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Home >> Chevrolet >> 2009 >> HHR SS, Standard >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 3 (Engine Mechanical - 2.2L Or 2.4L) >> Repair Instructions - Off Vehicle >> Engine Block Cleaning and Inspection >> Cleaning & Inspection Procedure

Cleaning & Inspection Procedure

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    Fig 1: View Of Cleaning Sealing Material From Gasket Mating Surfaces
    GM2146315Courtesy of GENERAL MOTORS CORP.
  1. Clean the sealing material from the gasket mating surfaces (2) with a suitable tool (1).
  2. Clean the engine block and lower crankcase in a cleaning tank with solvent appropriate for aluminum.
  3. Flush the engine block with clean water or steam.
  4. Clean the oil passages.
  5. Clean the blind holes.
  6. Spray the cylinder bores and the machined surfaces with engine oil.
  7. Inspect the threaded holes. Clean the threaded holes with a rifle brush. If necessary, drill out the holes and install thread inserts. Refer to Thread Repair .
    8. Fig 2: Checking Deck Surface For Flatness
    GM2146316Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not attempt to machine the lower crankcase to engine block surfaces.
  8. Use a straight edge (1) and a feeler gage (2) to check the deck surface for flatness. Carefully machine minor irregularities. Replace the block if more than 0.254 mm (0.010 in) must be removed.
  9. Inspect the oil pan rail for nicks. Inspect the front cover attaching area for nicks. Use a flat mill file to remove any nicks.
    10. Fig 3: View Of Cleaning Sealing Material From Gasket Mating Surfaces On Lower Crankcase Engine Block Side
    GM2146317Courtesy of GENERAL MOTORS CORP.
  10. Clean the sealing material from the gasket mating surfaces on the lower crankcase engine block side with a suitable tool (1).
    11. Fig 4: View Of Cleaning Sealing Material From Gasket Mating Surfaces On Lower Crankcase Oil Pan Side
    GM2146318Courtesy of GENERAL MOTORS CORP.
  11. Clean the sealing material from the gasket mating surfaces on the lower crankcase oil pan side with a suitable tool (1).
    12. Fig 5: Inspecting Mating Surfaces Of Transmission Face
    GM2146319Courtesy of GENERAL MOTORS CORP.
  12. Inspect the mating surfaces of the transmission face.
    13. CAUTION: A broken flywheel may result if the transmission case mating surface is not flat.
  13. Use the following procedure in order to measure the engine block flange runout at the mounting bolt hole bosses:
    1. Temporarily install the crankshaft and upper bearings. Measure the crankshaft flange runout using the EN-7872:  dial indicator (1)
    2. Hold the gage plate flat against the crankshaft flange.
    3. Place the dial indicator stem on the transmission mounting bolt hole boss. Set the indicator to 0.
    4. Record the readings obtained from all of the bolt hole bosses. The measurements should not vary more than 0.203 mm (0.008 in).
    5. Recheck the crankshaft flange runout if the readings vary more than 0.203 mm (0.008 in).
    6. Remove the crankshaft and bearings.
    14. Fig 6: Measuring Bearing Bore
    GM2146320Courtesy of GENERAL MOTORS CORP.
  14. Install the bed plate and bolts. Tighten the bed plate bolts to specification.
  15. Inspect the crankshaft main bearing bores. Use the EN-8087:  gage (1) to measure the bearing bore concentricity and alignment. Refer to Engine Mechanical Specifications (2.2L)  or Engine Mechanical Specifications (2.4L) .
  16. Replace the engine block and bed plate if the crankshaft bearing bores are out of specification.
  17. Remove the bed plate.
    18. Fig 7: Inspect Cylinder Bores Using Special Tool EN-8087 Gage
    GM2146321Courtesy of GENERAL MOTORS CORP.
  18. Inspect the cylinder bores using the EN-8087:  gage (1). Inspect for the following items:
    • Wear
    • Taper
    • Runout
    • Ridging
  19. If the cylinder bores are out of specification, install a NEW cylinder bore sleeve. Refer to Cylinder Sleeve Removal (2.2L)  or Cylinder Sleeve Removal (2.4L )  and Cylinder Sleeve Installation (2.2L)  or Cylinder Sleeve Installation (2.4L) .
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