Check/repair connecting rod

AR03.10-B-6111TA

Check/repair connecting rod

12.02.16



Remove

1

Remove the piston

AR03.10-B-7021TA



Inspect

2

Check the connecting rod (1), the connecting rod bearing cover (2) and the connecting rod shells (3) for wearing

 Connecting rods (1) and connecting rod bearing covers (2) with bluish color (excessive heating), resulting i damage in the bearing, can not be used anymore.



Indications to asses the connecting rod bearing and the connecting rod bearing neck

AH03.10-B-0001-03A

3

Check the connecting rod bushing internal diameter (5)

 If the value is exceeded:



*BE03.10-B-1011-01C

Replace the connecting rod (1).



*001589532100

4

Check the connecting rod (1) for torsion and measurements runout

 Measure the distance between the connecting rod bearing housing and the connecting rod shell hole (A) in both sides. If the value is exceeded:



*BE03.10-B-1014-01C

Replace the connecting rod (1).

Measure the runout allowed in the axles parallelism between the connecting rod bearing housing and the connecting rod shell drilling (B) in relation to the measurement distance (C). If the value is exceeded:



*BE03.10-B-1004-01C

Replace the connecting rod (1).

5

Assemble the connecting rod (1), the connecting rod bearing cover (2) and the connecting rod shells (3), assemble and disassemble again

 Tighten the connecting rod bearing cover (2) and the connecting rod (1) only with the connecting rod shells (3) installed to prevent damages.

AR03.10-B-6111-06TA

 The connecting rod shells (3) in the connecting rod bearing cover (2) and in the connecting rod (1) are different. The connecting rod shells (3) are supplied with different thickness (repairs). Observe the abbreviated identification on at the back of the connecting rod bearing shells (3).

Internal diameter of the connecting rod bearing with the connecting rod shells installed

*BE03.10-B-1001-01C

Connecting rod radial play

*BE03.10-B-1003-01C

Connecting rod bolt length

*BE03.10-B-1013-01C

Connecting rod neck diameter

*BE03.20-B-1003-02C



*BA03.10-B-1001-01B



*001589532100

6

Determine the connecting rod axial play

Connecting rod axial play

*BE03.10-B-1003-01C

Connecting rod neck width

*BE03.20-B-1011-02C



Install

7

Install the piston

AR03.10-B-7021TA

Número

Denominação

Engine 904.9 and 906.9; up to final no. 456372

Engine 902.9, 904.9 and 906.9 from the final no. 456373

BE03.10-B-1001-01C

Sleeves internal diameter (assembled in the connecting rod)

Normal

mm

70.054...70.093

70.054...70.093

Normal I

mm

69.954...69.993

69.954...69.993

Repair I

mm

69.804...69.843

69.804...69.843

repair II

mm

69.554...69.593

69.554...69.593

repair III

mm

69.304...69.343

69.304...69.343

repair IV

mm

69.054...69.093

69.054...69.093

BE03.10-B-1003-01C

Connecting for play (with sleeves) in the crankshaft neck

radial

mm

0.029...0.088

0.029...0.088

axial

mm

0.170...0.470

0.170...0.470

BE03.10-B-1004-01C

Maximum allowed deviation for parallelism and torsion (B) between the center lines of the sleeves housing and the connecting rod bushing, in the distance (C)

Deviation B

mm

0.025

0.025

distance of measurement C

mm

50

50

BE03.10-B-1011-01C

Connecting rod bushing internal diameter

mm

40.03...40.04

42.04...42.05

BE03.10-B-1013-01C

Connecting rod bolt

Thread

M

12 x 1.25

12 x 1.25

Length (L) - new bolt

mm

55.5...56.0

55.5...56.0

Length (L) - used bolt

mm

57.0

57.0

BE03.10-B-1014-01C

Distance from the connecting rod bearing seat to the connecting rod busing internal diameter

mm

155.500...155.425

157.510....157.445

Número

Denominação

Engine 904.9

Engine 902.9; 906.9, 924.9, 926.9

BE03.20-B-1003-02C

Connecting rod neck diameter in the crankshaft

Normal

mm

69.995...70.015

69.995...70.015

Normal I

mm

69.895...69.915

69.895...69.915

Repair I

mm

69.745...69.765

69.745...69.765

repair II

mm

69.495...69.515

69.495...69.515

repair III

mm

69.245...69.265

69.245...69.265

repair IV

mm

68.995...69.015

68.995...69.015

BE03.20-B-1011-02C

Connecting rod neck width

Normal

mm

34.0...34.2

34.0...34.2

repair

mm

-

-

Número

Denominação

Engine 902.9, 904.9; 906.9

BA03.10-B-1001-01B

Attachment bolt for the connecting rod cover

1st stage

Nm

10

2nd stage

Nm

40...50

3rd stage

degrees

90...100