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Pistons and Connecting Rods: Section 12 - Base Engine

The document provides instructions for removing and replacing pistons and connecting rods. It includes labeled diagrams and lists the necessary tools and torque specifications. The procedure involves removing bearing caps and shells from the connecting rods and inspecting components for wear before replacing.

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Ali Zerifi
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16 views1 page

Pistons and Connecting Rods: Section 12 - Base Engine

The document provides instructions for removing and replacing pistons and connecting rods. It includes labeled diagrams and lists the necessary tools and torque specifications. The procedure involves removing bearing caps and shells from the connecting rods and inspecting components for wear before replacing.

Uploaded by

Ali Zerifi
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
Download as pdf or txt
Download as pdf or txt
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Section 12 - Base Engine

Pistons and Connecting Rods


Big End Bearing
Table 1. Component Identification Removal
K Fig 1. ( T 12-43), K Fig 3. ( T 12-43)
1 Bearing cap 1 It is recommended that the big end bearing caps are
removed in pairs, cylinders 1 and 4 and cylinders 2
2 Bearing cap fixing bolts (2 off) and 3. Rotate the crankshaft so that the big end
3 Connecting rod bearing caps on cylinders 2 and 3 are positioned as
shown. Undo bolts 2 and lift off the bearing caps 1
4 Big end bearing shell - upper
from the connecting rods 3. Note that the bolts MUST
5 Big end bearing shell - lower NOT be re-used. Discard the bolts 2.
X Cast pip
Important: The connecting rod and bearing cap have
Y Fracture split surfaces
been fracture split and must be kept together as a set.
Utmost care must be taken to avoid contamination and / or
Table 2. Service Parts damage to the fracture split surfaces Y.
P1 Sealing compound
P2 Bearing cap fixing bolts 2 Lift out the bearing shells 5 from the caps 1. Carefully
rotate the crank to disengage from the connecting
P3 Big end bearing shells rods and gain access to the upper bearing shells 4.
Lift out the upper bearing shells. It is recommended
Table 3. Service Tools that the shells are renewed. If however they are to be
Item Part Number Description reused, label the shells to ensure they are refitted in
T1 General Star drive socket their original positions on assembly.

T2 General Torque wrench 3 Carefully rotate the crankshaft to position the big end
T3 General Angle gauge bearing caps of cylinders 1 and 4. Make sure that the
crank does not foul the connecting rods of cylinders 2
Table 4. Torque Settings and 3. Remove the bearing caps and bearing shells
as described in steps 1 and 2 of Removal.
Item Nm lbf ft Angle
2 35 25.8 - 1st stage Inspection
65 47.9 - 2nd stage
1 Check the bearing shell surfaces for signs of damage
- - +90° Final stage
and excessive wear.

Before Removing 2 Measure the crank pin diameters to confirm they are
within service limits, see Section 1 Technical Data.
1 This procedure requires service parts. Make sure you
have obtained the correct service parts before you Replacement
start, see Service Parts.
Replacement is the reverse of removal but note the
2 Disconnect and remove the fuel lines from the following:
injectors, see Section 7 Fuel System - Fuel Lines.
1 Ensure that all items are clean and free from damage
3 Remove the rocker cover, see Rocker Cover - and corrosion.
Removal and Replacement.
2 Fit the upper bearing shell 4 to the connecting rod 3.
4 Remove the fuel injectors, see Section 7 Fuel Lubricate the bearing shell with clean engine oil.
System - Fuel Injectors (Atomisers).
3 Fit the lower bearing shell 5 to the bearing cap 1.
5 Drain the oil from the engine, see Section 3 Routine Lubricate the bearing shell with clean engine oil, then
Maintenance. fit the bearing cap to the connecting rod. Ensure that
the cast pip X on the bearing cap faces to the front of
6 Remove the oil pan, see Section 9 Lubrication the engine.
System - Oil Pan.
Note: Use compressed air to clean the fracture surfaces Y
7 Position the engine upside down in a suitable jig or before assembly.
fixture, supported at the front of cylinder block.
4 Renew the fixing bolts. Torque tighten new bolts 2 in
three stages, K Table 4. Torque Settings
( T 12-44).

12-44 9806/4300-1 12-44

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