Service Manual2007 Captiva UNIT REPAIR

Captiva

UNIT REPAIR

Cylinder Head and Valve Train Components

Tools Required

KM-571-B Gauge

KM-340-0 Cutter Set

KM-340-7 Guide Drift

KM-340-13 Cutters

KM-340-26 Cutters

KM-348 Valve Spring Compressor

KM-653 Adapter

KM-805 Valve Guide Reamer

Disassembly Procedure

Remove the cylinder head with the intake manifold and the exhaust manifold attached. Refer to "Cylinder Head and Gasket" in this section.
Remove the exhaust manifold heat shield.

Remove the exhaust manifold retaining nuts in the sequence shown.
Remove the exhaust manifold.
Remove the exhaust manifold gasket.
Remove the exhaust manifold studs.

Remove the thermostat housing mounting bolts.
Remove the thermostat housing assembly.
Remove the coolant bypass housing mounting bolts and the housing.
Remove the fuel rail assembly. Refer to Section 1F2, Engine Controls - FAM II 2.4D.

Remove the intake manifold retaining bolt and nuts in the sequence shown.
Remove the intake manifold support bracket.
Remove the intake manifold.
Remove the intake manifold gasket.
Remove the intake manifold stud.

Remove the cylinder head cover. Refer to "Cylinder Head Cover"in this section.
Remove the direct ignition system (DIS) coil and the exhaust gas recirculation (EGR) valve adapter retaining bolts.
Remove the DIS coil and the EGR valve adapter.
Remove the spark plugs.

Remove the camshaft bearing cap bolts gradually in the sequence shown for each camshaft cap.

Remove the intake camshaft caps. Maintain the correct positions for installation.
Remove the intake camshaft.
Remove the intake valve tappet adjusters.
Remove the exhaust camshaft caps. Maintain the correct positions for installation.
Remove the exhaust camshaft.
Remove the exhaust valve tappet adjusters.

Compress the valve springs with the valve spring compressor KM-348 and the adapter KM-653.
Remove the valve retainers.
Remove the valve spring compressor KM-348 and the adapter KM-653.
Remove the valve spring caps.
Remove the valve springs. Maintain the original position of the valve springs for installation.
Remove the valves. Maintain the original position of the valves for installation.

Cylinder Head Inspection

Clean the sealing surfaces.
Inspect the cylinder head for the following.

Cracks, damage or pitting in the combustion chambers.
Debris in the oil galleries. Continue to clean the galleries until all debris is removed.
Coolant leaks or damage to the deck face sealing surface. ·Damage to any gasket surfaces.
Damage to any threaded bolt holes.
Burnt or eroded areas in the combustion chamber.
Cracks in the exhaust ports and combustion chambers.
External cracks in the water passages.
Restrictions in the intake or exhaust passages.
Restrictions in the cooling system passages.
Rusted, damaged or leaking core plugs.

If the cylinder head is cracked or damaged, it must be replaced. No welding or patching of the cylinder head is recommended.
Measure the clearance between the straight-edge and the cylinder head deck face using a feeler gauge at four points along the straight-edge.
Check the sealing surfaces for deformation and warpage. The cylinder head sealing surfaces must be flat within 0.025 mm (0.001 in.) maximum.

Measure the height of the cylinder head from sealing surface to sealing surface. The cylinder head height should be 133.975 to 134.025 mm (5.274 to 5.276 in.). If the cylinder head height is less than 133.9 mm (5.271 in.), replace the cylinder head.

Valve Inspection

Inspect the valve for damage from the head to tip for the following conditions.

pitting in the valve seat area (1)
lack of valve margin (2)
bending in the valve stem (3)
pitting or excessive wear in the stem (4)
worn valve key grooves (5)
worn valve tip (6)

Replace the valve if any of these conditions exist.
Inspect the valve springs. If the valve spring ends are not parallel, replace the valve spring.
Inspect the valve spring seating surface of the valve rotators for wear or gouges. Replace as required.

Cleaning Procedure

Clean the cylinder head.
Clean the valve guides.
Clean all of the threaded holes.
Clean the valves of carbon, oil, and varnish.

Cylinder Head Overhaul

Valve Grind-in

Lubricate the valve seat using a fine-grained paste.
Lift the valve rhythmically from the seat with a commercially available valve grinding tool in order to distribute the paste.

Check the contact pattern on the valve head and in the cylinder head.
Clean the valves, valve guides and the cylinder head.

Valve Grind

Ensure that there is no crater line burns on the valve cone.
The valve may be reground only two times. Do not grind the valve stem end.
Ensure that the angle at the valve face is 45 degrees.
Inspect the assembly height of the intake valves and exhaust valves.

Valve Guide - Ream

Measure the diameter of the valve guide using the gauge MKM-571-B and a commercially available inside micrometer.

Important : Valve oversize may already have been fitted in production.

An oversize service code is on the valve guide and the valve stem end. The following table gives the correct size, reamer and production code for each service.

Size	Reamer	Production Code	Service Code
Normal	-	-	K
0.075	KM-805	1	K1
0.150	-	2	K2

Ream the valve guide from the upper side of the cylinder head to the next oversize.
After reaming, cross out the code and emboss the valve guide with the new code.

Valve Seat - Cut

Place the cylinder head on wooden blocks.
Cut the intake and the exhaust valve seats using the guide drift KM-340-7 as follows :

Valve seat – 45° surface using the cutter KM-340-13.
Upper correction angle – 30° surface using the cutter KM-340-13.
Lower the correction angle - 60° surface suing the cutter KM-340-26.

Clean the chippings from the cylinder head.
Inspect the dimension for the valve seat width.

Intake : 1.2 to 1.4 mm (0.047 to 0.055 in.)
Exhaust : 1.4 to 1.8 mm (0.055 to 0.070 in.)

Inspect the assembly height of the intake valves and the exhaust valves. If the dimension is exceeded, install new valves. Inspect the assembly height again. If the valve assembly height is still too large despite replacing the valves, replace the cylinder head.

Assembly Procedure

Lubricate the valve stems with engine oil.
Carefully install the valves in their original positions.
Install the valve springs in their original positions.
Install the valve spring caps.
Compress the valve springs with the valve spring compressor KM-348 and the adapter KM-653.
Install the valve keys.
Remove the valve spring compressor KM-348 and the adapter KM-653.

Lubricate the valve tappet adjusters with engine oil.
Install the valve tappet adjusters.

Install the intake camshaft.
Install the intake camshaft bearing caps in their original positions.
Install the exhaust camshaft.
Install the exhaust camshaft bearing caps in their original positions.
Install the camshaft bearing cap bolts gradually in the sequence shown for each camshaft cap.

Tighten

Tighten the camshaft bearing cap bolts to 8 N•m (71 lb-in.).

Install the spark plugs.

Tighten

Tighten the spark plugs to 25 N•m (18 lb-ft).

Install the DIS coil and EGR valve adapter.

Tighten

Tighten the direct ignition system coil and the exhaust gas recirculation valve adapter retaining bolts to 25 N•m (18 lb-ft).

Install the intake manifold studs.
Install the intake manifold gasket.
Install the intake manifold.
Install the intake manifold retaining bolt and nuts in the sequence shown.

Tighten

Tighten the intake manifold retaining bolt and nuts to 22 N•m (16 lb-ft).

Install the intake manifold support bracket.

Tighten

Tighten the intake manifold support bracket bolts to 25 N•m (18 lb-ft).

Install the fuel rail assembly. Refer to Section 1F2, Engine Controls - FAM II 2.4D.

Install the thermostat housing assembly.

Tighten

Tighten the thermostat housing assembly mounting bolts to 15 N•m (11 lb-ft).

Install the coolant bypass housing and mounting bolts.

Tighten

Tighten the coolant bypass housing bolts to 15 N•m (11 lb-ft).

Install the exhaust manifold studs.
Install the exhaust manifold gasket.
Install the exhaust manifold.
Install the exhaust manifold retaining nuts in the sequence shown.

Tighten

Tighten the exhaust manifold retaining nuts to 22 N•m (16 lb-ft).

Install the exhaust manifold heat shield.

Tighten

Tighten the exhaust manifold heat shield bolts to 8 N•m (71 lb-in.).

Install the cylinder head with the intake manifold and the exhaust manifold attached. Refer to "Cylinder Head and Gasket"in this section.

Crankshaft

Tools Required

DW100-030 Engine Overhaul Stand

KM-470-B Angular Torque Gauge

J-36972 or KM-635 Crankshaft Rear Oil Seal

Notice : Take extreme care to prevent any scratches, nicks or damage to the camshafts.

Disassembly Procedure

Remove the engine. Refer to "Engine" in this section.
Remove the flywheel or flexible plate bolts.
Remove the flywheel or flexible plate.

Remove the crankshaft rear oil seal.
Mount the engine assembly on the engine overhaul stand DW100-030.

Remove the crankshaft pulley bolts.
Remove the crankshaft pulley.

Remove the front timing belt cover bolts.
Remove the front timing belt cover.

Loosen the timing belt automatic tensioner bolt.
Rotate the timing belt automatic tensioner hex-key clockwise to release the tension.
Remove the timing belt idler pulley bolt and nut.
Remove the timing belt idler pulleys.
Remove the timing belt.
Remove the engine mount adapter support bracket bolts.
Remove the engine mount adapter support bracket.

Remove the ignition wires from the spark plugs.
Remove the cylinder head cover and gasket. Refer to "Cylinder Head Cover" in this section.

Notice : Take extreme care to prevent any scratches, nicks or damage to the camshafts.

While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt.
Remove the intake camshaft gear.
While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt.
Remove the exhaust camshaft gear.

Remove the crankshaft gear.

Remove the rear timing belt cover bolts and the cover.

Rotate the engine on the engine overhaul stand DW100-030.

Remove the oil pan retaining bolts.
Remove the oil pan.
Remove the oil suction pipe bolts.
Remove the oil suction pipe with O-ring.
Remove the oil pan scraper bolts.
Remove the oil pan scrapers.

Remove the crankshaft balancer unit assembly retaining bolts.
Remove the crankshaft balancer unit assembly.

Remove the oil pump retaining bolts.
Remove the oil pump.

Mark the order of the connecting rod bearing caps for installation.
Remove the connecting rod bearing cap bolts for all of the pistons.
Remove the connecting rod bearing caps and the lower connecting rod bearings.

Mark the order of the crankshaft bearing caps for installation.
Remove the crankshaft bearing cap bolts.
Remove the crankshaft bearing caps and the lower crankshaft bearings.
Remove the crankshaft.
Clean the parts if needed.

Assembly Procedure

Coat the crankshaft bearings with engine oil.
If replacing the crankshaft, transfer the reluctor wheel to the new crankshaft.

Install the crankshaft.
Install the lower crankshaft bearings in the bearing caps.
Inspect the crankshaft end play with the crankshaft bearings installed.
Check for permissible crankshaft end play. Refer to "Engine Specifications" in this section.

With the crankshaft mounted on the front and rear crankshaft bearings, check the middle crankshaft journal for permissible out-of-round (runout). Refer to "Engine Specifications"in this section.

Important : Grease the crankshaft journals and lubricate the crankshaft bearings slightly so that the plastic gauging thread does not tear when the crankshaft bearing caps are removed.

Inspect all crankshaft bearing clearances using a commercially available plastic gauging (ductile plastic threads).
Cut the plastic gauging threads to the length of the bearing width. Lay them axially between the crankshaft journals and the crankshaft bearings.
Install the crankshaft bearing caps and the bolts.

Tighten

Tighten the crankshaft bearing cap bolts to 50 N•m (37 lb-ft) plus 45° and 15°.

Remove the crankshaft bearing cap bolts and the caps.
Measure the width of the flattened plastic thread of the plastic gauging using a ruler. (Plastic gauging is available for different tolerance ranges.)
Inspect the bearing clearance for permissible tolerance ranges. Refer to "Engine Specifications" in this section.

Apply a bead of adhesive sealing compound to the grooves of the crankshaft bearing caps.
Install the crankshaft bearing caps to the engine block.
Tighten the crankshaft bearing caps using new bolts.

Tighten

TightenTighten the crankshaft bearing cap bolts to 50 N•m (37 lb-ft) using a torque wrench. Use the angular torque gauge KM-470-B to tighten the crankshaft bearings another 45° and 15°.

Important : Grease the connecting rod journals and lubricate the connecting rod bearings slightly so that the plastic gauging thread does not tear when the connecting rod bearing caps are removed.

Inspect all of the connecting rod bearing clearances using a commercially available plastic gauging (ductile plastic threads).
Cut the plastic gauging threads to the length of the connecting rod bearing width. Lay them axially between the connecting rod journals and the connecting rod bearings.
Install the connecting rod bearing caps.

Tighten

Tighten the connecting rod bearing cap bolts to 35 N•m (26 lb-ft) using a torque wrench. Use the angular torque gauge KM-470-B to tighten the connecting rod bearing cap bolts another 45° plus 15°.

Remove the connecting rod bearing caps.
Measure the width of the flattened plastic thread of the plastic gauging using a ruler. (Plastic gauging is available for different tolerance ranges.)
Inspect the bearing clearance for permissible tolerance ranges. Refer to "Engine Specifications" in this section.

Install the connecting rod bearing caps to the connecting rods.
Tighten the connecting rod bearing caps using new bolts.

Tighten

Install the oil pump.
Install the oil pump retaining bolts.

Tighten

Tighten the oil pump retaining bolts to 10 N•m (89 lb-in.).

Install the crankshaft balancer unit assembly.
Install the crankshaft balancer unit assembly retaining bolts.

Tighten

Tighten the crankshaft balancer unit assembly retaining bolts to 20 N•m (15 lb-ft) and turn the bolts another 45° using the angular torque gauge KM-470-B.

Install the oil pan scrapers.
Install the oil pan scraper retaining bolts.

Tighten

Tighten the oil pan scraper retaining bolts to 8 N•m (71 lb-in.).

Install the oil suction pipe with the new O-ring.
Install the oil suction pipe retaining bolts.

Tighten

Tighten the oil suction pipe bolts to 8 N•m (71 lb-in.).

Coat the sealant on the oil pan mating surface.
Install the oil pan.
Install the oil pan retaining bolts.

Tighten

Tighten the oil pan retaining bolts to 10 N•m (89 lb-in.).

Rotate the engine on the engine overhaul stand DW100-030.
Install the rear timing belt cover.
Install the rear timing belt cover bolts.

Tighten

Tighten the rear timing belt cover bolts to 7 N•m (62 lb-in.).

Install the crankshaft gear and the bolt.

Tighten

Tighten the crankshaft gear bolt to 135 N•m (100 lb-ft) plus 30° plus 10° using the angular torque gauge KM-470-B.

Install the engine mount adapter support bracket and the bolts.

Tighten

Tighten the engine mount adapter support bracket retaining bolts to 45 N•m (33 lb-ft).

Install the timing belt idler pulley.
Install the timing belt idler pulley bolt and nut.

Tighten

Tighten the timing belt idler pulley bolt and nut to 25 N•m (18 lb-ft).

Notice : Take extreme care to prevent any scratches, nicks or damage to the camshafts.

Install the intake camshaft gear.
Install the intake camshaft gear bolt while holding the intake camshaft firmly in place.

Tighten

Tighten the intake camshaft gear bolt to 50 N•m (37 lb-ft) plus 60° and 15° using the angular torque gauge KM-470-B.

Install the exhaust camshaft gear.
Install the exhaust camshaft gear bolt while holding the exhaust camshaft firmly in place.

Tighten

Tighten the exhaust camshaft gear bolts to 50 N•m (37 lb-ft) plus 60° and 15° using the angular torque gauge KM-470-B.

Install the timing belt automatic tensioner.

Tighten

Tighten the timing belt automatic tensioner bolts to 25 N•m (18 lb-ft).

Install the timing belt. Refer to "Timing Belt" in this section.
Adjust the timing belt tension. Refer to "Timing Belt Check and Adjust" in this section.

Apply a small amount of gasket sealant to the corners of the front camshaft caps and to the top of the rear cylinder head cover to cylinder head seal.
Install the cylinder head cover and the cylinder head cover gasket. Refer to "Cylinder Head and Gasket"in this section.

Tighten

Tighten the cylinder head cover bolts to 8 N•m (71 lb-in.).

Connect the ignition wires to the spark plugs.
Connect the breather hose and PCV hose to the cylinder head cover.

Install the front timing belt cover.
Install the front timing belt cover bolts.

Tighten

Tighten the front timing belt cover bolts to 6 N•m (53 lb-in.).

Install the hoist to the engine support bracket and lift the engine assembly far enough to take the weight off the engine overhaul stand DW100-030.
Remove the engine from the engine overhaul stand DW100-030.

Install a new crankshaft rear oil seal using the crankshaft rear oil seal installer J-36792.

Install the flywheel or flexible plate.
Install the flywheel or flexible plate bolts.

Tighten

Tighten the flywheel bolts to 65 N•m (48 lb-ft).

Use the angular torque gauge KM-470-B to tighten the flywheel bolts another 30° plus 15°.

For the automatic transaxle, tighten the flexible plate bolts to 45 N•m (33 lb-ft).

Install the engine. Refer to "Engine"in this section.

Crankshaft Bearings and Connecting Rod Bearings - Gauging Plastic

Tools Required

KM-470-B Angular Torque Gauge

Inspection Procedure - Crankshaft

Coat the crankshaft bearings with engine oil.
Install the upper crankshaft bearings into the engine block crankshaft journals.
Install the lower crankshaft bearings into the crankshaft bearing caps.
Install the crankshaft.
Inspect the crankshaft end play with the crankshaft bearings installed.
Check for permissible crankshaft end play. Refer to "Engine Specifications" in this section.

With the crankshaft mounted on the front and rear crankshaft bearings, check the middle crankshaft journal for permissible out-of-round (runout). Refer to "Engine Specifications" in this section.

Important : Grease the crankshaft journals and lubricate the crankshaft bearings slightly so that the plastic gauging thread does not tear when the crankshaft bearing caps are removed.

Inspect all crankshaft bearing clearances using a commercially available plastic gauging (ductile plastic threads).
Cut the plastic gauging threads to the length of the bearing width. Lay them axially between the crankshaft journals and the crankshaft bearings.

Install the crankshaft bearing caps.
Install the crankshaft bearing cap bolts.

Tighten

Tighten the crankshaft bearing cap bolts to 50 N•m (37 lb-ft). Using the angular torque gauge KM-470-B, tighten the crankshaft bearing cap bolts another 45° plus 15°.

Remove the crankshaft bearing caps.
Measure the width of the flattened plastic thread of the plastic gauging using a ruler. (Plastic gauging is available for different tolerance ranges.)
Inspect the bearing clearances for permissible tolerance ranges. Refer to "Engine Specifications" in this section.

Inspection Procedure - Connecting Rods

Coat the connecting rod bearings with engine oil.
Install the upper connecting rod bearings into the connecting rod journals.
Install the lower connecting rod bearings into the connecting rod bearing caps.

Inspect all of the connecting rod bearing clearances using a commercially available plastic gauging (ductile plastic threads).
Cut the plastic gauging threads to the length of the bearing width. Lay them axially between the connecting rod journals and the connecting rod bearings.

Install the connecting rod bearing caps.
Install the connecting rod bearing cap bolts.

Tighten

Tighten the connecting rod bearing cap bolts to 35 N•m (26 lb-ft). Using the angular torque gauge KM-470-B, tighten the connecting rod bearing cap bolts another 45° plus 15°.

Remove the connecting rod bearing caps.
Measure the width of the flattened plastic thread of the plastic gauging using a ruler. (Plastic gauging is available for different tolerance ranges.)
Inspect the bearing clearance for permissible tolerance ranges. Refer to "Engine Specifications" in this section.