Filed Under (Hyundai) by admin on 04-05-2011
1. 2. 3. 4. 5. Drain the coolant and disconnect the upper radiator hose. Remove the breather hose (between the air cleaner and the rocker cover). Remove the air-intake hose. Remove the vacuum hose, fuel hose and coolant hose. Remove the cables from the spark plugs. The cables should be removed by holding the boot portion. Remove the ignition coil. Remove the surge tank. Remove the intake manifold. Remove the heat protector and exhaust manifold assembly Remove the coolant pump pulley and the crankshaft pulley. Remove the timing belt cover. 6. 7. 8. 9. 10. 11. Zoom Sized for Print 12. Move the timing belt tensioner pulley toward the coolant pump and temporarily secure it. 13. Remove the timing belt. 14. Remove the rocker cover. 15. Remove the cylinder head assembly. The cylinder head bolts should be removed using Special Tool, Cylinder Head Bolt Wrench (09221-21000), in the sequence as shown in the illustration. 16. Remove the gasket pieces from the cylinder block top surface and cylinder head bottom surface. NOTE: 1. Make sure that the gasket pieces do not fall in to the engine. INSPECTION 1. Check the cylinder head for cracks, damage and coolant leakage. 2. Remove scale, sealing compound and carbon deposits completely. After cleaning oil passages, apply compressed air to make certain that the passages are not clogged. 3. Check the cylinder head surface for flatness using a straight edge in the direction of A, B, …as shown. If flatness exceeds service limit in any direction, replace the cylinder head, or lightly machine the cylinder head surface. Cylinder head flatness Standard value: Less than 0.03 mm (0.0012 inch) Limit: 0.08 mm (0.0031 inch) REASSEMBLY 1. Clean all gasket surfaces of the cylinder block and the cylinder head. 2. Install a new cylinder head gasket onto the cylinder head assembly. Do not apply sealant to the gasket and do not reuse the old cylinder head gasket.
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Filed Under (Ford) by admin on 25-10-2010
ISSUE Some 2004-2008 F-150, 2006-2008 Mark LT, 2005-2008 F-Super Duty, Expedition, and Navigator, with 5.4L 3-V engine; 2005-2008 Mustang, 2006-2008 Explorer, Mountaineer, and 2007-2008 Explorer Sport Trac with 4.6L 3-V engine; 2005-2008 F-Super Duty, 2006-2008 and F-Stripped Chassis, with 6.8L 3-V engine may experience difficulty with spark plug removal. This may cause damage to the spark plug and leave part of the spark plug in the cylinder head. Affected engine build dates are as follows: 5.4L 3-V and 6.8L 3-V before 10/9/07, 4.6L 3-V before 11/30/07. ACTION Refer to the following Service Procedure for techniques to remove the spark plugs and extract broken spark plugs. SERVICE PROCEDURE The engine build date can be read on the left hand cam cover information sticker. To remove spark plugs without damage, it is necessary to adhere exactly to this procedure before removal is attempted. CAUTION DO NOT REMOVE PLUGS WHEN THE ENGINE IS WARM OR HOT. THE ENGINE MUST BE AT ROOM TEMPERATURE WHEN PERFORMING SPARK PLUG SERVICE. REMOVING THE SPARK PLUGS FROM A WARM/HOT ENGINE INCREASES THE CHANCE THE THREADS COULD BE DAMAGED. Spark Plug Removal Procedure 1. Remove the coil-on-plug assemblies and thoroughly blow out the spark plug wells and surrounding valve cover area with compressed air. 2. Back out the spark plugs no more than 1/8 to 1/4 of a turn. Using Motorcraft(R) Carburetor Tune-Up Cleaner, fill the spark plug well just above where the jamb nut hex sits (1/2 – 3/4 teaspoon). A minimum period of 15 minutes of soak time is required. The cleaner will wick down to the ground electrode shield and soften the carbon deposits in this time. DO NOT WORK the spark plug back and forth at this point. NOTE COMPLETELY REVIEW THE PRODUCT LABEL FOR THE MOTORCRAFT CARBURETOR TUNE-UP CLEANER PRODUCT – USE AT ROOM TEMPERATURE AND SHAKE WELL.
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Filed Under (Jeep) by admin on 03-10-2010
may experience an incident of engine misfire during certain vehicle operating conditions. The misfire may occur when the vehicle is operated between 80 – 112 KPH (50 – 70 MPH) and under light loading conditions, e.g. slight uphill road grades. This condition may occur at all ambient conditions, but is more noticeable when ambient conditions are less than 0°C (32°F). If the vehicle is equipped with On-Board Diagnostic (OBD), a MIL illumination may also have occurred due to Diagnostic Trouble Code (DTC) P0300 – Multiple Cylinder Misfire. Various single cylinder misfire DTC’s may also be present. If the frequency of misfire is high the Powertrain Control Module (PCM) may place the engine in “Limp-In” mode. The misfire condition may be caused by one or more engine exhaust valves that are slow to close. Late closure of an exhaust valve may be the result of no valve rotation and associated build up of carbon on the exhaust valve stem. This condition may occur when the engine is not allowed to run at engine RPM’s that are greater than 3,200 RPM. At 3,200 RPM or higher the engine exhaust valves will rotate if not impeded by high carbon deposits. Low engine RPM’s and high carbon deposits are associated with short trip driving where the vehicle engine is not allowed to fully warm to normal engine operating temperatures. Cold ambient temperatures will increase engine warm-up time and add to the opportunity of carbon deposit build-up on the stem of the engine exhaust valve. Verify that an engine misfire condition is present. Use of the DRBIII(R) during a road test, or a Co-Pilot data recording, may help to determine engine misfire and misfire counts. If carbon deposit accumulation is severe, then a cylinder leak down test may detect one or more cylinders leaking greater than 15%. Save any misfire DTC Freeze Frame Data that was stored for later misfire correction verification. Verify that the engine misfire condition is not caused by faulty engine mechanical or electrical components. If the engine mechanical and electrical systems are operating properly perform
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When carbon deposits build up inside the combustion chamber, two problems can occur. Knock, or ping, sounds like marbles being dropped into a metal can. It is loudest when the engine is accelerating or climbing a hill. The second problem is afterrun (or dieseling) when the engine is shut off. Engine carbon cleaner loosens carbon from the combustion chamber in order to reduce knock and afterrun. There are two ways to use it: 1. Pour it into the gas tank. 2. With the engine running at warm idle, allow the cleaner to dribble slowly into the carburetor or fuel injection barrel. On engines with catalytic converters, the air pump belt must be disconnected first. NOTE: In late-model cars, knock and afterrun are often caused by problems in the emission, fuel, and/or ignition systems. These systems should be checked before engine carbon cleaner is used.