GROUP

NUMBER

ENGINE

Technical Service Bulletin
SUBJECT:

DATE

21-EM-004H
MODEL(S)

MARCH 2021

APPLICABLE
VEHICLES BELOW

BEARING CLEARANCE TEST SERVICE PROCEDURE

Description: This bulletin provides the service procedure for engine connecting rod bearing
clearance testing. Perform the procedure outlined in this bulletin to fulfill the Bearing Clearance Test
inspection requirements to determine next required steps.
Applicable Vehicles:
 Certain models as indicated per separate TSB.
 This TSB fulfills its Inspection Procedure requirements for the engine Bearing Clearance Test.

SST Information
Part Name

Part Number / Figure

Note
Confirm the following pressures
meet requirements. The correct
ranges for AP/VC air pressures
are also indicated with red/blue
decals on the gauges:
Shop air supply:
50 psi minimum
AP: 0.1 ~ 0.11MPa
VC: -73 ~ -83Kpa
(Refer to TSB 20-GI-009H or
later for calibration procedure)

1
BEARING
CLEARANCE
TESTER SET
(BEARING TOOL)

2

3
(1) TEST HOSE (2) MAIN HOSE
(3) POWER SUPPLY CABLE
One BEARING CLEARANCE
TESTER SET provided to dealers.
(Additional units can be ordered.)

KQ231-2T110QQH
KQ231-2T100QQH

For Bearing Clearance Tester
software related issues, contact
GITA at: 888-437-0308
For Bearing Clearance Tester
hardware related issues, contact
Techline at: 800-325-6604
BEARING CLEARANCE
TESTER SET (BEARING TOOL)
(includes A - F)
(A) BODY

Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service
Advisors, Technicians, Body Shop Manager, Fleet Repair

SUBJECT:

BEARING CLEARANCE TEST SERVICE PROCEDURE

KQ231-2T101QQH
(B) SPARK PLUG ROD
(M12 for GD and Theta II MPI
Hybrid engines)

 Upper body portion is
smooth with no grooves.

KQ231-2T107QQH

(B) SPARK PLUG ROD
(M14 for MPI engines)

 2 machined identification
grooves on upper body.

KQ231-2T102QQH
KQ231-2T103QQH
KQ231-2T104QQH
KQ231-2T105QQH

(C) CRANK ROTATOR TOOL
(D) CLEARANCE GAUGE
(E) POWER SUPPLY CABLE
(F) TEST HOSE (AIR HOSE FOR
CLEARANCE GAUGE)

Service Procedure: Bearing Clearance Test
1. Connect the main hose (shop air supply) and
test hose to the bearing tool (with other end of
the test hose disconnected). (The power to the
bearing tool main unit is not necessary at this
time.)
Confirm the shop air pressure and AP/VC
pressures on the bearing tool meet
requirements. The correct ranges for AP/VC air
pressures are also indicated with red/blue
decals on the gauges. Using STUI in the GDS,
take and submit a picture of the gauges with
the pressure levels clearly visible and the VIN
in the background of the photo (RO or last 6
digits written on paper) for records.
Shop air supply: 50 psi minimum
TSB #: 21-EM-004H

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BEARING CLEARANCE TEST SERVICE PROCEDURE

AP/VC air pressure calibration check:
a) Connect the main air compressor hose.
b) Connect the test hose. (The other end of the
test hose should be left disconnected from
the spark plug rod.)
c) Confirm that the AP/VC toggle switch at top
is in the middle position.
d) Inspect the AP/C gauge indicators and
compare to the specification range:
 AP: 0.1 ~ 0.11MPa
 VC: -73 ~ -83Kpa

NOTICE
Do not continue if any of the above readings are out of specification range.
 Adjust shop air to consistently provide at least 50 PSI of air pressure or greater.
 Do not use a portable air compressor to perform the bearing clearance testing.
 Be sure to check that the shop air water separator is functioning correctly.
 If any of the AP/VC air pressure indications are out of the specified range,
recalibration of the Bearing Clearance Tester is required.
o Refer to latest instructions outlined in the Engine Bearing Clearance Tester
Calibration Procedure TSB 20-GI-009H or later for calibration procedure.

NOTICE
For Bearing Clearance Tester software related issues, contact GITA at: 888-437-0308
For Bearing Clearance Tester hardware related issues, contact Techline at: 800-325-6604

TSB #: 21-EM-004H

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BEARING CLEARANCE TEST SERVICE PROCEDURE

2. Remove the engine cover and the 4 ignition
coils.
Tightening Torque (ignition coils):
9.8 - 11.8 Nꞏm
(1.0 - 1.2 kgfꞏm, 7.2 - 8.7 Ibꞏft)

3. Remove the 4 spark plugs.
Tightening Torque:
14.7 - 24.5 Nꞏm
(1.5 - 2.5 kgfꞏm, 10.9 - 18.0 Ibꞏft)

4. Insert the appropriate (use M12 for GDI and
Theta MPI Hybrid engines or M14 for all other
MPI engines) spark plug rod SST (A) into
Cylinder #1 spark plug hole and turn until hand
tight. Insert the clearance gauge SST into the
spark plug rod and tighten using the thumb
screw.

A

NOTICE
DO NOT connect the test air hose to the
clearance gauge at this time.

5. Connect the GDS to the vehicle and turn the
ignition ‘ON’.
6. Swipe up on the ‘More’ tab at the bottom of
the GDS home screen. Select the ‘Special
Inspection’ function.
7. Enter the vehicle info into the GDS as
prompted then select ‘Next’.

TSB #: 21-EM-004H

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BEARING CLEARANCE TEST SERVICE PROCEDURE

8. Connect the GDS to the clearance gauge
SST (gauge) via Bluetooth:
 Press the “Set’ button (B) on the gauge
to turn it on.
 Press the “Set” (B) and “Mode” (C)
buttons at the same time for about 4 sec
until the “reset” message is displayed.
 Select the gauge in the list of devices on
the GDS. Select the ‘Refresh’ icon (D) if
the gauge doesn’t appear automatically.

D

NOTICE
C



If more than one device appears in
the list of devices, there is another
device in range. Move away from
the other device to pair the gauge.

B

Check that the ball point tip (E) of the
clearance gauge SST is securely installed to
the tool as shown. Do not continue if ball
point tip (E) is loose or missing.

NOTICE

E

If loose, apply Blue Loctite (or equivalent)
to the tip thread and retighten securely to
the gauge plunger.
9. Turn the ignition ‘OFF’ and remove the VCI.
10. Follow the instructions on the GDS to start the test and select ‘Next’.

NOTICE



For the following steps, the Crank Rotator Tool or a long handled wrench should be
used for moving the crankshaft slowly and precisely.
Ensure the test hose is disconnected from the clearance gauge when finding TDC
piston depth.

Please take note of the following crank/piston position definitions.

BTDC (Before Top Dead Center)

TDC (Top Dead Center)  Find TDC during the compression stroke.

ATDC (After Top Dead Center)
In the following steps, the TDC point for testing must be at MAX (piston height) value
minus 0.03mm as the crank has moved slightly into ATDC (from its TDC dwell point).
 If TDC is difficult to find, refer to Shop Manual Section Location: Engine Mechanical
System > Timing System > Timing Chain
TSB #: 21-EM-004H

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11. To find TDC compression (TDC), rotate the crankshaft with the crank rotator SST at least one
cycle (1/2 turn). (If the SST does not fit the specific vehicle type, remove the front passenger wheel
and wheel liner or underbody tray as needed to rotate the crankshaft using standard shop tools.)

IMPORTANT



For the step below, the engine must be rotated SLOWLY using the crank rotator SST.
o Abrupt or erratic movements may cause improper TDC setup and test errors.
Do NOT stop rotating the engine before reaching MAX TDC, especially during the
initial rotation towards TDC where the value may be at 0mm and change all the
sudden.
o Be sure to find TDC correctly by slowly and slightly nudging the engine a little
more to verify no change in value to confirm that the piston is at MAX TDC.

 Monitor the piston height value on GDS screen
or the clearance gauge SST while rotating the
engine clockwise using the Crank Rotator Tool.
 Rotate the engine SLOWLY as the value
increases towards a MAX value. (BTDC 
TDC)
 When the value changes direction
(increasing/BTDC  TDC 
decreasing/ATDC), stop rotating the crank
when the piston height is at MAX value
minus 0.03mm.

NOTICE
The testing point is slightly towards ATDC
from TDC when the piston has moved
down 0.03mm from its highest position.
12. Select ‘Next’ when TDC is found.
 Ideal set point for testing from TDC is found
when the maximum value minus 0.03mm is
reached on the clearance gauge SST (F).
 The value is also displayed on the GDS.

F

13. Once the set point for bearing testing is found,
select ‘Start’ in the GDS screen and proceed
directly to the next step below.
 Do not turn the crank rotator SST until
instructed to do so.

NOTICE
The value at TDC varies depending on the
specific vehicle and engine type.
TSB #: 21-EM-004H

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14. Connect the test hose (1) to the spark plug rod
SST and to the bearing tool SST.

15. Connect the SST power cables to a fully
charged 12V battery or to an external AC/DC
power supply.
 Turn the bearing tool SST power switch
‘ON’.

NOTICE

*** Bearing Tool SST Power Check ***
a) Supply 12 volts (or an alternate external AC/DC 13.8 volt power supply with at least ~2
amp output) to the power cable (3) connected to the bearing tool SST.
b) Turn power switch to ON.
c) Toggle AP/VC transfer switch between AP VC.
 The solenoids should “click” while switching between AP/VC when the unit is ON.
 If the solenoids are not switching, then check the power cable or the power supply.

16. Locate the AP/VC switch on the bearing
tool SST and switch it to the AP Position.
17. Follow the instructions on the GDS to test
each cylinder. Cylinder #1 is checked first.
 The cylinders will be checked per the
engine firing order: #1→#3→#4→#2.
18. On the bearing tool SST, change the AP/VC
switch to the VC position when instructed by
the GDS.

TSB #: 21-EM-004H

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NOTICE
If the bearing measurement value does
not change when the AP/VC is
switched or the “Unable to measure”
message appears on the GDS, rotate
the crankshaft further as the exhaust
valves could be open. Set the
crankshaft to TDC again (Step 11).
Ensure the test hose is disconnected
from the clearance gauge SST when
finding TDC.

19. Continue following the instructions on the GDS to
complete the bearing inspection. Check the engine oil
level and select the level in the GDS.

20. If the test result is “PASS”:
a) Save a screenshot of the results screen.
b) Reinstall all components in the reverse order
of removal.
c) Check for DTCs and perform the appropriate
diagnostic service. Ensure no warning lights
are present to complete the procedure.

TSB #: 21-EM-004H

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If the test result is “NO PASS”:
a) Save a screenshot of the results screen.
b) Submit PA for engine replacement
approval.
c) Follow remainder of the separate
reference TSB to complete the service
procedure.
d) Check for DTCs and perform the
appropriate diagnostic service. Ensure
no warning lights are present to
complete the procedure.

NOTICE
PA Approval is required whenever an engine replacement is required. Submit PA and refer
to the applicable Dealer Best Practices guide for the latest requirements for engine
approval.

TSB #: 21-EM-004H

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