Service Manual2007 Captiva UNIT REPAIR

Captiva

UNIT REPAIR

Cylinder Head

Tools Required

09916-14510 Valve Spring Compressor

EN-48247 Valve Spring Compression Adapter

EN-48252 Camshaft Oil Seal Installer

Disassembly Procedure

Remove the cylinder head. 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.

Remove the camshaft sprocket.

Remove the camshaft cap.
Remove the camshaft.

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.

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.

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.

Assembly 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.

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

Install the camshaft.
Install the camshaft cap.

Tighten

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

Install the 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 oil pump case contact.

Install the camshaft sprocket.

Tighten

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

Engine Block

Tools Required

DW100-130 Engine Overhaul Stand

KM-470-B Angular Torque Gauge

EN-48251 Crankshaft Rear Oil Seal Installer

EN-48249 Piston Ring Compressor

Disassembly 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 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.

Remove the connecting rod and piston.
Remove the engine bed plate.
Remove the crankshaft with the rear oil seal ring.

Remove the oil nozzle tube.

Cleaning 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.

Assembly Procedure

Coat the crankshaft bearing with engine oil.
Install the oil nozzle tube.

Tighten

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

If replacing the crankshaft, transfer the CPS target wheel to the new crankshaft.

Tighten

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

Install the crankshaft with the journal bearings.
Install the engine bed plate. Refer to “Engine Bed Plate” in this section.

Inspect the crankshaft end play with the crankshaft bearings installed. Refer to “Engine Specifications” in this section.
Check for permissible crankshaft end play. Refer to “Engine Specifications” in this section.

Coat the piston and the rings with engine oil.
Insert the piston and connecting rod using by piston ring compressor EN-48249.

Install the connecting rod cap 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.

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

Install the crankshaft rear seal ring with new one using by crankshaft rear oil seal installer EN-48251.

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 flywheel or flexible plate.

Tighten

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