Crankcase Ventilation System Engines

24-29 Import3/3/082:38 PMPage 22Crankcase Ventilation SystemCheck For 1994-2007 BMWEnginesAll current BMW engines (M42(from 1/94), M44, M52, S52, M60,M62 and M73 engines) incorporatea pressure-controlled crankcase ventilation system. If oil consumptionissues are being diagnosed, thisinformation can be helpful.The crankcase ventilation systems use various crankcase ventilation valves depending on the enginetype as shown in Figure 1 below.Although the valves all look different, they function similarly usinga spring and diaphragm assembly tocontrol the crankcase pressure. Aproperly functioning pressure control valve is designed to maintain aFigure 1 Various BMW crankcaseventilation valves: No. 1, used in theM52/S52 engines; Nos. 2 and 3,used in the M73 (two valves perengine); No. 4, used in the M42 from1/94 production and M44; and No.5, used in the M60/M62.Figure 2 BMW slack tube manometertool.slight vacuum (approximately 10 15 mbar) in the crankcase whichensures reliable crankcase ventingduring all engine operating conditions.A malfunctioning crankcase ventilation valve may cause the following complaints: Engine runs rough; Whistling noise from crankcaseventilation valve; and Check engine light on - possible DME faults stored: misfire allcylinders, oxygen sensor/mixturefaults, etc.To assist in troubleshooting theabove complaints a special tool (p/n99 00 0 001 410) has been developed to quickly check a pressurecontrolled crankcase ventilation system. Also refer to service information bulletin number 04 08 98 forfurther information regarding theslack tube manometer tool.The slack tube manometer toolconsists of:1) Slack Tube Manometer2) Connecting Hose3) Modified Oil Filler CapFollow the instructions includedwith the slack tube manometer forthe initial tool set up and generaloperating procedures. Basic operation is as follows:1) Connect the slack tubemanometer to the engine oil fillerneck.2) With both valves (1) openapproximately 1/4 turn; zero theFigure 3 The values on both sides must beadded together to get the proper reading.22 AERA TECH SOLUTIONS GUIDE February 2008sliding scale using the knob (2) asshown in Figure 2, below.3) Start the engine and observethe column of water.4) With all electrical consumersand the air conditioning switched offand engine at operating temperaturethe reading should indicate from 3.0- 6.0 inches of water at idle.5) The values on both sides of theslack tube must be added together toget the proper reading as seen in theillustration below in Figure 3,below.6) Example: 2.5 2.5 5.0inches of water (The readings mayfluctuate 0.1 to 0.2 during themeasurement which is normal anddoes not indicate a defect).If a crankcase ventilation valve isdefective (damaged diaphragm) thecolumn of water will indicate an offthe scale reading (all of the water onone side of the slack tube) whichindicates a high crankcase vacuum.7) A higher than normalcrankcase vacuum will also cause thecrankshaft seals to leak outside airinto the crankcase during engineoperation. A whistling or howlingnoise is usually heard coming fromthe seal areas (front or rear) at idlewhen this occurs.Cylinder Head And Timing BeltUpdate On 2006-07 Hyundai 2.0LVIN D EnginesA cylinder head and timing beltupdate on 2006-’07 Hyundai 2.0LVIN D engines allows the 2.0L timing belt system to be changed to anautomatic adjustment type from theprevious fixed adjustment type.An updated cylinder head timingbelt tensioner and tensioner bolthave been implemented since June15, 2006, in production on all 2006and 2007 model year 2.0L equippedvehicles. This information fromHyundai provides the new partinformation and proper adjustment

24-29 Import3/3/082:39 PMPage 24ComponentPrevious P/NNew P/NRemarksCylinder Head22100-2376022100-23780Tensioner Mounting Bolt DiameterChanged: 10mm to oner Adjustment ChangedFrom Fixed Type toAuto Tensioner TypeTensioner Bolt24412-2300024412-23050Bolt Changed:M10 X 1.25 to M8 X 1.25Chart 1 Cylinder head and timing belt part numbers and information for Hyundai 2.0L engines.procedure for the new tensioner system (Chart 1, above).Vehicles Affected: 2006 Elantra, Tiburon andTucson 2.0L models produced fromJune 15, 2006 to current.Adjustment Procedure:1) Install the timing belt tension-er and tensioner bolt loose enoughfor the adjuster to rotate. Ensure thestopper is resting against the lowerseal cap on the cylinder head.2) Install the timing belt over theapplicable sprockets in this order.See Figure 4, page 25: CrankshaftSprocket (A) Idler Pulley (B)Camshaft Sprocket (C)Timing Belt Tensioner (D).Ensure there is no slack inthe belt between the twoshafts.3) Check the alignmentmarks on each sprocket.Refer to shop manual foryour specific model.4) Remove the lock pinwhich holds the tensionerarm in place during ship-ping.5) Using a 6mm hex wrench (F),turn the adjuster counterclockwiseto make the indicator of the arm (G)line up with the notch on the base(H) and tighten the tensioner bolt.See Figure 5, page 25, (Torque to16-21 ft.lbs., 22-28Nm)Do not rotate the tensioner clockwise as it will permanently damage the tensioner.Rear Engine Oil Leak On2003-2006 Isuzu Ascenderswith 5.3L VIN P EnginesA rear engine oil leak on2003-2006 Isuzu Ascenderswith 5.3L VIN P engines thatupon initial diagnosis seemsto be coming from the rearcover gasket area, may actually be caused by engine blockporosity on the engine blocksealing surface.If the leak has been determined to be coming from therear cover gasket area, removethe cover area and inspect thecylinder block for any indications of porosity in the sealing areas. If porosity is foundanywhere on the sealing surface, use RTV p/n 8-12778521-0 to fill in any porositylocations.Wipe a small amount ofthe RTV sealant onto thesurface using a plastic scraperto fill in the porosity holes onCircle 224 for more information24 AERA TECH SOLUTIONS GUIDE February 2008

24-29 Import3/3/082:39 PMPage 25the mating surface of cylinder block.Remove any excessive RTV thatmay have been applied, especiallyfrom the high pressure oil passage asshown with arrow in picture below.Allow the RTV to cure 10 minutesbefore installing the rear cover.When installing the rear cover,tighten the engine rear cover boltsto 18 ft.lbs.Figure 4 Hyundai 2.0L timing beltHead Bolt Caution & Installationinstallation.For 2001-’02 KIA 1.5L DOHCEngineswith the cylinder head. If eitherThe torque values published in the requires replacement, it’s necessary2001-2002 Rio Service Manuals for to replace both.The cam carrier alsothe 2001-2002 Kia 1.5L DOHC requires an oil tight seal between itengine are incorrect.and the cylinder head. This isThe manual incorrectly specifies accomplished with 4 special O-ringthe cylinder head bolt torque values seals (p/n 0K30E-10-122) aroundas 36.1 in.lbs. and 18 in.lbs.respectively (before a final90 degree tightening step).While the values are correct, the units should readft.lbs. The 2002 manualstates to rotate the headbolts two additional 90 turns, only once is correct.The correct listing shouldread as shown below. Usethe head bolt torquesequence in Figure 7, page26, as a reference. Torque all bolts insequence to 36.1 ft.lbs. Loosen all bolts inreverse sequence. Torque all bolts insequence to 18 ft.lbs. Rotate all bolts insequence an additional 90 turn.Also note that the cylinder head bolts used on Rioengines are the (stretch)type that must not be reused, they must be replacedany time they are removed.The cam carrier on theRio engine is align boredFigure 5 Hyundai 2.0L tensionerbolt torque.the spark plug cavities, and with asealant on the mating surfaces.Kia inadvertently specifiedsealant to be used on outside surfaces only. This is incorrect. Sealantshould be applied to all mating surfaces, while taking care not to allowCircle 225 for more informationwww.enginebuildermag.com ENGINE BUILDER25

24-29 Import3/3/082:39 PMPage 26Figure 6 Rear engine oil leak onIsuzu Ascenders 5.3L engines.Figure 7 KIA 1.5L torque sequence.Use the revised torque specification.Figure 8 Use Hylomar adhesive onKIA 1.5L cam carrier.sealant into oil or coolant passages.The specified sealant is for closefitting machined surfaces, and eliminates the need to re-torque after thesealant settles and cures. The sealantto be used when replacing or reinstalling the Rio’s cam carrier iseither Hylomar Anaerobic AdhesiveGrade 3000 or an equivalent, such asPermatex Anaerobic Gasket Maker.See Figure 8, above.Note: The part number shownabove for the cam carrier O-ringseals will eventually be eliminated.When that occurs, to obtain eithercomponent, you’ll have to orderthe cylinder head/cam carrierassembly.Circle 226 for more information26 AERA TECH SOLUTIONS GUIDE February 2008Revised Rocker Arm Assembly For1996-2004 Rover 4.6L EnginesA revised rocker arm assembly for1996-2004 Rover 4.6L engines hasbeen introduced to addressreports of noisy valve trainoperation.The affected vehicle models include: Range Rover (LP) –WA382672 to YA437311; Discovery Series ii (LT)– Up to YA265404; and Discovery (U) –WA753113 to XA795263.Customer complaints of arattling/tapping noise fromthe engine found to originatefrom rocker shaft area may bethe result of the hardenedpushrod cup being insecurein the rocker arm.Investigate customer complaints of valve rattling/tapping noise on vehicles withinthe above VIN ranges andidentify rocker arms withloose pushrod cups. If noisyor loose rocker arms areencountered during theinspection, replace all rockerarms with updated parts. 602154 left bank rockerarm; 602153 right bank rock-

24-29 Import3/3/082:39 PMPage 27This began with enginenumber M962561506314.Engines built prior to theM962561506314 that exhibitthe above mentioned noise,can be retrofitted with thenewcomponentp/n996.101.007.07.Figure 9 Range Rover rocker arm.er arm.Only rocker arms with datecodes ‘00’ or newer (01) may beused to repair valve trains. Use ofearly production rocker arms mayresult in a reccurrence ofthe problem (Figure 9,above).Revised Flywheel MountingBolt On 1991-’92 VW 2.8LEnginesA new flywheel mountingbolt has been introducedfor 1991-’92 Volkswagen2.8L engines. Engine buildersneed to consider that this engine isdesigned to use new flywheelmounting bolts during assembly.However, the bolts originally usedare no longer available. Thereplacement bolt will not endurethe listed torque for the originalbolt.The replacement bolt (p/nN902 061.03) will not endure thetorque specification listed for theold bolt in repair manuals andmicrofiche. If those values areused, it will result in strippedthreads.The correct torque for thereplacement bolt is 22 ft.lbs (30Nm) plus a 1/4 (90 ) turn.Always use new bolts. Thereplacement bolt now has a specialadhesive applied to the threads andcan only be used once. New boltsare not currently available in theaftermarket. TSGEngine Noise at 2,2003,000 RPM For 2005Porsche 2.7L BoxstersBelieve it or not, not allPorsche engine sounds aredesirable. The 2005 Porsche2.7L Boxster engines mayproduce a rattling, clickingor knocking sound atengine speeds of 2,2003,000 rpm.Porsche reports thatupon inspection of complete engines replacedunder warranty, it has beendetermined that engineswere being replaced unnecessarily. Until a manufacturing modification was madeon March 29, 2005, thereplacement engine couldexhibit the same noise.As of March 29, 2005, acrankshaft bearing housingwith new thrust blocksmade of nodular cast iron isinstalled on all 2.7L engines.Circle 227 for more informationwww.enginebuildermag.com ENGINE BUILDER27

Chart 1 Cylinder head and timing belt part numbers and information for Hyundai 2.0L engines. 24-29 Import 3/3/08 2:39 PM Page 24. the mating surface of cylinder block. Remove any excessive RTV that may have been applied, especially from the high pressure oil passage as shown with arrow in picture below. Allow the RTV to cure 10 minutes before installing the rear cover. When installing the rear .