Replace all connecting rod bearing shells
Preliminary work
- Refer to REMOVING THE COMPLETE FRONT AXLE WITH THE ENGINE AND TRANSMISSION .
- Refer to REMOVING THE ENGINE FROM THE FRONT AXLE .
- Refer to INSTALLING THE ENGINE ON THE ASSEMBLY JIG .
- Refer to RELEASING THE OIL DRAIN PLUG .
- Refer to TIGHTENING THE OIL DRAIN PLUG .
- Refer to REMOVING CHARGE AIR LINE .
- Refer to REMOVING ACOUSTIC COVER AT REAR .
- Refer to REMOVING ALL IGNITION COILS .
- Refer to REMOVING ALL SPARK PLUGS .
- Refer to REMOVING THE HIGH PRESSURE LINE BETWEEN THE HIGH PRESSURE PUMP AND THE RAIL .
- Refer to REMOVING HIGH PRESSURE PUMP .
- Refer to REMOVING THE HIGH-PRESSURE RAIL WITH INJECTORS OF CYLINDERS 1 TO 3 .
- Refer to REMOVING THE HIGH-PRESSURE RAIL WITH INJECTORS OF CYLINDERS 4 TO 6 .
- Refer to REMOVING BOTH ACTUATORS .
- Refer to REMOVING THE CYLINDER HEAD COVER .
- Refer to REMOVING TANK VENT VALVE .
- Refer to REMOVING THE INTAKE PLENUM .
- Refer to REMOVING THE LAMBDA OXYGEN SENSOR .
- Refer to REMOVING THE OXYGEN SENSOR MONITOR .
- Refer to REMOVING CATALYTIC CONVERTER .
- Refer to REMOVING THE OIL RETURN LINE FOR THE EXHAUST TURBOCHARGER .
- Refer to REMOVING THE COOLANT LINE BETWEEN THE COOLANT PUMP AND CYLINDER HEAD .
- Refer to BLOCKING ENGINE IN TDC FIRING POSITION .
- Refer to REMOVING CHAIN TENSIONER .
- Refer to RELEASING THE VANOS CENTRAL VALVE OF THE INTAKE ADJUSTER .
- Refer to RELEASING VANOS CENTRAL VALVE OF THE EXHAUST CAMSHAFT ADJUSTER .
- Refer to REMOVING THE VANOS CENTRAL VALVE OF THE INTAKE ADJUSTER .
- Refer to REMOVING THE VANOS CENTRAL VALVE OF THE EXHAUST CAMSHAFT ADJUSTER .
- Refer to REMOVING INTAKE ADJUSTER .
- Refer to REMOVING EXHAUST CAMSHAFT ADJUSTER .
- Refer to REMOVING THE TEST GAUGES FOR SECURING THE CAMSHAFTS .
- Refer to REMOVING THE CYLINDER HEAD .
- Refer to REMOVING THE CYLINDER HEAD GASKET .
- Refer to REMOVING FRONT AXLE DIFFERENTIAL .
- Refer to REMOVING OIL SUMP .
- Refer to REMOVING BEARING BRACKET .
- Refer to REMOVING OIL PUMP .
- Refer to REMOVING THE OIL DEFLECTOR .
- Refer to REMOVING ALL THE PISTONS WITH THE CONNECTING ROD .
Engine damage caused by incorrectly installed bearing shells and bearing brackets .
If the bearing shells and bearing brackets are installed incorrectly, then engine damage can occur .
- Always install all bearing shells and bearing brackets in the same position from which they were removed.
Piston, piston pin, connecting rod and connecting rod bearing shells are matched to each other and balanced.
Always install the pistons, piston pins, connecting rods and connecting rod bearing shells in the cylinder from which they were removed.
- Feed the connecting rod bearing shell (2)
out of the connecting rod (1)
and remove it.
- Feed the connecting rod bearing shell (2)
out of the connecting rod bearing cap (1)
and remove it.
- Note the different equipment specifications of the connecting rod bearing shells (1)
and (2)
.
- To avoid incorrect assembly: Observe marks (arrows).
The connecting rod bearing shell (1) and the connecting rod bearing shell (2) are equipped with a fuse to prevent incorrect assembly.
- To avoid incorrect assembly: Observe marks (arrows).
The connecting rod bearing shell (2) and the connecting rod (1) are equipped with a fuse to prevent incorrect assembly.
- Replace the connecting rod bearing shell (2)
and insert it in the connecting rod (1)
.
Parts: Connecting rod bearing shell
- Oil the connecting rod bearing shell (2)
.
- Replace the connecting rod bearing shell (2)
and insert in the connecting rod bearing cap (1)
.
Parts: Connecting rod bearing shell
- Oil the connecting rod bearing shell (2)
.
- Vacuum the crack surfaces (1) with a conventional vacuum cleaner (2) .
The crack surfaces (1) must not be blown off with compressed air.
Follow-up work
- Refer to MEASURING ALL PISTONS .
- Refer to MEASURING A CYLINDER .
- Refer to INSTALLING ALL THE PISTONS WITH THE CONNECTING ROD .
- Refer to INSTALLING THE OIL DEFLECTOR .
- Refer to INSTALLING OIL PUMP .
- Refer to REFITTING OIL PAN .
- Refer to INSTALLING FRONT AXLE DIFFERENTIAL .
- Refer to INSTALLING BEARING BRACKET .
- Refer to SEALING THE OIL DUCT .
- Refer to CLEANING SEALING SURFACES .
- Refer to INSTALLING THE CYLINDER HEAD GASKET .
- Refer to BLOCKING THE CRANKSHAFT IN THE TDC FIRING POSITION OF CYLINDER 1 .
- Refer to INSTALLING THE CYLINDER HEAD .
- Refer to ADJUSTING THE CAMSHAFTS WITH THE SPECIAL TOOL .
- Refer to INSTALLING THE INTAKE ADJUSTER .
- Refer to INSTALLING THE VANOS CENTRAL VALVE OF THE INTAKE ADJUSTER .
- Refer to INSTALLING EXHAUST CAMSHAFT ADJUSTER .
- Refer to INSTALLING THE VANOS CENTRAL VALVE OF THE EXHAUST CAMSHAFT ADJUSTER .
- Refer to PRE-TENSIONING THE TIMING CHAIN WITH THE SPECIAL TOOL .
- Refer to TIGHTENING THE VANOS CENTRAL VALVE OF THE EXHAUST CAMSHAFT ADJUSTER .
- Refer to TIGHTENING THE VANOS CENTRAL VALVE OF THE INTAKE ADJUSTER .
- Refer to DISASSEMBLING ALL SPECIAL TOOLS .
- Refer to INSTALLING CHAIN TENSIONER .
- Refer to CHECKING THE TIMINGS OF THE CAMSHAFT .
- Refer to INSTALLING THE COOLANT LINE BETWEEN THE CYLINDER HEAD AND THE COOLANT PUMP .
- Refer to INSTALLING THE OIL RETURN LINE FOR THE EXHAUST TURBOCHARGER .
- Refer to INSTALLING CYLINDER HEAD COVER .
- Refer to INSTALLING BOTH ACTUATORS .
- Refer to PREPARING THE INJECTORS FOR INSTALLATION .
- Refer to INSTALLING THE HIGH-PRESSURE RAIL WITH INJECTORS OF THE CYLINDERS 4 TO 6 .
- Refer to INSTALLING THE HIGH-PRESSURE RAIL WITH INJECTORS OF THE CYLINDERS 1 TO 3 .
- Refer to INSTALLING THE HIGH-PRESSURE LINE BETWEEN THE HIGH-PRESSURE PUMP AND THE HIGH-PRESSURE RAIL .
- Refer to INSTALLING HIGH PRESSURE PUMP .
- Refer to INSTALLING ALL SPARK PLUGS .
- Refer to INSTALLING ALL IGNITION COILS .
- Refer to INSTALLING CATALYTIC CONVERTER .
- Refer to INSTALLING THE OXYGEN SENSOR MONITOR .
- Refer to INSTALLING LAMBDA OXYGEN SENSOR .
- Refer to INSTALLING THE INTAKE PLENUM .
- Refer to INSTALLING THE TANK VENT VALVE .
- Refer to INSTALLING CHARGE AIR LINE .
- Refer to INSTALLING ACOUSTIC COVER AT REAR .
- Refer to FILLING ENGINE OIL .
- Refer to CHECK/ADD FRONT AXLE TRANSMISSION OIL .
- Refer to REMOVING THE ENGINE FROM THE ASSEMBLY JIG .
- Refer to MOUNTING THE ENGINE ON THE FRONT AXLE .
- Refer to INSTALLING THE COMPLETE FRONT AXLE WITH THE ENGINE AND TRANSMISSION .
Preliminary work
- Refer to REMOVING THE COMPLETE FRONT AXLE WITH THE ENGINE AND TRANSMISSION .
- Refer to REMOVING THE ENGINE FROM THE FRONT AXLE .
- Refer to INSTALLING THE ENGINE ON THE ASSEMBLY JIG .
- Refer to RELEASING THE OIL DRAIN PLUG .
- Refer to TIGHTENING THE OIL DRAIN PLUG .
- Refer to REMOVING CHARGE AIR LINE .
- Refer to REMOVING ACOUSTIC COVER AT REAR .
- Refer to REMOVING ALL IGNITION COILS .
- Refer to REMOVING ALL SPARK PLUGS .
- Refer to REMOVING THE HIGH PRESSURE LINE BETWEEN THE HIGH PRESSURE PUMP AND THE RAIL .
- Refer to REMOVING HIGH PRESSURE PUMP .
- Refer to REMOVING THE HIGH-PRESSURE RAIL WITH INJECTORS OF CYLINDERS 1 TO 3 .
- Refer to REMOVING THE HIGH-PRESSURE RAIL WITH INJECTORS OF CYLINDERS 4 TO 6 .
- Refer to REMOVING BOTH ACTUATORS .
- Refer to REMOVING THE CYLINDER HEAD COVER .
- Refer to REMOVING TANK VENT VALVE .
- Refer to REMOVING THE INTAKE PLENUM .
- Refer to REMOVING THE LAMBDA OXYGEN SENSOR .
- Refer to REMOVING THE OXYGEN SENSOR MONITOR .
- Refer to REMOVING CATALYTIC CONVERTER .
- Refer to REMOVING THE OIL RETURN LINE FOR THE EXHAUST TURBOCHARGER .
- Refer to REMOVING THE COOLANT LINE BETWEEN THE COOLANT PUMP AND CYLINDER HEAD .
- Refer to BLOCKING ENGINE IN TDC FIRING POSITION .
- Refer to REMOVING CHAIN TENSIONER .
- Refer to RELEASING THE VANOS CENTRAL VALVE OF THE INTAKE ADJUSTER .
- Refer to RELEASING VANOS CENTRAL VALVE OF THE EXHAUST CAMSHAFT ADJUSTER .
- Refer to REMOVING THE VANOS CENTRAL VALVE OF THE INTAKE ADJUSTER .
- Refer to REMOVING THE VANOS CENTRAL VALVE OF THE EXHAUST CAMSHAFT ADJUSTER .
- Refer to REMOVING INTAKE ADJUSTER .
- Refer to REMOVING EXHAUST CAMSHAFT ADJUSTER .
- Refer to REMOVING THE TEST GAUGES FOR SECURING THE CAMSHAFTS .
- Refer to REMOVING THE CYLINDER HEAD .
- Refer to REMOVING THE CYLINDER HEAD GASKET .
- Refer to REMOVING FRONT AXLE DIFFERENTIAL .
- Refer to REMOVING OIL SUMP .
- Refer to REMOVING BEARING BRACKET .
- Refer to REMOVING OIL PUMP .
- Refer to REMOVING THE OIL DEFLECTOR .
- Refer to REMOVING ALL THE PISTONS WITH THE CONNECTING ROD .
Engine damage caused by incorrectly installed bearing shells and bearing brackets .
If the bearing shells and bearing brackets are installed incorrectly, then engine damage can occur .
- Always install all bearing shells and bearing brackets in the same position from which they were removed.
Piston, piston pin, connecting rod and connecting rod bearing shells are matched to each other and balanced.
Always install the pistons, piston pins, connecting rods and connecting rod bearing shells in the cylinder from which they were removed.
- Feed the connecting rod bearing shell (2)
out of the connecting rod (1)
and remove it.
- Feed the connecting rod bearing shell (2)
out of the connecting rod bearing cap (1)
and remove it.
- Note the different equipment specifications of the connecting rod bearing shells (1)
and (2)
.
- To avoid incorrect assembly: Observe marks (arrows).
The connecting rod bearing shell (1) and the connecting rod bearing shell (2) are equipped with a fuse to prevent incorrect assembly.
- To avoid incorrect assembly: Observe marks (arrows).
The connecting rod bearing shell (2) and the connecting rod (1) are equipped with a fuse to prevent incorrect assembly.
- Replace the connecting rod bearing shell (2)
and insert it in the connecting rod (1)
.
Parts: Connecting rod bearing shell
- Oil the connecting rod bearing shell (2)
.
- Replace the connecting rod bearing shell (2)
and insert in the connecting rod bearing cap (1)
.
Parts: Connecting rod bearing shell
- Oil the connecting rod bearing shell (2)
.
- Vacuum the crack surfaces (1) with a conventional vacuum cleaner (2) .
The crack surfaces (1) must not be blown off with compressed air.
Follow-up work
- Refer to MEASURING ALL PISTONS .
- Refer to MEASURING A CYLINDER .
- Refer to INSTALLING ALL THE PISTONS WITH THE CONNECTING ROD .
- Refer to INSTALLING THE OIL DEFLECTOR .
- Refer to INSTALLING OIL PUMP .
- Refer to REFITTING OIL PAN .
- Refer to INSTALLING FRONT AXLE DIFFERENTIAL .
- Refer to INSTALLING BEARING BRACKET .
- Refer to SEALING THE OIL DUCT .
- Refer to CLEANING SEALING SURFACES .
- Refer to INSTALLING THE CYLINDER HEAD GASKET .
- Refer to BLOCKING THE CRANKSHAFT IN THE TDC FIRING POSITION OF CYLINDER 1 .
- Refer to INSTALLING THE CYLINDER HEAD .
- Refer to ADJUSTING THE CAMSHAFTS WITH THE SPECIAL TOOL .
- Refer to INSTALLING THE INTAKE ADJUSTER .
- Refer to INSTALLING THE VANOS CENTRAL VALVE OF THE INTAKE ADJUSTER .
- Refer to INSTALLING EXHAUST CAMSHAFT ADJUSTER .
- Refer to INSTALLING THE VANOS CENTRAL VALVE OF THE EXHAUST CAMSHAFT ADJUSTER .
- Refer to PRE-TENSIONING THE TIMING CHAIN WITH THE SPECIAL TOOL .
- Refer to TIGHTENING THE VANOS CENTRAL VALVE OF THE EXHAUST CAMSHAFT ADJUSTER .
- Refer to TIGHTENING THE VANOS CENTRAL VALVE OF THE INTAKE ADJUSTER .
- Refer to DISASSEMBLING ALL SPECIAL TOOLS .
- Refer to INSTALLING CHAIN TENSIONER .
- Refer to CHECKING THE TIMINGS OF THE CAMSHAFT .
- Refer to INSTALLING THE COOLANT LINE BETWEEN THE CYLINDER HEAD AND THE COOLANT PUMP .
- Refer to INSTALLING THE OIL RETURN LINE FOR THE EXHAUST TURBOCHARGER .
- Refer to INSTALLING CYLINDER HEAD COVER .
- Refer to INSTALLING BOTH ACTUATORS .
- Refer to PREPARING THE INJECTORS FOR INSTALLATION .
- Refer to INSTALLING THE HIGH-PRESSURE RAIL WITH INJECTORS OF THE CYLINDERS 4 TO 6 .
- Refer to INSTALLING THE HIGH-PRESSURE RAIL WITH INJECTORS OF THE CYLINDERS 1 TO 3 .
- Refer to INSTALLING THE HIGH-PRESSURE LINE BETWEEN THE HIGH-PRESSURE PUMP AND THE HIGH-PRESSURE RAIL .
- Refer to INSTALLING HIGH PRESSURE PUMP .
- Refer to INSTALLING ALL SPARK PLUGS .
- Refer to INSTALLING ALL IGNITION COILS .
- Refer to INSTALLING CATALYTIC CONVERTER .
- Refer to INSTALLING THE OXYGEN SENSOR MONITOR .
- Refer to INSTALLING LAMBDA OXYGEN SENSOR .
- Refer to INSTALLING THE INTAKE PLENUM .
- Refer to INSTALLING THE TANK VENT VALVE .
- Refer to INSTALLING CHARGE AIR LINE .
- Refer to INSTALLING ACOUSTIC COVER AT REAR .
- Refer to FILLING ENGINE OIL .
- Refer to CHECK/ADD FRONT AXLE TRANSMISSION OIL .
- Refer to REMOVING THE ENGINE FROM THE ASSEMBLY JIG .
- Refer to MOUNTING THE ENGINE ON THE FRONT AXLE .
- Refer to INSTALLING THE COMPLETE FRONT AXLE WITH THE ENGINE AND TRANSMISSION .