the best service manual

1. 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
Foreword
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
15 - 79 9813/6250-1 15 - 79
00 - General
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
Introduction
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.

3. 15 - Engine
30 - Valve
00 - General
15 - 80 9813/6250-1 15 - 80
Technical Data
Table 53.
DataDescription
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°
Table 54.
DataDescription
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.
0.05–0.075mm 0.25mm
Clearance be-
tween the in-
let valve and
the valve guide
Refer to Figure
119.
0.03–0.06mm 0.2mm
Diameter of the
exhaust valve
stem
6.94–6.955mm 6.84mm
Diameter of the
inlet valve stem
6.955–6.97mm 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.
0.65–0.95mm 1.8mm
DataDescription
Standard Service limit
Contact face
exhaust valve
Refer to Figure
122.
1.94–2.16mm 2.5mm
Contact face in-
let valve Refer
to Figure 122.
1.5–2mm 2.5mm
Figure 118.
A
B
D
E
G
C
F
H
A Valve spring
B Exhaust valve guide seal
C Inlet valve guide seal
D Valve spring recesses
E Exhaust valve guide
F Inlet valve guide
G Exhaust valve stem
H Inlet valve stem

4. 15 - Engine
30 - Valve
00 - General
15 - 81 9813/6250-1 15 - 81
Figure 119.
J
J Valve - valve guide clearance
Figure 120.
N
N Valve head thickness
Figure 121.
K
K Valve depth
Figure 122.
L
M
L Valve seat angle
M Contact face

5. 15 - Engine
30 - Valve
00 - General
15 - 82 9813/6250-1 15 - 82
Component Identification
Figure 123.
A
E
L
C
G
D
F
J
K
H
B
A Collets
B Valve spring retainer
C Valve spring
D Valve seal
E Valve guide
F Cylinder head
G Cylinder head gasket
H Push-rod
J Tappet
K Exhaust valve
L Inlet valve
Operation
The inlet valve and the exhaust valve are opened and
closed by the rotation and movement of the following
components:
• Crankshaft
• Idler gear
• Camshaft
• Valve tappets
• Push-rods
• Rocker arms
• Valve springs
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.
When the camshaft rotates the cam lobes act on the
tappets. The push rods act on the rockers which pivot
on the camshaft.
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.
A
E
L
C
G
D
F
J
K
H
B
A Collets
B Valve spring retainer
C Valve spring
D Valve seal
E Valve guide
F Cylinder head
G Cylinder head gasket
H Push-rod

6. 15 - Engine
30 - Valve
00 - General
15 - 83 9813/6250-1 15 - 83
J Tappet
K Exhaust valve
L Inlet valve
Check (Condition)
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.
1. If the camshaft and valve tappets show rapid
wear, look for fuel in the lubrication oil or dirty
lubrication oil as a possible cause.
2. The valve lash is measured between the top of
the valve stem and the rocker arm lever.
3. Remove the rocker cover and perform the
adjustment procedure to adjust the valve lash.
Refer to (PIL 15-30).
4. Inspect the valves for the cracks and other
damage.
5. Check the valve stems for wear.
6. Check that the valve springs are the correct
length under the test force. Refer to Valve-
Technical Data (PIL 15-30).

7. 15 - Engine
30 - Valve
00 - General
15 - 84 9813/6250-1 15 - 84
Valve Depth Check
1. 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.
2. Use the cylinder head face to zero the DTI.
3. Position the DTI holder and the DTI and measure
the valve depth.
Figure 125.
A
B
A DTI
B DTI holder
4. Measure the depth of the inlet valve and the
exhaust valve before the valve springs are
removed.
5. Make sure that the valve depth is within the
specified limits. Refer to Valve- Technical Data
(PIL 15-30).
5.1. If the valve depth below the cylinder head
face exceeds the service limit, replace the
valve and check the valve depth.
5.2. If the valve depth still exceeds the service
limit, renew the cylinder head or if installed,
renew the valve seat inserts.

8. 15 - Engine
30 - Valve
00 - General
15 - 85 9813/6250-1 15 - 85
Adjust
Valve Lash Adjustment
1. Make the machine safe. Refer to (PIL 01-03).
2. Remove the timing gear front case. Refer to (PIL
15-51).
3. Rotate the crankshaft in a clockwise direction
(viewed from the front of the engine).
4. 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.
FE
E Single dot on crankshaft pulley
F Middle dot on crankshaft pulley
4.1. 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.
4.2. The "Middle dot" on the crankshaft pulley is
the TDC reference point for No. 2 and No.
3 cylinders.
5. Check the valve lash of the inlet valve and the
exhaust valve of the No. 1 cylinder.
6. If necessary, make an adjustment as follows:
6.1. Loosen the locknut from the adjustment
screw.
6.2. Place the appropriate feeler gauge between
the rocker arm and the valve.

9. 15 - Engine
30 - Valve
00 - General
15 - 86 9813/6250-1 15 - 86
Figure 127.
A
D
C
B
A Feeler gauge B Adjusting screw
C Locknut D Rocker arm
6.3. Hold the locknut and turn the adjustment
screw.
6.4. Adjust the valve lash until the correct
specification is achieved.
6.5. After each adjustment, hold the adjusting
screw and tighten the locknut.
7. Rotate the crankshaft in a clockwise direction to
the specified angle.
Angle: 180°
8. 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.
9. Check the valve lash of the inlet valve and the
exhaust valve of the No. 3 cylinder. If necessary,
do the step 6
10. Rotate the crankshaft in a clockwise direction to
the specified angle.
Angle: 180°
11. 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.
12. Check the valve lash of the inlet valve and the
exhaust valve of the No. 4 cylinder. If necessary,
do the step 6
13. Rotate the crankshaft in a clockwise direction to
the specified angle.
Angle: 180°
14. 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.
15. Check the valve lash of the inlet valve and the
exhaust valve of the No. 2 cylinder. If necessary,
do the step 6
16. Install the timing gear front case. Refer to (PIL
15-51).

10. 15 - Engine
30 - Valve
00 - General
15 - 87 9813/6250-1 15 - 87
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.
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.
5. Check the depth of the valves below the face of
the cylinder head before you remove the valve
springs.
6. Mark the heads of the valves to help installation.
Do not stamp the heads of the valves, this can
cause the valves to fracture.
7. Compress the valve spring with the valve spring
compressor tool.
8. Make sure that you compress the valve spring
squarely or damage to the valve stem may occur.
9. Remove the valve keepers.
10. Do not compress the valve spring so that the
valve spring retainer touches the valve stem seal.
11. Remove the valve spring compressor tool.
12. Remove the valve spring retainer.
13. Remove the valve spring.
14. Remove the valve.
15. Remove the valve stem seal.
16. Do the step 7 to step 15 for the remaining valves.
Figure 128.
A
B
C
D
E
F
G
A
B
C
A Valve keeper B Spring retainer
C Valve spring D Valve stem seal
E Valve F Cylinder head
G Valve spring compressor tool

11. 15 - Engine
30 - Valve
00 - General
15 - 88 9813/6250-1 15 - 88
Install
1. Clean all components of the cylinder head
assembly.
2. Make sure that all ports, all coolant passages and
all lubrication passages in the cylinder head are
free from debris.
3. 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.
3.1. Check the condition of the cylinder head.
Refer to (PIL 15-06).
3.2. Check the condition of the valve seats.
3.3. Check the condition of the valve guide.
Refer to (PIL 15-30).
3.4. Check the condition of the valves.
3.5. Check the condition of the valve spring.
Make sure that its length is correct.
4. Make sure that the outer face of the valve guide
is clean and dry.
5. 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
6. Lubricate the valve stem with clean engine oil.
7. Install the valve in the correct position in the
cylinder head.
8. Check the depth of the valve below the face of
the cylinder head. Refer to (PIL 15-30).
9. Install the valve spring into the cylinder head.
Position the valve spring retainer on the valve
spring.
10. Compress the valve spring with the valve spring
compressor tool.
11. Make sure that you compress the valve spring
squarely or damage to the valve stem may occur.
12. Install the valve keepers.
13. Remove the valve spring compressor tool.
14. Do the step 7 to step 13 for the remaining valves.
15. Keep the cylinder head on a suitable support.
16. Make sure that the heads of the valves are not
obstructed.
17. Gently hit the top of the valves with a soft
hammer and make sure that the valve keepers
are correctly installed.
18. Install the cylinder head. Refer to (PIL 15-06).

12. 15 - Engine
30 - Valve
12 - Valve Spring
15 - 89 9813/6250-1 15 - 89
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.
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:
5.1. Install the tool1 and tool2 in position on the
cylinder head to compress the valve spring.
5.2. Compress the valve spring with the tool1
and open the valve slightly.
5.3. Do not compress the spring so that the
valve spring retainer touches the valve stem
seal.
5.4. Rotate the crankshaft carefully until the
piston touches the valve.
5.5. Do not use excessive force to turn the
crankshaft. The use of force can bend the
valve stems.
5.6. 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.
5.7. Make sure that you compress the valve
spring squarely or you may damage the
valve stem.
6. Compress the valve spring with the tool1 and
remove the valve keepers.
7. Do not turn the crankshaft when the valve springs
are removed.
8. Slowly release the pressure on the tool1.
9. Remove the valve spring retainer and remove the
valve spring.
10. Remove the tool1 and the tool2.
Figure 130.
A
B
C
D
E
A Valve keepers
B Spring retainer
C Valve spring
D Tool1
E Tool2
Install
1. The installation procedure is the opposite of the
removal procedure.

13. 15 - Engine
30 - Valve
15 - Valve Guide
15 - 90 9813/6250-1 15 - 90
15 - Valve Guide
Check (Condition)
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. Place a new valve in the valve guide.
5. Place the DTI (Dial Test Indicator) with the
magnetic base on the face of the cylinder head.
6. Lift the edge of the valve head to the specified
distance.
Length/Dimension/Distance: 15mm
7. Move the valve in a radial direction away from
the DTI.
7.1. Make sure that the valve moves away from
the DTI as far as possible.
Figure 131.
D E
C
B
A
A Valve guide
B Radial movement of the valve in the
valve guide
C Valve stem
D DTI
E Valve head
7.2. Position the contact point of the DTI on the
edge of the valve head.
7.3. Set the position of the needle of the DTI to
zero.
8. Move the valve in a radial direction towards the
DTI as far as possible.
9. Make a note of the distance of movement which
is indicated on the DTI.
9.1. 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).
9.2. If the clearance of the valve in the valve
guide is within the specified limit, replace
the valve guide. Refer to (PIL 15-30).

14. 15 - Engine
33 - Connecting Rod
00 - General
15 - 94 9813/6250-1 15 - 94
Technical Data
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
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
DataDescription
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
0.01–0.025mm 0.1mm
Clearance be-
tween the con-
necting rod
bore and the
connecting rod
bearing
0.1–0.3mm 0.7mm
Figure 132.
D
A
E
C
B
A Connecting rod
B Piston pin bearing
C Connecting rod bearing
D Bolt
E Nut
Table 58. Torque Values
Item Description Nm
D Bolt 52

15. 15 - Engine
33 - Connecting Rod
00 - General
15 - 95 9813/6250-1 15 - 95
Component Identification
Figure 133.
A
G
H
F
A Piston
F Connecting rod
G Piston pin
H Piston pin retainer
Figure 134.
F
K
L
N
M
F Connecting rod
K Connecting rod bearing (Upper half)
L Connecting rod bearing (Lower half)
M Connecting rod cap
N Nut
Calibrate
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.
1. Make sure that you use the correct gauges and
measuring pins to measure the distances for the
connecting rod.
2. Remove the connecting rod bearing before you
take the measurements.
3. Measure the connecting rod for distortion and
parallel alignment between the bores.
3.1. The measurements must be taken at a
specified distance from the connecting rod.
Refer to Figure 135.
Distance: 100mm
Figure 135.
D
F F GG
E
D Connecting rod
E Measuring pins
F Distance from the connecting rod
(100mm)
G 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
4. Inspect the piston pin bearing and the piston pin
for wear and other damage.
5. Measure the clearance of the piston pin in the
piston pin bearing.

16. 15 - Engine
33 - Connecting Rod
00 - General
15 - 96 9813/6250-1 15 - 96
Remove and Install
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).
Disassemble and Assemble
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).

17. 15 - Engine
33 - Connecting Rod
06 - Big-End Bearing
15 - 97 9813/6250-1 15 - 97
06 - Big-End Bearing
Introduction .................................................... 15-97
Check (Condition) .......................................... 15-98
Remove and Install ....................................... 15-98
Introduction
In a piston engine, the big-end bearings are the
bearings at the big-end of the connecting rod.

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19. 15 - Engine
33 - Connecting Rod
06 - Big-End Bearing
15 - 98 9813/6250-1 15 - 98
Check (Condition)
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.
Remove and Install
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)
1. Remove the suction pipe. Refer to (PIL 15-60).
2. Rotate the crankshaft until the piston is at the
BDC (Bottom Dead Centre).
3. Remove the nuts and the connecting rod cap
from the connecting rod.
4. Remove the lower connecting rod bearing from
the connecting rod cap.
5. Carefully push the connecting rod into the
cylinder bore.
6. Remove the upper connecting rod bearing from
the connecting rod.
7. 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.

20. 15 - Engine
33 - Connecting Rod
06 - Big-End Bearing
15 - 99 9813/6250-1 15 - 99
Figure 136.
A
B
G
C
D
F
E
A Connecting rod
B Connecting rod bolt
C Upper connecting rod bearing
D Lower connecting rod bearing
E Connecting rod cap
F Nut
G 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.
10. Install the lower connecting rod bearing to the
connecting rod cap.
11. Lubricate the pin of the crankshaft and the lower
connecting rod bearing with clean engine oil.
12. Install the connecting rod cap.
13. Install the nuts. Tighten the nuts to the correct
torque value.
14. 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.
15. Install the suction pipe. Refer to (PIL 15-60).
Install (Connecting rods off the position)
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.
10. Install the connecting rod cap in position on
the connecting rod and install the nuts to the
connecting rod bolts.
11. Tighten the nuts to the correct torque value.
12. Make sue that the identification marks must
face to the right of the engine for the correct
installation.
13. Install the suction pipe. Refer to (PIL 15-60).

21. 15 - Engine
33 - Connecting Rod
06 - Big-End Bearing
15 - 100 9813/6250-1 15 - 100
14. Install the engine oil sump. Refer to (PIL 15-45).
Table 59. Torque Values
Item Description Nm
F Nut 52