Service Manual2007 Captiva ENGINE MECHANICAL

SECTION 1C1

ENGINE MECHANICAL - FAM II 2.4D

Caution : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help to prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

SPECIFICATIONS

Engine Specifications

Application	Description		Unit	FAM II 2.4D
General Data	Engine Type		-	4 Cylinder (In-Line)
	Displacement		cm³	2,405
	Bore Stroke		mm (in.)	87.5 x 100 (3.44 x 3.94)
	Compression Ratio		-	9.6 : 1
	Firing Order		-	1-3-4-2
	Maximum Power		kw	100 kw @ 5,000 rpm
	Maximum Torque		N•m	220 N•m @ 2,200 rpm
Cylinder Bore	Diameter		mm (in.)	87.485~87.505 (3.444~3.445)
	Out of Round (MAX)		mm (in.)	0.013 (0.0005)
	Taper (MAX)		mm (in.)	0.013 (0.0005)
	Piston Protrusion		mm (in.)	0
	Oversize (Measure Replacement Piston before Re-boring)		mm (in.)	Available in 0.50 mm (0.019 in.) to suit bore
	Block Face Distortion		mm (in.)	0.01 MAX (0.00039)
Pistion	Diameter		mm (in.)	87.465~87.485 (3.443~3.445)
	Clearance to Bore		mm (in.)	0.010~0.030 (0.00039~0.0020)
	Ring Groove Width	Top	mm (in.)	1.230 ~ 1.250 (0.04842 ~ 0.04921)
	.	2nd	mm (in.)	1.510 ~ 1.530 (0.05945 ~ 0.0602)
	.	Oil	mm (in.)	2.530 ~ 2.550 (0.09961 ~ 0.10040)
	Ring Groove Inner Diameter	Top	mm (in.)	79.96 ~ 80.66 (3.1480 ~ 3.1756)
	.	2nd	mm (in.)	78.40 ~ 79.10 (3.0866 ~ 3.1142)
	.	Oil	mm (in.)	80.06 ~ 80.76 (3.15197 ~ 3.17953)
Piston Rings	Top Compression Ring End Gap		mm (in.)	0.21 ~ 0.36 (0.00827 ~ 0.01417)
	Second Compression Ring End Gap		mm (in.)	0.36 ~ 0.61 (0.01417 ~ 0.02402)
	Oil Ring End Gap		mm (in.)	0.16 ~ 0.76 (0.0063 ~ 0.02992)
	Piston Ring Width	Top	mm (in.)	1.170 ~ 1.190 (0.04606 ~ 0.04685)
	.	2nd	mm (in.)	1.466 ~ 1.490 (0.05772 ~ 0.05866)
	.	Oil	mm (in.)	2.5 (0.09842)
	Piston Ring Thickness	Top	mm (in.)	2.86 ~ 3.15 (0.11260 ~ 0.12402)
	.	2nd	mm (in.)	3.50 ~ 3.70 (0.13780 ~ 0.14567)
	.	Oil	mm (in.)	2.159 ~ 2.337 (0.085 ~ 0.092)
	Ring Groove Clearance	Top	mm (in.)	0.040 ~ 0.080 (0.00157 ~ 0.00315)
	.	2nd	mm (in.)	0.020 ~ 0.064 (0.00079 ~ 0.00252)
	.	Oil	mm (in.)	0.3 ~ 0.5 (0.01181 ~ 0.01969)
Piston Pin	Diameter		mm (in.)	20.9910~20.9970 (0.82641~0.82665)
	Pin Offset		mm (in.)	0.7~0.9 (0.0275~0.0354) Toward Thrust Side
	Clearance : In Piston		mm (in.)	0.011~0.014 (0.00043~0.00055)
	Clearance : In Rod		mm (in.)	Interference Fit in Rod
	Length		mm (in.)	61.5 (2.42)
Camshaft	Valve Lift	Intake	mm (in.)	9.2 (0.36)
	.	Exhaust	mm (in.)	9.2 (0.36)
	Camshaft Cap to Bearing Journal Clearance		mm (in.)	0.04~0.144 (0.0015~0.0056)
	Bearing Journal OD		mm (in.)	42.455~43.470 (1.6714~1.7114)
Crankshaft	Main Journal – Diameter (All)		mm (in.)	57.974 - 57.995 (2.2824~2.2833)
	Main Journal - Radial Runout (Shaft Support on No. 1 and No. 5 Bearings Measured at No. 3 Journal)		mm (in.)	0.03 (0.00118)
	Main Bearing Clearance (All)		mm (in.)	0.015~0.040 (0.00059~0.00157)
	End Play		mm (in.)	0.070~0.302 (0.0027~0.0118)
	Service Oversize (Available in 2 sizes)		mm (in.)	0.25 and 0.5 (0.00098 and 0.019)
Connecting Rod Journal	Diameter (All)		mm (in.)	48.970~48.988 (1.9279~1.9287)
	Out of Round (MAX)		mm (in.)	0.004 (0.00015)
	Rod Bearing Play		mm (in.)	0.006~0.031 (0.00023~0.00122)
	Rod Bearing Clearance		mm (in.)	0.013~0.041 (0.0005~0.0016)
Cylinder Head	Valve Stem Protrusion		mm (in.)	39.2 MAX (1.544)
	Valve Guide Height		mm (in.)	13.7~14.0 (0.53~0.55)
	Overall Height		mm (in.)	133.975~134.025 (5.2741~5.2759)
	Minimum Overall Height After Machining		mm (in.)	133.9 (5.271)
Valve System	Valve Lash Compensators		-	Hydraulic
	Seat Runout (MAX, All)		mm (in.)	0.03 (0.0018)
	Face Runout (MAX, All)		mm (in.)	0.03 (0.0018)
	Valve Diameter	Intake	mm (in.)	32 ± 0.1 (1.2598 ± 0.0039)
	.	Exhaust	mm (in.)	29 ± 0.1 (1.1417 ± 0.00039)
	Valve Stem Diameter	Intake	mm (in.)	5.955~5.970 (0.234~0.235)
	.	Exhaust	mm (in.)	5.945~5.960 (0.2346~0.2360)
	Valve Seat Width	Intake	mm (in.)	1.0~1.5 (0.039~0.059)
	.	Exhaust	mm (in.)	1.7~2.2 (0.066~0.086)
	Valve Face Angle		mm (in.)	44°
	Valve Seat Angle		mm (in.)	45°
	Valve Guide Inside Diameter		mm (in.)	6.000~6.012 (0.2362~0.2367)
Oil Pump	Type		-	Rotary (Trochoild)
	Gear Lash		-	0.10~0.20 (0.0040~0.008)
	Outer Gear to Body		mm (in.)	0.11~0.19 (0.0043~0.0074)
	Outer Gear to Crescent		mm (in.)	0.11~0.24 (0.0043~0.009)
	Inner Gear to Crescent		mm (in.)	0.18~0.26 (0.007~0.010)
	End Clearance		mm (in.)	0.03~0.10 (0.001~0.004)
Sealants and Adhesives	Rear Main Bearing Cap		-	Three-Bond 1217F
	Camshaft Carrier-to-Cylinder Head		-	HN 1581 (Loctite® 515)
	Oil Pan Bolts		-	HN 1256 (Loctite® 542)
	Oil Pump Bolts		-	HN 1256 (Loctite® 542)
	Oil Pan Pickup Tube Bolts		-	HN 1256 (Loctite® 542)
	Oil Gallery Plug		-	HN 1256 (Loctite® 542)
	Coolant Jacket Caps and Plugs (Freeze Plugs)		-	HN 1756 (Loctite® 176)
	Exhaust Manifold Studs/Nuts		-	Anti-seize Compound
Lubricating System	Type		-	Forced Feed
	Oil Pump Type		-	Rotary (Trochoid)
	Oil Filter Type		-	Cartridge
	Oil Pan Capacity (Including Oil Filter)		L	4.5L
	Oil Pan Capacity (Excluding Oil Filter)		L	4.3L
	Engine Oil Type		-	API SL (ILSAC GF-III) grade SAE 5W-30 * Hot area : SAE 10W-30

Fastener Tightening Specifications

Application	N•m	Lb-Ft	Lb-In
Air Cleaner Element Cover Screws	2	-	18
Air Cleaner Housing Bolts	6	-	53
Battery Hold-Down Bar Bracket Retaining Nuts	10	-	89
Battery Tray Retaining Bolts	10	-	89
Camshaft Bearing Cap Bolts	8	-	71
Connecting Rod Cap Bearing Bolts	35 + 45° + 15°	26 + 45° + 15°	-
Coolant Bypass Housing Bolts	15	11	-
Crankshaft Balancer Unit Assembly Bolts	20 + 45°	15 + 45°	-
Crankshaft Bearing Cap Bolts	50 + 45° + 15°	37 + 45° + 15°	-
Crankshaft Pulley Bolts	20	15	-
Crankshaft Timing Belt Drive Gear Bolt	135 + 30° + 10°	100 + 30° + 10°	-
Cylinder Head Bolts	25 + 90° + 90° + 90°	18 + 90° + 90° + 90°	-
Cylinder Head Cover Bolts	8	-	71
Direct Ignition System and EGR Mounting Bracket Bolts	25	18	-
Engine Beautification Cover Bolts and Nuts	8	-	71
Engine Beautification Cover Bracket Retaining Bolt	20	15	-
Engine Fuse Block Lower Cover Bolts	10	-	89
Engine Fuse Block Retaining Bolts	3	-	27
Engine Mount Adapter Bolts	50	37	-
Engine Mount Adapter Support Bracket Bolts	45	33	-
Engine Mount Frame Side Bracket Bolt	100	74	-
Engine Mount Frame Side Bracket Nuts	90	66	-
Evaporative Emission Canister Purge Solenoid Brakcet Bolt	5	-	44
Exhaust Camshaft Gear Bolt	50 + 60° + 15°	37 + 60° + 15°	-
Exhaust Front Pipe Mounting Bracket Bolt and Nut	40	30	-
Exhaust Manifold Heat Shield Bolts	15	11	-
Exhaust Manifold Retaining Nuts	22	16	-
Flexible Plate Bolts	65	48	-
Flywheel Bolts	65 + 30° + 15°	48 + 30° + 15°	-
Front Timing Belt Cover Bolts	6	-	53
Fuel Rail Assembly Retaining Bolts	25	18	-
Generator-to-Generator Lower Support Bracket Through Bolt & Nut	40	30	-
Generator-to-Intake Manifold Strap Bracket Bolt at Intake Manifold	25	18	-
Generator-to-Intake Manifold Strap Bracket Bolt at Generator	35	26	-
Generator Lower Support Bracket Bolts	25	18	-
Generator Upper Bracket Bolts at Intake Manifold & Coolant Bypass housing	25	18	-
Generator Upper Bracket Bolt at Generator	35	26	-
Intake Camshaft Gear Bolt	50 + 60° + 15°	37 + 60° + 15°	-
Intake Manifold Retaining Bolt & Nuts	18	13	-
Intake Manifold Support Bracket Bolt	25	18	-
Interm Shaft Support Bracket Bolts	70	52	-
Oil Filter Adapter –to-Oil Pump Bolts	8	-	71
Oil Pan Drain Plug	18	13	-
Oil Pan Flange-to-Cradle Retaining Bolts	50	37	-
Oil Pan Retaining Bolts	20	15	-
Oil Pressure Switch	40	30	-
Oil Pump Rear Cover Bolts	20	15	-
Oil Pump Retaining Bolts	10	-	89
Oil Suction Pipe Retaining Bolts	8	-	71
Pup Converter-to-Exhaust Front Pipe Retaining Nuts	40	30	-
Rear Timing Belt Cover Bolts	7	-	62
Safety Relief Valve Bolt	30	22	-
Spark Plugs	25	18	-
Starter-to-Engine Block Mounting Bolt	75	55	-
Starter-to-Transmission Mounting Bolt	75	55	-
Timing Belt Automatic Tensioner Bolt	25	18	-
Timing Belt Idler Pulley Bolt & Nut	25	18	-
Transaxle Front Mount Retaining Bolts	50	37	-
Transaxle Front Mount-to-Transaxle Through Bolt	90	66	-
Transaxle Mount Assembly Retaining Bolts	37	27	-
Transaxle Mount Bracket Retaining Bolts	50	37	-
Transaxle Rear Mount Retaining Bolts	90	66	-
Transaxle Rear Mount Bracket Retaining Bolts	90	66	-
Transaxle Rear Mount-to-Bracket Through Bolt	90	66	-
Transaxle-to-Oil Pan Flange Bolt	50	37	-
Transaxle Torque Coverter Bolts	45	33	-

SPECIAL TOOLS

Special Tools Table

	KM-653 Valve Spring Compressor Adapter
	KM-135 Oil Pressure Gauge Adapter
	KM-805 Valve Guide Reamer
	J-36972 Crankshaft Rear Oil Seal Installer
	KM-571-B Gauge
	DW110-060 Engine Assembly Support Fixture
	DW100-030 Engine Overhaul Stand
	KM-348 Valve Spring Compressor
	KM-635 Crankshaft Rear Oil Seal Installer
	KM-427 Piston Pin Service Set
	J-8087 Cylinder Bore Check Gauge
	KM-340-0 Cutter Set Includes:KM-340-7 Guide Drift KM-340-13 Cutters KM-340-26 Cutters
	KM-470-B Angular Torque Gauge
	KM-498-B Oil Pressure Gauge
	J-8037 Universal Piston Ring Compressor
	EN-48243 Engine Assembly Remove/Install Pallet
	EN-48244 Engine Assembly Remove/Install Pallet Supporter

COMPONENT LOCATOR

Upper End

Nut
Engine Beautification Cover
Bolt
Oil Filler Cap
Bolt
Cylinder Head Cover
Cylinder Head Cover Gasket
Tappet Adjuster
Valve Key
Valve Spring Cap
Valve Spring
Valve Stem Seal
Valve Spring Seat
Valve Guide
Intake Valve Seat Ring
Exhaust Valve Seat Ring
Intake Valve
Exhaust Valve
Bolt
Front Camshaft Cap
Head Bolt
Bolt
Intermediate Camshaft Cap
Exhaust Gas Recirculation Adapter
Exhaust Gas Recirculation Adapter Gasket
Bolt
Exhaust Gas Recirculation Valve
Exhaust Gas Recirculation Valve Gasket
Cylinder Head
Exhaust Manifold Gasket
Exhaust Manifold
Nut
Exhaust Manifold Heat Shield
Cylinder Head Gasket
Bolt
Thermostat Housing
Thermostat Housing Gasket
Stud
Sleeve
Plug
Bolt
Camshaft Position Sensor
Oil Gallery Plug
Exhaust Camshaft
Seal Ring
Camshaft Gear
Washer
Camshaft Gear Bolt
Intake Camshaft
Intake Manifold Gasket
Intake Manifold
Throttle Body Gasket
Throttle Body
Nut
Evaporative Emission Canister Purge Solenoid

Lower End

Connecting Rod Cap
Bearing Set
Connecting Rod Bolt
Piston Ring Set
Piston Pin
Piston
Engine Block
Sleeve
Water Jacket Cap
Bolt (Manual Transaxle)
Flywheel (Manual Transaxle)
Flexible Plate (Automatic Transaxle)
Bolt (Automatic Transaxle)
Seal Ring
Crankshaft
Reluctor Ring
Screw
Crankshaft Balancer Unit Assembly
Bolt
Oil Pan Scraper
Oil Pan Scraper
Bolt
Bolt
Oil Suction Pipe
Oil Pan
Oil Pan Drain Plug
Sleeve
Sleeve
Gasket
Gasket
Bolt
Bolt
Oil Pump Cover
Ring Gear
Gear
Oil Pressure Switch
Washer
Washer
Oil Duct Outlet Plug
Connecting Piece
Seal Ring
Oil Filter
Bypass Valve
Pressure Relief Valve Plunger
Pressure Relief Valve Spring
Seal Ring
Pressure Relief Valve Plug
Rear Timing Belt Cover
Bolt
Special Bolt
Idler Pulley
Stud
Nut
Bolt
Tensioner
Bolt
Thrust Inner Washer
Woodruff Key
Crankshaft Gear
Thrust Outer Washer
Bolt
Camshaft Drive Belt
Gasket
Front Timing Belt Cover
Bolt
Bushing Plug
Bushing
Oil Gallery Plug
Bolt
Water Pump
Seal Ring
Crankshaft Position Sensor
Bolt
Knock Sensor
Bolt
Oil Filter Adapter

Air Intake System

Air Cleaner Upper Housing
Air Cleaner Element Seal
Air Cleaner Element
Air Cleaner Lower Housing
Air Cleaner Snorkel Assembly
Lower Intake Air Duct
Air Cleaner Resonator Duct Seal
Air Cleaner Resonater Duct Assembly
Air Cleaner Front Resonator
Air Cleaner Resonator Seal
Air Cleaner Rear Resonator
Air Cleaner Outlet Resonator Seal
Air Cleaner Outlet Resonator Lower Housing
Air Cleaner Outlet Resonator Upper Housing
PCV Hose
Intak Air Temperature (IAT) Sensor
Air Cleaner Outlet Resonator Tunning Tube

Engine Mount System

Transaxle Front Mount Assembly
Engine Mount Adapter Support Bracket
Engine Mount Assembly
Cradle Assembly
Transaxle Mount Assembly
Transaxle Rear Mount Bracket
Transaxle Rear Mount

DIAGNOSIS

Engine Diagnosis

Begin engine mechanical system diagnosis by reviewing the disassembled views. Reviewing the description and operation information provided will assist in determining whether the condition described by the customer is a fault or normal engine operation.

Symptoms

Strategy Based Diagnosis

Review the system operations to familiarise yourself with the system functions.
Perform an engine management Diagnostic System Check.

All diagnosis on a vehicle should follow a logical process. Strategy based diagnosis is a uniform approach for repairing all vehicle systems. The strategy based diagnostic flow chart may always be used to resolve a system problem. The diagnostic flow chart is the place to start when repairs are required.

Visual / Physical Inspection

Inspect the vehicle for aftermarket accessories which may adversely affect engine operation.
Inspect the easily accessible or visible system components for obvious signs of damage or conditions that may cause the symptom.
Check the engine lubrication system for the following:

correct oil level,
correct lubricant viscosity,
correct oil filter application, and
contaminated or burnt oil.

Confirm the exact operating conditions under which the fault occurs. Note factors such as:

engine speed (rpm),
ambient temperature,
engine temperature,
engine warm-up time, and
vehicle road speed.

Compare the engine sounds, if applicable, to a known good engine, and ensure you are not trying to diagnose a normal operating condition.

Intermittent

For intermittent faults, test the vehicle under the same conditions the customer reported in order to confirm whether the system is operating correctly.

Compression Pressure Check

Ensure that the vehicle battery is in good condition, and fully charged.
Operate the vehicle until the engine is at normal operating temperature.
Disconnect the ignition wires from the spark plug.
Disconnect the fuel injector electrical connector.
Remove all of the spark plugs.

Notice : Do not insert objects into the throttle plate opening. Damage to the electronic throttle body can result, requiring replacement of the electronic throttle body assembly.

Block the throttle linkage wide open.
Install the engine cylinder compression gage to the cylinder being tested.
Using the vehicle starter motor, rotate, or crank the engine for 4 compression strokes, or puffs, for the cylinder being tested. If the engine rotates for more than 4 compression strokes, test the cylinder again.
Record the compression reading.
Remove the engine cylinder compression gage from the cylinder being tested.
Repeat steps 8-11 for each additional cylinder. All cylinders must be tested to obtain valid test results.
If any cylinders have low compression, inject approximately 15 ml of engine oil into the cylinder through the spark plug hole.
Repeat steps 8-11 for all low compression cylinders.
The minimum compression in any one 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 one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). Multiply the highest cylinder pressure by 70 percent, 1035 kPa x 70 percent = 725 kPa (150 psi x 70 percent = 105 psi), in order to determine the lowest allowable pressure in any other cylinder.

Normal : The compression builds up quickly and evenly to the specified compression.
Piston rings leaking : Compression is low on the first compression stroke. The compression builds up on the following strokes, but does not reach normal. Compression improves considerably when you add oil.
Valves leaking : Compression is low on the first compression stroke. The compression does not build up on the following strokes, and does not reach normal. Compression does not improve much, if at all, when you add oil.
Head gasket leaking : Compression is low on the first stroke. The compression does not build up on the following strokes, and does not reach normal. Compression does not improve much, if at all, when you add oil. Adjacent cylinders have the same, or similar, low compression readings.

If one or more cylinders fail to meet the minimum specified compression, repair or replace all damaged or worn components and test the engine again.

Oil Pressure Check

With the vehicle on a level surface, allow adequate drain down time, 2-3 minutes, and measure for a low engine oil level. Add the recommended grade engine oil, and fill the crankcase until the oil level measures FULL on the oil level indicator.
Operate the engine and verify low or no oil pressure on the vehicle oil pressure gage or the oil indicator light. Listen for a noisy valve train or a knocking noise.
Inspect for the following :

Engine oil diluted by moisture or unburned fuel mixtures
Improper engine oil viscosity for the expected temperature
Incorrect or faulty oil pressure gage sensor
Incorrect or faulty oil pressure gage
Plugged oil filter
Malfunctioning oil filter bypass valve

Remove the oil pressure switch from the oil filter adapter.

Install the oil pressure gage adapter KM-135 and the oil pressure gauge KM-498-B at the place of the oil pressure switch.
Start the engine and then allow the engine to reach normal operation temperature.
Measure the engine oil pressure at idle speed.
The minimum oil pressure should be 200 kPa (29 psi).

If the engine oil pressure is below minimum specifications, inspect the engine for one or more of the following :

Oil pump worn or dirty
Malfunctioning oil pump pressure relief valve
Oil pump screen loose, plugged, or damaged
Excessive bearing clearance
Cracked, porous or restricted oil galleries
Engine block oil gallery plugs missing or incorrectly installed
Broken valve lifters
Loose oil filter adapter

After checking the oil pressure, remove the oil pressure gauge and adapter and then install the oil pressure switch to 40 N•m (30 lb-ft).
Check the oil level. Add oil until it reaches the MAX mark if needed.

Oil Leak Diagnosis

Important : You can repair most fluid leaks by first visually locating the leak, repairing or replacing the component, or by resealing the gasket surface. Once the leak is identified, determine the cause of the leak. Repair the cause of the leak as well as the leak itself.

Step	Action	Value(s)	Yes	No
1	Operate the vehicle until it reaches normal operating temperature. Park the vehicle on a level surface, over a large sheet of paper or other clean surface. Wait 15 minutes. Inspect for drippings. Are drippings present?	-	Go to Step 2	System OK
2	Can you identify the type of fluid and the approximate location of the leak?	-	Go to Step 10	Go to Step 3
3	Visually inspect the suspected area. Use a small mirror to assist in looking at hard to see areas. Inspect for leaks at the following locations : Sealing surfaces Fittings Cracked or damaged components Can you identify the type of fluid and the approximate location of the leak?	-	Go to Step 10	Go to Step 4
4	Completely clean the entire engine and surrounding components. Operate the vehicle for several kilometers, miles, at normal operating temperature and at varying speeds. Park the vehicle on a level surface, over a large sheet of paper or other clean surface. Wait 15 minutes. Identify the type of fluid, and the approximate location of the leak. Can you identify the type of fluid and the approximate location of the leak?	-	Go to Step 10	Go to Step 5
5	Visually inspect the suspected area. Use a small mirror to assist in looking at hard to see areas. Inspect for leaks at the following locations : Sealing surfaces Fittings Cracked or damaged components Can you identify the type of fluid and the approximate location of the leak?	-	Go to Step 10	Go to Step 6
6	Completely clean the entire engine and surrounding components. Apply an aerosol-type powder, baby powder, foot powder, etc., to the suspected area. Operate the vehicle for several kilometers, miles, at normal operating temperature and at varying speeds. Identify the type of fluid, and the approximate location of the leak, from the discolorations in the powder surface. Can you identify the type of fluid and the approximate location of the leak?	-	Go to Step 10	Go to Step 7
7	Visually inspect the suspected area. Use a small mirror to assist in looking at hard to see areas. Inspect for leaks at the following locations : Sealing surfaces Fittings Cracked or damaged components Can you identify the type of fluid and the approximate location of the leak?	-	Go to Step 10	Go to Step 8
8	Use the black light kit in order to identify the type of fluid, and the approximate location of the leak. Refer to the manufacturer's instructions when using the tool. Can you identify the type of fluid and the approximate location of the leak?	-	Go to Step 10	Go to Step 9
9	Visually inspect the suspected area. Use a small mirror to assist in looking at hard to see areas. Inspect for leaks at the following locations : Sealing surfaces Fittings Cracked or damaged components Can you identify the type of fluid and the approximate location of the leak?	-	Go to Step 10	System OK
10	Inspect the engine for mechanical damage. Special attention should be shown to the following areas : Higher than recommended fluid levels Higher than recommended fluid pressures Plugged or malfunctioning fluid filters or pressure bypass valves Plugged or malfunctioning engine ventilation system Improperly tightened or damaged fasteners Cracked or porous components Improper sealants or gaskets, where required Improper sealant or gasket installation Damaged or worn gaskets or seals Damaged or worn sealing surfaces Inspect the engine for customer modifications. Is there mechanical damage, or customer modifications to the engine?	-	Go to Step 11	System OK
11	Repair or replace all damaged or modified components. Does the engine still leak oil?	-	Go to Step 11	System OK

Crankcase Ventilation System Inspection/Diagnosis

Results Of Incorrect Operation

A plugged positive crankcase ventilation (PCV) orifice or hose may cause the following conditions :

- Rough idle

- Stalling or slow idle speed

- Oil leaks

- Oil in air cleaner

- Sludge in engine

A leaking PCV orifice or hose may cause the following conditions :

- Rough idle

- Stalling

- High idle speed

Functional Check

With these systems, any blow-by in excess of the system capacity, from a badly worn engine, sustained heavy load, etc., is exhausted into the air cleaner and is drawn into the engine.

Proper operation of the crankcase ventilation system depends upon a sealed engine. If oil slugging or dilution is noted and the crankcase ventilation system is functioning properly, check the engine for a possible cause. Correct any problems.

If an engine is idling rough, inspect for a clogged PCV orifice, a dirty vent filter, air cleaner element, or plugged hose. Replace as required. Use the following procedure :

Remove the PCV hose from the cylinder head cover.
Operate the engine at idle.
Place your thumb over the end of the hose in order to check for a vacuum. If there is no vacuum at the hose, inspect for the following items :

- Plugged hoses

- The manifold port

Turn OFF the engine.
Inspect the PCV orifice in the cylinder head cover for debris or blockage.

Base Engine Misfire without Internal Engine Noises

Cause	Correction
High oil pressure.	Verify oil pressure. Refer to "Oil Pressure Check" in this section. Repair or replace damaged components as required.
Worn, damaged, or improperly installed accessory drive belt - severe cracking, bumps or missing segments. A misfire DTC may be present without an actual misfire condition.	Inspect the accessory drive system components. Repair or replace damaged components as required. Refer to Section 1C1, Engine Mechanical - FAM II 2.4D.
Worn, damaged, or improperly installed accessory drive system components. A misfire DTC may be present without an actual misfire condition.	Inspect the accessory drive system components. Repair or replace damaged components as required.
Damaged, loose or improperly installed crankshaft pulley. A misfire DTC may be present without an actual misfire condition.	Inspect the crankshaft pulley. Repair or replace damaged components as required. Refer to Section 1C1, Engine Mechanical - FAM II 2.4D.
Worn, damaged, or improperly installed crankshaft reluctor wheel. A worn or damaged crankshaft reluctor wheel can result in different symptoms depending on the severity and location of the wear or damage. Systems with electronic communications, DIS or coil per cylinder, and severe reluctor ring damage may exhibit periodic loss of crankshaft position, stop delivering a signal, and then re-sync the crankshaft position. Systems with electronic communication, DIS or coil per cylinder, and slight reluctor ring damage may exhibit no loss of crankshaft position and no misfire may occur. Systems with mechanical communications, high voltage switch, and severe reluctor ring damage may cause additional pulses and effect fuel and spark delivery.	Inspect the crankshaft position sensor. Inspect the crankshaft reluctor wheel. Inspect the crankshaft. Repair or replace damaged components as required.
Damaged, loose or improperly installed engine flywheel. A misfire DTC may be present without an actual misfire condition.	Inspect the flywheel. Repair or replace damaged components as required. Refer to Section 1C1, Engine Mechanical - FAM II 2.4D.
Damaged, improperly installed or restricted exhaust system, collapsed or dented pipes, plugged mufflers or malfunctioning catalytic converters. A DTC may be present without an actual fault condition.	Inspect the exhaust system components. Repair or replace damaged components as required.
Worn, damaged or improperly installed vacuum hoses.	Inspect the vacuum system components. Repair or replace damaged components as required.
Damaged or improperly installed MAP sensor, sealing grommet nicked, torn or missing.	Inspect the MAP sensor. Repair or replace damaged components as required.
Damaged or improperly installed electronic throttle body.	Inspect the electronic throttle body. Repair or replace damaged components as required.
Damaged or improperly installed intake manifold.	Inspect the intake manifold. Repair or replace damaged components as required.
Damaged or improperly installed cylinder head. Oil consumption may or may not cause the engine to misfire.	Inspect the spark plugs. Refer to "Checking Spark Plug" in this section in Engine Controls. Verify engine compression. Refer to "Compression Pressure Check" in this section. Inspect the cylinder heads. Inspect the engine block. Repair or replace damaged components as required.
Worn, damaged, loose or broken valve spring.	Inspect the valve springs. Repair or replace damaged components as required.
Worn, damaged or stuck valve, carbon on the valve stem or valve seat.	Inspect the valves. Inspect the valve guides. Repair or replace damaged components as required.
Worn or damaged valve guide.	Inspect the valve guides. Inspect the valve guides.Inspect the valves. Repair or replace damaged components as required.
Worn, damaged or dirty valve lifter.	Inspect the valve lifters. Inspect the camshaft. Repair or replace damaged components as required.
Worn or damaged camshaft lobe.	Inspect the camshaft. Inspect the valve lifters. Repair or replace damaged components as required.
Worn, damaged or loose timing belt and sprockets.	Inspect the timing belt and sprockets. Repair or replace damaged components as required.
Worn, damaged or improperly installed piston. Pistons must be installed with the mark, or dimple, on the top of the piston, facing the front of the engine; piston pins must be centered in the connecting rod pin bore. Oil consumption may or may not cause the engine to misfire.	Inspect the spark plugs. Refer to "Checking Spark Plug" in this section. Verify engine compression. Refer to "Compression Pressure Check" in this section. Inspect the cylinder bores. Inspect the pistons. Inspect the piston pins. Inspect the connecting rods. Repair or replace damaged components as required.

Base Engine Misfire with Abnormal Internal Lower Engine Noises

Cause	Correction
Worn, damaged, or improperly installed accessory drive belt - severe cracking, bumps or missing segments. A misfire DTC may be present without an actual misfire condition.	Inspect the accessory drive system components. Repair or replace damaged components as required. Refer to Section 1C1, Engine Mechanical - FAM II 2.4D.
Worn, damaged, or improperly installed accessory drive system components. A misfire DTC may be present without an actual misfire condition.	Inspect the accessory drive system components. Repair or replace damaged components as required. Refer to Section 1C1, Engine Mechanical - FAM II 2.4D.
Worn, damaged, improperly installed or loose crankshaft pulley. A misfire code may be present without an actual misfire condition.	Inspect the crankshaft pulley. Repair or replace damaged components as required. Refer to Section 1C1, Engine Mechanical - FAM II 2.4D.
Worn, damaged, improperly installed or loose engine flywheel. A misfire code may be present without an actual misfire condition.	Inspect the engine flywheel. Repair or replace damaged components as required. Refer to Section 1C1, Engine Mechanical - FAM II 2.4D.
Worn, damaged or improperly installed piston. Pistons must be installed with the mark, or dimple, on the top of the piston, facing the front of the engine; piston pins must be centered in the connecting rod pin bore. Oil consumption may or may not cause the engine to misfire.	Inspect the spark plugs. Refer to Section 1A2, General Engine Information – FAM II 2.4D. Verify engine compression. Refer to "Compression Pressure Check" in this section. Inspect the cylinder bores. Inspect the pistons. Inspect the piston pins. Inspect the connecting rods. Repair or replace damaged components as required. Refer to Section 1C1, Engine Mechanical - FAM II 2.4D.
Worn, damaged or improperly installed crankshaft thrust bearing. A misfire code may be present without an actual misfire condition.	Inspect the crankshaft. Inspect the crankshaft thrust bearing. Repair or replace damaged components as required.

Base Engine Misfire with Abnormal Valve Train Noise

Cause	Correction
Worn, damaged or stuck valve, carbon on the valve stem or valve seat.	Inspect the valves. Inspect the valve guides. Repair or replace damaged components as required.
Worn, damaged or dirty valve lifter.	Inspect the valve lifters. Inspect the camshaft. Repair or replace damaged components as required.
Worn or damaged camshaft lobe.	Inspect the camshaft. Inspect the valve lifters. Repair or replace damaged components as required.
Worn, damaged or loose timing belt and sprockets.	Inspect the timing belt and sprockets. Repair or replace damaged components as required.

Base Engine Misfire with Coolant Consumption

Cause	Correction
Damaged or improperly installed cylinder head. Coolant consumption may or may not cause the engine to misfire.	Inspect the spark plugs. Refer to Section 1C1, Engine Mechanical - FAM II 2.4D. Verify engine compression. Refer to "Compression Pressure Check" in this section. Inspect the cylinder heads. Inspect the engine block. Repair or replace damaged components as required.

Base Engine Misfire with Excessive Oil Consumption

Cause	Correction
Worn or damaged valve.	Inspect the valves. Inspect the valve guides. Repair or replace damaged components as required.
Worn, damaged or improperly installed piston rings. Piston rings must be installed with the mark, or dimple, on the top of the piston ring, facing up.	Inspect the spark plugs. Refer to Section 1A2, General Engine Information - FAM II 2.4D. Verify engine compression. Refer to "Compression Pressure Check" in this section. Inspect the cylinder bores. Inspect the pistons. Inspect the piston pins. Inspect the connecting rods. Repair or replace damaged components as required.

Engine Noise on Start-Up, but Only Lasting a Few Seconds

Cause	Correction
Incorrect engine oil, viscosity.	Install the correct engine oil and oil filter. Refer to Section 1C1, Engine Mechanical - FAM II 2.4D.
Incorrect oil filter, without anti-drainback feature.	Install the correct engine oil and oil filter. Refer to Section 1C1, Engine Mechanical - FAM II 2.4D.
Worn, damaged, or improperly installed oil filter by-pass valve.	Inspect the oil filter by-pass valve. Repair or replace damaged components as required.
High valve lifter leak down rate.	Inspect the valve lifters. Repair or replace damaged components as required.
Worn, damaged, or improperly installed crankshaft thrust bearing.	Inspect the crankshaft. Inspect the crankshaft thrust bearing. Repair or replace damaged components as required.

Upper Engine Noise, Regardless of Engine Speed

Cause	Correction
Low oil pressure.	Verify oil pressure. Refer to "Oil Pressure Check" in this section. Repair or replace damaged components as required.
Improper lubrication of the valve train components.	Verify oil pressure. Refer to "Oil Pressure Check" in this section. Inspect the valve lifters. Inspect the oil filter bypass valve. Inspect the oil pump and pump screen. Inspect the engine block oil galleries. Repair or replace damaged components as required.
Broken valve spring.	Inspect the valve springs. Repair or replace damaged components as required.
Worn, damaged or stuck valves, carbon on the valve stem or valve seat.	Inspect the valves. Inspect the valve guides. Repair or replace damaged components as required.
Worn or damaged valve guide.	Inspect the valve guides. Inspect the valves. Repair or replace damaged components as required.
Worn, damaged or dirty valve lifter.	Inspect the valve lifters. Repair or replace damaged components as required.
Worn or damaged camshaft lobes.	Inspect the engine camshaft lobes. Repair or replace damaged components as required.
Worn, damaged, improperly installed or loose timing belt and sprockets.	Inspect the timing belt and sprockets. Repair or replace damaged components as required.
Worn, damaged or improperly installed timing belt tensioner, if equipped.	Inspect the timing belt tensioner. Repair or replace damaged components as required.

Lower Engine Noise, Regardless of Engine Speed

Cause	Correction
Low oil pressure.	Verify oil pressure. Refer to "Oil Pressure Check" in this section. Repair or replace damaged components as required.
Detonation or spark knock.	Verify the operation of the ignition controls system. Refer to Section 1F2, Engine Controls - FAM II 2.4D in Vehicle DTC Information. Repair or replace damaged components as required.
Worn, damaged, or improperly installed accessory drive belt - severe cracking, bumps or missing segments in the accessory drive belt.	Inspect the accessory drive system components. Repair or replace damaged components as required.
Worn, damaged, or improperly installed accessory drive system components.	Inspect the accessory drive system components. Repair or replace damaged components as required.
Worn, damaged, or improperly installed crankshaft pulley.	Inspect the crankshaft pulley. Inspect the crankshaft. Repair or replace damaged components as required.
Worn, damaged, or improperly installed engine flywheel.	Inspect the engine flywheel. Inspect the engine flywheel bolts. Inspect the torque converter. Inspect the torque converter bolts. Inspect the crankshaft. Repair or replace damaged components as required.
Worn, damaged, or improperly installed torque converter.	Inspect the torque converter. Inspect the torque converter bolts. Inspect the engine flywheel. Repair or replace damaged components as required.
Damaged oil pan, contacting the oil pump screen - an oil pan that has been damaged may loosen, improperly position, or restrict oil flow at the oil pump screen, preventing proper oil flow to the oil pump.	Inspect the oil pan. Inspect the oil pump screen. Repair or replace damaged components as required.
Worn, damaged, improperly installed or restricted oil pump screen - an oil pan that has been damaged may loosen, improperly position, or restrict oil flow at the oil pump screen, preventing proper oil flow to the oil pump.	Inspect the oil pan. Inspect the oil pump screen. Repair or replace damaged components as required.
Worn, damaged, or improperly installed piston - pistons must be installed with the mark, or dimple, on the top of the piston, facing the front of the engine.Piston pins must be centered in the connecting rod pin bore.	Inspect the spark plugs. Refer to Section 1A2, General Engine Information – FAM II 2.4D. Verify engine compression. Refer to "Oil Pressure Check" in this section. Inspect the cylinder bores. Inspect the pistons. Inspect the piston pins. Inspect the connecting rods. Repair or replace damaged components as required.
Worn, damaged, or improperly installed connecting rod bearing.	Inspect the connecting rods. Inspect the connecting rod bearings. Inspect the crankshaft connecting rod journals. Repair or replace damaged components as required.
Worn, damaged, or improperly installed crankshaft bearing.	Inspect the crankshaft bearings. Inspect the crankshaft journals. Repair or replace damaged components as required.

Engine Noise Under Load

Cause	Correction
Low oil pressure.	Verify oil pressure. Refer to "Oil Pressure Check" in this section. Repair or replace as required.
Detonation or spark knock.	Verify the correct operation of the ignition controls. Refer to Section 1F2, Engine Controls - FAM II 2.4D in Vehicle DTC Information. Repair or replace damaged components as required.
Worn, damaged, or improperly installed engine flywheel.	Inspect the engine flywheel. Inspect the engine flywheel bolts. Inspect the torque converter. Inspect the torque converter bolts. Inspect the crankshaft. Repair or replace damaged components as required.
Worn, damaged, or improperly installed torque converter.	Inspect the torque converter. Inspect the torque converter bolts. Inspect the engine flywheel. Repair or replace damaged components as required.
Worn, damaged, or improperly installed pistons-pistons must be installed with the mark, or dimple, on the top of the piston, facing the front of the engine.Piston pins must be centered in the connecting rod pin bore.	Inspect the cylinder bores. Inspect the pistons. Inspect the piston pins. Inspect the connecting rods. Repair or replace damaged components as required.
Worn, damaged, or improperly installed connecting rod bearing.	Inspect the connecting rods. Inspect the connecting rod bearings. Inspect the crankshaft connecting rod journals. Repair or replace damaged components as required.
Worn, damaged, or improperly installed crankshaft bearing.	Inspect the crankshaft bearings. Inspect the crankshaft journals. Repair or replace damaged components as required.

Engine Will Not Crank - Crankshaft Will Not Rotate

Cause	Correction
Seized accessory drive system component.	Remove accessory drive belts. Rotate crankshaft by hand at the pulley or flywheel location.
Hydraulically locked cylinder. Coolant/antifreeze in cylinder Oil in cylinder Fuel in cylinder	Remove spark plugs and check for fluid. Inspect for broken head gasket. Inspect for cracked engine block or cylinder head. Inspect for a sticking fuel injector.
Seized automatic transaxle torque converter.	Remove the torque converter bolts. Rotate crankshaft by hand at the pulley or flywheel location.
Seized manual transaxle.	Disengage the clutch. Rotate crankshaft by hand at the pulley or flywheel location.
Broken timing belt and/or gears.	Inspect timing belt and gears. Repair as required.
Seized crankshaft.	Inspect crankshaft. Repair as required.
Material in cylinder. Broken valve Piston material Foreign material	Inspect cylinder for damaged components and/or foreign materials. Repair or replace as required.
Seized crankshaft or connecting rod bearings.	Inspect crankshaft and connecting rod bearings. Repair as required.
Bent or broken connecting rod.	Inspect connecting rods. Repair as required.
Broken crankshaft.	Inspect crankshaft. Repair as required.

Coolant in Combustion Chamber

Definition : Excessive white smoke and/or coolant type odor coming from the exhaust pipe may indicate coolant in the combustion chamber. Low coolant levels, an inoperative cooling fan, or a faulty thermostat may lead to an "over temperature" condition which may cause engine component damage.

Cause	Correction
A slower than normal cranking speed may indicate coolant entering the combustion chamber. Refer to Engine Will Not Crank - Crankshaft Will Not Rotate. Remove the spark plugs and inspect for spark plugs saturated by coolant or coolant in the cylinder bore. Inspect by performing a cylinder leak-down test. During this test, excessive air bubbles within the coolant may indicate a faulty gasket or damaged component. Inspect by performing a cylinder compression test. Two cylinders "side-by-side" on the engine block, with low compression, may indicate a failed cylinder head gasket. Refer to "Compression Pressure Check" in this section.
Cracked intake manifold or failed gasket.	Replace the components as required.
Faulty cylinder head gasket.	Replace the head gasket and components as required. Refer to Section 1C1, Engine Mechanical - FAM II 2.4D.
Warped cylinder head.	Machine the cylinder head to the proper flatness, if applicable and replace the cylinder head gasket. Refer to Section 1C1, Engine Mechanical - FAM II 2.4D.
Cracked cylinder head.	Replace the cylinder head and gasket.
Cracked cylinder liner or engine block.	Replace the components as required.
Cylinder head or engine block porosity.	Replace the components as required.

Coolant in Engine Oil

Definition : Foamy or discolored oil or an engine oil "overfill" condition may indicate coolant entering the engine crankcase. Low coolant levels, an inoperative cooling fan, or a faulty thermostat may lead to an "over temperature" condition which may cause engine component damage. Contaminated engine oil and oil filter should be changed.

Cause	Correction
Inspect the oil for excessive foaming or an overfill condition. Oil diluted by coolant may not properly lubricate the crankshaft bearings and may lead to component damage. Refer to Lower Engine Noise, Regardless of Engine Speed. Inspect by performing a cylinder leak-down test. During this test, excessive air bubbles within the cooling system may indicate a faulty gasket or damaged component. Inspect by performing a cylinder compression test. Two cylinders "side-by-side" on the engine block with low compression may indicate a failed cylinder head gasket. Refer to "Compression Pressure Check" in this section.
Faulty cylinder head gasket.	Replace the head gasket and components as required. Refer to Section 1C1, Engine Mechanical - FAM II 2.4D.
Warped cylinder head.	Machine the cylinder head to proper flatness, if applicable, and replace the cylinder head gasket. Refer to Section 1C1, Engine Mechanical - FAM II 2.4D.
Cracked cylinder head.	Replace the cylinder head and gasket.
Cracked cylinder liner or engine block.	Replace the components as required.
Cylinder head or engine block porosity.	Replace the components as required.

Accessory Drive Belt Diagnosis

Drive Belt Chirping Diagnosis

Definition : Accessory drive belt chirping can be defined as a high-pitched noise that is heard once per revolution of the drive belt or a pulley. The following items are indications of chirping :

A high pitched noise that is heard once per revolution of the drive belt or a accessory drive pulley.
Chirping may occur on cold damp startup conditions and will subside once the vehicle reaches normal operating temperature.

Diagnostic Aids

The chirping noise may be intermittent due to moisture on the drive belt or the accessory drive pulley(s). In order to duplicate the customer's concern, It may be necessary to spray a small amount of water onto the drive belt. If spraying water onto the drive belt duplicates the symptom, cleaning the accessory belt pulley(s) may be the most probable solution.

A loose or improper installation of a body or suspension component, or other item(s) on the vehicle may also cause the chirping noise.

Test Description

The number(s) below refer to the step(s) in the diagnostic table.

The chirping noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with his table.
The noise may be an internal engine noise. Remove the drive belt and operate the engine for a few seconds, this will verify if the chirping noise is related to the drive belt or not. With the drive belt removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt removed.
Inspect the drive belt for signs of pilling. Pilling is the small balls, pills, or strings in the drive belt grooves caused by the accumulation of rubber dust.
Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of an accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure for that pulley.
Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed.
Inspect the accessory drive pulley(s) should include inspecting for bends, dents or other damage to the pulley(s) that would prevent the drive belt from seating properly in the pulley grooves, or on the smooth surface of the pulley when the back side of the drive belt is used to drive the pulley.
Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair.

Step	Action	Value(s)	Yes	No
1	Did you review the Symptoms - Engine Mechanical diagnostic information, and perform the necessary inspections?	-	Go to Step 2	Go to Symptoms
2	Verify that there is a chirping noise. Does the engine make the chirping noise?	-	Go to Step 3	Go to Diagnostic Aids
3	Remove the drive belt. Refer to Section 1C1, Engine Mechanical - FAM II 2.4D. Operate the engine for no longer than 30 to 40 seconds. Does the chirping noise still exist?	-	Go to Engine Noise on Start-Up, but Only Lasting a Few Seconds	Go to Step 4
4	Inspect for severe drive belt pilling exceeding 1/3 of the drive belt groove depth. Does the drive belt grooves have pilling?	-	Go to Step 5	Go to Step 6
5	Clean the accessory drive belt pulley(s) with a suitable wire brush. Were the accessory drive belt pulley(s) cleaned?	-	Go to Step 15	-
6	Inspect for a misaligned accessory drive pulley(s). Is there a misaligned pulley(s)?	-	Go to Step 7	Go to Step 8
7	Replace and/or repair the misaligned accessory drive pulley(s). Were the misaligned accessory drive pulley(s) replaced and/or repaired?	-	Go to Step 15	-
8	Inspect for a bent or cracked accessory drive bracket(s). Is there a bent and/or cracked accessory drive bracket(s)?	-	Go to Step 9	Go to Step 10
9	Replace the bent and/or cracked accessory drive bracket(s). Was the bent and/or cracked accessory drive bracket(s) replaced?	-	Go to Step 15	-
10	Inspect for incorrect, loose and/or missing fasteners. Were there any incorrect, loose, and/or missing fasteners found?	-	Go to Step 11	Go to Step 12
11	Replace any incorrect and/or missing fasteners. Tighten any loose fasteners. Refer to "Fastener Tightening Specifications" in this section. Were the fasteners replaced and/or tightened?	-	Go to Step 15	-
12	Inspect for a bent accessory drive pulley(s). Was a bent accessory drive pulley(s) found?	-	Go to Step 13	Go to Step 14
13	Replace the bent accessory drive pulley(s). Was the bent accessory drive pulley(s) replaced?	-	Go to Step 15	-
14	Replace the drive belt. Refer to Section 1C1, Engine Mechanical - FAM II 2.4D. Was the drive belt replaced?	-	Go to Step 15	-
15	Clear any codes. Run the engine in order to verify the repair. Does the chirping noise still exist?	-	-	System OK

Drive Belt Squeal Diagnosis

Definition : Accessory drive belt squealing can be defined as a loud screeching noise caused by a slipping drive belt. Belt squeal is unusual in multi-rib belts. Drive belt squeal generally occurs when a heavy load is applied to the drive belt, such as an air-conditioning compressor engagement, snapping the throttle, seized pulley or a faulty accessory drive component.

A loud screeching noise that is caused by a slipping drive belt (this is unusual for a drive belt with multiple ribs)
The squeal occurs when a heavy load is applied to the drive belt, such as an A/C compressor engagement, snapping the throttle, slipping on a seized pulley, or a faulty accessory drive component.

Diagnostic Aids

A loose or improper installation of a body or suspension component, or other item(s) on the vehicle may cause the squeal noise.

If the squeal is intermittent, verify that it is not the accessory drive component(s) by varying their load(s), making sure they are operating to their maximum capacity. An overcharged air conditioning (A/C) system, a power steering system restriction or the incorrect fluid, or a failing generator is suggested items to inspect.

Test Description

The number(s) below refer to the step(s) in the diagnostic table.

The squeal may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table.
The squeal may be an internal engine noise. Remove the drive belt and operate the engine for a few seconds, this will verify if the squealing noise is related to the drive belt or an accessory drive component. With the drive belt removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt removed.
This test is to verify that an accessory drive component(s) does not have a seized bearing. With the belt removed test the bearings in the accessory drive component(s) for smooth operation. Also test the accessory drive components with the engine operating by varying the load on the accessory drive component(s) to verify that the component(s) is operating properly.
This test is to verify that the drive belt tensioner is operating properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which could cause a squealing noise.
This test is to verify that the drive belt is not too long, which would prevent the drive belt tensioner from operating properly. Also if the incorrect length drive belt was installed, it may not be routed correctly and may be turning an accessory drive component in the incorrect direction.
Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of a accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure for that pulley.
Inspect the accessory drive pulley(s) to verify that they are the correct diameter or width. Using a known good vehicle, compare the accessory drive pulleys.

Step	Action	Value(s)	Yes	No
1	Did you review the Symptoms - Engine Mechanical diagnostic information, and perform the necessary inspections?	-	Go to Step 2	Go to Symptoms - Engine Mechanical
2	Verify that there is a squealing noise. Does the engine make the squeal noise?	-	Go to Step 3	Go to Diagnostic Aids
3	Remove the drive belt. Refer to Section 1C1, Engine Mechanical - FAM II 2.4D. Operate the engine for no longer than 30 to 40 seconds. Does the chirping noise still exist?	-	Go to Engine Noise on Start-Up, but Only Lasting a Few Seconds	Go to Step 4
4	Inspect for a seized accessory drive component bearing or a faulty accessory drive component. Did you find and correct the condition?	-	Go to Step 9	Go to Step 5
5	Inspect the drive belt tensioner for proper operation. Refer to Drive Belt Tensioner Diagnosis. Did you find and correct the condition?	-	Go to Step 9	Go to Step 6
6	Check for the correct length drive belt. Did you find and correct the condition?	-	Go to Step 9	Go to Step 7
7	Inspect for a misaligned pulley. Did you find and correct the condition?	-	Go to Step 9	Go to Step 8
8	Inspect for an incorrect size pulley. Did you find and correct the condition?	-	Go to Step 9	-
9	Install the drive belt. Refer to Section 1C1, Engine Mechanical - FAM II 2.4D. Clear any codes. Run the engine in order to verify the repair. Does the squealing noise still exist?	-	-	System OK

Drive Belt Whine Diagnosis

Definition : Accessory drive belt whine can be defined as a high-pitched continuous noise that is most likely to be caused by a failed bearing in one of the accessory drive components.

Diagnostic Aids

The drive belt will not cause the whine.

If the whine is intermittent, verify that it is not the accessory drive component(s) by varying their loads, making sure they are operating to their maximum capacity. An overcharged air conditioning (A/C) system, a power steering system restriction or the incorrect fluid, or a failing generator are suggested items to inspect.

Test Description

The number(s) below refer to the step(s) in the diagnostic table.

This test is to verify that the whine is being caused by the accessory drive component(s). Remove the drive belt and operate the engine for a few seconds, this will verify if the whining noise is related to the accessory drive component. With the drive belt removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt removed.
This inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings. The drive belt may have to be installed and the accessory drive component(s) operated separately by varying their loads. Refer to the suspected accessory drive component for the proper removal and replacement procedure.

Step	Action	Value(s)	Yes	No
1	Did you review the Symptoms - Engine Mechanical diagnostic information, and perform the necessary inspections?	-	Go to Step 2	Go to Symptoms - Engine Mechanical
2	Verify that there is a whining noise. Does the engine make the whine noise?	-	Go to Step 3	Go to Diagnostic Aids
3	Remove the drive belt. Drive Belt Replacement. Operate the engine for no longer than 30 to 40 seconds. Does the whining noise still exist?	-	Go to Engine Noise on Start-Up, but Only Lasting a Few Seconds	Go to Step 4
4	Inspect for a failed accessory drive component bearing. Install the drive belt. Drive Belt Replacement. Did you find and correct the condition?	-	Go to Step 5	-
5	Clear any codes. Run the engine in order to verify the repair. Does the whining still exist?	-	-	System OK

Drive Belt Rumbling Diagnosis

Definition : Accessory drive belt rumble can be defined as a low pitch tapping, knocking or thumping noise heard at or just above idle, once per rotation of the drive belt or a specific component. Drive belt rumble is generally caused by one of the following :

A low pitch tapping, knocking, or thumping noise heard at or just above idle.
Heard once per revolution of the drive belt or a pulley(s).
Rumbling may be caused from :

Pilling, the accumulation of rubber dust that forms small balls (pills) or strings in the drive belt pulley groove
The separation of the drive belt
A damaged drive belt

Diagnostic Aids

Vibration from the engine operating may cause a body component or another part of the vehicle to make a rumbling noise.

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

If after replacing the drive belt and completing the diagnostic table, the rumbling is only heard with the drive belt is installed, there might be an accessory drive component failure. Varying the load on the accessory drive component(s) may aid in identifying which component is causing the rumbling noise.

Test Description

The number(s) below refer to the step(s) in the diagnostic table.

This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom.
This test is to verify that the drive belt is causing the rumbling. Rumbling may be confused with an internal engine noise due to the similarity in the description. Operate the engine for a few seconds, this will verify if the rumbling noise is related to the drive belt or not. With the drive belt removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt removed.
Inspect the drive belt to ensure that the drive belt is not the cause of the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plies of the belt separating, this may be seen at the edge of the belt or felt as a lump in the belt.
Small amounts of pilling is a normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation.

Step	Action	Value(s)	Yes	No
1	Did you review the Symptoms - Engine Mechanical diagnostic information, and perform the necessary inspections?	-	Go to Step 2	Go to Symptoms - Engine Mechanical
2	Verify that there is a rumbling noise. Does the engine make the rumbling noise?	-	Go to Step 3	Go to Diagnostic Aids
3	Remove the drive belt(s). Refer to Section 1C1, Engine Mechanical - FAM II 2.4D. Operate the engine for no longer than 30 to 40 seconds. Does the chirping noise still exist?	-	Go to Engine Noise on Start-Up, but Only Lasting a Few Seconds	Go to Step 4
4	Inspect the drive belt for damage, separation, or sections of missing ribs. Were any of these conditions found?	-	Go to Step 7	Go to Step 5
5	Inspect for severe pilling of more than 1/3 of the drive belt groove depth. Do the drive belt grooves have pilling?	-	Go to Step 6	Go to Step 7
6	Clean the drive belt pulleys using a suitable wire brush. Install the drive belt. Refer to Section 1C1, Engine Mechanical - FAM II 2.4D. Did you complete the repair?	-	Go to Step 8	-
7	Install a new drive belt. Refer to Section 1C1, Engine Mechanical - FAM II 2.4D. Did you complete the replacement?	-	Go to Step 8	-
8	Clear any codes. Run the engine in order to verify the repair. Does the rumbling noise still exist?	-	-	System OK

Drive Belt Vibration Diagnosis

Definition : Accessory drive belt vibration can be defined as a drive belt that jumps, shakes or rattles. Accessory drive belt vibration is usually indicated by one of the following :

The vibration is engine-speed related.
The vibration may be sensitive to accessory load.

Diagnostic Aids

The accessory drive components may have an affect on engine vibration. An overcharged air conditioning (A/C) system, a power steering system restriction, or the incorrect fluid, or an extra load placed on the generator is suggested items to inspect. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components.

Test Description

The number(s) below refer to the step(s) in the diagnostic table.

This test is to verify that the vibration is present during diagnosing. Other vehicle components may cause a similar symptom such as the exhaust system, or the drive train.
This test is to verify that the drive belt or accessory drive components may be causing the vibration. Remove the drive belt and operate the engine for a few seconds, this will verify if the vibration is related to the drive belt or not. With the drive belt removed the water pump will not operate and the engine may overheat. Also diagnostic trouble codes (DTCs) may set when the engine is operated with the drive belt removed.
The drive belt may cause a vibration. While the drive belt is removed this is the best time to inspect the condition of the drive belt.
Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut, spacer, or washer was installed.
This step should only be performed if the fan is driven by the drive belt. Inspect the engine cooling fan for bent, twisted, loose, or cracked blades. Inspect the fan clutch for smooth operation. Inspect for a bent fan shaft or bent mounting flange.
Inspect the water pump drive shaft for being bent. Also inspect the water pump bearings for smooth operation and excessive play. Compare the water pump with a known good water pump.
Accessory drive component brackets that are bent, cracked, or loose may put an extra strain on that accessory drive component causing it to vibrate.

Step	Action	Value(s)	Yes	No
1	Did you review the Symptoms - Engine Mechanical diagnostic information, and perform the necessary inspections?	-	Go to Step 2	Go to Symptoms - Engine Mechanical
2	Verify that the vibration is engine related. Does the engine make the vibration?	-	Go to Step 3	Go to Diagnostic Aids
3	Remove the drive belt. Refer to Section 1C1, Engine Mechanical - FAM II 2.4D. Operate the engine for no longer than 30 to 40 seconds. Does the engine still make the vibration?	-	Go to Diagnostic Starting Point - Vibration Diagnosis and Correction in Vibration Diagnosis and Correction	Go to Step 4
4	Inspect the drive belt for wear, damage, debris build-up and missing drive belt ribs. Were any of these conditions found?	-	Go to Step 5	Go to Step 6
5	Install a new drive belt. Refer to Section 1C1, Engine Mechanical - FAM II 2.4D. Did you complete the replacement?	-	Go to Step 11	-
6	Inspect for incorrect, loose and/or missing fasteners. Were any of these conditions found?	-	Go to Step 7	Go to Step 8
7	Replace any incorrect and/or missing fastener.Tighten any loose fasteners. Refer to "Fastener Tightening Specifications" in this section. Were the fasteners replaced and/or tightened?	-	Go to Step 11	-
8	Inspect for damaged fan blades or a bent fan clutch shaft. Did you find and correct the condition?	-	Go to Step 11	Go to Step 9
9	Inspect for a bent water pump shaft. Did you find and correct the condition?	-	Go to Step 11	Go to Step 10
10	Inspect for bent or cracked accessory drive bracket(s). Did you find and correct the condition?	-	Go to Step 11	-
11	Clear any codes. Run the engine in order to verify the repair. Does the vibration still exist?	-	-	System OK

Drive Belt Falls Off Diagnosis

Definition : The drive belt falls off the pulleys or may not ride correctly on the pulleys.

Diagnostic Aids

If the drive belt repeatedly falls off the accessory drive belt pulley(s), this may be caused by a pulley misalignment.

An extra load that is quickly applied or released by an accessory drive component may also cause the drive belt to fall off. Verify that the accessory drive component(s) are operating properly.

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

Test Description

The number(s) below refer to the step(s) on the diagnostic table.

This inspection is to verify the condition of the drive belt. Damage may have occurred to the drive belt when the drive belt fell off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plies.
Misalignment of the accessory drive pulley(s) may be caused from improper mounting or incorrect installation of a accessory drive component, or the pulley may be bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper removal and installation procedure of that pulley.
Inspection of the accessory drive pulley(s) should include inspecting for bends, dents or other damage to the pulleys that would prevent the drive belt from seating properly in the pulley grooves or on the smooth surface of a pulley when the back side of the drive belt is used to drive the pulley.
Accessory drive component brackets that are bent or cracked will also cause the drive belt to fall off.
Inspection of the fasteners can eliminate the possibility that a incorrect bolt, nut , spacer, or washer was installed. Missing, loose, or incorrect fasteners may cause pulley misalignment from the accessory drive bracket(s) moving under load. Over tightening the fasteners may cause misalignment of the accessory component bracket(s).

Step	Action	Value(s)	Yes	No
1	Did you review the Symptoms - Engine Mechanical diagnostic information, and perform the necessary inspections?	-	Go to Step 2	Go to Symptoms - Engine Mechanical
2	Inspect for a damaged drive belt. Was a damaged drive belt found?	-	Go to Step 3	Go to Step 4
3	Install a new drive belt. Refer to Section 1C1, Engine Mechanical - FAM II 2.4D. Does the drive belt continue to fall off?	-	Go to Step 4	System OK
4	Inspect for misaligned accessory drive pulley. Did you find and correct the condition?	-	Go to Step 12	Go to Step 5
5	Inspect for a bent or dented accessory drive pulley. Did you find and correct the condition?	-	Go to Step 12	Go to Step 6
6	Inspect for a bent or a cracked accessory drive bracket(s). Did you find and correct the condition?	-	Go to Step 12	Go to Step 7
7	Inspect for incorrect, loose and/or missing fasteners. Were there any incorrect, loose and/or missing fasteners?	-	Go to Step 8	Go to Step 9
8	Replace any incorrect and/or missing fasteners. Tighten any loose fasteners. Refer to "Fastener Tightening Specifications" in this section. Does the drive belt continue to fall off?	-	Go to Step 9	System OK
9	Test the drive belt tensioner for correct operation. Refer to Drive Belt Tensioner Diagnosis. Does the drive belt tensioner operate correctly?	-	Go to Step 11	Go to Step 10
10	Replace the drive belt tensioner. Refer to Drive Belt Tensioner Replacement. Does the drive belt continue to fall off?	-	Go to Step 11	System OK
11	Inspect for a failed drive belt idler and/or tensioner pulley bearings. Did you find and repair the condition?	-	Go to Step 12	-
12	Run the engine in order to verify the repair. Does the drive belt still fall off?	-	-	System OK

Drive Belt Excessive Wear Diagnosis

Definition : Wear at the outside ribs of the drive belt due to an incorrectly installed drive belt.

Diagnostic Aids

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

Minor misalignment of the accessory drive belt pulley(s) will not cause excessive wear, but will probably cause the drive belt to make a noise or fall off.

Excessive misalignment of the accessory drive pulley(s) will cause excessive wear and may also make the drive belt fall off.

Test Description

The number(s) below refer to the step(s) in the diagnostic table.

This inspection is to verify that the drive belt is correctly installed on all of the accessory drive pulleys. Wear on the drive belt may be caused by mis-positioning the drive belt by one groove on a pulley(s).
The installation of a drive belt that is too wide or too narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on the pulleys.
This inspection is to verify the drive belt is not contacting any part of the engine or body while the engine is operating. There should be sufficient clearance when the accessory drive components load varies. The drive belt should not come in contact with an engine or a body component when snapping the throttle.

Step	Action	Value(s)	Yes	No
1	Did you review the Symptoms - Engine Mechanical diagnostic information, and perform the necessary inspections?	-	Go to Step 2	Go to Symptoms - Engine Mechanical
2	Inspect the drive belt(s) for proper installation. Is the drive belt installed properly?	-	Go to Step 5	Go to Step 3
3	Inspect for the correct drive belt. Is the correct drive belt installed?	-	Go to Step 5	Go to Step 4
4	Inspect the drive belt for signs of rubbing against a bracket, hose, or wiring harness. Was the drive belt rubbing against anything?	-	Go to Step 5	Go to Diagnostic Aids
5	Replace the drive belt. Refer to Section 1C1, Engine Mechanical - FAM II 2.4D. Did you complete the replacement?	-	Go to Step 6	-
6	Run the engine in order to verify the repair. Is there still excessive drive belt wear?	-	-	System OK