2GR-FE Engine Ticking Noise and/or MIL “ON” P0014, P0015, P0024, P0025, P0017, or P0018

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Filed Under (Toyota) by admin on 20-05-2011

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Introduction IMPORTANT It is mandatory that the VVT-i gear actuator bolts, actuator center section alignment, and actuator body be inspected BEFORE performing this TSB. If no concerns are noted with these parts, this TSB does NOT apply. Some 2005 – 2009 model year vehicles with 2GR-FE engines may exhibit a ticking/clicking type noise from the cylinder head cover area which may be accompanied by a MIL “ON” and one or more VVT-i related Diagnostic Trouble Codes (DTCs). Please use the following repair procedure to address customer concerns. Inspection Procedure 1. Start the engine and listen for any ticking/clicking type noises coming from the VVT-i gear area of the engine. NOTE This condition may or may not be accompanied by one or more of the following DTCs stored in the Engine Control Module (ECM) (SAE term: Powertrain Control Module/PCM): • P0014: Camshaft Position “B” – Timing Advanced or System Performance (Bank 1) • P0015: Camshaft Position “B” Timing Over Retarded (Bank 1) • P0017: Crankshaft Position Camshaft Position Correlation (Bank 1 Sensor B) • P0018: Crankshaft Position Camshaft Position Correlation (Bank 2 Sensor A) • P0024: Camshaft Position “B” – Timing Over-Advanced or System Performance (Bank 2) • P0025: Camshaft Position “B” – Timing Over-Retarded (Bank 2) 2. Remove the cylinder head cover and inspect the exhaust VVT-i gear assembly on the affected cylinder bank. NOTE If NO concerns are found with the VVT-i gear actuator bolts, the actuator center section alignment, or actuator body, this TSB does NOT apply. Refer to Repair Manual procedures for further diagnosis. Repair Procedure 1. If any concerns are noted with the exhaust VVT-i gear bolts or actuator follow the four steps below: A. Replace the camshaft housing sub-assembly, exhaust camshaft, and exhaust VVT-i gear assembly on the affected bank. B. Inspect the intake VVT-i gear assembly and bolts on the affected bank. Replace the intake VVT-i gear assembly if necessary. C. Inspect the opposite bank exhaust VVT-i gear actuator and bolts. If any concerns are noted replace the opposite bank camshaft housing sub-assembly, exhaust camshaft, and exhaust VVT-i gear assembly. D. Inspect the opposite bank intake gear actuator assembly and bolts. Replace the intake VVT-i gear assembly if necessary. For complete disassembly procedures refer to the Technical Information System (TIS), applicable model and model year Repair Manual: • 2005 Avalon: Engine/Hybrid System – Engine Mechanical – “Engine Mechanical: Camshaft (LH Bank) / (RH Bank) (2GR-FE): Replacement” • 2006 / 2007 / 2008 / 2009 Avalon: Engine/Hybrid System – Engine Mechanical – “2GR-FE Engine Mechanical: Engine Unit: Disassembly” • 2007 / 2008 / 2009 Camry: Engine/Hybrid System – Engine Mechanical – “2GR-FE Engine Mechanical: Engine Unit: Disassembly” • 2008 / 2009 Highlander: Engine/Hybrid System – Engine Mechanical – “2GR-FE Engine Mechanical: Engine Unit: Disassembly” • 2006 / 2007 / 2008 / 2009 RAV4: Engine/Hybrid System – Engine Mechanical – “2GR-FE Engine Mechanical: Engine Unit: Disassembly”

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2002–2004 Toyota Camry Intake Manifold Noise

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Filed Under (Toyota) by admin on 19-05-2011

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Some 2002 – 2004 model year non-PZEV Camry vehicles with the 2AZ–FE engine may experience the following condition: • A rattle noise from the engine area, most noticeable at idle or on light acceleration. The noise may be caused by the intake air as it ?ows through the intake manifold. The intake manifold has been modi?ed to improve this condition. Repair Procedure 1. Verify noise is from the intake manifold. 2. Replace the intake manifold. Refer to the Technical Information System (TIS): • 2002 / 2003 model year Camry Repair Manual, Engine/Hybrid System – Engine Mechanical – “Cylinder Head Gasket (2AZ-FE): Replacement”. • 2004 model year Camry Repair Manual, Engine/Hybrid System – Engine Mechanical – “Cylinder Head Gasket (2AZ-FE)(from July, 2003): Replacement”. 3. Verify that the noise is NOT present after repair.

2004-2008 Ford E-Series Cooling System – Fuel Contamination Diagnostics

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Filed Under (Ford) by admin on 04-05-2011

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6.0L DIESEL FUEL IN ENGINE COOLANT DIAGNOSTICS FORD: 2003-2005 Excursion 2003-2007 F-Super Duty 2004-2008 E-Series ISSUE Some 2003-2005 Excursion, 2003-2007 F-Super Duty and 2004-2008 E-Series vehicles equipped with a 6.OL engine may exhibit fuel in the engine coolant, due to leaks in the cylinder head fuel injector area. Symptoms may include fuel in engine coolant and coolant expulsion from the degas bottle. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Inspect the degas bottle for evidence of fuel in engine coolant. If diesel fuel is present, refer to the following Service Procedure. If not, follow normal diagnostics. NOTE IT IS VERY IMPORTANT TO ENSURE A COMPLETE FLUSHING OF THE ENGINE COOLING SYSTEM IS PERFORMED TO REMOVE ALL CONTAMINANTS FOLLOWING REPAIR. 1. Drain coolant from cooling system. 2. Remove all injectors from both cylinder heads. Refer to Workshop Manual (WSM), Section 313-04C. 3. Wipe injector bore clean of oil and fuel then apply a thin layer of bubbly type liquid hand soap, dish soap or laundry soap inside each injector bore. Ensure injector sleeve lip and cylinder head casting are coated with a soap layer. (Adding a small amount of water to the soap aids in creating bubbles) 4. Fit the cooling system pressure tester, refer to WSM, Section 303-03. (Do not add coolant) 5. Apply 5-10 psi (34-69 kPa) of air pressure to sealed cooling system. It is suggested to use a hand operated pressure tester or regulated shop air with tee in degas hose to degas bottle. NOTE MORE THAN 10 PSI (69 kPa) AIR PRESSURE CAN PUSH THE SOAP FROM THE LEAK POINT AND NO BUBBLES WILL BE PRESENT OR CREATED, MAKING DIAGNOSIS DIFFICULT. 6. Inspect each injector bore for bubbles. (A light and mirror or bore-scope may aid in pinpointing a leak location.) If bubbles are observed, determine if bubbles originate from the injector sleeve lip (Figure 1) or cylinder head casting. (Figure 2) Refer to cutaway view of the cylinder head. (Figure 3) a. Replace the injector sleeve if found to be leaking at sleeve lip, refer to WSM 303-04C. b. Replace cylinder head if leaking through casting, refer to WSM 303-01C. c. Flush cooling system, refer to another applicable Technical Service Bulletin (TSB) for proper cooling system flush procedures.

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3126E TRUCK ENGINE CKM Unit Injector – Removal Procedure

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Filed Under (General) by admin on 30-04-2011

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Start By: A. Remove the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover – Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. Removal Of The Injector 1. Remove oil drain plugs (1) at each end of the cylinder head. 2. Allow the engine oil to drain from the ports in the cylinder head before the injector is removed. 3. Disconnect harness connector (2) . Note: Some of these engines were built without the deflector. During the installation of the unit injectors, the deflectors (Y) should be installed. 4. Remove bolt (3) . 5. Remove bolt (4) . 6. Place Tooling (A) under clamp (5) on the flywheel side of the injector. 7. Tooling (A) should be placed at this location in order to gently remove the injector. Use Tooling (A) to remove the injector. 8. Do not pry at location (Z) . 9. Remove the O-Ring seals (6) from the injector. 10. Repeat Step 3 through Step 9 for the remainder of the injectors. Cleanliness is very important in the area around the sleeve and the sleeve bore when you are reinstalling the injector. This injector has a metal seal (7) between the bottom of the injector’s case and a seat in the cylinder head. Clean the carbon from the seat area that is inside of the cylinder head. Also clean the carbon from the end of the injector if the injector should be reinstalled. The fine grade of the Scotch Brite material is preferred. Scotch Brite is available from the Tools And Shop Products Guide as the abrasive material and as the surface reconditioning pad. If the sleeve of the injector has been removed from the engine, use a reamer to remove carbon deposits from the angled surface. Note: Do not use the reamer in order to remove metal from the sleeve. Use the reamer in order to remove carbon only.

2001 Ford F-150 Cylinder Head DISASSEMBLY AND ASSEMBLY

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Filed Under (Ford) by admin on 08-04-2011

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Cylinder Head Special Tool(s) Compressor, Valve Spring 303-567 (T97P-6565-AH) Spacer, Valve Spring Compressor 303-382 (T91P-6565-AH) Installer, Valve Stem Oil Seal 303-383 (T91P-6571-A) Material Metal Surface Cleaner F4AZ-19A536-RA Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP Disassembly All engines 1. On Windsor engines, remove the Camshaft Position Aligner from the camshaft (6250). Item Specification WSE-M5B392-A WSS-M2C153-H 2. CAUTION: Do not remove the camshaft before removing the roller followers. CAUTION: Place the cylinder head (6049) on a cardboard or wood surface to prevent damage to the joint face. Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage. 3. NOTE: The roller followers must be reinstalled in their original locations. Record roller follower locations. Use the Valve Spring Compressor to compress the valve springs (6513), and remove the roller followers. 4. NOTE: The hydraulic lash adjusters must be installed in their original locations. Record hydraulic lash adjuster locations. Remove the hydraulic lash adjusters. 5. NOTE: Windsor engine shown; Romeo engine is similar. Use the Valve Spring Compressor to compress the valve springs. 6. CAUTION: Keep the valves and valve spring retainer keys (6518) in order so they can be installed in the same positions. NOTE: Shown without camshaft for clarity. Remove the (A) valve spring retainer keys, the (B) valve spring retainers (6514), the (C) valve springs, and the valves. 7. Remove the valve stem seals (6571). Romeo engine (4.6L) 8. NOTE: The camshaft bearing caps must be installed in their original location. Record camshaft bearing cap location. Remove the bolts, the bearing caps and the camshaft. Windsor engine (5.4L) Assembly All engines 1. CAUTION: Do not use metal scrapers or other tools to clean the cylinder head or damage to the head can occur. Use a plastic scraper and metal surface cleaner to clean the cylinder head. 2. Lubricate the camshaft journals with clean engine oil.