Check/repair connecting rod

AR03.10-T-6111BB

Check/repair connecting rod

11.12.08



Removing

1

Remove pistons

For model 613.358/388, model 671

AR03.10-T-7021BB

For model 613.367/368

AR03.10-T-7021CB



Checking

2

Check connecting rod (1)

 Connecting rods with blue discoloration (caused by bearing damage), with cross scores and notches must not be re-used and must be replaced.

3

Inspect cracked contact surface at connecting rod (1) and at connecting rod bearing cap (2) for damage

 Replace connecting rod, if necessary.

4

Inspect connecting rod (1) for distortion and dimensional tolerance

 The connecting rod must not be straightened due to danger of engine damage.

Permissible out-of-roundness of basic bores

*BE03.10-N-1006-01J

Basic bore for connecting rod bearing

*BE03.10-N-1004-01J

Permissible variation of axle parallelism between connecting rod bearing bore and connecting rod bush bore referred to measuring distance (B)

*BE03.10-N-1005-01J

Distance from middle of connecting rod bearing bore to middle of connecting rod bush bore (A)

*BE03.10-N-1007-01J

The connecting rod must be replaced if the permissible values are not observed.

5

Inspect inner  of connecting rod bush (5)

Connecting rod bush inner 

*BE03.10-N-1009-01J



*001589532100

Micrometer

Quick calipers for internal measurements

 If permissible value is not maintained: 

Replace connecting rod bush.

AR03.10-T-6111-03BB

Permissible out-of-roundness of basic bores

*BE03.10-N-1006-01J

Connecting rod bush inner 

*BE03.10-N-1009-01J

Basic bore  for connecting rod bush

*BE03.10-N-1010-01J

Connecting rod bush outer 

*BE03.10-N-1011-01J

Overlap between outer and basic bore  of connecting rod bush

*BE03.10-N-1012-01J



*001589532100

Micrometer

Quick calipers for internal measurements

6

Install and gauge connecting rod bearing shells (3)

AR03.10-T-6111-06BB

Connecting rod bearing play

*BE03.10-N-1001-01J

Connecting rod bolt

*BE03.10-N-1002-01J

Connecting rod bearing inner  with connecting rod bearing shells inserted

*BE03.10-N-1003-01J

Connecting rod bearing journal 

*BE03.20-N-1001-02J



*BA03.10-N-1001-01H



*001589532100

Micrometer

Quick calipers for internal measurements

7

Inspect connecting rod bearing axial play

Axial play

*BE03.10-N-1001-01J

Connecting rod width at connecting rod bearing

*BE03.10-N-1008-01J

Connecting rod bearing journal width

*BE03.20-N-1002-02J



Install

8

Install pistons

For model 613.358/388, model 671

AR03.10-T-7021BB

For model 613.367/368

AR03.10-T-7021CB

Number

Designation

Engine
457.941/942/944/945/946

BE03.10-N-1001-01J

Connecting rod bearing play

radial

mm

0.060 to 0.120

axial

mm

0.130 to 0.292

BE03.10-N-1002-01J

Connecting rod bolt

Thread Ø

M

161.5

Shank length (L) when new

mm

67.0 to 67.5

permissible shank length (L)

mm

68.5

BE03.10-N-1003-01J

Connecting rod bearing inside Ø with connecting rod bearing shells inserted

Normal

mm

90.060 to 90.102

Standard I

mm

89.960 to 90.002

Repair size I

mm

89.810 to 89.852

Repair size II

mm

89.560 to 89.602

Repair size III

mm

89.310 to 89.352

Repair size IV

mm

89.060 to 89.102

BE03.10-N-1004-01J

Basic bore Ø for connecting rod bearing

mm

95.000 to 95.022

BE03.10-N-1005-01J

Permissible deviation of axle parallelism between connecting rod bearing bore and connecting rod bush bore

Variation (B)

mm

0.030

Measuring distance (C)

mm

50

BE03.10-N-1006-01J

Permissible out-of-roundness of basic bore

Connecting rod bearing

mm

0.008

Connecting rod bush

mm

0.008

BE03.10-N-1007-01J

Distance from middle of connecting rod bearing bore to middle of connecting rod bush bore

mm

250.970 to 251.030

BE03.10-N-1008-01J

Connecting rod width at connecting rod bearing

mm

45.808 to 45.870

BE03.10-N-1009-01J

Connecting rod bush inner Ø

mm

52.05 to 52.07

BE03.10-N-1010-01J

Basic bore Ø for connecting rod bush

mm

57.000 to 57.030

BE03.10-N-1011-01J

Connecting rod bush outer Ø

mm

57.080 to 57.100

BE03.10-N-1012-01J

Overlap between outer Ø and basic bore of connecting rod bush

mm

0.050 to 0.100

Number

Designation

Engine
457.941/942/944

BE03.20-N-1001-02J

Connecting rod bearing journal Ø

Normal

mm

89.980 to 90.000

Standard I

mm

89.880 to 89.900

Repair size I

mm

89.730 to 89.750

Repair size II

mm

89.480 to 89.500

Repair size III

mm

89.230 to 89.250

Repair size IV

mm

88.980 to 89.000

BE03.20-N-1002-02J

Connecting rod bearing journal width

mm

46.0 to 46.1

Number

Designation

Engine 457.941/
942

Engine 457.944

BA03.10-N-1001-01H

Bolt, connecting rod bearing cap to connecting rod

Stage 1

Nm

100

100

Stage 2

°

90

90