W03.10-0018-12
1 Connecting rods
2 Connecting rod bearing cap
3 Connecting rod bearing shells
4 Connecting rod bolt
5 Connecting rod bush
L Shank length of the connecting rod bolt
W03.10-0019-06
1 Connecting rods
3 Connecting rod bearing shells
5 Connecting rod bush
6 Gauge stand
7 Dial gage
A Distance from middle of connecting rod bearing bore to middle of connecting rod bush bore
B Permissible variation of axle parallelism between connecting rod bearing bore and connecting rod bush bore referred to distance measured
C Distance measured
| Removing | ||
1 | Remove pistons | The connecting rod is removed at the same time. | |
| Checking | ||
2 | Inspect connecting rod bearing seat in connecting rod for blue discoloration, cross scores and notches | Connecting rods with blue discoloration (caused by bearing damage), with transverse scoring or notches must not be reused. connecting rod must be replaced. Before mounting connecting rod bearing cap on the connecting rod: | |
Check connecting rod bolt-shank length (L) | |||
Micrometer 50 - 75 mm | |||
3 | Clamp connecting rod into the vise | Use soft protective jaws (e.g. protective jaws made out of aluminum) to clamp in. - The lug of the connecting rod bearing shell must be located in slot of connecting rod. - If connecting rod bearing shells are re-used, pay attention to installation marking. | |
4 | Mount connecting rod bearing cap on connecting rod | Screw in connecting rod bolts, pretighten to prescribed value and then tighten to specified rotation angle. - Mark wrench socket to check tightening angle. - Pay attention to marking on connecting rod bearing cap. - Coat thread of connecting rod bolt with lead carbonate. - The lug of the connecting rod bearing shell must be located in slot for the connecting rod bearing cap. - If connecting rod bearing shells are re-used, pay attention to installation marking. | |
| |||
| |||
| Measure | Insert dial gauge into quick caliper for internal measurements and set to the prescribed nominal dimension. Perform measurement at least three locations. | |
5 | Measure inside diameter of connecting rod bushing | Connecting rod bush internal diameter | |
| |||
Micrometer | |||
Quick calipers for internal measurements | |||
The connecting rod must be replaced for exceeding of the nominal dimension for the inside diameter. | |||
6 | Measure inside diameter of connecting rod bearing with engaged connecting rod bearing shell | Connecting rod bearing inside diameter for engaged connecting rod bearing shells | |
| |||
Micrometer | |||
Quick calipers for internal measurements | |||
7 | Check connecting rod for distortion and dimensional accuracy | If the specifications are exceeded, replace connecting rod. Connecting rods must not be straightened. | |
Permissible deviation of axle parallelism between connecting rod bearing bore and connecting rod bush bore | |||
Distance from middle of connecting rod bearing bore to middle of connecting rod bush bore | |||
Permissible weight difference for connecting rod within an engine | |||
8 | Remove connecting rod bearing bolt, connecting rod bearing cap and connecting rod bearing shell | ||
9 | Mount connecting rod bearing cap without connecting rod bearing shell | ||
10 | Measure basic bore diameter for connecting rod bearing | The connecting rod must be replaced for exceeding of the basic bore diameter. | |
| |||
Micrometer | |||
Quick calipers for internal measurements | |||
Basic bore for connecting rod bearing | |||
11 | Remove connecting rod bearing cap from connecting rod | ||
| Install | ||
12 | Install pistons |
Test and adjustment values for connecting rod
Number | Designation | Engine 447 | Engine 489 | ||
BE03.10-N-1001-01F | Connecting rod bearing inner with connecting rod bearing shells inserted | Default | mm | 90.060-90.102 | 90.060-90.102 |
Deviation 0.1 | mm | 89.960-90.002 | 89.960-90.002 | ||
Deviation 0.25 | mm | 89.810-89.852 | 89.810-89.852 | ||
Deviation 0.5 | mm | 89.560-89.602 | 89.560-89.602 | ||
Deviation 1.0 | mm | 89.060-89.102 | 89.060-89.102 | ||
BE03.10-N-1002-01F | Basic bore for connecting rod bearing | mm | 95.00-95.022 | 95.00-95.022 | |
BE03.10-N-1004-01F | Permissible deviation of axle parallelism between connecting rod bearing bore and connecting rod bush bore | max. | mm | 0.02 | 0.02 |
BE03.10-N-1005-01F | Distance from middle of connecting rod bearing bore to middle of connecting rod bush bore | mm | 250.98-251.02 | 250.98-251.02 | |
BE03.10-N-1006-01F | Connecting rod bush inner | mm | 23.8-24.00 | 23.8-24.00 | |
BE03.10-N-1007-01F | Permissible weight difference for connecting rod within an engine | g | 60 | 60 | |
BE03.10-N-1008-01F | Connecting rod bolt - inner | Thread | M | 16X1.5 | 16X1.5 |
Shank length (L) when new | mm | 67.5-0.3 | 67.5-0.3 | ||
Connecting rod
Number | Designation | Engine 447 | Engine 489 | ||
BA03.10-N-1001-01F | Bolt of connecting rod bearing cap to connecting rod | Stage 1 | Nm | 100 | 100 |
Stage 2 | ° | 95 | 95 | ||
000 589 64 21 00
Torque wrench
Dial indicator
001 589 53 21 00