Connecting Bearing / Rod Cap Installation - Lombardini LDW 502 Workshop Manual

II DISASSEMBLY/REASSEMBLY
Match the piston protrusion dimension determined
above with dimension(A) from the chart. Install the
corresponding head gasket. If a head gasket cannot
be chosen based upon
measured, check the connecting rod length, rod
bearings, wrist pin bushing, etc. for the cause of the
problem.
Completely clean the deck surface of oil, old gasket
material, varnish, coolant, etc. Remove all traces of
fluid from the cylinder head bolt bores. Install the
head gasket so that the gasket aligns with the deck
dowels and the brand name or "TOP" printed on the
gasket faces up.
COMPILER TECO/ATI
52
the piston protrusion
REG. CODE MODEL N°
1-5302-351

CONNECTING BEARING / ROD CAP INSTALLATION

Install the connecting rod bearing inserts into the connecting rod and
connecting rod cap. Make sure that the back of the bearing insert and
the connecting rod and connecting rod cap bore is free of dirt, rust,
oil etc. Insert the bearing inserts so that the tab on the bearing aligns
with the slot in the connecting rod or connecting rod cap. Push the
bearing completely into the connecting rod and connecting rod cap.
Liberally oil the bearings with clean engine oil. Install the connecting
rod cap onto the connecting rod making sure that the respective
tang/slot locks on the connecting rod cap aligns with the tang/ slot
lock on the connecting rod.
Torque the connecting rod bolts to 40 Nm in 5 Nm steps.
PISTON PROTRUSION
Rotate each cylinder to exact TDC. TDC may be determined by the
use of a dial indicator mounted to the cylinder deck and indicating
piston height as a function of crankshaft rotation.
After TDC is established, measure the protrusion of the piston (A)
from the cylinder deck plane using a calibrated depth micrometer.
The height should be measured on a line corresponding to the wrist
pin axis as shown. Record the protrusion. Repeat the TDC
establishment and piston protrusion procedure for each cylinder,
recording the value for each cylinder. The HIGHEST protrusion
measured will be used to establish the proper head gasket selection
as presented below.
HEAD GASKET SELECTION/ INSTALLATION
Three(3) separate head gasket thickness' are available for FOCS
engines depending on the measured piston protrusion as measured
above. The head gaskets are identified by notches cut in the edge
located at point (B) as detailed below. Head gaskets are provided
with "0 notch", "1 notch" or "2 notches" to
For 502,602,903,1204,1204/T
A (mm)
(PISTON PROTRUSION)
Head Clearance (mm)
0.97/1.06
1.07/1.16
1.17/1.25
For 702,1003
A (mm)
(PISTON PROTRUSION)
Head Clearance (mm)
0.82/0.91
0.92/1.01
1.02/1.10
For 1404
A (mm)
(PISTON PROTRUSION)
Head Clearance (mm)
0.82/0.91
0.92/1.01
1.02/1.10
assist in the identification of the different gaskets.
DATE OF ISSUE
50563 04.90
No. of hole Piston to Cylinder
0
1
2
No. of hole Piston to Cylinder
0
1
2
No. of Notches Piston to Cylinder
1
2
3
DATE ENDORSED
04
REVISION
15.11.99
0.39/0.48
0.40/0.48
0.54/0.63
0.55/0.63
0.52/0.61
0.53/0.61