(9) If bearing-to-journal clearance exceeds the
specification, install a pair of 0.0254 mm (0.001 inch)
undersize bearing inserts. All the odd size inserts
must be on the bottom. The sizes of the service
replacement bearing inserts are stamped on the
backs of the inserts. Measure the clearance as
described in the previous steps.
(10) The clearance is measured with a pair of
0.0254 mm (0.001 inch) undersize bearing inserts
installed. This will determine if two 0.0254 mm
(0.001 inch) undersize inserts or another combination
is needed to provide the correct clearance (refer to
Connecting Rod Bearing Fitting Chart).
CONNECTING ROD BEARING FITTING CHART
CRANKSHAFT JOURNAL CORRESPONDING ROD BEARING INSERT
Color Code Diameter Upper Insert Size Lower Insert Size
Yellow
53.2257 - 53.2079 mm
Yellow - Standard Yellow - Standard
(2.0955 - 2.0948 in.)
Orange
53.2079 - 53.1901 mm
Yellow - Standard
Blue - Undersize(2.0948 - 2.0941 in.)
0.0178 mm (0.0007 in.) 0.025 mm (0.001 in.)
Undersize
Blue
53.1901 - 53.1724 mm
Blue - Undersize Blue - Undersize(2.0941 - 2.0934 in.)
0.0356 mm (0.0014 in.) 0.025 mm (0.001 in.) 0.025 mm (0.001 in.)
Undersize
Red
52.9717 - 52.9539 mm
Red - Undersize Red - Undersize(2.0855 - 2.0848 in.)
0.254 mm (0.010 in.) 0.254 mm (0.010 in.) 0.254 mm (0.010 in.)
Undersize
(11) FOR EXAMPLE: If the initial clearance was
0.0762 mm (0.003 inch), 0.025 mm (0.001 inch)
undersize inserts would reduce the clearance by
0.025 mm (0.001 inch). The clearance would be 0.002
inch and within specification. A 0.051 mm (0.002
inch) undersize insert would reduce the initial clear-
ance an additional 0.013 mm (0.0005 inch). The
clearance would then be 0.038 mm (0.0015 inch).
(12) Repeat the Plastigage measurement to verify
your bearing selection prior to final assembly.
(13) Once you have selected the proper insert,
install the insert and cap. Tighten the connecting rod
bolts to 45 N·m (33 ft. lbs.) torque.
SIDE CLEARANCE MEASUREMENT
Slide snug-fitting feeler gauge between the con-
necting rod and crankshaft journal flange (Fig. 34).
Refer to Engine Specifications for the proper clear-
ance. Replace the connecting rod if the side clearance
is not within specification.
Fig. 33 Measuring Bearing Clearance with
Plastigage
1 – PLASTIGAGE SCALE
2 – COMPRESSED PLASTIGAGE
9 - 82 4.0L ENGINE XJ
SERVICE PROCEDURES (Continued)
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