Repairing connecting rod · ar0310s6111a · Mercedes-Benz WIS

AR03.10-S-6111A

Repairing connecting rod

9.2.95

ENGINE 111.948 /978 in MODEL 638

ENGINE 111.979 in MODEL 901, 902, 903, 904

S03.10-3003-05

P03.10-0206-06

1 Conrod

2 Conrod bearing cap

3 Conrod bush

4 Dowel sleeve

5 Conrod bolt

6 Balancing weight

7 Field for identification

8 Slots for locating conrod bearing shells

9 Oil hole

10 Oil spray drilling

"b" Width at conrod bush bore

"B" Width at conrod bearing bore

"d" Conrod bush inner 

"d1" Conrod bush basic bore 

"D1" Conrod bearing shell basic bore 

"L" Distance from center of conrod bearing bore to conrod bush bore

 	Remove, Install
1	Remove pistons	Engine 111.948/978 in model 638	AR03.10-S-7021A
		Engine 111.979 in model 901, 902, 903, 904	AR03.10-D-7021C
	Inspect
2	Check conrods for blue discoloration, cross scores and notches	 Never re-use connecting rods that exhibit a bluish discoloration (resulting from bearing damage), with scoring or notches. 
		Replace conrods and compensate for different conrod weights by milling off the balancing weight (6).	*BE03.10-N-1005-01A
		Conrod as-built configuration description	GF03.10-S-0800A
			*BE03.10-N-1001-01A
			*BE03.10-N-1002-01A
			*BE03.10-N-1006-01A
			*BE03.10-N-1007-01A
3	Screw conrod bearing cap to conrod	Conrod and conrod bearing caps are marked together and located with two dowel sleeves. Tighten connecting rod bearing caps to initial torque. 
		Tighten conrod bolts.	AR03.10-S-6111-02A
			*BA03.10-N-1001-01A
4	Measure conrod bearing basic bore, repair	If the max. permissible diameter is exceeded, grind down contact surface on conrod bearing cap by max. 0.02 mm.	*BE03.10-N-1002-01A
			*001589322100
			*WH58.30-Z-1001-12A
			*WH58.30-Z-1002-12A
5	Check conrod bush inside diameter		*BE03.10-N-1006-01A
			*001589322100
			*WH58.30-Z-1001-12A
			*WH58.30-Z-1002-12A
		If excessive wear is present 
		Press in new conrod bush	AR03.10-S-6111-03A
			*BE03.10-N-1001-01A
			*BE03.10-N-1006-01A
			*BE03.10-N-1007-01A
			*BE03.10-N-1009-01A
6	Align conrod		AR03.10-S-6111-04A
			*WH58.30-Z-1008-05A
			*WH58.30-Z-1009-05A
			*BE03.10-N-1003-01A
			*BE03.10-N-1004-01A
7	Install in the reverse order

Test values for conrod

Number	Designation			Engine 111.948	Engine 111.978	Engine 111.979


BE03.10-N-1001-01A	Dim-en-sion	Distance from middle of conrod bearing bore up to conrod bush bore (L)	mm	154	149	149
		Width of conrod at conrod bearing bore (B) and at conrod bush bore (b)	mm	21,948-22,000	21,948-22,000	21,948-22,000
BE03.10-N-1002-01A		Conrod bearing shell basic bore (D1) 	mm	51,600-51,614	51,600-51,614	51,600-51,614
		Permissible out-of-roundness and conicity of basic bore	mm	0,02	0,02	0,02
BE03.10-N-1003-01A		Permissible twist of conrod bearing bore to conrod bush bore over a length of 100 mm	mm	0,1	0,1	0,1
BE03.10-N-1004-01A		Permissible variation of axial parallelism of conrod bearing bore to conrod bush bore over a length of 100 mm	mm	0,045	0,045	0,045
BE03.10-N-1005-01A		permissible difference in weight of complete conrod of an engine	G	4	4	4
BE03.10-N-1006-01A		Conrod bush inner  (d)	mm	22,007-22,013	22,007-22,013	22,007-22,013
BE03.10-N-1007-01A		Conrod bush basic bore  (d1)	mm	24,500-24,521	24,500-24,521	24,500-24,521
BE03.10-N-1008-01A		Piston pin play in conrod bush	mm	0,007-0,018	0,007-0,018	0,007-0,018
BE03.10-N-1009-01A		Peak-to-valley height (Rz) of inner conrod bush	μm	5	5	5
BE03.10-N-1010-01A		Radial conrod bearing play	mm	0,03-0,05	0,03-0,05	0,03-0,05

 Conrod

001 589 32 21 00

Dial gage

Commercially available tools

Number	Designation
WH58.30-Z-1008-05A	Connecting rod tester
WH58.30-Z-1009-05A	Conrod straightening equipment
WH58.30-Z-1001-12A	Quick calipers for internal measurements
WH58.30-Z-1002-12A	Micrometer