctor wheel to the PARK position. Inspect for proper alignment of the mark on the face of the sprocket (1) with the flat edge of the reluctor wheel (2). If the reluctor wheel is not properly positioned, the internal components of the actuator are sticking or the return spring is broken and the actuator should be replaced as an assembly.
- Nicked or damaged edges on the camshaft position reluctor wheel
- Damaged timing sprocket teeth
Inspect the camshaft position actuator for dirt, debris, or restrictions within the oil passages (1, 2, 3).
Clean the components with cleaning solvent.
- Dry the components with compressed air.
- Inspect the timing chain (1) for binding or wear.
- Inspect the crankshaft sprocket (2) for worn, damaged, or chipped teeth.
- Inspect for a damaged keyway.
- Inspect for worn oil pump drive splines.
Inspect the timing chain tensioner for the following conditions:
- Damaged or broken tension spring (1)
- Excessive wear or scoring on the chain guide surfaces (2, 3)
Refer to Safety Glasses Warning .
When cleaning the sealing surfaces of engine components, DO NOT use bristle discs, abrasive pads, wire wheels or surface conditioning discs. These types of devices should not be used because they produce a very fine grit that is abrasive and known to cause internal engine damage. The bristle discs and pads are embedded with abrasive material and wear down as they clean, continually exposing fresh abrasive to the surface of the component.
Do not attempt to repair the welded areas that retain the ring gear to the flex plate. Install a new flex plate.
Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant