Service Manual2008 Captiva UNIT REPAIR

Captiva

UNIT REPAIR

Cylinder Head

Removal Procedure

Remove the cylinder head and the gasket. Refer to "Cylinder Head and Gasket" in this section.

Remove the intake manifold. Refer to “Intake Manifold” in this section.

Remove the exhaust manifold. Refer to “Exhaust Manifold” in this section.

Remove the vacuum pump. Refer to Section 1F1, Engine Controls - 2.0 Diesel.

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 0.05 mm (0.002 in.) maximum.

Measure the height of the cylinder head from sealing surface to sealing surface. The cylinder head height should be 129.9 to 130.1 mm (5.1142 to 5.1220 in.). If the cylinder head height is out of specifications, replace the cylinder head.

Installation Procedure

Install the vacuum pump. Refer to Section 1F1, Engine-Controls-2.0 Diesel. Section 1F1, Engine-Controls-2.0 Diesel.

Install the exhaust manifold. Refer to “Exhaust Manifold” in this section.

Install the intake manifold. Refer to “Intake Manifold” in this section.

Install the cylinder head and the gasket. Refer to “Cylinder Head and Gasket” in this section.

Camshaft

Tools Required

EN-48252 Camshaft Oil Seal Installer

Removal Procedure

Remove the cylinder head. Refer to “UNIT REPAIR-Cylinder Head” in this section.

Remove the camshaft sprocket.

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

Mark and confirm the camshaft cap position sequence to not confuse.
Remove the camshaft cap.

Remove the camshaft and oil seal.

Installation Procedure

Lubricate the camshaft surface with the clean engine oil.
Install the camshaft.

Coat the sealant(LOCTITE 573) on the camshaft front/rear cap sealing surface.

Important : Check and confirm the camshaft cap bearing surface. If some damages or dusts, it is needed to clean or replace.

Install the camshaft caps and bolts on the original position.

Tighten

Tighten the camshaft cap bolts to 28 N•m (20.7 lb-ft).

Install the NEW camshaft front seal ring using by Camshaft Oil Seal Installer EN-48252(a).

Notice : If the camshaft front oil seal is damaged, replace it with new oil seal. When installing the camshaft front oil seal to the oil pump, make the oil seal groove faced toward the cylinder head contact.

Install the camshaft sprocket.

Tighten

Tighten the camshaft sprocket bolt to 133 N•m (98.1 lb-ft).

Remove the cylinder head. Refer to “UNIT REPAIR-Cylinder Head” in this section.

Valve Train Components

Tools Required

09916-14510 Valve Spring Compressor

EN-48252 Valve Spring Compression Adapter

Removal Procedure

Remove the cylinder head. Refer to “UNIT REPAIR-Cylinder Head” in this section.

Remove the camshaft. Refer to “Camshaft” in this section.

Remove the intake/exhaust roller finger-followers.
Remove the intake/exhaust valve bridge.
Remove the intake/exhaust valve lash adjuster.

Install the valve spring compressor 09916-14510(a) with the valve spring compression adapter EN-48247(b) to the cylinder head.
Turn the handle of the valve spring compressor 09916-14510 for compressing the valve spring.
Remove the valve key.
Remove the valve spring retainer.
Remove the valve spring.
Remove the valves.

Remove the valve stem oil seal.

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.

Installation Procedure

Lubricate the valve stems with engine oil.
Carefully install the valves in their original positions.
Install the valve stem oil seal.

Install the valve spring.
Install the valve spring seat.
Install the valve.
Install the valve spring retainer.
Compress the valve springs with the valve spring compressor 09916–14510(a) and the valve spring compression adapter EN–48247(b).
Install the valve key.
Remove the valve spring compressor 09916–14510(a) and the valve spring compression adapter EN–48247(b).

Install the valve lash adjusters.
Install the valve bridges.
Install the valve roller finger–followers.

Install the camshaft. Refer to “Camshaft” in this section.

Install the cylinder head. Refer to “UNIT REPAIR-Cylinder Head" in this section.

Engine Block

Tools Required

DW100-130 Engine Overhaul Stand

KM-470-B Angular Torque Gauge

Removal Procedure

Remove the engine. Refer to “Engine Assembly” in this section.
Remove the flywheel or flexible plate bolts.
Remove the flywheel or flexible plate.

Mount the engine assembly on the engine overhaul stand DW100–130.
Remove the cylinder head. Refer to “Cylinder Head and Gasket” in this section.

Remove the oil pan. Refer to “Oil Pan” in this section.
Remove the oil strainer. Refer to “Oil Strainer” in this section.
Remove the crankshaft balancer. Refer to “Crankshaft Balancer” in this section.

Remove the oil pump. Refer to “Oil Pump” in this section.

Remove the starter. Refer to Section 1E1, Engine Electrical – 2.0 Diesel.

Remove the generator. Refer to Section 1E1, Engine Electrical – 2.0 Diesel.
Remove the A/C compressor. Refer to Section 7D, Automatic Temperature Control Heating, Ventilation, and Air Conditioning System.

Remove the A/C compressor and generator bracket.

Installation Procedure

Install the A/C compressor and generator bracket.

Tighten

Tighten the A/C compressor and generator bracket bolts to 35 N•m (25.8 lb-ft).

Install the A/C compressor. Refer to Section 7D, Automatic Temperature Control Heating, Ventilation, and Air Conditioning System.
Install the generator. Refer to Section 1E1, Engine Electrical – 2.0 Diesel.

Install the starter. Refer to Section 1E1, Engine Electrical – 2.0 Diesel.

Install the oil pump. Refer to “Oil Pump” in this section.

Install the crankshaft balancer. Refer to “Crankshaft Balancer” in this section.
Install the oil strainer. Refer to “Oil Strainer” in this section.
Install the oil pan. Refer to “Oil Pan” in this section.

Install the cylinder head. Refer to “Cylinder Head and Gasket” in this section.

Install the flywheel or flexible plate.

Tighten

Tighten the flywheel or flexible plate tightening bolts to 105 N•m (77.4 lb-ft).

Pistons and Rings

Tools Required

KM-470-B Angular Torque Gauge

EN-48249 Piston Ring Compressor

Removal Procedure

Remove the engine block. Refer to “UNIT REPAIR-Engine Block” in this section.
Mark and confirm the connecting rod cap position sequence to not confuse.
Remove the connecting rod caps and bolts.

Remove the piston assembly.

Caution : Use care when handling the piston. Worn piston rings are sharp and may cause injury.

Using a piston ring expander, remove the piston rings from the piston.

Inspection Procedure

Measure the piston ring gap using a feeler gauge. Refer to “Engine Specifications” in this section.
If the piston ring gap is out of specification, replace the piston ring.

Measure the piston ring groove clearance using a feeler gauge. Refer to “Engine Specifications” in this section. “Engine Specifications” in this section.
If the piston ring groove clearance is out of specification, replace the piston and rings.

Inspect the bearing bore for concentricity and alignment using cylinder bore gauge. Refer to “Engine Specifications” in this section. If the bearing bore is beyond specifications, replace the engine block “Engine Specifications” in this section. If the bearing bore is beyond specifications, replace the engine block.
Inspect the engine block cylinder bore for wear, runout, ridging and taper using a bore gauge. Refer to “Engine Specifications” in this section.

Install the connecting rod to the crankshaft.
Inspect the connecting rod end play. Refer to “Engine Specifications” in this section.

Installation Procedure

Caution : Use care when handling the piston. Worn piston rings are sharp and may caused injury.

Using a piston ring expander, install the piston rings to the piston.

Important : Check and confirm the piston assembly sequence to not confuse.

Lubricate the piston rings, cylinder bore surface and EN-48249 inner surface with the clean engine oil.
Insert the piston assembly in the cylinder using by piston ring compressor EN-48249.

Important : Check and confirm the connecting rod cap bearing surface. If some damages or dusts, it is needed to clean or replace.

Lubricate the crankshaft that contacts the connecting rod with clean engine oil.
Install the connecting rod caps and bolts.

Tighten

Tighten the connecting rod cap bolts to 25 N•m (18.4 lb-ft). Using the angular torque gauge KM-470-B, tighten the connecting rod cap bolts another 90 degrees.

Install the engine block. Refer to “UNIT REPAIR-Engine Block” in this section.

Connecting Rods and Bearings

Tools Required

KM-470-B Angular Torque Gauge

Removal Procedure

Remove the piston assembly. Refer to “Pistons and Rings” in this section. “Pistons and Rings” in this section.

Important : Check and confirm the connecting rod bearing sequence to not confuse.

Notice : Take extreme care to prevent any scratches or damage to the connecting rod cap bearings.

Remove the snap rings.
Remove the piston pin.
Separate connecting rod from the piston.
Separate the connecting rod cap bearings.

Installation Procedure

Notice : When settle the connecting rod cap bearings on the original position, put the bearings connecting rod grooves.

Install the connecting rod cap bearings to the connecting rod.

Install the connecting rod to the piston.
Install the piston pin and snap rings.

Install the piston assembly. Refer to “Pistons and Rings” in this section.

Cranshaft and Bearings

Tools Required

KM-470-B Angular Torque Gauge

EN-48252 Crankshaft Oil Seal Installer

Removal Procedure

Remove the engine block. Refer to “UNIT REPAIR-Engine Block” in this section.
Mark and confirm the connecting rod cap position sequence to not confuse.
Remove the connecting rod caps and bolts. Refer to “Connecting Rods and Bearing” in this section.

Remove the engine bed plate. Refer to “Engine Bed Plate” in this section.

Important : Check and confirm the crankshaft bearing sequence to not confuse.

Remove the crankshaft and main bearings with the crankshaft oil seal.

Remove the oil nozzle tube.

Remove the CPS target wheel.

Clean Procedure

Clean the bed plate sealing surface.
Clean the engine block sealing surface.
Clean the bed plate tightening bolts.
Clean the bed plate bolt holes.

Inspection Procedure

Inspect the crankshaft end play with the crankshaft bearing installed. Refer to “Engine specifications” in this section.
Check the permissible crankshaft end play. Refer to “Engine specifications” in this section.

Installation Procedure

Install the CPS target wheel.

Tighten

Tighten the CPS target wheel tightening bolts to 12 N•m (8.9 lb-ft).

Install the oil nozzle tube.

Tighten

Tighten the oil nozzle tube retaining bolts to 23 N•m (17 lb-ft).

Important : Check the crankshaft and main bearing whether damages, scratches and strange materials or not.

Lubricate the main bearings and crankshaft with new engine oil.
Install the main bearings on the original position.
Install the crankshaft.

Remove the engine bed plate. Refer to “Engine Bed Plate” in this section.

Install the crankshaft rear sealing with NEW one using by crankshaft rear oil seal installer EN-48251.