Engine Mechanical - 5.3L: Diagnosis Saab 9-7X I

Diagnostic Starting Point - Engine Mechanical

Begin the system diagnosis by reviewing the Disassembled Views , Engine Component Description , Lubrication Description - Main Pressure Below 55 psi with Cylinder Deactivation (Active Fuel Management) Off , Lubrication Description - Main Pressure Above 55 psi with Cylinder Deactivation (Active Fuel Management) Off , Lubrication Description - Main Pressure Below 55 psi with Cylinder Deactivation (Active Fuel Management) On Lubrication Description - Main Pressure Above 55 psi with Cylinder Deactivation (Active Fuel Management) On and Cylinder Deactivation (Active Fuel Management) System Description . Reviewing the description and operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the description and operation information will also help 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 a «Diagnostic System Check - Vehicle»(ref-268112-S10851617502007101800000) before using the symptom tables.
2. Review the system operations in order to familiarize yourself with the system functions. Refer to «Disassembled Views»(ref-268156-S02474815362007101800000) , «Engine Component Description»(ref-268156-S35075599072007101800000) , «Lubrication Description - Main Pressure Below 55 psi with Cylinder Deactivation (Active Fuel Management) Off»(ref-268156-S12029510422007101800000) , «Lubrication Description - Main Pressure Above 55 psi with Cylinder Deactivation (Active Fuel Management) Off»(ref-268156-S34265895632007101800000) , «Lubrication Description - Main Pressure Below 55 psi with Cylinder Deactivation (Active Fuel Management) On»(ref-268156-S09809170962007101800000) , «Lubrication Description - Main Pressure Above 55 psi with Cylinder Deactivation (Active Fuel Management) On»(ref-268156-S38073590072007101800000) , «Cylinder Deactivation (Active Fuel Management) System Description»(ref-268156-S17534889482007101800000) and «Drive Belt System Description»(ref-268156-S14604136802007101800000) .

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. For a detailed explanation, refer to Strategy Based Diagnosis .

Visual/Physical Inspection

1. Inspect for aftermarket devices which could affect the operation of the engine. Refer to «Checking Aftermarket Accessories»(ref-268113-S34470778152007101800000) .
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 make sure 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-268156-S12606728242007101800000)
2. «Base Engine Misfire with Abnormal Internal Lower Engine Noises»(ref-268156-S30336106572007101800000)
3. «Base Engine Misfire with Abnormal Valve Train Noise»(ref-268156-S36906880362007101800000)
4. «Base Engine Misfire with Coolant Consumption»(ref-268156-S35821365552007101800000)
5. «Base Engine Misfire with Excessive Oil Consumption»(ref-268156-S09242636142007101800000)
6. «Engine Noise on Start-Up, but Only Lasting a Few Seconds»(ref-268156-S20570430632007101800000)
7. «Upper Engine Noise, Regardless of Engine Speed»(ref-268156-S19840242902007101800000)
8. «Lower Engine Noise, Regardless of Engine Speed»(ref-268156-S16196572582007101800000)
9. «Engine Noise Under Load»(ref-268156-S35056038532007101800000)
10. «Engine Will Not Crank - Crankshaft Will Not Rotate»(ref-268156-S21893620982007101800000)
11. «Coolant in Combustion Chamber»(ref-268156-S41723029282007101800000)
12. «Coolant in Engine Oil»(ref-268156-S11690180662007101800000)
13. «Cylinder Deactivation (Active Fuel Management) System Diagnosis»(ref-268156-S06014198242007101800000)
14. «Engine Compression Test»(ref-268156-S15051681542007101800000)
15. «Cylinder Deactivation (Active Fuel Management) System Compression Test»(ref-268156-S15820533642007101800000)
16. «Cylinder Leakage Test»(ref-268156-S30721394302007101800000)
17. «Oil Consumption Diagnosis»(ref-268156-S17752162312007101800000)
18. «Oil Pressure Diagnosis and Testing»(ref-268156-S32142893232007101800000)
19. «Cylinder Deactivation (Active Fuel Management) Oil Pressure Relief Valve Diagnosis and Testing»(ref-268156-S29238599152007101800000)
20. «Cylinder Deactivation (Active Fuel Management) Valve Lifter Oil Manifold Diagnosis and Testing»(ref-268156-S04110005032007101800000)
21. «Oil Leak Diagnosis»(ref-268156-S03195715642007101800000)
22. «Crankcase Ventilation System Inspection/Diagnosis»(ref-268156-S33879260422007101800000)
23. «Drive Belt Chirping, Squeal, and Whine Diagnosis»(ref-268156-S37364423322007101800000)
24. «Drive Belt Rumbling and Vibration Diagnosis»(ref-268156-S08204040972007101800000)
25. «Drive Belt Falls Off and Excessive Wear Diagnosis»(ref-268156-S19641438322007101800000)
26. «Drive Belt Tensioner Diagnosis»(ref-268156-S05261739492007101800000)

Cylinder Deactivation (Active Fuel Management) System Diagnosis

1. Measure the engine oil level. Fill, as required.
2. Using the scan tool, inspect for diagnostic codes within the engine control module (ECM). Refer to «Diagnostic System Check - Vehicle»(ref-268112-S10851617502007101800000) . Repair, as required.
3. Verify proper engine oil pressure and operation of the active fuel management oil pressure relief valve. Refer to «Oil Pressure Diagnosis and Testing»(ref-268156-S32142893232007101800000) .
4. Verify proper operation of the active fuel management system components. Refer to «Cylinder Deactivation (Active Fuel Management) System Compression Test»(ref-268156-S15820533642007101800000) .
5. Remove the valve lifter oil manifold. Refer to «Valve Lifter Oil Manifold Replacement»(ref-268156-S26985514792007101800000) .
6. Verify proper operation of the valve lifter oil manifold. Refer to «Cylinder Deactivation (Active Fuel Management) Valve Lifter Oil Manifold Diagnosis and Testing»(ref-268156-S04110005032007101800000) .
7. Replace the active fuel management valve lifters, as required. Both intake and exhaust lifters should be replaced in pairs. Refer to «Valve Lifter Replacement»(ref-268156-S41892789692007101800000) .

Engine Compression Test

1. Charge the battery if the battery is not fully charged.
2. Disable the ignition system.
3. Disable the fuel injection system.
4. Remove all spark plugs.
5. Turn the ignition to the ON position.
6. Depress the accelerator pedal to position the throttle plate wide open.
7. Start with the compression gage at zero and crank the engine through 4 compression strokes, 4 puffs.
8. Measure the compression for each cylinder. Record the readings.
9. If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Measure the compression again and record the reading.
10. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the following strokes, but does not reach normal. Compression improves considerably when you add oil. Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. If 2 adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders.

Cylinder Deactivation (Active Fuel Management) System Compression Test

The Cylinder Deactivation (Active Fuel Management) System Compression Test is a functional test of the valve lifter oil manifold and valve lifters. Using a compression gage, the technician can monitor the specific cylinders ability to go into and out of active fuel management, as commanded by the scan tool. The actual pressure values on the compression gage are not as critical as is observing the on-off switching action of the solenoid and valve lifters.

1. Measure the engine oil level. Fill, as required.
2. Perform the Diagnostic System Check - Vehicle. Refer to «Diagnostic System Check - Vehicle»(ref-268112-S10851617502007101800000) .
3. Disable the ignition system for the cylinder to be tested, by disconnecting the electrical wire harness to the ignition coil.
4. Disable the fuel injection system for the cylinder to be tested, by disconnecting the electrical wire harness to the fuel injector.
5. Remove the spark plug and wire for the cylinder to be tested.
6. Install a 0-1378 kPa (0-200 psi) compression gage.
7. Start the engine.
8. Using the scan tool output controls, command the solenoid ON, for the cylinder to be deactivated.
9. Depress the Schrader valve on the compression gage in order to release the pressure and zero the gage. With the engine running and the cylinder in active fuel management mode, the compression reading should be less than 172 kPa (25 psi).
10. Using the scan tool, de-energize the solenoid while observing the reading on the compression gage. With the engine running and the cylinder NOT in active fuel management mode, the compression gage reading should increase quickly to greater than 345 kPa (50 psi).
11. Test each of the 4 active fuel management cylinders, one at a time. If the readings are not within specifications, remove and test the valve lifter oil manifold, as required. Refer to «Valve Lifter Oil Manifold Replacement»(ref-268156-S26985514792007101800000) and «Cylinder Deactivation (Active Fuel Management) Valve Lifter Oil Manifold Diagnosis and Testing»(ref-268156-S04110005032007101800000) . IMPORTANT: Only one cylinder can be tested at a time. When testing has been completed on a specific cylinder, the wire harness electrical connectors, spark plug, and spark plug wire must be installed prior to testing of each additional cylinder.
12. If the compression test has been performed and all active fuel management cylinders are operating within specifications, the active fuel management system is performing as designed and no repairs are required.
13. Clear the diagnostic trouble codes (DTCs) with a scan tool.

Oil Consumption Diagnosis

Oil Consumption Diagnosis

Oil Pressure Diagnosis and Testing

Tools Required

1. EN-47971 Oil Pressure Gage Adapter. See «Special Tools»(ref-268156-S11321246192007101800000) .
2. J 21867 Pressure Gage. See «Special Tools»(ref-268156-S11321246192007101800000) .

Scheme 313

1. With the vehicle on a level surface, run the vehicle for a few minutes, allow adequate drain down time, 2-3 minutes, and measure the oil level.
2. If required, 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 briefly, 10-15 seconds, 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 water or glycol antifreeze Refer to «Coolant in Engine Oil»(ref-268156-S11690180662007101800000) . Foamy oil, which may be caused by a cut or damaged oil pump screen O-ring seal
6. Remove the oil filter and install the EN-47971 (1). See «Special Tools»(ref-268156-S11321246192007101800000) .
7. Install the J 21867 (2), or equivalent to the EN-47971 (1). See «Special Tools»(ref-268156-S11321246192007101800000) .
8. Run the engine and measure the engine oil pressure.
9. Compare the readings to «Engine Mechanical Specifications»(ref-268156-S06431639902007101800000) .
10. 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 Cleaning and Inspection»(ref-268156-S39014939872007101800000) . Oil pump-to-engine block bolts loose Refer to «Oil Pump, Screen and Crankshaft Oil Deflector Installation»(ref-268156-S13582161162007101800000) . Oil pump screen loose, plugged, or damaged Oil pump screen O-ring seal missing or damaged Oil filter tube loose or a leaking or damaged gasket Malfunctioning oil pump pressure relief valve Excessive bearing clearance Cracked, porous, or restricted oil galleries Oil gallery plugs missing or incorrectly installed Refer to «Engine Block Plug Installation»(ref-268156-S07041385332007101800000) . Improper operation of the active fuel management oil pressure relief valve Refer to «Cylinder Deactivation (Active Fuel Management) Oil Pressure Relief Valve Diagnosis and Testing»(ref-268156-S29238599152007101800000) .

Cylinder Deactivation (Active Fuel Management) Oil Pressure Relief Valve Diagnosis and Testing

Tools Required

1. EN-47971 Oil Pressure Gage Adapter. See «Special Tools»(ref-268156-S11321246192007101800000) .
2. J 21867 Pressure Gage. See «Special Tools»(ref-268156-S11321246192007101800000) .
3. J-21867-16 Oil Pressure Adapter. See «Special Tools»(ref-268156-S11321246192007101800000) .

Scheme 314

Scheme 315

1. Remove the oil filter and install the EN-47971 (1). See «Special Tools»(ref-268156-S11321246192007101800000) . IMPORTANT: This test is performed to verify the operation of the active fuel management oil pressure relief valve. Refer to «Cylinder Deactivation (Active Fuel Management) System Description»(ref-268156-S17534889482007101800000) , «Lubrication Description - Main Pressure Below 55 psi with Cylinder Deactivation (Active Fuel Management) Off»(ref-268156-S12029510422007101800000) , «Lubrication Description - Main Pressure Above 55 psi with Cylinder Deactivation (Active Fuel Management) Off»(ref-268156-S34265895632007101800000) , «Lubrication Description - Main Pressure Below 55 psi with Cylinder Deactivation (Active Fuel Management) On»(ref-268156-S09809170962007101800000) , and «Lubrication Description - Main Pressure Above 55 psi with Cylinder Deactivation (Active Fuel Management) On»(ref-268156-S38073590072007101800000) .
2. Install the J 21867 (2), or equivalent, to the EN-47971 (1). See «Special Tools»(ref-268156-S11321246192007101800000) .
3. Remove the oil pressure sensor and install the J-21867-16 . See «Special Tools»(ref-268156-S11321246192007101800000) .
4. Install the J 21867 (1), or equivalent, to the J-21867-16 (2). See «Special Tools»(ref-268156-S11321246192007101800000) .
5. Run the engine and measure the engine oil pressure while observing both gages. Operate the throttle, as required, to increase and decrease the engine oil pressure. With the engine running and the lower pressure gage (2) measuring below 379 kPa (55 psi), both gages should display the same pressure reading. If the readings are not the same and the lower gage (2) has a higher reading, the active fuel management oil pressure relief valve is stuck in the open position or the valve lifter oil manifold filter is plugged. With the engine running and the lower pressure gage (2) measuring above 379 kPa (55 psi), the upper gage (1) should display no greater than 379-517 kPa (55-75 psi). If the reading on the upper gage (1) is greater than 517 kPa (75 psi), the active fuel management oil pressure relief valve is stuck in the closed position.
6. Repair, as required.

Cylinder Deactivation (Active Fuel Management) Valve Lifter Oil Manifold Diagnosis and Testing

Tools Required

1. EN-46999 Active Fuel Management Tester. See «Special Tools»(ref-268156-S11321246192007101800000) .
2. EN-46999-1 Active Fuel Management Tester Air Adapter. See «Special Tools»(ref-268156-S11321246192007101800000) .
3. EN-46999-5 Active Fuel Management Tester Harness - Small Block V8. See «Special Tools»(ref-268156-S11321246192007101800000) .

The manifold bench test provides a maximum 206 kPa (30 psi) of filtered shop air to the manifold and will test each solenoid/valve for the following conditions

Scheme 316

1. Proper operation
2. A stuck open condition - constant air flow
3. A stuck closed condition - no air flow
4. A flow restriction within the manifold IMPORTANT: This component test applies only to vehicles with functional active fuel management. A minimum shop air source of 206 kPa (30 psi) is required for manifold testing. A water bleed is located on the EN-46999 . Occasionally, depress the valve in order to remove excess water from the tool.

Scheme 317

Scheme 318

Scheme 319

Scheme 320

Scheme 321

Scheme 322

1. Individually depress each of the buttons 1-4 on the EN-46999 in order to activate each of the solenoid/valves. When activating each solenoid/valve, a loud click should be heard from the solenoid and an increased amount of air will exit the outlet ports. Button 1 will energize the solenoid/valve 1 for engine cylinder number 1. Button 2 will energize the solenoid/valve 2 for engine cylinder number 4. Button 3 will energize the solenoid/valve 3 for engine cylinder number 6. Button 4 will energize the solenoid/valve 4 for engine cylinder number 7.
2. Do not lift the manifold assembly by the electrical lead frame.
3. Install the EN-46999-1 (1) to the manifold. See «Special Tools»(ref-268156-S11321246192007101800000) .
4. Install 2 of the manifold bolts (2) to the EN-46999-1 . See «Special Tools»(ref-268156-S11321246192007101800000) . Tighten: Tighten the bolts to 25 N.m (18 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
5. Connect the air out hose (2) of the EN-46999 (5) to the EN-46999-1 (1). See «Special Tools»(ref-268156-S11321246192007101800000) . Verify the air supply switch (4) is in the off position.
6. Connect the air in hose (6) of the EN-46999 (5) to a shop air source.
7. Connect the 12-volt power supply connectors (7) of the EN-46999 (5) to a 12-volt power supply. Verify the Power light (8) on the tool is illuminated. If the light on the tool is not illuminated when connected to a 12-volt power supply, test and/or replace the 3 amp fuse.
8. Connect the EN-46999-5 power cable (3) to the electrical connector of the manifold. See «Special Tools»(ref-268156-S11321246192007101800000) .
9. Turn the air supply switch of the EN-46999 to the ON position. With the air supply connected to the manifold assembly and the solenoid/valves in the closed position, a limited amount of air will exit each of the bleed holes (3) and outlet ports (1, 2) of the manifold.
10. Position the manifold assembly onto a bench at a 45 degree angle in order to test solenoid/valves 1 and 4. IMPORTANT: The manifold must be tested in the proper position to ensure the solenoid/valves operate as designed.
11. Depress button number 1 on the tool to activate solenoid/valve 1. With button 1 depressed, the solenoid/valve (1) should open, allowing an increased amount of air to exit the outlet ports (2) of the manifold.
12. Depress button number 4 on the tool to activate solenoid/valve 4. With button 4 depressed, the solenoid/valve (4) should open, allowing an increased amount of air to exit the outlet ports (3) of the manifold.
13. Reposition the manifold assembly onto a bench at a 45 degree angle in order to test solenoid/valves 2 and 3.
14. Depress button number 2 on the tool to activate solenoid/valve 2. With button 2 depressed, the solenoid/valve (2) should open, allowing an increased amount of air to exit the outlet ports (4) of the manifold.
15. Depress button number 3 on the tool to activate solenoid/valve 3. With button 3 depressed, the solenoid/valve (3) should open, allowing an increased amount of air to exit the outlet ports (1) of the manifold.
16. When the test is completed, turn the air source switch on the EN-46999 to the off position and disconnect the tool from the 12-volt power supply, shop air source and manifold assembly.
17. If after testing, it has been determined that 1 or more of the solenoid/valves is not functioning properly, replace the manifold as an assembly.
18. If after testing, it has been determined that the solenoid/valves are functioning properly, replace the valve lifters, as required. Both intake and exhaust lifters should be replaced in pairs.

Oil Leak Diagnosis

Oil Leak Diagnosis

Crankcase Ventilation System Inspection/Diagnosis

Crankcase Ventilation System Inspection/Diagnosis

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 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.

Engine Block Cleaning and Inspection

Tools Required

1. J 8087 Cylinder Bore Gage. See «Special Tools»(ref-268156-S11321246192007101800000) .
2. J 42385-100 Head/Main Bolt Thread Repair Kit. See «Special Tools»(ref-268156-S11321246192007101800000) .

Scheme 323

Note. Do not use a caustic solution to clean the aluminum engine block.

Clean the following components

1. Remove all sludge, dirt, or debris using a cleaning solvent or thermal type oven. Refer to «Cleanliness and Care»(ref-268156-S06496902282007101800000) .
2. Gasket surfaces Refer to «Replacing Engine Gaskets»(ref-268156-S26340062372007101800000) .
3. Coolant passages
4. Oil galleries
5. Main bearing caps
6. Cylinder head bolt holes to remove threadlocking material Thread repair tool J 42385-107 may be used to clean the threads of any residual threadlocking material.

Inspection Procedure

1. Inspect the following components: Cylinder walls for excessive scratches, gouging, or ring ridge Cylinder bores for excessive ring ridge at the top of the cylinder Coolant jacket for cracks Valve lifter bores for excessive scoring or wear Crankshaft bearing webs for cracks Gasket sealing surfaces for excessive scratches or gouging Refer to «Replacing Engine Gaskets»(ref-268156-S26340062372007101800000) . Oil galleries for restrictions Threaded bolt holes for damaged threads Cylinder bores for excessive ring ridge at the top of the cylinder
2. Measure the cylinder bores for an oversize condition

Scheme 324

Scheme 325

1. Adjust the micrometer to a dimension slightly smaller than the bore size. Refer to «Engine Mechanical Specifications»(ref-268156-S06431639902007101800000) .
2. Insert the J 8087 into the micrometer and zero the bore gage dial.
3. Using the J 8087 , measure the cylinder bore for oversize. Slide the bore gage up and down throughout the length of the cylinder bore. Measure the bore, both parallel and perpendicular to the centerline of the crankshaft, at the top, center, and bottom of the bore. A cylinder bore that exceeds the maximum diameter must be serviced with an oversized piston. Refer to «Engine Mechanical Specifications»(ref-268156-S06431639902007101800000) .

Crankshaft and Bearings Cleaning and Inspection

Tools Required

1. J 7872 Magnetic Base Dial Indicator Set. See «Special Tools»(ref-268156-S11321246192007101800000) .
2. J 43690 Rod Bearing Checking Tool. See «Special Tools»(ref-268156-S11321246192007101800000) .
3. J 43690-100 Rod Bearing Checking Tool - Adapter Kit. See «Special Tools»(ref-268156-S11321246192007101800000) .

Scheme 326

1. Clean the crankshaft with solvent. IMPORTANT: Use care when handling the crankshaft. Avoid damage to the bearing surfaces or the lobes of the crankshaft position (CKP) reluctor ring. Damage to the teeth of the CKP reluctor ring may affect on-board diagnostics (OBD) II system performance.
2. Thoroughly clean all oil passages (2) and inspect for restrictions or burrs.
3. Dry the crankshaft with compressed air. CAUTION: Refer to «Safety Glasses Caution»(ref-268087-S01092725012007101800000) .

Scheme 327

Scheme 328

Scheme 329

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Scheme 331

Scheme 332

Scheme 333

Scheme 334

Scheme 335

1. Inspect the CKP reluctor ring teeth (1) for damage. IMPORTANT: The reluctor ring teeth should not have imperfections on the rising or falling edges. Imperfections of the reluctor ring teeth may effect OBD II system performance.
2. Inspect the crankshaft journals for wear. Journals should be smooth (1) with no signs of scoring, wear, or damage.
3. Inspect the crankshaft journals for grooves or scoring (2).
4. Inspect the crankshaft journals for scratches or wear (3).
5. Inspect the crankshaft journals for pitting or imbedded bearing material (4).
6. Inspect the crankshaft rear oil seal surface (5) for grooves or scoring.
7. Inspect the crankshaft key (122), keyway (1), and threaded hole (2) for damage.
8. Measure the connecting rod journals for out-of-round and taper.
9. Measure the crankshaft thrust wall width. A crankshaft with a thrust wall width in excess of 26.2 mm (1.0315 in) (a) must be replaced.
10. Measure the crankshaft runout. Use wooden V-blocks or a fixture to support the crankshaft on the front and rear journals.
11. Use the J 7872 in order to measure the crankshaft runout at the front and rear intermediate journals.
12. Use the J 7872 in order to measure the runout of the crankshaft rear flange.
13. Use the J 7872 in order to measure the runout of the CKP reluctor ring. Reluctor ring runout should be measured 1.0 mm (0.04 in) below the ring teeth. If the reluctor ring has runout in excess of 0.7 mm (0.028 in), replace the crankshaft.
14. Inspect crankshaft bearings for craters or pockets. Flattened sections on the bearing halves also indicate fatigue.
15. Inspect the crankshaft bearings for excessive scoring or discoloration.
16. Inspect the crankshaft bearings for dirt or debris imbedded into the bearing material.
17. 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.

Scheme 336

Scheme 337

1. Remove the bearing caps, bearing half, and bolts. Refer to «Crankshaft and Bearings Removal»(ref-268156-S32640213422007101800000) . IMPORTANT: 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 CKP sensor signals and may effect on-board diagnostics (OBD) II system operation. Remove the bearing cap side bolts prior to cap removal.
2. Install gaging plastic onto the crankshaft journal. Install the gaging plastic the full width of the crankshaft bearing journal.
3. Install the bearing caps, bearing half, and bolts. Refer to «Crankshaft and Bearings Installation»(ref-268156-S35952702612007101800000) .
4. Remove the bearing caps, bearing half, and bolts. Refer to «Crankshaft and Bearings Removal»(ref-268156-S32640213422007101800000) .
5. Using the scale supplied with the plastic gaging kit, measure the gaging plastic at its widest area. If the gaging plastic 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. Refer to «Engine Mechanical Specifications»(ref-268156-S06431639902007101800000) .

Camshaft and Bearings Cleaning and Inspection

Tools Required

1. J 7872 Magnetic Base Dial Indicator Set. See «Special Tools»(ref-268156-S11321246192007101800000) .
2. J 8520 Camshaft Lobe Lift Indicator. See «Special Tools»(ref-268156-S11321246192007101800000) .

Scheme 338

Scheme 339

Scheme 340

Scheme 341

1. Clean the components in solvent.
2. Dry the components with compressed air. CAUTION: Refer to «Safety Glasses Caution»(ref-268087-S01092725012007101800000) .
3. Inspect the camshaft bearing journals (1) for scoring or excessive wear.
4. Inspect the camshaft valve lifter lobes (2) for scoring or excessive wear.
5. Inspect the threaded bolt holes (3) in the front of the camshaft for damaged threads or debris.
6. Inspect the camshaft sprocket pin (204) for damage.
7. Inspect the camshaft retainer plate for wear or a damaged sealing gasket. If the camshaft retainer plate sealing gasket is not cut or damaged, it may be used again.
8. Inspect the camshaft bearings for 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.
9. Inspect the camshaft bearings for excessive wear or scoring. Bearings with excessive scoring or wear must be replaced.
10. Using a micrometer, measure the camshaft journals for wear and out-of-round. If the camshaft bearing journals are greater than 0.025 mm (0.001 in) out-of-round, replace the camshaft. If the camshaft bearing journal diameter is less than 54.99 mm (2.164 in), replace the camshaft.
11. Using a micrometer, measure the camshaft lobes for wear. Refer to «Engine Mechanical Specifications»(ref-268156-S06431639902007101800000) .
12. Measure the camshaft runout. Mount the camshaft in wooden V-blocks or between centers on a fixture. Using the J 7872 , measure the runout of the intermediate camshaft bearing journals. If camshaft runout exceeds 0.05 mm (0.002 in), the camshaft is bent and should be replaced.

Scheme 342

1. Using the J 8520 , measure camshaft lobe lift. See «Special Tools»(ref-268156-S11321246192007101800000) . IMPORTANT: Measuring camshaft lobe lift is a procedure used to determine if the camshaft lobes have worn. This test is to be performed prior to engine disassembly and with the camshaft and valve train components installed in the engine.
2. Remove the valve rocker arms and bolts.
3. Install the dial indicator mounting stud into the valve rocker arm bolt hole.
4. Assemble the components of the J 8520 and position onto the stud. See «Special Tools»(ref-268156-S11321246192007101800000) .
5. Position the shaft of the dial indicator onto the end of the pushrod.
6. Rotate the face of the dial indicator to zero.
7. Slowly rotate the crankshaft clockwise, until the dial indicator obtains its highest and lowest readings.
8. Compare the total to specifications. Refer to «Engine Mechanical Specifications»(ref-268156-S06431639902007101800000) .

Cylinder Head Cleaning and Inspection

Tools Required

1. J 8089 Carbon Removal Brush. See «Special Tools»(ref-268156-S11321246192007101800000) .
2. J 9666 Valve Spring Tester. See «Special Tools»(ref-268156-S11321246192007101800000) .

Scheme 343

Scheme 344

Scheme 345

1. Clean the following components: Use the J 8089 in order to remove the carbon from the combustion chambers. See «Special Tools»(ref-268156-S11321246192007101800000) . Gasket surfaces Refer to «Replacing Engine Gaskets»(ref-268156-S26340062372007101800000) . Valve stems and heads on a buffing wheel Bolt hole threads Remove all dirt, debris, or threadlocking material from the bolt holes. CAUTION: Refer to «Safety Glasses Caution»(ref-268087-S01092725012007101800000) . IMPORTANT: When cleaning a cylinder head in a thermal type oven, do not exceed 204°C (400°F). Be careful not to scuff the chamber.
2. 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 Refer to «Replacing Engine Gaskets»(ref-268156-S26340062372007101800000) . Bolt hole threads for debris or damaged threads Refer to «Thread Repair»(ref-268156-S28306433452007101800000) or «Thread Repair Specifications»(ref-268156-S28464222222007101800000) .
3. Inspect the cylinder head for warpage. Refer to «Engine Mechanical Specifications»(ref-268156-S06431639902007101800000) .
4. Use the J 9666 in order to measure the valve spring tension. See «Special Tools»(ref-268156-S11321246192007101800000) . Refer to «Engine Mechanical Specifications»(ref-268156-S06431639902007101800000) .

Oil Pump Cleaning and Inspection

1. Clean the parts in solvent. IMPORTANT: The internal parts of the oil pump assembly are not serviced separately, excluding the spring. If the oil pump components are worn or damaged, replace the oil pump as an assembly. The oil pump pipe and screen are to be serviced as an assembly. Do not attempt to repair the wire mesh portion of the pump and screen assembly.
2. Dry the parts with compressed air. CAUTION: Refer to «Safety Glasses Caution»(ref-268087-S01092725012007101800000) in Cautions and Notices.
3. Inspect the oil pump housing (413) and the cover (409) for cracks, excessive wear, scoring, or casting imperfections.
4. Inspect the oil pump housing-to-engine block oil gallery surface for scratches or gouging.
5. Inspect the oil pump housing for damaged bolt hole threads.
6. Inspect the relief valve plug (416) and plug bore for damaged threads.
7. Inspect the oil pump internal oil passages for restrictions.
8. Inspect the drive gear (410) and driven gear (412) for chipping, galling or wear. Minor burrs or imperfections on the gears may be removed with a fine oil stone.
9. Inspect the drive gear splines for excessive wear.
10. Inspect the pressure relief valve (414) and bore for scoring or wear. The valve must move freely in the bore with no restrictions.
11. Inspect the oil pump screen (407) for debris or restrictions.
12. Inspect the oil pump screen for broken or loose wire mesh.

Engine Front Cover Cleaning and Inspection

1. Remove the crankshaft oil seal (4) from the front cover. IMPORTANT: Do not use the crankshaft oil seal again. Install a NEW crankshaft oil seal during assembly. Do not use the front cover-to-engine block gasket again. Install a NEW gasket during assembly.
2. Clean the cover in solvent. Remove the sealant from the cover oil pan surface. Refer to «Replacing Engine Gaskets»(ref-268156-S26340062372007101800000) .
3. Dry the cover with compressed air. CAUTION: Refer to «Safety Glasses Caution»(ref-268087-S01092725012007101800000) .
4. Inspect the gasket sealing surfaces for excessive scratches or gouging.
5. Inspect the threaded bolt holes for damaged threads or debris.
6. Inspect the crankshaft oil seal and camshaft position (CMP) sensor mounting bores for damage.

Scheme 346

1. Remove the crankshaft oil seal (141) from the rear housing. IMPORTANT: Do not use the crankshaft rear oil seal again. Install a NEW crankshaft oil seal during assembly. Do not use the rear housing-to-engine block gasket again. Install a NEW gasket during assembly.
2. Clean the housing in solvent. Remove the sealant from the housing oil pan surface. Refer to «Replacing Engine Gaskets»(ref-268156-S26340062372007101800000) .
3. Dry the housing with compressed air. CAUTION: Refer to «Safety Glasses Caution»(ref-268087-S01092725012007101800000) .
4. Inspect the gasket sealing surfaces for excessive scratches or gouging.
5. Inspect the housing-to-oil pan threaded bolt holes for damaged threads or debris.
6. Inspect the crankshaft oil seal mounting bore for damage.

Scheme 347

Scheme 348

Scheme 349

1. Do not lift the manifold assembly by the electrical lead frame. IMPORTANT: Do not allow dirt or debris to enter the oil passages of the manifold. Plug, as required. Do not disassemble the electrical components from the manifold. Do not submerge the electrical components in cleaning solvent. Do not use the manifold exterior gasket again. Remove the exterior gasket and install a NEW service gasket during assembly.
2. Remove the oil pressure sensor (706) and washer (707).
3. Remove the oil screen (452) with O-ring (454).
4. Clean the manifold with compressed air. CAUTION: Refer to «Safety Glasses Caution»(ref-268087-S01092725012007101800000) .
5. Inspect for loose electrical solenoids (1-4) or loose or missing bolts.
6. Inspect for damage to the electrical lead frame (5).
7. Inspect for a damaged electrical connector, for bent or corroded pins.
8. Inspect for damaged interior sealing gaskets (1-8). If the interior sealing gaskets are damaged, the manifold must be replaced as an assembly.
9. Inspect for a damaged exterior sealing gasket (9) or scored gasket surfaces.
10. Inspect for debris or restrictions within the oil passages of the manifold. Refer to «Cylinder Deactivation (Active Fuel Management) Valve Lifter Oil Manifold Diagnosis and Testing»(ref-268156-S04110005032007101800000) .

Scheme 350

1. Inspect the oil fill tube (423) for a loose fit or damage. IMPORTANT: Do not use the valve rocker arm cover gasket again. Install a NEW gasket during assembly. Remove the ignition coils before cleaning the cover in solvent. Do not submerge the ignition coils in solvent. Do not remove the oil fill tube from the covers unless service is required. If the tube is removed from the cover, install a NEW tube (423) and seal (422) during assembly.
2. Inspect the covers (505) for the following conditions: Scoring or damage to the gasket surfaces Ventilation system passages for restrictions Threaded bolt holes for damage or debris

Scheme 351

Scheme 352

Scheme 353

1. Remove the oil filter tube bolts (435, 446) and gaskets (445, 448). IMPORTANT: When installing a NEW oil pan gasket, it is not necessary to install the rivets that retain the NEW gasket to the pan.
2. Remove the oil filter tube (447).
3. Remove the plugs (449) from the oil galleries.
4. Remove the oil pan baffle and bolts.
5. Remove the oil filter fitting, as required. Refer to «Oil Filter and Adapter Removal»(ref-268156-S25517267042007101800000) .
6. Clean the oil pan in solvent. Be sure to thoroughly clean all of the oil passages and recesses of the pan.
7. Dry the oil pan with compressed air. CAUTION: Refer to «Safety Glasses Caution»(ref-268087-S01092725012007101800000) .
8. Inspect the oil pan for the following conditions: Damaged gasket surfaces Restrictions within the oil passages of the pan Threaded bolt holes for damage
9. Inspect the oil filter tube for restrictions or damaged gasket surfaces.
10. Inspect the active fuel management oil pressure relief valve for proper operation. Lightly depress the valve (2). The valve spring (1) should seat the valve to the proper closed position.
11. The oil pressure relief valve (455) is press-fit into the oil filter tube and is serviceable separately.

Coolant Air Bleed Pipe Cleaning and Inspection

1. Remove the seals (308) from the pipe (307) and covers. IMPORTANT: Do not use the engine coolant air bleed pipe and cover seals again. Upon installation of the pipe and covers, install NEW seals.
2. Clean the pipe and covers in solvent.
3. Dry the pipe and covers with compressed air. CAUTION: Refer to «Safety Glasses Caution»(ref-268087-S01092725012007101800000) in Cautions and Notices.
4. Inspect the pipe and covers for damaged sealing surfaces or restrictions within the pipe.

Water Pump Cleaning and Inspection

1. Remove the old gasket from the water pump sealing surfaces. Refer to «Replacing Engine Gaskets»(ref-268156-S26340062372007101800000) .
2. Clean all excess dirt and debris from the water pump housing.
3. Inspect the water pump (1) for the following conditions: Gasket and hose sealing surfaces for excessive scratches or gouging Restrictions within the internal coolant passages Excessive side-to-side play in the pulley shaft Leakage at the water outlet housing or rear cover gasket Leakage at the water pump vent hole A stain around the vent hole is acceptable. If leakage, such as dripping, occurs with the engine running and the cooling system pressurized, replace the water pump. Wear or damage in the belt tracking area of the pulley

Engine Mechanical Diagnostic Procedure Revisions

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. For a detailed explanation, refer to Diagnostic Starting Point - Engine Mechanical .