Inspection

8. Remove and discard big-end bearing shell from connecting rod. NOTE: Engine Serial No. Prefixes 10P to 14P:– The 'sputter type' connecting rod bearing shells fitted to these engines, identified by them having a slightly darker colour than the bearing cap shells should be replaced with the 'plain type' bearing shells fitted to Engine Serial No. Prefixes 15P to 19P.
9. Repeat above procedures for remaining bigend bearings. Keep bearing caps in their fitted order.

Inspection

1. If crankshaft is to be removed, big-end bearing journals should be checked when crankshaft is inspected.

2. Check each big-end bearing journal for scoring, wear and ovality, make 3 checks at 120° intervals in centre of journal: l Big-end bearing journal diameter = 54.000 ± 0.01 mm (2.125 ± 0.0004 in)

CAUTION: Big-end journals may not be ground undersize, only one size of big-end bearing shell is available and if journals are found to be scored, oval or worn, crankshaft must be replaced. Big-end bearing shells must be replaced whenever they are removed.

Reassembly

1. Clean connecting rod journals and bearing shell locations.
2. Lubricate new big-end bearing shells with engine oil and fit to connecting rods and bearing caps.

CAUTION: Do not fit the 'sputter type' bearings fitted to early engines.

3. Rotate crankshaft until No.1 big-end bearing journal is at BDC.
4. Taking care not to damage oil squirt jet or to displace bearing shell, pull connecting rod on to crankshaft journal.
5. Check that bearing shell is correctly located in big-end bearing cap.
6. Fit No.1 big-end bearing cap ensuring that reference marks are aligned
7. Fit new big-end bearing cap bolts and tighten to: l Stage 1 - 20 Nm (15 lbf.ft) l Stage 2 - Further 80°

CAUTION: Do not carry out stages 1 and 2 in one operation.

8. Carefully move connecting rod to one side of journal and using feeler gauges measure endfloat of connecting rod on journal: l Connecting rod end-float = 0.2 to 0.5 mm (0.008 to 0.021 in)
9. Repeat end-float check for remaining connecting rods.
10. If end-float exceeds limits given, replace connecting rod and repeat end-float check. ENGINE - Td5, OVERHAUL, Pistons, connecting rods and cylinder bores.
11. Fit oil pump. ENGINE - Td5, OVERHAUL, Pump - oil.