Measuring Bearing Clearance Using Plastigage

The engine crankshaft bearing clearances can be determined by the use of a Plastigage or equivalent. The following is the recommended procedure for the use of the Plastigage:





1. Remove any oil film from the surface to be checked. The Plastigage will dissolve in oil.
2. Place a piece of the Plastigage (1) across the entire width of the bearing shell in the cap approximately 1/4 inch (6.35 mm) off center, and away from the oil holes (In addition, suspected areas can be checked by placing the Plastigage in the suspected area). Torque the bearing cap bolts of the bearing being checked to the proper torque specifications.
3. Remove the bearing cap and compare the width of the flattened Plastigage with the metric scale provided on the package of the Plastigage. Locate the band closest to the same width. This band shows the amount of clearance in thousandths of a millimeter. Differences in readings between the ends indicate the amount of taper present. Record all the readings taken. Compare the clearance measurements to the specifications found in the engine specifications. Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric scale.

Note: Plastigage is available in a variety of clearance ranges. Use the most appropriate range for the specifications you are checking.

4. Install the proper crankshaft bearings to achieve the specified bearing clearances.


REMOVAL
1. Disconnect the negative battery cable.
2. Remove the air cleaner housing assembly.
3. Drain the cooling system.
4. Remove the radiator with the radiator fan.
5. Remove the accessory drive belt.





6. Remove the mass air flow sensor.
7. Disconnect the vacuum hoses at the vacuum booster, the intake manifold, and the purge valve.
8. Remove the oil from the power steering pump reservoir.
9. Disconnect the ground lead at the power steering pump.





10. Disconnect the pressure (2) and return (1) lines from the power steering pump.





11. Relieve the fuel pressure at the service valve (1) on the fuel rail.





12. Disconnect the fuel supply line (1) at the fuel rail.
13. Disconnect the engine wire harness.
14. Raise and support the vehicle.





15. Remove the lower splash shield screws (1) and the splash shield.
16. Drain the engine oil.
17. Remove the propeller shaft.





18. Disconnect the ground cable (1) at the transmission.





19. Disconnect the backup lamp switch harness connector (1) (with manual transmission).
20. Disconnect the transmission wire harness connector and the shift selector cable (with automatic transmission).





21. Disconnect the pressure line (1) from the clutch slave cylinder (manual transmission only).
22. Remove the pressure line retaining bolt (2) and position the pressure line aside.
23. Disconnect the reverse lockout cable.





24. Disconnect the shift rod (1) from the ball stud (2) (manual transmission only).
25. Disconnect the starter harness connectors.





26. Remove the front engine mount bolt (1).





27. Remove the lower radiator hose (1) and the coolant bypass hose (2) from the water pump.
28. Lower the vehicle.





29. Remove the upper radiator hose (1) from the thermostat housing.
30. Disconnect the heater hoses at the intake manifold and the engine block.
31. Remove the A/C compressor mounting bolts.
32. Position the A/C compressor aside with lines attached.





33. Position a floor jack under the transmission and raise the transmission slightly.
34. Remove the transmission mount bolts (1), the crossmember bolts (2) and the transmission mount with crossmember.





35. Attach the engine lifting device to the engine lifting eyes.
36. Lower the rear of the transmission with the floor jack.
37. Remove the engine and transmission assembly from the vehicle.
38. Separate the engine and transmission.





39. Remove the clutch if equipped.
40. Remove the flywheel bolts (1), the spacer (2) and the flywheel (3).
41. Mount the engine on an engine stand.


INSTALLATION
1. Attach the lifting device to the engine lifting eyes.
2. Remove the engine from the engine stand.
3. Install the flywheel.
4. Install the clutch if equipped.
5. Install the transmission to the engine.
6. Install the starter.
7. Position the engine and transmission in the vehicle on the front axle carrier with the transmission resting on the floor jack.
8. Raise the transmission with the floor jack.





9. Install the transmission mount with crossmember. Install the transmission mount bolts (1) and the crossmember bolts (2)
10. Raise and support the vehicle.





11. Install the front engine mount bolt (1).
12. Tighten the crossmember to body bolts to 40 Nm (30 ft. lbs.).
13. Tighten the transmission mount to transmission bolts to 50 Nm (36 ft. lbs.).
14. Tighten the engine mount to front axle carrier bolts to 55 Nm (41 ft. lbs.).
15. Bolt on the A/C compressor.





16. Connect the shift rod (1) to the ball stud (2). Connect the reverse lockout cable. (manual transmission).





17. Connect the pressure line (1) to the clutch slave cylinder. Install the pressure line retainer bolt (2) and tighten to 15 Nm (11 ft. lbs.) (manual transmission).





18. Connect the backup lamp switch harness connector (1) (manual transmission). Connect the transmission wire harness connector and the shift selector cable (automatic transmission).





19. Bolt on the ground cable at the transmission and tighten to 40 Nm (30 ft. lbs.).
20. Install the propeller shaft.





21. Connect the lower radiator hose (1) and the coolant bypass hose (2) at the water pump.





22. Install the lower splash shield (2). Tighten the screws (1) to 5 Nm (44 in. lbs.).
23. Lower the vehicle.
24. Connect the heater hoses at the engine block and the intake manifold.





25. Connect the upper radiator hose (1) at the thermostat housing.
26. Connect the engine wire harness.





27. Connect the fuel supply line (1) at the fuel rail. Tighten the fitting to 38 Nm (28 ft. lbs.).





28. Connect the power steering pressure (2) and return line (1) to the power steering pump. Tighten the high pressure fitting to 45 Nm (33 ft. lbs.).
29. Connect the ground lead at the power steering pump. Tighten the bolt to 25 Nm (18 ft. lbs.).
30. Refill the power steering pump fluid reservoir.
31. Connect the vacuum hoses at the purge valve, brake booster and intake manifold.
32. Install and connect the mass air flow sensor.





33. Install the accessory drive belt.
34. Install and connect the radiator with the radiator fan.
35. Install the air cleaner.
36. Connect the negative battery cable.
37. Fill the cooling system.
38. Fill the engine with engine oil.
39. Start the engine and check for leaks.
40. Recheck all fluid levels.