Engine Mechanical - 2.0L: Diagnosis Pontiac Solstice I

Diagnostic Starting Point - Engine Mechanical

Begin the system diagnosis by reviewing the Disassembled Views , Engine Component Description , Lubrication Description , and Drive Belt System Description . Reviewing the description and operation information helps you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the description and operation information also helps you determine if the condition described by the customer is normal operation. Refer to Symptoms - Engine Mechanical in order to identify the correct procedure for diagnosing the system and where the procedure is located.

Strategy Based Diagnostics

1. Perform the «Diagnostic System Check - Vehicle»(ref-267923-S26873286382007101700000) before using the symptom tables, if applicable.
2. Review the system operations in order to familiarize yourself with the system functions. Refer to «Disassembled Views»(ref-267961-S08893335842007101700000) , «Engine Component Description»(ref-267961-S00722991012007101700000) , and «Lubrication Description»(ref-267961-S39009854602007101700000) .

All diagnosis on a vehicle should follow a logical process. Strategy based diagnostics is a uniform approach for repairing all systems. The diagnostic flow may always be used in order to resolve a system condition. The diagnostic flow is the place to start when repairs are necessary.

Visual/Physical Inspection

1. Inspect for aftermarket devices which could affect the operation of the engine.
2. Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom.
3. Inspect for the correct oil level, proper oil viscosity, and correct filter application.
4. Verify the exact operating conditions under which the concern exists. Note factors such as engine RPM, ambient temperature, engine temperature, amount of engine warm-up time, and other specifics.
5. Compare the engine sounds, if applicable, to a known good engine and ensure you are not trying to correct a normal condition.

Symptom List

Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom

1. «Base Engine Misfire without Internal Engine Noises»(ref-267961-S10873904462007101700000)
2. «Base Engine Misfire with Abnormal Internal Lower Engine Noises»(ref-267961-S32294545412007101700000)
3. «Base Engine Misfire with Abnormal Valve Train Noise»(ref-267961-S23167880122007101700000)
4. «Base Engine Misfire with Coolant Consumption»(ref-267961-S15431829262007101700000)
5. «Base Engine Misfire with Excessive Oil Consumption»(ref-267961-S25194966092007101700000)
6. «Engine Noise on Start-Up, but Only Lasting a Few Seconds»(ref-267961-S05900310552007101700000)
7. «Upper Engine Noise, Regardless of Engine Speed»(ref-267961-S24211251512007101700000)
8. «Lower Engine Noise, Regardless of Engine Speed»(ref-267961-S02275341482007101700000)
9. «Engine Noise Under Load»(ref-267961-S41471791332007101700000)
10. «Engine Will Not Crank - Crankshaft Will Not Rotate»(ref-267961-S05319037722007101700000)
11. «Coolant in Combustion Chamber»(ref-267961-S13585881692007101700000)
12. «Coolant in Engine Oil»(ref-267961-S38214982202007101700000)
13. «Turbocharger Whine Noise»(ref-267961-S39201516292007101700000)
14. «Turbocharger Hissing Noise»(ref-267961-S23085927692007101700000)
15. «Turbocharger Oil Leak From Compressor Seal»(ref-267961-S11112656632007101700000)
16. «Turbocharger Oil Leak From Turbine Seal»(ref-267961-S07244326592007101700000)
17. «Turbocharger Lack of Oil Supply»(ref-267961-S38745026792007101700000)
18. «Engine Compression Test»(ref-267961-S05600630302007101700000)
19. «Cylinder Leakage Test»(ref-267961-S41214146592007101700000)
20. «Oil Consumption Diagnosis»(ref-267961-S04942559942007101700000)
21. «Oil Pressure Diagnosis and Testing»(ref-267961-S39266706592007101700000)
22. «Oil Leak Diagnosis»(ref-267961-S08831691442007101700000)
23. «Crankcase Ventilation System Inspection/Diagnosis»(ref-267961-S05749185892007101700000)
24. «Drive Belt Chirping, Squeal, and Whine Diagnosis»(ref-267961-S29154004552007101700000)
25. «Drive Belt Rumbling and Vibration Diagnosis»(ref-267961-S13176653602007101700000)
26. «Drive Belt Falls Off and Excessive Wear Diagnosis»(ref-267961-S19185285312007101700000)
27. «Drive Belt Tensioner Diagnosis»(ref-267961-S04975560572007101700000)

Engine Compression Test

Perform the following steps to conduct a compression test.

1. Conduct the following steps to check cylinder compression. Engine should be at room temperature. Disconnect wiring from the ignition module. Remove the spark plugs. Throttle body valve should be wide open. Battery should be at or near full charge.
2. For each cylinder, crank engine through 4 compression strokes.
3. The lowest reading cylinder should not be less than 70 percent of the highest.
4. No cylinder reading should be less than 689 kPa (100 psi).

Cylinder Leakage Test

Tools Required

J 35667-A Cylinder Head Leakdown Tester or equivalent. See Special Tools .

1. Worn or burnt valves
2. Broken valve springs
3. Stuck valve lifters
4. Incorrect valve lash/adjustment
5. Damaged piston
6. Worn piston rings
7. Worn or scored cylinder bore
8. Damaged cylinder head gasket
9. Cracked or damaged cylinder head
10. Cracked or damaged engine block

1. Disconnect the battery ground negative cable.
2. Remove the spark plugs. Refer to «Spark Plug Replacement»(ref-267939-S10442214322007101700000) .
3. Rotate the crankshaft to place the piston in the cylinder being tested at top dead center (TDC) of the compression stroke.
4. Install the J 35667-A or equivalent. See «Special Tools»(ref-267961-S27586171862007101700000) .
5. Apply shop air pressure to the J 35667-A and adjust according to the manufacturers instructions. See «Special Tools»(ref-267961-S27586171862007101700000) .
6. Record the cylinder leakage value. Cylinder leakage that exceeds 25 percent is considered excessive and may require component service. In excessive leakage situations, inspect for the following conditions: Air leakage sounds at the throttle body or air inlet hose that may indicate a worn or burnt intake valve or a broken valve spring. Air leakage sounds at the exhaust system tailpipe that may indicate a worn or burnt exhaust valve or a broken valve spring. Air leakage sounds from the crankcase, oil level indicator tube, or oil fill tube that may indicate worn piston rings, a damaged piston, a worn or scored cylinder bore, a damaged engine block or a damaged cylinder head. Air bubbles in the cooling system may indicate a damaged cylinder head or a damaged cylinder head gasket.
7. Perform the leakage test on the remaining cylinders and record the values.

Oil Consumption Diagnosis

Excessive oil consumption, not due to leaks, is the use of 0.9 L (1 qt) or greater of engine oil within 3 200 kilometers (2,000 miles). The causes of excessive oil consumption include the following conditions

1. External oil leaks Tighten bolts and/or replace gaskets and oil seals as necessary.
2. Incorrect oil level or improper reading of oil level indicator With the vehicle on a level surface, allow adequate drain down time and inspect for the correct oil level.
3. Improper oil viscosity Use recommended SAE viscosity for the prevailing temperatures.
4. Continuous high speed driving and/or severe usage
5. Crankcase ventilation system restrictions or malfunctioning components
6. Valve guides and/or valve stem oil seals worn, or the seal omitted Ream guides and install oversize service valves and/or new valve stem oil seals.
7. Piston rings broken, improperly installed, worn, or not seated properly Allow adequate time for rings to seat. Replace broken or worn rings, as necessary.
8. Piston improperly installed or mis-fitted

Oil Pressure Diagnosis and Testing

1. With the vehicle on a level surface, allow adequate drain down time of 2-3 minutes and measure for a low oil level.
2. Add the recommended grade engine oil and fill the crankcase until the oil level measures full on the oil level indicator.
3. Run the engine, and verify low, or no oil pressure on the vehicle gage or light.
4. Listen for a noisy valve train or a knocking noise.
5. Inspect for the following conditions: Oil diluted by moisture or unburned fuel mixtures Improper oil viscosity for the expected temperature Incorrect or malfunctioning oil pressure sender Incorrect or malfunctioning oil pressure gage Plugged oil filter Malfunctioning oil bypass valve
6. Remove the oil pressure sender or another engine block oil gallery plug.
7. Install an oil pressure gage and measure the engine oil pressure.
8. Compare the readings to the specifications. Refer to «Engine Mechanical Specifications»(ref-267961-S30602847122007101700000) .
9. If the engine oil pressure is below specifications, inspect the engine for 1 or more of the following conditions: Oil pump worn or dirty Refer to «Oil Pump Disassemble»(ref-267961-S42239746632007101700000) . Oil pump-to-engine front cover bolts loose Refer to «Engine Front Cover and Oil Pump Installation»(ref-267961-S16026939172007101700000) . Oil pump screen loose, plugged, or damaged Oil pump screen O-ring seal missing or damaged Malfunctioning oil pump pressure regulator valve Excessive bearing clearance Refer to «Crankshaft and Bearings Cleaning and Inspection»(ref-267961-S31814249452007101700000) . Cracked, porous or restricted oil galleries Oil gallery plugs missing or incorrectly installed Refer to «Engine Block Assemble»(ref-267961-S28402014622007101700000) . Broken lash adjusters

Oil Leak Diagnosis

Oil Leak Diagnosis

Crankcase Ventilation System Inspection/Diagnosis

1. Disconnect the positive crankcase ventilation (PCV) line.
2. Start the engine.
3. Check for vacuum at the PCV line. If there is no vacuum, inspect for a plugged line or camshaft cover port. Inspect for a hose that collapses when blocked with vacuum applied. Replace the plugged or the deteriorated hoses.
4. Allow the engine to idle at normal operating temperature.
5. Remove the engine oil level indicator. Install a vacuum gage into the indicator tube opening.
6. Block off the PCV system fresh air intake passage.
7. Run the engine at 1,500 RPM for 30 seconds, then read the vacuum gage while engine is running at 1,500 RPM. If vacuum is present, the crankcase ventilation system is functioning properly. If no vacuum is indicated, the engine may not be sealed and is drawing in outside air. Check the valve covers, the oil pan gasket, or other sealing areas for leaks. If the vacuum gage registers a pressure, or if the vacuum gage is pushed out of the indicator tube, check for a plugged PCV port, a plugged line, or excessive engine blow-by.

Diagnostic Aids

1. A chirping or squeal noise may be intermittent due to moisture on the drive belts or the pulleys. It may be necessary to spray a small amount of water on the drive belts in order to duplicate the customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt pulleys may be the probable solution.
2. If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect.
3. A chirping, squeal or whine noise may be caused by a loose or improper installation of a body or suspension component. Other items of the vehicle may also cause the noise.
4. The drive belts will not cause a whine noise.

The accessory drive components can have an affect on engine vibration. Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. Vibration can be caused by, but not limited to the air conditioning (A/C) system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components.

The drive belt may have a rumbling condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom.

If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the drive belts are installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise.

If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment.

An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly.

If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt.

Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt for the application.

Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt to make a noise or to fall off.

Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt fall off.

Drive Belt Tensioner Diagnosis

Drive Belt Tensioner Diagnosis

Engine Mount Inspection

1. Install a engine hoist to the lift brackets and raise the engine slightly putting pressure on the engine mounts.
2. Observe the engine mount while slightly lifting the engine. Lifting the engine removes the weight from the engine mount and creates slight tension on the rubber.
3. Replace the engine mount if the engine mount exhibits any of the following conditions: The hard rubber is covered with heat check cracks. The rubber is separated from the metal plate of the engine mount. The rubber is split through the center of the engine mount. The engine mount is leaking fluid, if applicable.
4. For engine mount replacement, refer to «Engine Mount Replacement - Left Side»(ref-267961-S23671655342007101700000) and/or «Engine Mount Replacement - Right Side»(ref-267961-S39338710732007101700000) .

Engine Block Cleaning and Inspection

Tools Required

1. J 7872 Magnetic Base Dial Indicator. See «Special Tools»(ref-267961-S27586171862007101700000) .
2. J 8087 Cylinder Bore Gage. See «Special Tools»(ref-267961-S27586171862007101700000) .

1. Clean the sealing material from the gasket mating surfaces.
2. Clean the engine block and lower crankcase in a cleaning tank with solvent appropriate for aluminum.
3. Flush the engine block with clean water or steam.
4. Clean the oil passages.
5. Clean the blind holes.
6. Spray the cylinder bores and the machined surfaces with engine oil.
7. Inspect the threaded holes.
8. Clean the threaded holes with a rifle brush. If necessary, drill out the holes and install thread inserts. Refer to «Thread Repair»(ref-267961-S12076076942007101700000) .
9. Use a straight edge and a feeler gage to inspect the deck surface for flatness. Carefully machine minor irregularities. Replace the block if greater than 0.254 mm (0.010 in) must be removed.
10. Inspect the oil pan rail for nicks. Inspect the front cover attaching area for nicks. Use a flat mill file to remove any nicks.
11. Clean the sealing material from the gasket mating surfaces on the lower crankcase engine block side.
12. Clean the sealing material from the gasket mating surfaces on the lower crankcase oil pan side.
13. Inspect the mating surfaces of the transmission face.
14. Use the following procedure in order to measure the engine block flange runout at the mounting bolt hole bosses: Temporarily install the crankshaft and upper bearings. Measure the crankshaft flange runout using the J 7872 . See «Special Tools»(ref-267961-S27586171862007101700000) . Hold the gage plate flat against the crankshaft flange. Place the dial indicator stem on the transmission mounting bolt hole boss. Set the indicator to 0. Record the readings obtained from all of the bolt hole bosses. The measurements should not vary more than 0.203 mm (0.008 in). Check the crankshaft flange runout again if the readings vary greater than 0.203 mm (0.008 in). Remove the crankshaft and bearings.
15. Install the bed plate and bolts. Tighten the bed plate bolts to specification.
16. Inspect the crankshaft main bearing bores. Use the J 8087 to measure the bearing bore concentricity and alignment. See «Special Tools»(ref-267961-S27586171862007101700000) . Refer to «Engine Mechanical Specifications»(ref-267961-S30602847122007101700000) .
17. Replace the engine block and bed plate if the crankshaft bearing bores are out of specification.
18. Remove the bed plate.
19. Using the J 8087 , inspect the cylinder bores for the following conditions: Wear Taper Runout Ridging
20. If the cylinder bores are out of specification, install a NEW cylinder bore sleeve. Refer to «Cylinder Sleeve Removal»(ref-267961-S00646627272007101700000) and «Cylinder Sleeve Installation»(ref-267961-S13689045702007101700000) .

Crankshaft Balancer Cleaning and Inspection

1. Clean the crankshaft balancer.
2. Clean the belt grooves of all dirt or debris with a wire brush.
3. Dry the crankshaft balancer with compressed air.
4. Inspect the crankshaft balancer for the following conditions: Worn, grooved, or damaged hub seal surface A crankshaft balancer hub seal surface with excessive scoring, grooves, rust, or other damage must be replaced. Axial cracks in and around the keyway IMPORTANT: In order for the belt to track properly, the belt grooves should be free of all dirt or debris. Dirty or damaged belt grooves The balancer belt grooves 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

Engine Flywheel Cleaning and Inspection

1. Clean the flywheel in solvent.
2. Dry the flywheel with compressed air.
3. Inspect the manual transmission flywheel for the following conditions: Damaged ring gear teeth Loose or improperly positioned ring gear The ring gear has an interference fit onto the flywheel and should be positioned completely against the flange of the flywheel. A scored, grooved or damaged friction surface
4. Inspect the automatic transmission flywheel for the following conditions: Damaged ring gear teeth Stress cracks around the flywheel-to-crankshaft bolt hole locations Weight saving holes

Crankshaft and Bearings Cleaning and Inspection

Tools Required

J 7872 Magnetic Base Dial Indicator Set. See Special Tools .

1. Clean the crankshaft with solvent.
2. Thoroughly clean all oil passages and inspect for restrictions or burrs.
3. Dry the crankshaft with compressed air.
4. Perform a visual inspection of the crankshaft for damage.
5. The crankshaft position reluctor ring may be replaced if damaged. Tighten: Tighten the crankshaft position reluctor ring bolts to 15 N.m (11 lb ft).
6. Inspect the crankshaft journals for wear (1). The journals should be smooth, with no signs of scoring, wear, or damage.
7. Inspect the crankshaft journals for grooves or scoring (2).
8. Inspect the crankshaft journals for scratches or wear (3).
9. Inspect the crankshaft journals for pitting or imbedded bearing material (4).
10. Measure the crankshaft journals for out-of-round.
11. Measure the crankshaft journals for taper.
12. Measure the crankshaft runout. Using wooden V-blocks, support the crankshaft on the front and rear journals.
13. Use the J 7872 in order to measure the crankshaft runout at the front and rear intermediate journals. See «Special Tools»(ref-267961-S27586171862007101700000) .
14. Use the J 7872 in order to measure the runout of the crankshaft rear flange. See «Special Tools»(ref-267961-S27586171862007101700000) .
15. Replace the crankshaft if the measurements are not within specifications.
16. Inspect crankshaft bearings for craters or pockets. Flattened sections on the bearing halves also indicate fatigue.
17. Inspect the crankshaft bearings for excessive scoring or discoloration.
18. Inspect the crankshaft bearings for dirt or debris imbedded into the bearing material.
19. Inspect the crankshaft bearings for improper seating indicated by bright, polished sections of the bearing. If the lower half of the bearing is worn or damaged, both upper and lower halves should be replaced. Generally, if the lower half is suitable for use, the upper half should also be suitable for use.

Camshaft Cleaning and Inspection

1. Inspect the camshaft journals and lobes for wear or scoring.
2. Inspect the camshaft sprocket alignment notch for damage.
3. Inspect the camshaft cover for damage or loose oil control baffles.
4. Clean the camshaft cover.
5. Wash the camshaft in solvent.
6. Oil the camshaft.
7. Inspect the camshaft cover for cracks or other signs of damage.

Timing Chain and Sprockets Cleaning and Inspection

1. Inspect the timing chain guides for cracking or wear.
2. Replace the timing chain guides if wear exceeds 1.12 mm (0.045 in) depth on the chain guide surface.
3. Inspect the timing chain tensioner shoe for wear.
4. Replace the timing chain tensioner shoe if wear exceeds 1.12 mm (0.045 in) depth on the chain guide surface.
5. Inspect the timing chain and actuators for wear.
6. Inspect the camshaft actuator faces for signs of movement.
7. Inspect the camshaft actuator teeth and chain for signs of excessive wear, chipping, or seizure of the timing chain links.
8. Inspect the oil nozzle body for collapse or cracks at the bolt boss. Discard and replace the oil nozzle body if it is damaged.
9. Inspect the timing chain tensioner for the scoring or free movement.
10. Inspect the timing chain seal for damage. If damaged, replace the seal.

Balance Shaft Cleaning and Inspection

1. Clean the balance shafts in solvent.
2. Inspect the bearing surfaces on the balance shafts for scoring or unusual wear.
3. Inspect the balance shaft drive sprockets for wear, damage, or missing teeth.
4. Measure the rear bearing journals on the balance shafts, the journals should be 36.723-36.743 mm (1.4458-1.4466 in) in diameter.
5. Measure the front bearing journals on the balance shafts, the front bearing journals should be 20.020-20.000 mm (0.7881-0.7874 in) in diameter.
6. When the balance shafts have been installed in the engine block, check for smooth rotation, sticking, binding, or roughness.

Balance Shaft Drive Chain and Sprockets Cleaning and Inspection

1. Inspect the balance shaft drive chain guides for cracking or wear.
2. Replace the balance shaft drive chain guides if wear exceeds 1.12 mm (0.045 in) depth on the chain guide surface.
3. Inspect the balance shaft drive chain tensioner guide shoe for wear. Replace the balance shaft drive chain tensioner guide shoe if wear exceeds 1.12 mm (0.045 in) depth on the chain guide surface.
4. Inspect the balance shaft drive chain and sprockets for wear.
5. Inspect the crankshaft sprocket faces for signs of movement.
6. Inspect the alignment notch in the balance shaft for cracking or damage.
7. Inspect the water pump, crankshaft, and balance shaft sprocket teeth and chain for signs of excessive wear, chipping, or seizure of the balance shaft drive chain links.
8. Inspect the timing chain tensioner for damage or wear.

Valve Cleaning and Inspection

1. Clean the valves of carbon, oil and varnish. Carbon can be removed with a wire brush. Varnish can be removed by soaking in Parts Immersion Solvent GM P/N 12345368 (Canadian P/N 10953514) or equivalent.
2. Clean the valve guides.
3. Inspect the valve stem for wear (4).
4. Inspect the valve keeper groove for chipping or wear (5). Replace the valve if chipped or worn.
5. Inspect the valve face for burning or cracking (1). If pieces are broken off, inspect the corresponding piston and cylinder head area for damage.
6. Inspect the valve stem for burrs and scratches. Burrs and minor scratches may be removed with an oil stone.
7. Inspect the valve stem for straightness and the valve head for bending or distortion (3) using V-blocks. Bent or distorted valves must be replaced.
8. Clean the deposits from the valve face. Inspect the valve face for grooving.
9. Replace the valve if the face is grooved. Valve faces cannot be machined. If worn, or damaged, the valves must be replaced.
10. The valves may be lightly lapped to the valve seats.

Cylinder Head and Gasket Surface Cleaning and Inspection

1. Remove the spark plugs.
2. Inspect the cylinder head gasket and mating surfaces for leaks, corrosion, and blow-by. If the gasket has failed, use the following faults to determine the cause: Improper installation Loose or warped cylinder head Missing, off location or not fully seated dowel pins Corrosion in the seal area around the coolant passages Chips or debris in the cylinder head bolt holes Bolt holes in the cylinder block not drilled or tapped deep enough
3. Inspect the cylinder head gasket surface. The cylinder head may be reused if corrosion is found only outside a 4 mm (0.375 in) band around each combustion chamber (1). Replace the cylinder head if the area between the valve seats is cracked (2). Replace the cylinder head if corrosion has been found inside a 4 mm (0.375 in) band around each combustion chamber (3).
4. Clean the cylinder head bolts.
5. Clean the cylinder head. Remove all varnish, soot and carbon to the bare metal.
6. Clean the valve guides.
7. Clean the threaded holes. Use a nylon bristle brush.
8. Clean the remains of the sealer from the plug holes.
9. Inspect the cylinder head bolts for damaged threads or stretching and damaged heads caused by improper use of tools.
10. Replace all suspect bolts.
11. Inspect the cylinder head for cracks. Inspect between the valve seats and in the exhaust ports.
12. Inspect the cylinder head deck for corrosion, sand inclusions and blow holes.
13. Inspect the cylinder head deck surface for flatness. Refer to «Engine Mechanical Specifications»(ref-267961-S30602847122007101700000) . If the cylinder head is out of specification, replace the cylinder head. Do not machine the cylinder head.
14. Inspect all the threaded holes for damage. Threads may be reconditioned with thread inserts.
15. Inspect the sealing surfaces.
16. Inspect the cylinder head plugs.
17. Install the spark plugs. Tighten: Tighten the spark plugs to 20 N.m (15 lb ft).

Turbocharger Cleaning and Inspection

1. Clean all mating surfaces.
2. Inspect all threaded holes for damage.
3. Inspect the hoses, solenoid, and wastegate actuator rod for damage.
4. Inspect the compressor and turbine blades for damage or foreign material.
5. Clean the turbocharger inlet mating surfaces.
6. Inspect the turbocharger inlet mating surfaces for damage.
7. The positive crankcase ventilation (PCV) fitting and O-ring may be serviced if damaged or leaking. Tighten: Tighten the PCV fitting bolt to 10 N.m 89 lb in.

Fuel Rail and Injectors Cleaning and Inspection

Tools Required

1. EN-47909 Injector Bore and Sleeve Cleaning Kit
2. EN-48266 Injector Seal Installer and Sizer

1. Unplug the electrical connections from the fuel injectors.
2. Remove the injectors from the fuel rail.
3. Remove and discard the fuel injector hold-down clamp.
4. Remove and discard the fuel injector O-ring and plastic spacer.
5. Remove and discard the fuel injector seal.
6. Clean the exterior of the fuel rail and injectors in solvent.
7. Inspect the high pressure fuel sensor for damage. If replacing, lubricate the threads and tapered seat with 5W30 engine oil. Tighten: Tighten the high pressure fuel sensor to 33 N.m (25 lb ft).
8. Clean the injector bore using the EN-47909 .
9. Inspect the fuel rail and components for the following conditions: Damage, debris, or restrictions to the fuel rail Damage, debris, or restrictions to the fuel ports in the fuel rail Damage to the mounting area for the fuel rail Damage to the fuel rail mounting bolts Damage to the threads on the fuel rail fuel feed fitting
10. Inspect the fuel injectors for the following conditions: Damage to the fuel injector connector (1) Damage to the fuel injector harness connector Damage to the plastic fuel injector spacer (2) Damage to the fuel injector tip (3) Damage to the tolerance ring (4)
11. Replace the fuel rail or injector if any damage is found. Do not attempt to repair a fuel rail or injector.
12. Lubricate the NEW O-ring with 5W30 engine oil.
13. Install a NEW O-ring and plastic spacer on the injector.
14. Install a NEW seal on the injector using the EN-48266-1. The seal must be installed/slid into the recessed area of the fuel injector. Compress the seal with your fingers before resizing the seal using the EN-48266-2.
15. Using the EN-48266-2, resize the seal.
16. Install a NEW fuel injector hold-down clamp.
17. Install the injector into the fuel rail.
18. Connect the electrical connection to the fuel rail.

Intake Manifold Cleaning and Inspection

1. Clean the intake manifold mating surfaces.
2. Inspect the intake manifold for damage.
3. Inspect the intake manifold for cracks near metallic inserts.
4. Inspect the crankcase ventilation passages in the intake manifold face for blockage.
5. Clean the crankcase ventilation passages with compressed air, if necessary. Use a maximum of 172 kPa (25 psi) of air pressure.
6. Replace the intake manifold, as necessary.

Exhaust Manifold Cleaning and Inspection

1. Clean the exhaust manifold in solvent.
2. Dry the exhaust manifold with compressed air.
3. Internal heat cracks are allowed. Do not replace the exhaust manifold for this condition.
4. Inspect the heat shield for damage.
5. Use a straight edge and a feeler gage and measure the exhaust manifold mounting face for warpage. An exhaust manifold face with warpage in excess of 0.25 mm (0.0100 in) may cause an exhaust leak and may affect OBD II system performance. Exhaust manifolds not within specifications must be replaced.

Oil Pan Cleaning and Inspection

1. Clean the oil pan mating surface.
2. Remove the oil pan baffle bolts.
3. Remove the oil pan baffle.
4. Clean the oil pan. Remove all the sludge and the oil deposits.
5. Inspect the engine oil drain plug threads.
6. Inspect the oil pan for cracking near the pan rail and the transmission mounting points.
7. Inspect the oil pan for cracking resulting from impact or flying road debris.
8. Inspect the oil pan baffle and pickup screen.
9. Install the oil pan baffle.
10. Install the oil pan baffle bolts. Tighten: Tighten the oil pan baffle bolts to 14 N.m 10 lb ft.