Crankshaft and Bearings Clean and Inspect (Inspection)

^ Tools Required
- J 7872 Magnetic Base Dial Indicator
- J 36660 Electronic Torque Angle Meter

CAUTION: Refer to Safety Glasses Caution in Service Precautions.

IMPORTANT: Use care when handling the crankshaft. Avoid damage to the crankshaft bearing surfaces.

1. Clean the crankshaft in cleaning solvent. Remove all sludge or restrictions from the oil passages.
2. Dry the crankshaft with compressed air.

3. Clean the crankshaft bearings in cleaning solvent. Wipe the crankshaft bearings clean with a soft cloth, do not scratch the crankshaft bearing surfaces.
4. Dry the crankshaft bearings with compressed air.

5. Inspect the crankshaft for the following:
^ Crankshaft journals (1) should be smooth with no evidence of scoring or damage.
^ Deep grooves (2).
^ Scratches or uneven wear (3).
^ Pitted surfaces (4).
^ Wear of damage to the thrust journal surfaces.
^ Scoring or damage to the front or rear seal surface.
^ Restrictions to the oil passages.
^ Damage to the threaded bolt holes.

6. Inspect the crankshaft balancer key (1), the keyway (2), and the threaded hole (3) for damage.

7. Measure the crankpins for out-of-round and taper.

8. Use a suitable support to support the crankshaft on the front and rear journals.
9. Use the a/ 7872 in order to measure the crankshaft journal runout.
The crankshaft runout should not exceed 0.025 mm (0.001 inch).

10. Measure the crankshaft end play.

IMPORTANT: In order to properly measure the crankshaft end play, the crankshaft, the crankshaft bearing, the crankshaft bearing caps, and the crankshaft bearing cap bolts must be installed into the engine block and the bolts tightened to specifications.

10.1. Firmly thrust the crankshaft first rearward, then forward.This will align the crankshaft rear bearings and the crankshaft thrust surfaces.
10.2. With the crankshaft pushed forward, insert a feeler gauge between the crankshaft and the crankshaft bearing surface and then measure the clearance.
10.3. If the correct end play cannot be obtained, verify that the correct size crankshaft bearing has been installed.
10.4. Inspect the crankshaft for binding. Turn the crankshaft to check for binding. If the crankshaft does not turn freely, then loosen the crankshaft bearing cap bolts, one crankshaft bearing cap at a time, until the tight crankshaft bearing is located.
Burrs on the crankshaft bearing cap, foreign matter between the crankshaft bearing and the engine block or the crankshaft bearing cap, or a faulty crankshaft bearing could cause a lack of clearance at the crankshaft bearing.

11. Inspect the crankshaft bearings for craters or pockets. Flattened sections on the crankshaft bearing halves also indicate fatigue.

12. Inspect the crankshaft bearings for excessive scoring or discoloration.
13. Inspect the crankshaft bearings for dirt or debris imbedded into the crankshaft bearing material.

14. Inspect the crankshaft bearings for improper seating indicated by bright, polished sections of the crankshaft bearings.
^ If the lower half of the crankshaft bearing is worn or damaged, both the upper and lower halves of the crankshaft bearing should be replaced.
^ Generally, if the lower half of the crankshaft bearing is suitable for use, the upper half of the crankshaft bearing should also be suitable for use.

BEARING CLEARANCE MEASURING PROCEDURES

The crankshaft bearings are of the precision insert type and do not use shims for adjustment. If the clearances are excessive, then new upper and lower crankshaft bearings will be required. The service crankshaft bearings are available in the standard size and an undersize.
The selective fitting of the crankshaft bearings are necessary in production in order to obtain close tolerances. For this reason, in one journal bore you may use one-half of a standard crankshaft bearing with one-half of a undersize crankshaft bearing.

IMPORTANT: Do not use the plastic gauge method to measure connecting rod bearing clearances. The plastic gauge method for measuring connecting rod bearing clearances will result in unreliable measurements. Use only the micrometer method to correctly determine the connecting rod bearing clearances.
In order to determine the correct replacement crankshaft bearing size, the crankshaft bearing clearance must be measured accurately. Either the micrometer or plastic gauge method may be used; however, the micrometer method gives more reliable results and is preferred.

MICROMETER METHOD FOR CRANKSHAFT BEARINGS
1. Measure the crankshaft journal diameter with a micrometer in several places, approximately 90 degrees apart, and then average the measurements.
2. Determine the taper and the out-of-round of the crankshaft journal.

3. Install the crankshaft bearings into the engine block.

4. Install the crankshaft bearings into the crankshaft bearing caps.

5. Install the crankshaft bearing caps in the original positions and with the arrow on the crankshaft bearing caps in the direction of the front of the engine block.

NOTICE: Refer to Fastener Notice in Service Precautions.

6. Install the crankshaft bearing cap bolts.
6.1. Tighten the crankshaft bearing cap bolts on the first pass to 20 Nm (15 ft. lbs.).
6.2. Tighten the crankshaft bearing cap bolts on the final pass an additional 73 degrees using the J 36660.

7. Measure the crankshaft bearing inside diameter (ID) at the top and the bottom using an inside micrometer.
8. In order to determine the crankshaft bearing clearance, subtract the journal diameter from the crankshaft bearing ID.
9. Compare the crankshaft bearing clearance to the specifications.
10. If the crankshaft bearing clearances exceeds specifications, install the new crankshaft bearings as follows:
10.1. Measure the crankshaft bearing inside diameter (ID) at the top and the bottom using an inside micrometer.
10.2. Compare the crankshaft bearing clearance to the specifications.

11. Replace or repair the crankshaft if the proper clearances cannot be obtained.

MICROMETER METHOD FOR CONNECTING ROD BEARINGS

NOTICE: Do not shim, scrape, or file bearing inserts. Do not touch the bearing surface of the insert with bare fingers. Skin oil and acids will etch the bearing surface.

1. Measure the crankpin diameter with a micrometer in several places, approximately 90 degrees apart, and then average the measurements.
2. Determine the taper and the out-of-round.
3. Install the connecting rod bearings into the connecting rod cap and the connecting rod.

NOTICE: Refer to Fastener Notice in Service Precautions.

4. Install the connecting rod caps and the nuts.
4.1. Tighten the connecting rod nuts in the first pass, evenly to 27 Nm (20 ft. lbs.).
4.2. Tighten the connecting rod nuts in the final pass an additional 70 degrees using the J 36660.

5. Measure the connecting rod bearing inside diameter (ID) at the top and the bottom using an inside micrometer.
6. Compare the connecting rod bearing clearance to the specifications.
7. If the connecting rod bearing clearance is within specifications, the connecting rod bearing is satisfactory.
^ Replace the connecting rod bearing if the clearance is not within specifications.
^ Always replace both the upper and the lower connecting rod bearings as an assembly.

8. A standard or undersize connecting rod bearing combination may result in the proper clearance.
If the proper connecting rod bearing clearance cannot be achieved using the standard or the undersize connecting rod bearings, it will be necessary to replace or repair the crankshaft.

PLASTIC GAUGE METHOD FOR CRANKSHAFT BEARINGS

1. Install the crankshaft bearings into the engine block.

2. Install the crankshaft.

3. Install the gauging plastic the full width of the journal.

4. Install the crankshaft bearings into the crankshaft bearing caps.

9. Without removing the gauging plastic, measure the compressed width at the widest point using the graduated scale on the edge of the gauging plastic envelope. If the flattened gauging plastic tapers toward the middle or the ends, there may be a difference in clearance indicating taper, low spot or other irregularity of the crankshaft bearing or the crankshaft bearing journal.
^ Normally the crankshaft bearing journals wear evenly and are not out-of-round. However, if a crankshaft bearing is being fitted to an out-of-round 0.0254 mm (0.001 inch) (maximum) crankshaft bearing journal, be sure to fit to the maximum diameter of the crankshaft bearing journal. If the crankshaft bearing is fitted to the minimum diameter and the crankshaft bearing journal is excessively out-of-round, the interference between the crankshaft bearing and the crankshaft bearing journal will result in rapid crankshaft bearing failure.
^ If the crankshaft bearing clearance is within specifications, the crankshaft bearing is satisfactory. If the clearance is not within specifications, replace the crankshaft bearing.
Always replace both the upper and lower crankshaft bearings as a unit.
^ A standard or undersize crankshaft bearing combination may result in the proper clearance. If the proper crankshaft bearing clearance cannot be achieved using the standard or the undersize crankshaft bearings, it may be necessary to repair or replace the crankshaft.

NOTICE: Do not shim, scrape, or file bearing inserts. Do not touch the bearing surface of the insert with bare fingers. Skin oil and acids will etch the bearing surface.

10. Remove the flattened gauging plastic.
11. Measure the remaining crankshaft bearing journals.

CONNECTING ROD SIDE CLEARANCE MEASURING PROCEDURE

1. Insert a feeler gauge between the connecting rod caps and measure the connecting rod side clearance.
2. Connecting rod side clearances may also be measured with a dial indicator set.