32. Crankshaft and Bearing Cleaning and Inspection

Crankshaft and Bearings Cleaning and Inspection

Tools Required

^ J 6125-1B Slide Hammer
^ J 7872 Magnetic Base Dial Indicator Set
^ J 41818 Crankshaft Bearing Cap Remover
^ J 43690 Rod Bearing Checking Tool
^ J 43690-100 Rod Bearing Checking Tool - Adapter Kit
^ J 45059 Angle Meter

Cleaning Procedure





1. Important: Use care when handling the crankshaft. Avoid damage to the bearing surfaces or the lobes of the crankshaft position reluctor ring. Damage to the teeth of the crankshaft position (CKP) reluctor ring may affect on-board diagnostics (OBD) II system performance.

Clean the crankshaft with solvent.
2. Thoroughly clean all oil passages and inspect for restrictions or burrs.

3. Caution: Refer to Safety Glasses Caution.

Dry the crankshaft with compressed air.

Inspection Procedure





1. Important: The reluctor ring teeth should not have imperfections on the rising or falling edges.

Imperfections of the reluctor ring teeth may affect OBD II system performance.
Perform a visual inspection of the crankshaft for damage.
2. Inspect the CKP reluctor ring lobes for damage.





3. Inspect the crankshaft journals for wear (1).Journals should be smooth with no signs of scoring, wear, or damage.
4. Inspect the crankshaft journals for grooves or scoring (2).
5. Inspect the crankshaft journals for scratches or wear (3).
6. Inspect the crankshaft journals for pitting or imbedded bearing material (4).





7. Inspect the crankshaft key (122), keyway (1), and threaded hole (2) for damage.





8. Measure the crankpins for the out-of-round.
9. Measure the crankpins for taper.





10. Measure the crankshaft thrust wall width.A crankshaft with a thrust wall width in excess of 26.2 mm (1.0315 inch) must be replaced.





11. Measure the crankshaft Runout wooden V-blocks or a fixture to support the crankshaft on the front and rear journals.
12. Use the J 7872 in order to measure the crankshaft runout at the front and rear intermediate journals.
13. Use the J 7872 in order to measure the runout of the crankshaft rear flange.
14. Use the J 7872 in order to measure the runout of the crankshaft position reluctor ring. Reluctor ring runout should be measured 1.0 mm (0.04 inch) below the ring teeth. If the reluctor ring has runout in excess of 0.7 mm (0.028 inch), replace the crankshaft.





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





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





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

Measuring Main Bearing Clearance - Gaging Plastic Method





1. Important:
^ The crankshaft main bearings are a precision insert type. Main bearing caps are machined with the engine block for proper clearance and cannot be shimmed or filed for bearing fit. If the clearances are found to be excessive, new bearings and/or engine block and cap repair or replacement may be required.
^ Do not rotate the crankshaft while gaging plastic is between the crankshaft journal and the bearing surface.
^ The crankshaft bearing clearances are critical. Excessive bearing clearance may affect crankshaft position sensor signals and may affect OBD II system operation.
^ Remove the bearing cap side bolts prior to cap removal.

Remove the bearing cap M8 side bolts.





2. Remove the bearing cap M10 bolts and studs.





3. Notice: Refer to Fastener Notice in Service Precautions.

Install the J 41818 to the bearing cap.
Tighten the J 41818 bolts to 11 Nm (100 inch lbs.).
4. Install the J 6125-1B to the J 41818 in order to remove the bearing cap.





5. Remove the bearing cap and lower bearing.





6. Install gaging plastic onto the crankshaft journal. Install the gaging plastic the full width of crankshaft bearing journal.





7. Install the bearing, bearing cap, bolts, and studs.
1. Tighten the M10 bolts (1-10) a first pass in sequence to 20 Nm (15 ft. lbs.).
2. Tighten the M10 bolts (1-10) a final pass in sequence to 80° using the J 45059.
3. Tighten the M10 studs (11-20) a first pass in sequence to 20 Nm (15 ft. lbs.).
4. Tighten the M10 studs (11-20) a final pass in sequence to 53° using the J 45059.
5. Tighten the M8 bolts to 25 Nm (18 ft. lbs.).Tighten the bolt on 1 side of the bearing cap and then tighten the bolt on the opposite side of the same bearing cap.





8. Important: Remove the bearing cap side bolts prior to cap removal.

Remove the bearing cap M8 bolts.





9. Remove the bearing cap M10 bolts and studs.





10. Use the J 41818 and the J 6125-1B in order to remove the bearing cap.





11. Measure the gaging plastic at its widest area using the scale supplied with the plastic gaging kit.
^ If the gaging plastic shows irregularity in the journal exceeding 0.025 mm (0.001 inch), remove the crankshaft and measure the journal with a micrometer.
^ If the bearing clearance is greater than 0.065 mm (0.0025 inch), select and install an undersized bearing set, and measure the clearance with gaging plastic.
^ If clearance cannot be brought to specifications, replace the crankshaft or grind the crankshaft for use with the next undersized bearing.





12. Measure the crankshaft end play.
1. Thrust the crankshaft forward or rearward.
2. Insert a feeler gage between the center crankshaft bearing and the bearing surface of the crankshaft and measure the bearing clearance. The proper crankshaft end play clearance is 0.04 - 0.2 mm (0.0015 - 0.0078 inch).
2. If the bearing clearance is not within specifications:
^ Inspect the thrust surfaces for nicks, gouges or raised metal. Minor imperfections may be removed with a fine stone.
^ Replace the thrust bearings and measure the end play.
^ If the correct measurements cannot be obtained, repair the crankshaft thrust surfaces or replace the crankshaft.

Measuring Connecting Rod Bearing Clearance - Gaging Plastic Method





1. Important:
^ Connecting rod bearings are a precision insert type. Connecting rods are of a powdered metal design and cannot be shimmed or filed for bearing fit. If clearances are found to be excessive, a new bearing and/or connecting rod are required.
^ Do not rotate the crankshaft while gaging plastic is between the crankshaft journal and the bearing surface.

Remove the bearing cap, bearing half and bolts.





2. Install the gaging plastic onto the connecting rod bearing journal. Install the gaging plastic the full width of the journal.





3. Install the bearing cap, bearing, and bolts.
1. Tighten the connecting rod bolts first pass to 20 Nm (15 ft. lbs.).
2. Tighten the connecting rod bolts a final pass to 75° using the J 45059. Refer to Piston, Connecting Rod, and Bearing Installation.
4. Remove the bearing cap, bearing, and bolts.





5. Measure the gaging plastic at its widest area using the scale supplied with the plastic gaging kit. The connecting rod bearing clearance should be 0.023 - 0.076 mm (0.0009 - 0.003 inch).

Measuring Connecting Rod Bearing Clearance - Using J 43690/J 43690-100
J 43690 and J 43690-100 have been developed as a more accurate method to measure connecting rod bearing clearances. The instructions below provide an overview of tool set-up and usage. For more detailed information, refer to the tool instruction sheets as supplied by the tool manufacturer.





^ J 43690 Rod Bearing Checking Tool
^ J 43690-20 Swivel Base (1)
^ J 43690-19 Dial Indicator (2)
^ J 43690-2 Base (3)
^ J 43690-5, J 43690-6 Handle (4)
^ J 43690-10, J 43690-11 Foot (5)
^ 280307 Screw (6)
^ J 43690-1 Pivot Arm Assembly (7)
^ J 43690-3, J 43690-7, J 43690-8 Screws (8)
^ 280319 Screw (9)
^ 280311 Screw (10)
^ J 43690-17, J 43690-18 Adapter (11)
^ 280310 Pin (12)





^ J 43690-100 Rod Bearing Checking Tool - Adapter Kit
^ J 43690-104 Spacer (1)
^ J 43690-105 Retainer Plate (2)
^ 505478 Bolt (3)
^ 511341 Bolt (4)
^ J 43690-106 Retainer Plate (5)
^ J 43690-107 Cap (6)
^ J 43690-102 Foot (7)
^ J 43690-101 Pivot Arm Assembly (8)
^ J 43690-103 Adapter (9)
^ 505439 Adapter (10)





1. Important: The crankshaft must be secure with no movement or rotation in order to obtain an accurate reading.

Rotate the crankshaft until the journal/connecting rod to be measured is in the 12 o'clock position.
2. Remove a bearing cap and bolts (1).
3. Remove the bearing half (2).
4. Insert a piece of paper card stock onto the crankshaft journal.
5. Install the bearing half (2) and cap and bolts (1). Refer to Fastener Tightening Specifications.





6. Install the following:
1. J 43690-2 (5)
2. J 43690-3 (4)
3. J 43690-101 (2)
4. 280310 (3)
5. J 43690-5 (1)





7. Install the swivel base (1) and dial indicator (2).
8. Adjust per the manufacturers instructions and measure the connecting rod bearing clearance. A connecting rod with a clearance in excess of 0.076 mm (0.003 inch) is considered excessive. Service components, as required.

Repair Instructions



Crankshaft Balancer Cleaning and Inspection





1. Clean the crankshaft balancer in solvent.
2. Clean the belt grooves of all dirt or debris with a wire brush.
3. Dry the crankshaft balancer with compressed air.
4. Inspect the crankshaft balancer for the following conditions:
^ Worn, grooved, or damaged hub seal surface A crankshaft balancer hub seal surface with excessive scoring, grooves, rust or other damage must be replaced. Minor imperfections on the hub seal surface may be removed with polishing compound or fine grade emery cloth.

^ Important: In order for the belt to track properly, the belt grooves should be free of all dirt or debris.

Dirty or damaged belt grooves The balancer belt grooves should be free of any nicks, gouges, or other damage that may not allow the belt to track properly. Minor imperfections may be removed with a fine file.
^ Worn, chunking or deteriorated rubber between the hub and pulley

Repair Instructions



Engine Flywheel Cleaning and Inspection





1. Important: In order to maintain the proper component balance, contact surface taper, and heat transfer, manual transmission flywheels are NOT to be machined.

Clean the flywheel in solvent.
2. Dry the flywheel with compressed air.
3. Inspect the manual transmission flywheel for the following conditions:
^ Pitted surfaces (1)
^ Grooves or scoring (2)
^ Rusted surface (3)
^ Damaged ring gear teeth (4)
^ Loose or improperly positioned ring gear The ring gear has an interference fit onto the flywheel and should be positioned completely against the flange of the flywheel.
^ Missing, bent, or damaged pressure plate locating pins The 2 locating pins are installed into the flywheel and spaced 170° apart.





4. Inspect the automatic transmission flex plate for the following conditions:
^ Damaged ring gear teeth
^ Stress cracks around the flex plate-to-crankshaft bolt hole locations

^ Important: Do not attempt to repair the welded areas that retain the ring gear to the flex plate. Install a new flex plate.

Welded areas that retain the ring gear onto the flex plate for cracking

Repair Instructions



Electric Machine Cleaning and Inspection





1. Caution: Refer to Safety Glasses Caution.

Clean the flex plate, stator, and rotor with compressed air.
2. Inspect the flex plate (1) for stress cracks around the flex plate-to-rotor bolt hole locations.
3. Inspect the stator for the following conditions:
^ Rust or corrosion at the electrical terminal connection or the electrical windings (2 and 3)
^ Scoring or gouging in the electrical winding surfaces (3)
^ Bent or damaged stator
^ Damage to the exterior of the housing and/or coolant jacket
4. Inspect the rotor for the following conditions:
^ Rust or corrosion of the electrical windings (4)
^ Scoring or gouging in the electrical winding surfaces
^ Bent or damaged rotor
^ Stress cracks around the rotor-to-crankshaft bolt hole locations (5)
5. Inspect the electrical terminal studs and the electrical connection for corrosion.

Repair Instructions



Piston and Connecting Rod Disassemble





1. Remove the connecting rod bearings from the rod and cap.





2. Using piston ring pliers, remove the piston rings from the piston.





3. Rotate the piston pin retainer until the ring end gap is positioned in the cutout area (1) of the pin bore.





4. Remove the retainers starting in the cutout area of the pin bore.





5. Remove the pin from the piston and connecting rod.
6. The piston and pin are a matched set and are not to be serviced separately. Mark, sort, or organize the piston and the matching piston pin.

Repair Instructions



Piston, Connecting Rod, and Bearings Cleaning and Inspection

Piston, Pin, and Piston Rings





1. Important:
^ Replace pistons, pins, and connecting rods that are damaged or show signs of excessive wear.
^ Do not wire brush any part of the piston.
^ Measurement of the components should be taken with the components at normal room temperature.

Clean the varnish and carbon from the piston (107) using cleaning solvent.

2. Caution: Refer to Safety Glasses Caution.

Dry the components with compressed air.





3. Clean the piston ring grooves with a suitable ring groove cleaning tool.
4. Clean the oil lubrication holes and slots.





5. Inspect the piston for the following conditions:
^ Cracks in the piston ring lands, the piston skirt, or pin bosses
^ Piston ring grooves for nicks, burrs, or warpage which may cause the piston ring to bind MINOR imperfections may be removed from the piston with a fine file.
^ Scuffed or damaged skirts (2)
^ Eroded areas at the top of the piston (1)
^ Scoring to the full-floating design piston pin bore (3) or piston pin





6. Insert the edge of the piston ring into the piston ring groove .Roll the piston ring completely around the piston. If binding is caused by distorted ring groove, MINOR imperfections may be removed with a fine file. If binding is caused by a distorted piston ring, replace the rings, as required.





7. Measure the piston ring side clearance with a feeler gage. If side clearance is not within specifications, try another piston ring. If the proper ring-to-groove clearance cannot be obtained, replace the piston, pin, and connecting rod assembly.





8. To determine piston pin-to-bore clearance, use a micrometer and measure the piston pin outside diameter (OD).





9. To determine the piston pin-to-bore clearance, use an inside micrometer and measure the piston pin bore inside diameter (ID).
10. Subtract the piston pin OD measurement from the piston pin bore ID measurement to determine pin-to-bore clearance. Refer to Engine Mechanical Specifications (LR4 VIN V) Engine Mechanical Specifications (LM7 VIN T) Engine Mechanical Specifications (L33 VIN B) Engine Mechanical Specifications (L59 VIN Z) Engine Mechanical Specifications (LQ4 VIN U) Engine Mechanical Specifications (LQ9 VIN N).

Measuring Piston Ring End Gap





1. Important:
^ Do not attempt to file the end of the piston ring to achieve the proper end gap clearance.
^ Measure the piston ring in the cylinder in which it will be used.

Place the piston ring into the cylinder bore 6.5 mm (0.25 inch) below the top of the ring travel area.
2. Insert a feeler gage and measure the piston ring end gap. Refer to Engine Mechanical Specifications (LR4 VIN V) Engine Mechanical Specifications (LM7 VIN T) Engine Mechanical Specifications (L33 VIN B) Engine Mechanical Specifications (L59 VIN Z) Engine Mechanical Specifications (LQ4 VIN U) Engine Mechanical Specifications (LQ9 VIN N).

Connecting Rod and Bearings





1. Important:
^ The powdered metal connecting rod and cap are machined for proper clearances. The connecting rod and cap must be used as an assembly with no repair or modifications to either mating surface. Do not attempt to repair the rod or cap. If service is required, replace the connecting rod as an assembly.
^ Do not attempt to repair the bolt hole threads of the connecting rod.

Clean the connecting rod (105) and cap (103) in solvent.

2. Caution: Refer to Safety Glasses Caution.

Dry the components with compressed air.





3. Inspect the connecting rod for the following conditions:
^ Twisting (1)
^ Proper fit of the connecting rod and cap mating surfaces (2)
^ Nicks or gouges in the bearing bore (3)
^ Damage to the bearing locating slots (4)





4. Measure the connecting rod bearing bore (1) for an out-of-round condition.





5. To determine full-floating piston pin-to-connecting rod bore clearance, use a micrometer and measure the piston pin OD.





6. To determine the full-floating piston pin-to-connecting rod bore clearance, use a micrometer and measure the connecting rod pin bore (1) ID.
7. Subtract the piston pin OD measurement from the connecting rod pin bore ID measurement to determine pin-to-bore clearance. Refer to Engine Mechanical Specifications (LR4 VIN V) Engine Mechanical Specifications (LM7 VIN T) Engine Mechanical Specifications (L33 VIN B) Engine Mechanical Specifications (L59 VIN Z) Engine Mechanical Specifications (LQ4 VIN U) Engine Mechanical Specifications (LQ9 VIN N).





8. Inspect the connecting rod bearings for craters or pockets. Flattened sections on the bearing halves indicate fatigue.





9. Inspect the connecting rod bearings for excessive scoring or discoloration.
10. Inspect the connecting rod bearings for dirt or debris imbedded into the bearing material.





11. Inspect the connecting rod bearings for improper seating indicated by bright, polished sections of the bearing surface.

Repair Instructions



Piston and Connecting Rod Assemble





1. Install the retainer. The retainer should be seated in the groove of the pin bore.





2. Assemble the piston and connecting rod. The mark (1) on the top of the piston and the tab (2) on the side of the connecting rod should be facing the same direction.





3. Install the piston pin to the piston and connecting rod.
4. Install the retainers. The retainers should be seated in the groove of the pin bore.





5. Important: When installing piston rings, use a ring expander plier type tool. Do not roll the rings into the grooves of the piston. Use caution and care to expand the rings only slightly larger than the outside diameter (OD) of the piston.

Using piston ring pliers, install the piston rings onto the piston. The dimple or mark on the piston ring should face the top of the piston. If no dimple or mark can be found on the top compression ring, it may be installed in either direction.
6. Position the oil control ring end gaps a minimum of 25 mm (1.0 inch) from each other.
7. Position the compression ring end gaps 180 degrees opposite each other.





8. Install the connecting rod bearings to the rod and cap.