Inspection and Service Procedures Part 2

TIMING CHAIN AND SPROCKETS CLEAN AND INSPECT
1. Clean the components with cleaning solvent.

CAUTION: Wear safety glasses in order to avoid eye damage.

2. Dry the components with compressed air.

NOTICE: Do not replace only the tensioner or the chain to correct a noise condition caused by the camshaft drive components. When replacing the tensioner or chain to correct a noise condition all of the camshaft drive components must be replaced.





3. Inspect the timing chain for binding or wear.





4. Inspect the timing chain guide pads for unusual contact, excessive wear, or chain misalignment.





5. Inspect the camshaft and crankshaft sprockets for:
- Worn valleys between the sprocket teeth
- One edge of the sprocket teeth worn
- Crankshaft sprocket keyway for wear
- Crankshaft sprocket key for wear

VALVE ROCKER ARM AND PUSH RODS CLEAN AND INSPECT

IMPORTANT: Parts that are to be reused must be marked, sorted or organized for assembly.

1. Mark, sort, or organize the components for assembly.
Refer to Separating Parts. Description and Operation
2. Clean the components with cleaning solvent.

CAUTION: Wear safety glasses in order to avoid eye damage.

3. Dry the components with compressed air.
4. Inspect the valve rocker arms bearings for binding or roughness.





5. Inspect the valve rocker arm pushrod sockets and valve stem mating surfaces. These surfaces should be smooth with no scoring or exceptional wear.
6. Inspect the rocker arm pedestals and mounts for damage.





7. Inspect the pushrods for worn or scored ends. These surfaces should be smooth with no scoring or exceptional wear.
8. Inspect the pushrods for bends. Roll the pushrod on a flat surface to determine if the pushrod is bent.
9. Inspect the pushrod oil passages for restrictions.

VALVE LIFTERS AND GUIDES CLEAN AND INSPECT

IMPORTANT: Components that are to be reused must be marked, sorted or organized for assembly.

1. Mark, sort, or organize the components for assembly. Refer to Separating Parts. Description and Operation
2. Clean the components in cleaning solvent.

CAUTION: Wear safety glasses in order to avoid eye damage.

3. Dry the components with compressed air.





4. Inspect the valve lifters for the following:
- Bent or broken clip (1)
- Worn pushrod socket (2)
- Scuffed or worn sides (3)
If the valve lifter shows wear, inspect the engine block lifter bores for wear or damage.
- Flat spots on the roller (4)
- Loose or damaged pin (5)
- Plugged oil hole (6)
- Worn or damaged roller bearing
The roller should rotate freely with no binding or roughness.





5. Inspect the valve lifter guides for the following:
- For cracks or damage
- Excessive wear in the lifter mounting bores

CYLINDER HEAD DISASSEMBLE

Tool Required
J 8062 Valve Spring Compressor

IMPORTANT: Remove the spark plugs from the cylinder head with the components at room temperature. Mark, organize, or sort the cylinder head components for assembly. Return the components to their original location during assembly. Do not remove the cylinder head valve guides, or valve seats unless service is required.

1. Remove the spark plugs from the cylinder head.
2. Use the J 8062 in order to compress the valve spring.





3. Remove the valve stem keys.
4. Remove the valve spring retainer.





5. Remove the valve spring.
6. Remove the valves.
7. Remove the valve stem oil seal.
8. Refer to Separating Parts. Description and Operation

CYLINDER HEAD CLEAN AND INSPECT

Tools Required
J 9666 Valve Spring Tester
J8001 Dial Indicator

1. Use the J 8089 in order to clean the carbon from the combustion chambers and the valve parts. Be careful not to scuff the chamber.
2. Clean the following areas:
- The carbon and the sludge from the valve pushrods and the valve rocker arms.
- The valve stems and heads on a buffing wheel.
- The cylinder head and engine block gasket surfaces.
- The bolt hole threads in the cylinder heads and the engine block.
3. Inspect the following areas:
- The cylinder head for cracks in the exhaust ports and combustion chambers.
- The cylinder head for external cracks in the water chamber.
- The valves for burned heads, cracked faces, or damaged stems.
- The valve springs for squareness.





4. Use the J 9666 in order to measure the valve spring.
Replace the spring if the spring tension is less than 321-361 Nm (72.8-81.2 lb) at 40.64 mm (1.600 inch).





5. Measure the valve stem-to-guide clearance.
- Excessive valve stem-to-guide clearance will cause an excessive oil consumption and may cause a valve to break. Insufficient clearance will result in noisy and sticky functioning of the valve and will disturb the engine assembly smoothness.
- Clamp the J 8001 on the exhaust port side of the cylinder head. Locate the indicator so that the movement of the valve stem from side to side (crosswise to the cylinder head) will cause a direct movement of the indicator stem.
The indicator stem must contract the side of the valve stem just above the valve guide.
- Drop the valve head about 1.6 mm (0.0064 inch) off the valve seat.
- Use light pressure when moving the valve stem from side to side in order to obtain a clearance reading.
- Ream the intake valve guides for oversize valves if the clearance exceeds 0.053 mm (0.0020 inch) on the intake valve.
- Ream the exhaust valve guides for oversize valves if the clearance exceeds 0.076 mm (0.0029 inch).

VALVE GUIDE REAMING





1. Measure the valve stem-to-guide clearance.
Refer to Cylinder Head Clean and Inspect.
2. Inspect the valve stems for excessive scoring, wear or bending.
- Excessive valve stem-to guide clearance may cause a noisy valve train, premature valve stem oil seal wear, component damage, and/or excessive engine oil consumption.
- Insufficient valve stem-to-guide clearance will result in noisy or sticking valves. Valves that are too tight may disturb engine smoothness or lead to component damage.





3. Ream the valve guides if necessary.

IMPORTANT: Carefully follow the manufacturers instructions when using valve guide reaming tools.

4. Valves are available in standard and in 1 mm oversize.





5. Ream the valve guide to obtain the proper stem-to-guide clearance.

VALVE AND SEAT GRINDING

IMPORTANT: Reconditioning the valve seats is very important. The seating of the valves must be perfect for the engine to deliver optimum power and performance. Another important factor is the cooling of the valve head. Good contact between the valve and the seat will ensure that heat will be properly dissipated. Several different types of equipment are available for grinding valve seats. The recommendations of the manufacturer of the equipment should be followed carefully to obtain the proper results. Regardless of what type of equipment is used, it is essential that valve guide bores be free from carbon or dirt to ensure proper centering of the tool pilot in the guide.





IMPORTANT: Valves that are pitted must be refaced to the proper angle. Valve stems that show excessive wear, or valves that are warped excessively must be replaced. When a valve head that is warped excessively is refaced, a knife edge may be ground on part or all of the valve head due to the amount of metal that must be removed. Knife edges lead to breakage, burning or preignition due to heat localizing on this knife edge. If the edge of the valve head is less than 0.80 mm (0.031 inch) after grinding, replace the valve. Several different types of equipment are available for refacing valves. The recommendation of the manufacturer of the equipment should be carefully followed to obtain the proper results.





1. Inspect the valve for the following:
- Burnt or eroded areas (1)
- A worn margin (2)
- A bent stem (3)
- A worn or scored stern (4)
- A worn key groove (5)
- A worn stem tip (6)
2. Inspect the valve face for the following:
- Worn or no margin (1, 4)
- Pitted surfaces (2)
- Burnt or eroded areas (3)





3. Inspect the valve margin.
The exhaust valve may be refaced if the margin is greater than 1.25 mm (0.050 inch) thick before grinding.
4. Reface pitted exhaust valves on a suitable valve refacing machine.
5. Replace the valve if the margin is less than 0.80 mm (0.031 inch) thick after grinding.
6. If the valve face has been ground, it may be necessary to shim the valve spring to obtain the proper spring installed height.

IMPORTANT: Excessive valve stem-to guide clearance may cause a noisy valve train, premature valve stem oil seal wear, component damage, and/or excessive engine oil consumption.

Insufficient valve stem-to-guide clearance will result in noisy or sticking valves. Valves that are too tight may disturb engine smoothness or lead to component damage.





7. Inspect for excessive valve stem (1) to guide (2) clearance.





8. Measure the valve stem-to-guide clearance.
Refer to Cylinder Head Clean and Inspect.
9. A valve guide bore that is oversized must be repaired or replaced prior to valve seat grinding.
10. Inspect for a loose valve seat in the cylinder head. The valve seat has an interference fit to the cylinder head.
11. Clean the valve guide bores with a suitable tool. Remove all carbon or dirt from the bores.
The valve guide must be clean for the seat grinding tool to obtain proper results.
12. The valve seats should be concentric to within 0.05 mm (0.0021 inch) total indicator reading.
13. If the valve seat has be ground, it may be necessary to shim the valve spring in order to obtain the proper spring installed height.

CYLINDER HEAD ASSEMBLE

Tools Required
J 38820 Valve Stem Seal Installer
J 8062 Valve Spring Compressor

1. Clean the cylinder head valve spring seat area.

IMPORTANT: When reusing the valves and related components, install the parts in their original location.

2. Install the valves fully seated into their proper ports.
Refer to Separating Parts. Description and Operation





3. Lubricate the outside diameter of the valve guide with engine oil.





4. Using the J 38820 install the valve spring seat and seal unit.
Push and twist the valve seal into position on the valve guide until the spring seat flange is flush with the cylinder head surface.

IMPORTANT: The LN2 Engine uses a unique valve spring seat and seal combination unit. Under no circumstances should this seal and seat unit be replaced with a different type of seal.

5. Install the valve stem oil seal onto the guide. Do not use excessive force or a hammer to install the seal on the guide. The seal will go on if straight and properly lubricated using hand pressure only.

IMPORTANT: Use care to ensure that the valve stem seal and spring seat are not damaged during installation.

Push the seal flange flush against the head surface.





6. Install the valve spring.
7. Install the valve spring retainer.
8. Compress the valve spring using the J 8062.
9. Install the valve stem keys.
9.1. Use grease to hold the keys in place and remove the J 8062.
9.2. Make sure the keys seat properly in the groove of the valve stem and in the tapered seat of the spring retainer.
9.3. Tap the end to the valve stem with a plastic faced hammer to seat the keys (if necessary).





10. Measure the valve spring installed height using a ruler.
Measure from the surface of the valve stem seal under the valve spring to the top of the valve spring.

Specification
- If the installed height exceeds 43.43 mm (1.709 inch), install a valve seat spring shim of approximately 0.25 mm (0.010 inch) thick.

IMPORTANT: Never place a valve spring shim beneath the bottom of the valve stem seal flange.

- Do not shim the valve spring to obtain less than the specified height.

11. Install the remaining valves, springs, and other components.

OIL PUMP DISASSEMBLE





1. Remove the shaft and retainer.
- The oil pump screen has a press fit in to the pump cover.
- Do not remove the pickup tube from the cover unless it is loose or broken. The oil pump is serviced as a complete assembly.





2. Remove the cover bolts.





3. Remove the pump cover.





4. Remove the drive gear and the driven gear.
Match-mark the gear teeth for assembly.





5. Remove the following items:
- The retaining pin
- The pressure regulator spring
- The pressure regulator valve

OIL PUMP CLEAN AND INSPECT
1. Clean all of the parts in cleaning solvent. Dry the parts with compressed air.





2. Inspect the following areas:
- The oil pump housing and cover for cracks, scoring, casting imperfections, and damaged threads (3).
- The drive gear shaft (5) (If the shaft is loose in the oil pump housing, replace the oil pump.).
- The pressure relief valve for scoring and sticking (Burrs may be removed with a fine oil stone.).
- The relief valve spring for loss of tension.
- The oil pump screen for broken wire mesh or looseness (If the pipe is loose or has been removed from the screen, the oil pump screen must be replaced.).
- The gears for chipping, galling, and wear (1), (2).

IMPORTANT: If the drive gear and driveshaft are worn, replace the entire oil pump.

- The drive gear and driveshaft for looseness and wear.

OIL PUMP ASSEMBLE

IMPORTANT: Replace the pressure relief valve spring when you reuse the oil pump.





1. Install the following items:
- The pressure regulator valve.
- The pressure regulator spring.
- The retaining pin.





2. Fill the gear cavity with petroleum jelly.
3. Install the drive gear and the driven gear into the pump body. Align the matchmarks on the gears. Install the smooth side of the gear toward the pump cover.





4. Install the pump cover.





5. Install the cover bolts.

NOTICE: Refer to Fastener Notice in Service Precautions. Vehicle Damage Warnings

Tighten
Tighten the bolts to 10 Nm (89 inch lbs.).





6. Install the shaft and the retainer.

VALVE ROCKER ARM COVER CLEAN AND INSPECT
- Clean the valve rocker arm cover mating surface.
- Clean the valve rocker arm cover. Remove all sludge and oil deposits.
- Ensure that the oil/air separator passages in the cover are clean by flushing them with solvent.
- Inspect the valve rocker arm cover for damage.
Replace the valve rocker arm cover if any damage is found.





- Install a new rocker arm cover gasket when installing the rocker arm cover.

OIL PAN CLEAN AND INSPECT





1. Clean the oil pan mating surface.
2. Clean the oil pan. Remove all sludge and oil deposits.
3. Inspect the threads for the engine oil drain plug.
4. Inspect the oil pan for dents or distortion.
5. Repair or replace the oil pan if necessary.

INTAKE MANIFOLD CLEAN AND INSPECT
1. Clean the intake manifold mating surfaces.
2. Inspect the intake manifold for Carnage.
3. Inspect the intake manifold for cracks near compression limiters.
4. Inspect the crankcase ventilation passages in the intake manifold face for blockage and clean as necessary.





5. Replace the intake manifold as necessary.

EXHAUST MANIFOLD CLEAN AND INSPECT

IMPORTANT:
- Do not reuse the exhaust manifold-to-cylinder head gaskets. Upon installation of the exhaust manifold, install a NEW gasket. A improperly installed gasket or leaking exhaust system may effect On-Board Diagnostics (OBD) II system performance.
- Remove the oxygen sensor prior to cleaning the manifold, do not submerge the oxygen sensor in cleaning solvent.





1. Remove the oxygen sensor from the manifold.
2. Clean the exhaust manifold in solvent.

CAUTION: Wear safety glasses in order to avoid eye damage.

3. Dry the exhaust manifold with compressed air.
4. Inspect for a loose or damaged heat shield.





5. Use a straight edge and a feeler gauge and measure the exhaust manifold mounting face for warpage.
An exhaust manifold face with warpage in excess of 0.25 mm (0.010 inch), may cause an exhaust leak and may effect OBD II system performance. Exhaust manifolds not within specifications must be replaced.