Check/repair connecting rod

AR03.10-D-6111A

Check/repair connecting rod

31.7.08

 

Remove/install

1

Remove pistons

Engine 602.980/982/984/985

AR03.10-D-7021A

Engine 601.943



Checking

2

Check connecting rods for blue discoloration, cross scores and notches

 Never reuse connecting rods that exhibit a bluish discoloration (resulting from bearing damage), with scoring or notches. 

Replace connecting rods and compensate for different connecting rod weights by milling off the balancing mass.

*BE03.10-N-1005-01D

3

Bolt, rod bearing cap to connecting rod

 The connecting rod and connecting rod bearing cap are drawn together and are located with two fitting sleeves.

Tighten connecting rod bolts to initial torque. 

Tighten connecting rod bolts.

AR03.10-D-6111-02A



*BA03.10-N-1001-01A

4

Measure connecting rod bearing basic bore, repair

If the max. permissible diameter is exceeded, grind down contact surface on connecting rod bearing cap by max. 0.02 mm.

*BE03.10-N-1002-01D



*001589322100

Quick calipers for internal measurements

Outside micrometer

5

Check connecting rod bushing inside diameter

*BE03.10-N-1006-01D



*001589322100

Quick calipers for internal measurements

Outside micrometer

If excessive wear is present 

Press in new connecting rod bushing.

AR03.10-D-6111-03A

*BE03.10-N-1006-01D

*BE03.10-N-1007-01D

*BE03.10-N-1009-01D

*BE03.10-N-1010-01D

6

Align connecting rod

AR03.10-D-6111-04A

Connecting rod tester

Connecting rod aligning tool

*BE03.10-N-1003-01D

*BE03.10-N-1004-01D

7

Install in the reverse order

Number

Designation

Engine
601.943

BE03.10-N-1001-01D

Dimension

Distance from center of connecting rod bearing bore to connecting rod bushing bore (L)

mm

144.97 to 145.03

Width of connecting rod at connecting rod bearing bore (B) and at connecting rod bushing bore (b)

mm

21.95 to 22.00

See picture

-

BE03.10-N-1002-01D

Connecting rod bearing shell basic bore (D1) 

mm

51.600 to 51.614

Permissible out-of-roundness and taper of basic bore

mm

0.02

See picture

-

BE03.10-N-1003-01D

Permissible twist of connecting rod bearing bore to connecting rod bushing bore over a length of 100 mm

mm

0.1

BE03.10-N-1004-01D

Permissible axial deviation from parallel of connecting rod bearing bore to connecting rod bushing bore over a length of 100 mm

mm

0.05

BE03.10-N-1005-01D

Permissible weight difference between complete connecting rods in the same engine

g

2

BE03.10-N-1006-01D

Connecting rod bushing inside  (d)

mm

26.012 to 26.018

See picture

-

BE03.10-N-1007-01D

Connecting rod bushing outside Ø

mm

28.575 to 28.600

BE03.10-N-1008-01D

Connecting rod bushing basic bore (d1)

mm

28.500 to 28.521

See picture

-

BE03.10-N-1009-01D

Piston pin play in connecting rod bushing

mm

0.007 to 0.018

BE03.10-N-1010-01D

Peak-to-valley height (Rz) inside connecting rod bushing

μm

5

BE03.10-N-1011-01D

Connecting rod bolt

Thread Ø

M

9 x 1

BE03.10-N-1012-01D

Connecting rod bolt

Length (L)

New

mm

52 -0.3

max.

mm

52.9

Number

Designation

Engine
602.980/982/
983/984/985

BE03.10-N-1001-01D

Dimension

Distance from center of connecting rod bearing bore to connecting rod bushing bore (L)

mm

144.97 to 145.03

Width of connecting rod at connecting rod bearing bore (B) and at connecting rod bushing bore (b)

mm

21.95 to 22.00

See picture

-

BE03.10-N-1002-01D

Connecting rod bearing shell basic bore (D1) 

mm

51.600 to 51.614

Permissible out-of-roundness and taper of basic bore

mm

0.02

See picture

-

BE03.10-N-1003-01D

Permissible twist of connecting rod bearing bore to connecting rod bushing bore over a length of 100 mm

mm

0.1

BE03.10-N-1004-01D

Permissible axial deviation from parallel of connecting rod bearing bore to connecting rod bushing bore over a length of 100 mm

mm

0.05

BE03.10-N-1005-01D

Permissible weight difference between complete connecting rods in the same engine

g

2

BE03.10-N-1006-01D

Connecting rod bushing inside (d)

mm

28.018 to 28.024

See picture

-

BE03.10-N-1007-01D

Connecting rod bushing outside Ø

mm

30.575 to 30.600

BE03.10-N-1008-01D

Connecting rod bushing basic bore (d1)

mm

30.500 to 30.525

See picture

-

BE03.10-N-1009-01D

Piston pin play in connecting rod bushing

mm

0.007 to 0.018

BE03.10-N-1010-01D

Peak-to-valley height (Rz) inside connecting rod bushing

μm

5

BE03.10-N-1011-01D

Connecting rod bolt

Thread Ø

M

9 x 1

BE03.10-N-1012-01D

Connecting rod bolt

Length (L)

New

mm

52 -0.3

max.

mm

52.9

Number

Designation

Engine
601.943

Engine 602.980/982/983/984/985

BA03.10-N-1001-01A

Connecting rod bolt

Stage 1

Nm

42

42

Stage 2

°

90

90