JCB 55Z-1, 57C-1 Mini Excavator Service Repair Manual Instant Download (Perkins Engine)

1
Foreword
SERVICE MANUAL 55Z-1, 57C-1 EN -
9813/6250 - ISSUE 1 - 03/2016 This
manual contains original instructions, verified
by the manufacturer (or their authorized
representative). Copyright 2016 JCB
SERVICE All rights reserved. No part of this
publication may be reproduced, stored in a
retrieval system, or transmitted in any form or
by any other means, electronic, mechanical,
photocopying or otherwise, without prior
permission from JCB SERVICE. www.jcb.com
The Operator's Manual
You and others can be killed or seriously injured
if you operate or maintain the machine without
first studying the Operator's Manual. You must
understand and follow the instructions in the
Operator's Manual. If you do not understand
anything, ask your employer or JCB dealer to
explain it.
Do not operate the machine without an Operator's
Manual, or if there is anything on the machine
you do not understand.
Treat the Operator's Manual as part of the
machine. Keep it clean and in good condition.
Replace the Operator's Manual immediately if it
is lost, damaged or becomes unreadable.
Contents 01 - Machine
03 - Attachments and Options
06 - Body and Framework
09 - Operator Station
12 - Heating, Ventilating and Air- Conditioning
(HVAC)
15 - Engine 18 - Fuel and Exhaust System 21 -
Cooling System
27 - Driveline
30 - Hydraulic System
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
78 - After Sales
2
15 - Engine 30 - Valve 00 - General
00 - General
Introduction
Introduction .....................................
............... 15-79 Technical Data
...............................................
15-80 Component Identification ...................
............ 15-82 Operation ....................
................................... 15-82 Check
(Condition) ......................................
.... 15-83 Adjust ................................
............................ 15-85 Remove and
Install .......................................
15-87
The valve train system opens and closes the
valves with correct timing in relation to the
piston movements. The valve train system
controls the flow of air into the cylinders and
out of the cylinders during engine operation.
The cylinder head assembly has two valves for
each cylinder. Each valve has one valve spring.
The ports for the inlet valve and the exhaust
valve are on the left side of the cylinder head.
Each push rod has one end in a valve tappet and
the other end under a rocker arm. The valves
extend through the cylinder head. The valves are
made from a special metal to provide a long
service life. Damaged or worn valves cannot be
lapped or reground and must be replaced with new
ones. Each valve stem has an oil seal. The Valve
seat inserts are pressed into the cylinder head.
The seat inserts are also made from a special
metal to provide for a long service life. Damaged
or worn valve seat inserts can be removed and
replaced with new ones. The valve moves along a
steel valve guide. These valve guides are
installed in the cylinder head and can be
replaced.
9813/6250-1
15 - 79
3
15 - Engine 30 - Valve 00 - General
Technical Data Table 53.
Description Data Data
Description Standard Service limit
Contact face exhaust valve Refer to Figure 122. 1.942.16mm 2.5mm
Contact face in- let valve Refer to Figure 122. 1.52mm 2.5mm
Description Data Data
Description Inlet valve Exhaust valve
Number of valves per cylin- der 1 1
Valve lash 0.2mm 0.2mm
Valve guide seal Black garter spring with a la- bel "EX" Silver garter spring
Valve seat an- gle Refer to Fig- ure 122. 45 45
Figure 118.
A
C

B
D
Table 54.
F
Description Data Data
Description Standard Service limit
Valve spring free length 35mm 33.5mm
Valve spring test force 79N 68.6N
Valve spring length under test force 30.4mm -
Clearance be- tween the ex- haust valve and the valve guide Refer to Figure 119. 0.050.075mm 0.25mm
Clearance be- tween the in- let valve and the valve guide Refer to Figure 119. 0.030.06mm 0.2mm
Diameter of the exhaust valve stem 6.946.955mm 6.84mm
Diameter of the inlet valve stem 6.9556.97mm 6.89mm
Thickness of the valve head Refer to Figure 120. 0.925 1.075mm 0.5mm
Valve depth be- low the cylinder head face Refer to Figure 121. 0.650.95mm 1.8mm
E
H
G

• Valve spring
• Exhaust valve guide seal
• Inlet valve guide seal D Valve spring recesses
  E Exhaust valve guide F Inlet valve guide
• Exhaust valve stem
• Inlet valve stem

9813/6250-1
15 - 79
4
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15 - Engine 30 - Valve 00 - General
Figure 119.
Figure 122.
L
M
J

1. Valve seat angle
2. Contact face

J Valve - valve guide clearance Figure 120.
N N Valve head thickness Figure 121. K
K Valve depth
6
15 - Engine 30 - Valve 00 - General
Component Identification
Operation
Figure 123.
The inlet valve and the exhaust valve are opened
and closed by the rotation and movement of the
following components
B
A
D

• Crankshaft
• Idler gear
• Camshaft
• Valve tappets
• Push-rods
• Rocker arms
• Valve springs

C
F
E
H
The camshaft drive gear is driven by the idler
gear at half the speed of the crankshaft. The
camshaft gear, the idler gear and the crankshaft
gear are timed together. The camshaft lobes, two
for each cylinder, (operating exhaust and inlet
valves) actuate the valve tappets.
J
L
When the camshaft rotates the cam lobes act on
the tappets. The push rods act on the rockers
which pivot on the camshaft.
G
K

• Collets
• Valve spring retainer
• Valve spring D Valve seal E Valve guide
• Cylinder head
• Cylinder head gasket
• Push-rod
• Tappet
• Exhaust valve
• Inlet valve

Each valve has a compression spring. The function
of the spring is to close the valve and at the
same time return the rocker arm and push rod to
ensure that the tappets follow the camshaft
lobes. The spring is located on the valve stem
by a retainer and collets.
Figure 124.
B
A
D
C
F
E
H
J
L
G
K

• Collets
• Valve spring retainer
• Valve spring D Valve seal E Valve guide
• Cylinder head
• Cylinder head gasket
• Push-rod

7
15 - Engine 30 - Valve 00 - General
Check (Condition)

1. Tappet
2. Exhaust valve
3. Inlet valve

Valve Lash Setting The valve lash setting given
below is applicable only when the engine is
cold. Table 55.
Inlet valve 0.2 0.05mm
Exhaust valve 0.2 0.05mm

• Valve Lash Inspection
• If the valve lash requires adjustment several
  times in a short period of time, excessive wear
  exists in a different part of the engine. You
  must repair the problem to prevent further
  damage to the engine.
• Not enough valve lash can cause rapid wear of the
  camshaft and the valve tappets. Not enough valve
  lash can indicate that the valve seats are worn.
  The valves become worn due to the following
  causes
• Incorrect operation of the fuel injectors.
• Excessive dirt and oil are present in the inlet
  air filter.
• Incorrect fuel settings on the fuel injection
  pump.
• The load capacity of the engine is frequently
  exceeded.
• The excessive valve lash can cause broken valve
  stems, springs and the spring retainers. This
  excessive valve lash can be an indication of the
  following problems
• Worn camshaft and valve tappets.
• Worn rocker arms.
• Bent push-rods.
• Broken socket on the upper end of a push-rod.
• Loose the adjustment screw for the valve lash.
• If the camshaft and valve tappets show rapid
  wear, look for fuel in the lubrication oil or
  dirty lubrication oil as a possible cause.
• The valve lash is measured between the top of
  the valve stem and the rocker arm lever.
• Remove the rocker cover and perform the
  adjustment procedure to adjust the valve lash.
  Refer to (PIL 15-30).
• Inspect the valves for the cracks and other
  damage.

8
15 - Engine 30 - Valve 00 - General

• Valve Depth Check
• Use the DTI (Dial Test Indicator) with the DTI
  holder to check the depths of the inlet valves
  and the exhaust valves below the face of the
  cylinder head.
• Use the cylinder head face to zero the DTI.
• Position the DTI holder and the DTI and measure
  the valve depth.
• Figure 125.
• A
• B

• DTI
• DTI holder
• Measure the depth of the inlet valve and the
  exhaust valve before the valve springs are
  removed.
• Make sure that the valve depth is within the
  specified limits. Refer to Valve- Technical Data
  (PIL 15-30).
• If the valve depth below the cylinder head face
  exceeds the service limit, replace the valve and
  check the valve depth.
• If the valve depth still exceeds the service
  limit, renew the cylinder head or if installed,
  renew the valve seat inserts.

9
15 - Engine 30 - Valve 00 - General
Adjust
Valve Lash Adjustment

• The "Single dot" on the crankshaft pulley is the
  reference point for the TDC (Top Dead Centre)
  position of No. 1 and No. 4 cylinders.
• The "Middle dot" on the crankshaft pulley is the
  TDC reference point for No. 2 and No. 3
  cylinders.
• Check the valve lash of the inlet valve and the
  exhaust valve of the No. 1 cylinder.
• If necessary, make an adjustment as follows
• Loosen the locknut from the adjustment screw.
• Place the appropriate feeler gauge between the
  rocker arm and the valve.

• Make the machine safe. Refer to (PIL 01-03).
• Remove the timing gear front case. Refer to (PIL
  15-51).
• Rotate the crankshaft in a clockwise direction
  (viewed from the front of the engine).
• When the inlet valve of the No. 4 cylinder has
  started to open and the exhaust valve of the No.
  4 cylinder has not completely closed, make sure
  that the "Top" mark on the timing case aligns
  with the "Single dot" on the crankshaft pulley.
• Figure 126.

F
E

1. Single dot on crankshaft pulley
2. Middle dot on crankshaft pulley

10
15 - Engine 30 - Valve 00 - General
Figure 127. B C D
A
A Feeler gauge C Locknut
B Adjusting screw D Rocker arm

• Hold the locknut and turn the adjustment screw.
• Adjust the valve lash until the correct
  specification is achieved.
• After each adjustment, hold the adjusting screw
  and tighten the locknut.
• Rotate the crankshaft in a clockwise direction to
  the specified angle.
• Angle 180
• When the inlet valve of the No. 2 cylinder has
  started to open and the exhaust valve of the No.
  2 cylinder has not completely closed, make sure
  that the "Top" mark on the timing case aligns
  with "Middle dot" on the crankshaft pulley.
• Check the valve lash of the inlet valve and the
  exhaust valve of the No. 3 cylinder. If
  necessary, do the step 6

• Check the valve lash of the inlet valve and the
  exhaust valve of the No. 4 cylinder. If
  necessary, do the step 6
• Rotate the crankshaft in a clockwise direction to
  the specified angle.
• Angle 180
• When the inlet valve of the No. 3 cylinder has
  started to open and the exhaust valve of the No.
  3 cylinder has not completely closed, make sure
  that the "Top" mark on the timing case aligns
  with "Middle dot" on the crankshaft pulley.
• Check the valve lash of the inlet valve and the
  exhaust valve of the No. 2 cylinder. If
  necessary, do the step 6
• Install the timing gear front case. Refer to (PIL
  15-51).

• Rotate the crankshaft in a clockwise direction to
  the specified angle.
• Angle 180
• When the inlet valve of the No. 1 cylinder has
  started to open and the exhaust valve of the No.
  1 cylinder has not completely closed, make sure
  that the "Top" mark on the timing case aligns
  with "Single dot" on the crankshaft pulley.

11
15 - Engine 30 - Valve 00 - General
Remove and Install
WARNING Personal injury can result from being
struck by parts propelled by a released spring
force. Make sure to wear all necessary protective
equipment. Follow the recommended procedure and
use all recommended tools to release the spring
force. WARNING The valve spring keepers can be
thrown from the valve when the valve spring
compressor is released. Make sure that the valve
spring keepers are properly installed on the
valve stem. To help prevent personal injury,
keep away from the front of the valve spring
keepers and valve springs during the
installation of the valves.

1. Check the depth of the valves below the face of
   the cylinder head before you remove the valve
   springs.
2. Mark the heads of the valves to help
   installation. Do not stamp the heads of the
   valves, this can cause the valves to fracture.
3. Compress the valve spring with the valve spring
   compressor tool.
4. Make sure that you compress the valve spring
   squarely or damage to the valve stem may occur.
5. Remove the valve keepers.

1. Do not compress the valve spring so that the
   valve spring retainer touches the valve stem
   seal.
2. Remove the valve spring compressor tool.
3. Remove the valve spring retainer.
4. Remove the valve spring.
5. Remove the valve.
6. Remove the valve stem seal.
7. Do the step 7 to step 15 for the remaining valves.

Remove

1. Make the machine safe. Refer to (PIL 01-03).
2. Make sure that the engine is safe to work on. If
   the engine has been running, let it cool before
   you start the service work.
3. Remove the cylinder head. Refer to (PIL 15-06).
4. Clean the bottom face of the cylinder head.

Figure 128.
A B
A B
C
C
G
D
F E
A Valve keeper C Valve spring E Valve G Valve
spring compressor tool
B Spring retainer D Valve stem seal F Cylinder
head
12
15 - Engine 30 - Valve 00 - General
Install

1. Install the valve spring into the cylinder head.
   Position the valve spring retainer on the valve
   spring.
2. Compress the valve spring with the valve spring
   compressor tool.
3. Make sure that you compress the valve spring
   squarely or damage to the valve stem may occur.
4. Install the valve keepers.
5. Remove the valve spring compressor tool.
6. Do the step 7 to step 13 for the remaining
   valves.
7. Keep the cylinder head on a suitable support.
8. Make sure that the heads of the valves are not
   obstructed.
9. Gently hit the top of the valves with a soft
   hammer and make sure that the valve keepers are
   correctly installed.
10. Install the cylinder head. Refer to (PIL 15-06).

• Clean all components of the cylinder head
  assembly.
• Make sure that all ports, all coolant passages
  and all lubrication passages in the cylinder
  head are free from debris.
• Do the step 3.1 to step 3.5 to inspect the
  components of the cylinder head assembly.
  Replace any components that are worn or damaged.
• Check the condition of the cylinder head. Refer
  to (PIL 15-06).
• Check the condition of the valve seats.
• Check the condition of the valve guide. Refer to
  (PIL 15-30).
• Check the condition of the valves.
• Check the condition of the valve spring. Make
  sure that its length is correct.
• Make sure that the outer face of the valve guide
  is clean and dry.
• Install the new valve stem seals on each of the
  valve guides with the valve stem seal
  installation tool.
• Figure 129.

H
D

• D Valve stem seal
• H Valve stem seal installation tool
• Lubricate the valve stem with clean engine oil.
• Install the valve in the correct position in the
  cylinder head.
• Check the depth of the valve below the face of
  the cylinder head. Refer to (PIL 15-30).

13
15 - Engine 30 - Valve 12 - Valve Spring
12 - Valve Spring Remove and Install WARNING
Personal injury can result from being struck by
parts propelled by a released spring force. Make
sure to wear all necessary protective equipment.
Follow the recommended procedure and use all
recommended tools to release the spring
force. WARNING The valve spring keepers can be
thrown from the valve when the valve spring
compressor is released. Make sure that the valve
spring keepers are properly installed on the
valve stem. To help prevent personal injury,
keep away from the front of the valve spring
keepers and valve springs during the
installation of the valves.

1. Do not turn the crankshaft when the valve springs
   are removed.
2. Slowly release the pressure on the tool1.
3. Remove the valve spring retainer and remove the
   valve spring.

10. Remove the tool1 and the tool2. Figure 130.
A B
C
D
E
Remove

1. Make the machine safe. Refer to (PIL 01-03).
2. Make sure that the engine is safe to work on. If
   the engine has been running, let it cool before
   you start the service work.
3. Remove the rocker shaft assembly. Refer to (PIL
   15-42).
4. Make sure that the appropriate piston is at TDC
   (Top Dead Centre) before you remove the valve
   spring.
5. Position the appropriate piston at TDC as
   follows
6. Install the tool1 and tool2 in position on the
   cylinder head to compress the valve spring.
7. Compress the valve spring with the tool1 and
   open the valve slightly.
8. Do not compress the spring so that the valve
   spring retainer touches the valve stem seal.
9. Rotate the crankshaft carefully until the piston
   touches the valve.
10. Do not use excessive force to turn the
    crankshaft. The use of force can bend the valve
    stems.
11. Continue to rotate the crankshaft and gradually
    release the pressure on tool1 until the piston
    is at TDC. The valve is now held in position
    that allows the valve spring to be safely
    removed.
12. Make sure that you compress the valve spring
    squarely or you may damage the valve stem.
13. Compress the valve spring with the tool1 and
    remove the valve keepers.

• A Valve keepers B Spring retainer C Valve
  spring
• Tool1
• Tool2

Install
1. The installation procedure is the opposite of
the removal procedure.
9813/6250-1
15 - 89
14
15 - Engine 30 - Valve 15 - Valve Guide
15 - Valve Guide Check (Condition)

1. Make sure that the clearance of the valve in the
   valve guide is within the specified limit. Refer
   to Valve- Technical data (PIL 15-30).
2. If the clearance of the valve in the valve guide
   is within the specified limit, replace the valve
   guide. Refer to (PIL 15-30).

• Make the machine safe. Refer to (PIL 01-03).
• Make sure that the engine is safe to work on. If
  the engine has been running, let it cool before
  you start the service work.
• Remove the cylinder head. Refer to (PIL 15-06).
• Place a new valve in the valve guide.
• Place the DTI (Dial Test Indicator) with the
  magnetic base on the face of the cylinder head.
• Lift the edge of the valve head to the specified
  distance.
• Length/Dimension/Distance 15mm
• Move the valve in a radial direction away from
  the DTI.
• Make sure that the valve moves away from the DTI
  as far as possible.
• Figure 131.

A
E
D
B C

• Valve guide
• Radial movement of the valve in the valve guide
• Valve stem
• DTI
• Valve head
• Position the contact point of the DTI on the
  edge of the valve head.
• Set the position of the needle of the DTI to
  zero.
• Move the valve in a radial direction towards the
  DTI as far as possible.
• Make a note of the distance of movement which is
  indicated on the DTI.

9813/6250-1
15 - 89
15
15 - Engine 33 - Connecting Rod 00 - General
Technical Data
Figure 132.
Table 56. Diameter of connecting rod bearing
journal
Journals Diameter Service limit
Standard 51.964 51.975mm 51.9mm
Undersize 0.25mm 51.714 51.725mm 51.65mm
Undersize 0.5mm 51.464 51.475mm 51.4mm
B
A
D
If the diameter of the connecting rod bearing
journal is less than the maximum undersize
service limit, then the crankshaft must be
replaced. Table 57. Clearances
Description Data Data
Description Standard clearance Service limit
Clearance be- tween the con- necting rod bearing and the connecting rod bearing journal 0.035 0.085mm 0.2mm
Clearance be- tween the pis- ton pin and the piston pin bear- ing 0.010.025mm 0.1mm
Clearance be- tween the con- necting rod bore and the connecting rod bearing 0.10.3mm 0.7mm
C
E

• Connecting rod
• Piston pin bearing
• Connecting rod bearing
• Bolt
• Nut
• Table 58. Torque Values

Item Description Nm
D Bolt 52
9813/6250-1
15 - 94
16
15 - Engine 33 - Connecting Rod 00 - General
Component Identification
Calibrate
Figure 133.
This procedure determines the following
characteristics of the connecting rod

• The distortion of the connecting rod.
• The parallel alignment of the bores of the
  connecting rod.
• Make sure that you use the correct gauges and
  measuring pins to measure the distances for the
  connecting rod.
• Remove the connecting rod bearing before you
  take the measurements.
• Measure the connecting rod for distortion and
  parallel alignment between the bores.
• The measurements must be taken at a specified
  distance from the connecting rod. Refer to
  Figure 135.
• Distance 100mm
• Figure 135.

F
A
G
H

• A Piston
• Connecting rod
• Piston pin
• Piston pin retainer
• Figure 134.

G
G
F
F
E
D
F

• Connecting rod
• Measuring pins
• Distance from the connecting rod (100mm)
• Length (Should not be more than 0 0.08mm)
• 3.2. The total difference in measurements of
  length from each side should not vary more than
  the specified.
• Length 0 0.08mm
• Inspect the piston pin bearing and the piston pin
  for wear and other damage.
• Measure the clearance of the piston pin in the
  piston pin bearing.

K
L
M
N
F Connecting rod K Connecting rod bearing (Upper
half) L Connecting rod bearing (Lower half) M
Connecting rod cap N Nut
9813/6250-1
15 - 94
17
15 - Engine 33 - Connecting Rod 00 - General
Remove and Install
Disassemble and Assemble
The removal and installation procedure for one
piston and connecting rod assembly is exactly the
same. Refer to Piston- Remove and Install (PIL
15-36).
The disassemble and assemble procedure for one
piston and connecting rod assembly is exactly the
same. Refer to Piston- Disassemble and Assemble
(PIL 15-36).
9813/6250-1
15 - 94
18
15 - Engine 33 - Connecting Rod 06 - Big-End
Bearing
06 - Big-End Bearing
Introduction
Introduction .....................................
............... 15-97 Check (Condition)
..........................................
15-98 Remove and Install .........................
.............. 15-98
In a piston engine, the big-end bearings are the
bearings at the big-end of the connecting rod.
9813/6250-1
15 - 94
19
15 - Engine 33 - Connecting Rod 06 - Big-End
Bearing
Check (Condition)
Remove and Install

1. Check the bearing shell surfaces for signs of
   damage and excessive wear.
2. Measure the crank pin diameters to confirm they
   are within service limits, refer to Technical
   Data (PIL 15-33).
3. Renew any parts that are worn or not within the
   specified tolerances.

If all of the connecting rod bearings require
replacement on a four cylinder engine, the
procedure can be carried out two cylinders at
the same time. The procedure can be carried out
on the following pairs of cylinders

• 1 and 4 cylinders.
• 2 and 3 cylinders.

• Make sure that both pairs of the connecting rod
  bearings are installed before changing from one
  pair of cylinders to another pair of cylinders.
• The connecting rod and the connecting rod cap
  should have matching identification numbers. If
  necessary, make a temporary mark on the
  connecting rod and on the connecting rod cap.
• Remove (Connecting rods in position)
• Remove the suction pipe. Refer to (PIL 15-60).
• Rotate the crankshaft until the piston is at the
  BDC (Bottom Dead Centre).
• Remove the nuts and the connecting rod cap from
  the connecting rod.
• Remove the lower connecting rod bearing from the
  connecting rod cap.
• Carefully push the connecting rod into the
  cylinder bore.
• Remove the upper connecting rod bearing from the
  connecting rod.
• Apply tape or rubber tubing on the connecting
  rod bolts to protect the crankshaft journals. The
  sharp edges of the connecting rod bolts could
  damage the crankshaft journals.

9813/6250-1
15 - 94
20
15 - Engine 33 - Connecting Rod 06 - Big-End
Bearing
Figure 136.

1. Install the lower connecting rod bearing to the
   connecting rod cap.
2. Lubricate the pin of the crankshaft and the lower
   connecting rod bearing with clean engine oil.
3. Install the connecting rod cap.
4. Install the nuts. Tighten the nuts to the correct
   torque value.
5. Make sure that the installed connecting rod
   assembly has tactile side play. Carefully rotate
   the crankshaft in order to ensure that there is
   no binding.
6. Install the suction pipe. Refer to (PIL 15-60).

A
B
C
D
G
Install (Connecting rods off the position)
F
E

1. Check the clearance between the connecting rod
   bearing and the connecting rod bearing journal
   of the crankshaft. Install the connecting rod
   bearings dry when the clearance checks are made.
2. Clean the bearing surface of the connecting rod
   and the connecting rod cap.
3. Make sure that the identification number on the
   connecting rod cap aligns with the identification
   number on the connecting rod.
4. Clean the upper connecting rod bearing and
   lubricate the bearing face with clean engine oil.
5. Clean the lower connecting rod bearing and
   lubricate the bearing face with clean engine oil.
6. Align the tabs on the back of the connecting rod
   bearings with the tab grooves in the connecting
   rod and the tab grooves on the connecting rod
   cap.
7. Install the upper connecting rod bearing to the
   connecting rod.
8. Position the connecting rod against the
   crankshaft.
9. Install the lower connecting rod bearing in the
   connecting rod cap.

• Connecting rod
• Connecting rod bolt
• Upper connecting rod bearing D Lower connecting
  rod bearing E Connecting rod cap
• Nut
• Identification mark

Install (Connecting rods in position)

1. Inspect the pins of the crankshaft for damage.
   If the crankshaft is damaged, replace the
   crankshaft or recondition the crankshaft. Refer
   to (PIL 15-12).
2. Make sure that the connecting rod bearings are
   clean and free from wear or damage. If
   necessary, replace the connecting rod bearings.
   Refer to (PIL 15-33).
3. Clean the bearing surface of the connecting rod
   and the connecting rod cap.
4. Make sure that the identification number on the
   connecting rod cap aligns with the identification
   number on the connecting rod.
5. Install the upper connecting rod bearing to the
   connecting rod.
6. Lubricate the bearing surface of the connecting
   rod bearing with clean engine oil.
7. Carefully pull the connecting rod against the
   crankshaft pin.
8. Apply tape or rubber tubing on the connecting
   rod bolts to protect the crankshaft journals. The
   sharp edges of the connecting rod bolts could
   damage the crankshaft journals.
9. Clean the connecting rod cap.

1. Install the connecting rod cap in position on
   the connecting rod and install the nuts to the
   connecting rod bolts.
2. Tighten the nuts to the correct torque value.
3. Make sue that the identification marks must face
   to the right of the engine for the correct
   installation.
4. Install the suction pipe. Refer to (PIL 15-60).

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15 - Engine 33 - Connecting Rod 06 - Big-End
Bearing
14. Install the engine oil sump. Refer to (PIL
15-45). Table 59. Torque Values
Item Description Nm
F Nut 52
15 - 100
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