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Freelander 1. Manual - part 59

ENGINE - K SERIES 1.8

REPAIRS

12-2-9

Connecting rod bearings - engine set

$% 12.17.16

Remove

1. Disconnect battery earth lead.
2. Remove cylinder head.

ENGINE - K SERIES 1.8, REPAIRS,

Gasket - cylinder head.

3. Remove engine sump.

ENGINE - K SERIES 1.8, REPAIRS,

Sump - engine reseal.

4. Temporarily remove cylinder liner clamps,

LRT-12-144. Do not rotate crankshaft with liner
clamps removed.

CAUTION: Ensure that cylinder head bolts
are kept in their original fitted order.

5. Remove 2 bolts securing oil pick-up strainer to

oil rail.

6. Remove oil pick-up strainer.
7. Remove and discard 'O' ring from oil pick-up

strainer.

8. Remove 2 nuts securing oil rail to bearing

ladder and remove oil rail.

9. Fit cylinder liner clamps. LRT-12-144, using the

nylon nuts supplied to retain liner clamps.
Ensure that the feet of the liner clamps do not
protrude over cylinder liner bores.

10. Retain clamps using cylinder head bolts

ensuring that bolts used are those originally
fitted in that location.

11. Temporarily fit crankshaft timing gear and

pulley, fit retaining bolt and washer, lightly
tighten bolt.

12. Rotate crankshaft clockwise and bring numbers

2 and 3 pistons to BDC.

13. Make cylinder number reference marks on big-

end bearing caps.

14. Remove 4 dowel bolts and 2 big-end bearing

caps from numbers 2 and 3 connecting rods,
keep dowel bolts and bearing caps in their fitted
order.

LRT-12-144

M12 7037

ENGINE - K SERIES 1.8

12-2-10 REPAIRS

15. Release connecting rods from crankshaft

journals and carefully push pistons to top of
cylinder bore. Remove and discard bearing
shells from connecting rods and bearing caps.

16. Rotate crankshaft clockwise and bring numbers

1 and 4 pistons to BDC.

17. Make cylinder number reference marks on big-

end bearing caps.

18. Remove 4 dowel bolts and 2 big-end bearing

caps from numbers 1 and 4 connecting rods.
Keep dowel bolts and bearing caps in their
fitted order.

19. Release connecting rods from crankshaft

journals and carefully push pistons to top of
cylinder bore. Remove and discard bearing
shells from connecting rods and bearing caps.

Refit

1. Using a micrometer, measure crankshaft big-

end journal diameters, taking 4 measurements
around each journal.

2. Record big-end journal code letters from

crankshaft rear web. Reading from left to right,
the first letter is Number 1 big-end bearing.

GENERAL DATA, Engine – K1.8

Petrol.

3. Record big-end bearing bore numbers. This will

be 5, 6 or 7 located on the connecting rod
bearing cap. Select required bearings.

GENERAL DATA, Engine – K1.8

Petrol.

4. Colour code on edge of bearing denotes

bearing thickness as follows: YELLOW = Thin,
BLUE = Intermediate, RED = Thick. If two
bearing colours are to be used, the thicker
bearing must be fitted to the big-end bearing
cap.

5. Clean crankshaft journals and bearing

locations in connecting rods.

6. Select the appropriate big-end bearing shells.
7. Lubricate connecting rod journals and bearing

shells with clean engine oil.

8. Fit bearing shells to connecting rods and caps.
9. Carefully pull connecting rods into place, fit big

end caps noting that featherways are on
opposite sides and lightly tighten dowel bolts.

10. Tighten big-end bearing dowel bolts to:

Stage 1 - 20 Nm (15 lbf.ft)

Stage 2 - Further 45

Note: Until the cylinder head is fitted,
crankshaft will prove difficult to rotate once big-
end bolts are tightened.

11. Using feeler gauges, check that end-float of

each big-end bearing/connecting rod is
between 0.10 (0.004 in) to 0.25 mm (0.010 in).

12. Clean oil rail, oil pick up and mating faces.
13. Blow out oil ways in oil rail and oil pick up.

CAUTION: A new oil rail must be fitted if a
thread is damaged. Thread inserts (Helicoil)
are not acceptable.

14. Temporarily remove cylinder liner clamps,

LRT-12-144.

CAUTION: Do not rotate crankshaft with
liner clamps removed. Ensure that cylinder
head bolts used to retain clamps are kept in
their original fitted order.

M12 7040