Modification notes
22.2.07 | Connecting rod bearing inside dia. for an engaged connecting rod bearing shell, standard | Engine 541.9, from engine end no. 054766 Engine 542.9 from engine end no. 054766 | |
22.2.07 | Connecting rod journal dia. connecting rod journal width, dia. standard width | Engine 541.9 EURO standardⅡ as of engine no. 098132 engine 541.9 EURO standard Ⅲ Engine 542.9 EURO standard II as of engine no. 098132 engine 542.9 EURO standard Ⅲ Engine 542.9 EURO IV standard with code MS4 EURO V standard with code MS5 |
Test specifications for connecting rod
Number | Designation | Engine | Engine | Engine | ||
BE03.10-N-1001-01C | Connecting rod bearing inside dia. for connecting rod bearing shells inserted | Default | mm | 94.054 to 94.096 | 94.064 to 94.110 | 94.064 to 94.110 |
Deviation 0.10 | mm | 93.954 to 93.996 | 93.964 to 94.010 | 93.964 to 94.010 | ||
Deviation 0.25 | mm | 93.804 to 93.846 | 93.814 to 93.860 | 93.814 to 93.860 | ||
Deviation 0.50 | mm | 93.554 to 93.596 | 93.564 to 93.610 | 93.564 to 93.610 | ||
Deviation 0.75 | mm | 93.304 to 93.346 | 93.314 to 93.360 | 93.314 to 93.360 | ||
Oversize 1.00 | mm | 93.054 to 93.096 | 93.064 to 93.110 | 93.064 to 93.110 | ||
BE03.10-N-1005-01C | Bolt, connecting rod bearing cap to connecting rod | Thread dia. | M | 161.5 | 161.5 | 161.5 |
Permissible shank length | mm | 74.5 | 74.5 | 74.5 | ||
BE03.10-N-1006-01C | Connecting rod bearing radial play | mm | 0.064 to 0.126 | 0.064 to 0.126 | 0.064 to 0.126 | |
Check values for a crankshaft
Number | Designation | Engine 541.9 | Engine 542.9 | ||
BE03.20-N-1004-02C | Connecting rod journal dia., connecting rod journal width | Dia. standard | mm | 93.980...94.000 | 93.980 - 94.000 |
Dia. deviation 0.10 | mm | 93.880 - 93.900 | 93.880 - 93.900 | ||
Dia. deviation 0.25, | mm | 93.730 - 93.750 | 93.730 - 93.750 | ||
Dia. deviation 0.50 | mm | 93.480 - 93.500 | 93.480 - 93.500 | ||
Dia. deviation 0.75 | mm | 93.230 - 93.250 | 93.230 - 93.250 | ||
Dia. deviation 1.00 | mm | 92.980 - 93.000 | 92.980 - 93.000 | ||
Check values for a crankshaft
Number | Designation | Engine 541.9 | Engine 542.9 | ||
BE03.20-N-1004-02C | Connecting rod journal dia., connecting rod journal width | Dia. standard | mm | 93.980 - 94.000 | 93.980 - 94.000 |
Dia. deviation 0.10 | mm | 93.880 - 93.900 | 93.880 - 93.900 | ||
Dia. deviation 0.25, | mm | 93.730 - 93.750 | 93.730 - 93.750 | ||
Dia. deviation 0.50 | mm | 93.480 - 93.500 | 93.480 - 93.500 | ||
Dia. deviation 0.75 | mm | 93.230 - 93.250 | 93.230 - 93.250 | ||
Dia. deviation 1.00 | mm | 92.980 - 93.000 | 92.980 - 93.000 | ||
Check values for a crankshaft
Number | Designation | Engine 541.9 | Engine 542.9 | ||
BE03.20-N-1004-02C | Connecting rod journal dia., connecting rod journal width | Dia. standard | mm | 93.980 - 94.000 | 93.980 - 94.000 |
Dia. deviation 0.10 | mm | 93.880 - 93.900 | 93.880 - 93.900 | ||
Dia. deviation 0.25, | mm | 93.730 - 93.750 | 93.730 - 93.750 | ||
Dia. deviation 0.50 | mm | 93.480 - 93.500 | 93.480 - 93.500 | ||
Dia. deviation 0.75 | mm | 93.230 - 93.250 | 93.230 - 93.250 | ||
Dia. deviation 1.00 | mm | 92.980 - 93.000 | 92.980 - 93.000 | ||
Connecting rod
Number | Designation | Engine 541.9, 542.9 | ||
BA03.10-N-1001-01C | Bolt of connecting rod bearing cap to connecting rod | Stage 1 | Nm | 110 |
Stage 2 | ° | 90 | ||
001 589 53 21 00
Dial indicator
W03.20-1076-11
1 Clean connecting rod journals on crankshaft (1) with a chamois leather.
2 Measure connecting rod journal dia. of crankshaft (1) using the micrometer in three measuring directions (D, E, F) offset by about 60°. Calculate a mean value using the three measured values.
The crankshaft (1) must be machined or installed if one measurement of connecting rod journal dia. is outside the tolerance.
3 Assign connecting rod bearing shells according to the mean value of the connecting rod journal dia..
Observe machining stage (standard or deviation and corresponding width). All connecting rod journal dia. must have the same machining stage; machine or replace the crankshaft (1) as required.
4 Clean connecting rod bearing shells (3, 4), and their mounts in connecting rod (2) and connecting rod bearing cap (6) with a chamois leather and check for wear and damage.
In cases of wear, the connecting rod bearing shells (3, 4) must be replaced if all connecting rod journal Ø on crankshaft are within tolerance.
5 Assign marked connecting rod bearing shell (3, 4) on connecting rod (2) and connecting rod bearing cap (6) and insert.
The locking lugs on connecting rod bearing shells (3, 4) must be located in foreseen grooves (arrows) in connecting rod (2) and connecting rod bearing cap (6). The connecting rod bearing cap (6) and the connecting rod (2) are marked by numbers (e.g. 4185) for pairing and must not get mixed up with each other (cracked separating surfaces). They must be assigned according to marked installation position of connecting rod journal on crankshaft.
6 Measure connecting rod bolts (5).
Replace corresponding connecting rod bolt (5) if the shank length is exceeded.
7 Tighten connecting rod bearing cap (6) with connecting rod bolt (5) on connecting rod (2).
The connecting rod (2) and connecting rod bearing cap (6) must only be tightened using engaged connecting rod bearing shells (3, 4). Observe tightening torque stage.
W03.10-1032-03
8 Set dial indicator and quick connect calipers for inside measurements using the outside micrometer to dimension 92.0 mm (note pretension 5 mm) and set the scale of the dial indicator to "0".
9 Measure connecting rod bearing inside dia. in assembled connecting rod (2) using quick calipers for inside measurements in the measurement directions (A, B, C). Begin with measuring direction (A) 90° offset from separation point (arrows) and measure each remaining measuring direction (B, C) offset by about 60°.
The preset dimension 92.0 mm plus one read off measurement value gives in each case one measured connecting rod bearing inside Ø. If one of the three connecting rod bearing inside Ø lies outside tolerance then repeat the measurement procedure with new connecting rod bearing shells. Replace connecting rod (2) with connecting rod bearing cap (6) if necessary. Take mean value of three connecting rod bearing inside Ø.
10 Taking mean value of connecting rod journal Ø from mean value of connecting rod bearing inside Ø gives the connecting rod bearing play.
Example: 94.062 mm - 93.99 mm = 0.072 mm
11 Take off connecting rod bearing cap (6) again.
The connecting rod bearing inside dia. and connecting rod journal must have the same machining stage (standard or deviation) in order to achieve the correct connecting rod bearing play. The connecting rod bearing shells are delivered ready-to-install ex works and for repair purposes, also in oversizes. No reworking is permissible.
W03.10-1036-03