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Another story from the service bay #5441416 05/29/20 12:11 AM
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clinebarger Offline OP
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2003 Pontiac Aztek, 3.4L/4T65E, 135,xxx miles.
Compliant.....Misfire on #5 cylinder. Coils, ICM, Plug Wires, & Spark Plugs have been changed by another shop/mechanic.

It is indeed misfiring on #5 cylinder, LT Fuel trims are hovering @ negative 6% at idle.
Balance tested all 6 injectors, They were within 2% of each other.
Vacuum gauge was steady but low @ 14 inches.
Disabled spark & cranked the engine over, This revealed an uneven compression issue by the sound.

Called the customer & got the okay to pull the Bank 2 (rear) valve cover, Back off the rockers & do a Leak Down test on #5.
Pulled the cover & found the #5 Inlet Rocker laying on it's side. Threads pulled out out of the head, Pushrod was sitting off the lifter but was able the retrieve it with a pencil magnet.

I made the decision to Heli-Coil it blind using a mirror & flashlight. I drilled the hole out by hand using a Tap T-Handle tightened onto a 21/64" drill bit, Was able to watch the angle compared to the #3 Inlet Rocker bolt while drilling & tapping for the Heli-Coil insert. Used liberal amounts of wheel bearing grease on the tooling to catch most of the aluminum chips/debris.

Loctited the insert in & let it sit overnight, Broke the insert drive tang off with some hemostats, Ran in a thread chaser to clean out the left over Loctite, Torqued the Rocker Arm assembly down to spec. Barred the engine over & confirmed the Rocker had a little side to side movement (The lifter didn't stay pumped-up).....The lifter didn't want to bleed down by simply torquing the rocker.

Engine now runs on all 6 cylinders, Let it run to operating temp & change the oil & filter.






The Rocker threads were pulled during a LIM gasket change that was done by the same shop that sold all the tune-up parts. I checked the other rocker arm bolts on the rear bank...They held torque after back them off a little. Customer stated the engine ran fine for a couple weeks after the LIM gasket job.
Please don't ask about the cost, It's probably more than you think it's worth, There are no book times for fixing screw-up's that shouldn't have happened in the first place. I will say it was cheaper than pulling the head & repairing it on the bench.


[Linked Image from i.imgur.com]
[Linked Image from i.imgur.com]


2001 Chevy Camaro L92/4L80E
2006 Chevy 2500HD LBZ/Allison 1000
2010 Toyota Corolla 2ZR-FE/U341E
2000 Toyota Avalon 1MZ-FE/A541E
Re: Another story from the service bay [Re: clinebarger] #5441417 05/29/20 12:12 AM
Joined: Dec 2013
Posts: 4,645
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clinebarger Offline OP
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[Linked Image from i.imgur.com]
[Linked Image from i.imgur.com]


2001 Chevy Camaro L92/4L80E
2006 Chevy 2500HD LBZ/Allison 1000
2010 Toyota Corolla 2ZR-FE/U341E
2000 Toyota Avalon 1MZ-FE/A541E
Re: Another story from the service bay [Re: clinebarger] #5441420 05/29/20 12:51 AM
Joined: Jun 2012
Posts: 2,608
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oldhp Online Content
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A mechanic that uses his head and his hands. Awesome!!!! Good Job Sir!!!


"None of us are getting out here alive...drink that beer...eat that pizza...drive that Hot Rod"
"When others cut you down, remember where they came from."
"I don't run...........I just quietly wait"
Re: Another story from the service bay [Re: clinebarger] #5441433 05/29/20 01:58 AM
Joined: Sep 2010
Posts: 13,298
4WD Online Confused
Online Confused
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Posts: 13,298
DiL had one of those for 13 years … hard to look at … but it was actually reliable …

Re: Another story from the service bay [Re: clinebarger] #5441436 05/29/20 02:58 AM
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gfh77665 Offline
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Cline and Trav are two of the best ever!

Re: Another story from the service bay [Re: clinebarger] #5441460 05/29/20 05:58 AM
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WyrTwister Offline
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Guessing by the sludge on the rocker parts & head , some one has not been changing the oil / filter too often .


Wyr
God bless
Re: Another story from the service bay [Re: clinebarger] #5441461 05/29/20 05:58 AM
Joined: Jan 2018
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HemiBenny Offline
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Someone that actually figures out the problem instead of throwing countless parts at it is refreshing to see. Your stories from the service bay make for great posts. Job well done! cheers


2011 Ram 1500 5.7l
Shell RGT 5w20 / Fram TG2 oil filter

2015 Chrysler 200 2.4l multiar
Shell RGT 0w20 / Fram Ultra Guard XG10060

2016 Buick Encore 1.4l
Shell RGT 5w30 / Fram Extra guard CH10246
Re: Another story from the service bay [Re: gfh77665] #5441462 05/29/20 05:58 AM
Joined: Oct 2010
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Astro14 Offline
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Originally Posted by gfh77665
Cline and Trav are two of the best ever!


+1!


32 Packard 15W40
01 Volvo V70 T5 0W30 AMSOIL SS
02 Volvo V70 T5 0W30 Edge
02 Volvo V70 XC 0W40 Edge
05 MB S600 0W40 M1
16 Tundra 1794 5W30 Pennzoil Ultra
Re: Another story from the service bay [Re: clinebarger] #5441477 05/29/20 06:42 AM
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BMWTurboDzl Offline
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Thanks for sharing thumbsup


“It took untold generations to get you where you are. A little gratitude might be in order. If you’re going to insist on bending the world to your way, you better have your reasons.”

435i
Re: Another story from the service bay [Re: clinebarger] #5441481 05/29/20 06:46 AM
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bullwinkle Offline
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Nice work! That’s a lot of work/love for a 17 year old Aztec!


06 Ram 3500 CTD 4X4(FG Venturi), 89 F-450 7.3, 98 XJ 4.0(XG8A), 05 xB(XG3600), 18 Transit 3.7 (MC), 03 Merc Grand Marquis 4.6 2V(XG2), 11 Express 3500 6.0 (Fram PH10060 for now)
Re: Another story from the service bay [Re: WyrTwister] #5441486 05/29/20 06:55 AM
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supton Online Content
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Originally Posted by WyrTwister
Guessing by the sludge on the rocker parts & head , some one has not been changing the oil / filter too often .

17 years old, I'd guess "maybe", if it's been the same service all this time, then perhaps the oil is being towards its service limit. Then again, if oil is better than it was was 17 years ago, maybe not.

Sounds like it was a fun job! Ouch.


2011 Toyota Camry, base, 2.5L/6MT, 206k
2010 Toyota Tundra DC, 4.6L/6AT, 160k
2003 CRV, 2.4L/4AT, 161k
1999 Toyota Camry LE, 2.2L/4AT, 225k
Re: Another story from the service bay [Re: clinebarger] #5441488 05/29/20 06:58 AM
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Trav Offline
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My guess is the previous guy didn't bother with 14 ft.lb + 30° he just tightened them up good n tight. Nice job getting the helicoil in back there, its tight.
This sort of damage shows the need for good torque tools especially when working with aluminum.


ASE L1, Master. Deutsch Meisterbrief.
Re: Another story from the service bay [Re: clinebarger] #5441490 05/29/20 07:01 AM
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Snagglefoot Online Content
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Thanks for the post. Keep them coming. Greatly appreciated. smile


If you want the job done right......do it yourself.
Re: Another story from the service bay [Re: clinebarger] #5441492 05/29/20 07:06 AM
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OVERKILL Online Content
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Great work as always thumbsup


2019 RAM 1500 Sport - Mobil 1 EP 0w-20, FRAM Ultra
2020 Jeep Grand Cherokee SRT Ravenol SSL 0w-40, FRAM Ultra
Re: Another story from the service bay [Re: clinebarger] #5441506 05/29/20 07:28 AM
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andyd Offline
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An 8mm tapped into aluminum requires caution. Bug engines used a pair of them for the rockers. Caution, learned the hard way, 'cuz fools don't learn any other way. grin2

PS: I have the scars to prove it too. grin2


'16 Camry LE STP synth 0w20 and STP filter. the Fridge

1994 Ranger ,the Rat, 5w30 dino, STP filter

'16 Camry SE, Valvoline HM 0w20 and OEM filter
Thick oil is better grin2
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