Reconditioning and Squaring Connecting Rods

A Width of connecting rod bearing bore
B Width of connecting rod bushing bore


NOTE: Connecting rod bearing bore (A) and connecting rod bushing bore (B) are of different width.


Do not install these connecting rods on the other diesel engines.

It is also not possible to install the connecting rods of the other diesel engines in this engine.







The connecting rods are subdivided into weight classes.

Colored dots on shank serve to identify the individual weight classes.

Install only connecting rods with the same color dots in engine.







Connecting rods which are overheated as a result of bearing damage (blue discoloration) should no longer be used.

Connecting rod and connecting rod bearing cap are marked together. The connecting rod shank should have no transverse score marks and notches.

Connecting rods with machined connecting rod bushing are available as spare parts.

In the period from May to October 1980, connecting rod bearing shells of a second manufacturer (Karl Schmidt) were installed. Standard shells from Glyco.

In the period from May to October 1980, connecting rod bearing shells of a second manufacturer (Karl Schmidt) were installed. Standard shells from Glyco.







Installation
For reasons of standardization the same connecting rod bearing shells as for engines 615, 616 and 617.91 will be installed.







Production breakpoint: July 1984

Reconditioning







1 Check connecting rod bolts and renew, if required. Checking, Replacement and Tightening of Big-End Clamp Bolts







2 Check bores for connecting rod bolts.

Mount connecting rod bearing cap on a connecting rod bolt. If the connecting rod bearing cap is moving downwards under its own weight, the connecting rod must be replaced.







3 Mount connecting rod bearing caps, lubricate connecting rod nuts and tighten to 40 - 50 Nm preload and 90-100° angle of rotation torque.
4 Measure connecting rod bearing basic bore If basic bore exceeds a specified value of 55.62 mm or is conical in shape. refinish bearing cap supporting surface on a face plate up to max. 0.02 mm.







5 Press-in new connecting rod bushing in such a manner that the oil bores are in alignment.

Pressing-in pressure 2500 N.

6 Machine or ream connecting rod bushing.
7 Refinish lateral contact surfaces of connecting rod on a face plate.

Squaring







8 Square connecting rod by means of connecting rod tester.
9 Align connecting rod bearing bore in relation to connecting rod bushing bore (parallel alignment).







10 Check offset of connecting rod bearing bore in relation to connecting rod bushing bore and make corrections, if required.