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