CLEANING AND INSPECTION

1. Inspect the crankshaft for any signs of scoring or cracks and for clogged oil passages. Also, inspect for signs of discoloration which indicate overheating has occurred. Clogged oil passages must be cleaned in a solvent tank or with solvent and brushes (steam cleaning is not a suitable alternative). After the crankshaft is removed from the solvent, it must be flushed with fresh water, dried completely and coated with a generous film of clean engine oil. Inspect the crankshaft for scoring and minor scratching. This type of surface damage means that the crankshaft should be machined and undersize bearings installed; cracks may indicate the shaft must be replaced. Consult a competent machine shop in the case of the latter two problems. If work on the crankshaft is suspended for any length of time, fabricate a set of wood V-blocks to support the crankshaft.

   Fig. 1: With the crankshaft mounted in V-blocks, run-out can be checked using a dial gauge

   Fig. 2: If you prefer, run-out can instead be checked with the crankshaft mounted in the engine block

   Fig. 3: Position the dial indicator against the crankshaft's center main bearing journal

2. Support the crankshaft in metal V-blocks, mount a dial indicator on the center journal, and zero it. Now, rotate the crankshaft 360 degrees to check for runout. The reading of the indicator should not exceed 0.0012 in. (0.03mm) on the 1.5L, 1.6L and 2.2L engines, or 0.0016 in. (0.04mm) on the 3.0L engine. If it does, the crankshaft must be replaced.

   NOTE: If V-blocks are not available, the crankshaft run-out may instead be checked with the shaft installed in the engine block.

3. Using a caliper, check the diameters of all main journals and crankpins, in four places, as shown. If they are worn past the limit, they must be ground and undersize bearings installed. In addition, on 1981–89 engines, determine the elliptical measurement for each bearing journal by subtracting the smallest reading from the largest. This elliptical limit for both the main and rod journals is 0.0020 in. (0.05mm). If the wear is elliptical beyond the limit, the crankshaft must be machined and undersize bearings installed, regardless of the total wear.

   NOTE: If the crankshaft is machined, the rolled fillet area must not be removed. Make sure the machinist is aware of the fillet "R'' dimension of 0.12 in. (3mm)s.

   Fig. 4: Turn the crankshaft slowly by hand while checking the dial gauge for run-out

   Fig. 5: Measure all the crankshaft wear surface diameters

   Fig. 6: Each wear surface should be measured at four places, including two perpendicular readings

   Fig. 7: If the crankshaft must be machined, do not disturb the rolled fillet areas

   In addition, on 1983–87 2.0L engines, you must measure the front and rear oil seal sliding surface diameters. The rear seal surface must measure 3.5412–3.5434 in. (89.9–90.0mm). The front oil pump body assembly seal surface must measure 1.3371–1.3386 in. (33.96–34.00mm). Both must also be within the elliptical limit described above.

4. Inspect the bearings for scoring, flaking, grooving, bluish color (due to heat), partial elimination of the overlay (appearance of a different color in certain areas), or a polished appearance. Replace if any such indications appear.