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Checking/repairing a connecting rod - AR03.10-P-6111AW

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ENGINES 601, 602, 603 (except, 602.98) 

Fig 1: Checking Connecting Rod
G05438222Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Identifying Connecting Rod Specification
G05438223Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Connecting rods shown on engines 602.96, 603.96 and 603.97 USA ONLY (turbocharged engines)

Fig 3: Identifying Connecting Rod Specification
G05438224Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

IMPORTANT Engines 602.96, 603.96 as of 01/88 up to 08/88: 3 holes for piston pin lubrication

Engines 602.96, 603.96 and 603.97 USA ONLY as of 09/88: 2 holes for piston pin lubrication

REMOVINGINSTALLING Removing/installing    
1 Remove pistons   AR03.10-P-7021AW 
INSPECT Checking     
2 Inspect connecting rods for blue discoloration, cross scores and notches NOTES 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 weight. *BE03.10-P-1005-01C 
3 Bolt connecting rod bearing cap to connecting rod IMPORTANT Connecting rod and bearing cap are marked in sets and attached with two sleeves.
Tighten connecting rod bearing caps to initial torque. ↓
Tighten connecting rod bolts.		 AR03.10-P-6111-02AW 
TORQUE SPECIFICATION *BA03.10-P-1001-01C 
TORQUE SPECIFICATION *BA03.10-P-1002-01C 
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-P-1002-01C 
SPECIAL TOOL Fig 4
COMMERCIALLY AVAILABLE TOOLS *WH58.30-Z-1001-12A 
COMMERCIALLY AVAILABLE TOOLS *WH58.30-Z-1002-12A 
5 Inspect connecting rod bush inner diameter   *BE03.10-P-1006-01C 
SPECIAL TOOL Fig 4
COMMERCIALLY AVAILABLE TOOLS *WH58.30-Z-1001-12A 
COMMERCIALLY AVAILABLE TOOLS *WH58.30-Z-1002-12A 
If excessive wear is present ↓
Press in the new connecting rod bush		 AR03.10-P-6111-03AW 
*BE03.10-P-1006-01C 
*BE03.10-P-1007-01C 
*BE03.10-P-1008-01C 
*BE03.10-P-1009-01C 
*BE03.10-P-1010-01C 
6 Align connecting rod   AR03.10-P-6111-04AW 
COMMERCIALLY AVAILABLE TOOLS *WH58.30-Z-1008-05A 
COMMERCIALLY AVAILABLE TOOLS *WH58.30-Z-1009-05A 
*BE03.10-P-1003-01C 
*BE03.10-P-1004-01C 
*BE03.10-P-1001-01C 
7 Install in reverse order    
INSPECTION DATA FOR A CONNECTING ROD

Number Designation Engine 601.921 USA ONLY up to 09/84 Engine 601.921 USA ONLY as of 10/84
BE03.10-P-1001-01C Dimension Distance from center of connecting rod bearing bore to connecting rod bush bore (L) mm 144.97...145.03 144.97...145.03
Width of connecting rod at connecting rod bearing bore (B) and at connecting rod bush bore (b) mm 23.974...24.026 21.948...22.000
See picture in   AR03.10-P-6111AW  AR03.10-P-6111AW 
BE03.10-P-1002-01C Dimension Connecting rod bearing shell basic bore (D1) dia. Ø mm 51.600...51.619 51.600...51.614
Permissible out-of-roundness and conicity of basic bore mm 0.02 0.02
See picture in   AR03.10-P-6111AW  AR03.10-P-6111AW 
BE03.10-P-1003-01C Dimension permissible twist of connecting rod bearing bore to connecting rod bush bore over a length of 100 mm mm 0.1 0.1
BE03.10-P-1004-01C Dimension Permissible variation of axial parallelism of connecting rod bearing bore to connecting rod bush bore over a length of 100 mm mm 0.045 0.045
BE03.10-P-1005-01C Dimension Permissible weight difference between complete connecting rods in the same engine g 2 2
BE03.10-P-1006-01C Dimension Connecting rod bush inner Ø (d) mm 27.018...27.024 26.012...26.018
See picture in   AR03.10-P-6111AW  AR03.10-P-6111AW 
BE03.10-P-1007-01C Dimension Connecting rod bush outside dia. mm 29.560...29.600 28.575...28.600
BE03.10-P-1008-01C Dimension Connecting rod bush basic bore Ø (d1) mm 29.500...29.521 28.500...28.521
See picture in   AR03.10-P-6111AW  AR03.10-P-6111AW 
BE03.10-P-1009-01C Dimension Piston pin play in connecting rod bush mm 0.007...0.018 0.007...0.018
BE03.10-P-1010-01C Dimension Peak-to-valley height (Rz ) inside connecting rod bush μ M 5 5
INSPECTION DATA FOR CONNECTING ROD

Number Designation Engine 601 up to 09/84 except 601.921 USA ONLY Engine 601 as of 10/84 except 601.921 USA ONLY , engine 602.91, 603.91
BE03.10-P-1001-01C Dimension Distance from center of connecting rod bearing bore to connecting rod bush bore (L) mm 148.97...149.03 148.97...149.03
Width of connecting rod at connecting rod bearing bore (B) and at connecting rod bush bore (b) mm 23.974...24.026 21.948...22.000
See picture in   AR03.10-P-6111AW  AR03.10-P-6111AW 
BE03.10-P-1002-01C Dimension Connecting rod bearing shell basic bore (D1) dia. Ø mm 51.600...51.619 51.600...51.614
Permissible out-of-roundness and conicity of basic bore mm 0.02 0.02
See picture in   AR03.10-P-6111AW  AR03.10-P-6111AW 
BE03.10-P-1003-01C Dimension permissible twist of connecting rod bearing bore to connecting rod bush bore over a length of 100 mm mm 0.1 0.1
BE03.10-P-1004-01C Dimension Permissible variation of axial parallelism of connecting rod bearing bore to connecting rod bush bore over a length of 100 mm mm 0.045 0.045
BE03.10-P-1005-01C Dimension Permissible weight difference between complete connecting rods in the same engine g 2 2
BE03.10-P-1006-01C Dimension Connecting rod bush inner Ø (d) mm 27.018...27.024 26.012...26.018
See picture in   AR03.10-P-6111AW  AR03.10-P-6111AW 
BE03.10-P-1007-01C Dimension Connecting rod bush outside dia. mm 29.560...29.600 28.575...28.600
BE03.10-P-1008-01C Dimension Connecting rod bush basic bore dia. Ø (d1) mm 29.500...29.521 28.500...28.521
See picture in   AR03.10-P-6111AW  AR03.10-P-6111AW 
BE03.10-P-1009-01C Dimension Piston pin play in connecting rod bush mm 0.007...0.018 0.007...0.018
BE03.10-P-1010-01C Dimension Peak-to-valley height (Rz ) inside connecting rod bush μ M 5 5
INSPECTION DATA FOR CONNECTING ROD

Number Designation Engines 602.96, 603.96 Engine 603.97
BE03.10-P-1001-01C Dimension Distance from center of connecting rod bearing bore to connecting rod bush bore (L) mm 148.97...149.03 144.97...145.03
Width of connecting rod at connecting rod bearing bore (B) and at connecting rod bush bore (b) mm 21.948...22.000 21.948...22.000
See picture in   AR03.10-P-6111AW  AR03.10-P-6111AW 
BE03.10-P-1002-01C Dimension Connecting rod bearing shell basic bore (D1) dia. Ø mm 51.600...51.614 51.600...51.614
Permissible out-of-roundness and conicity of basic bore mm 0.02 0.02
See picture in   AR03.10-P-6111AW  AR03.10-P-6111AW 
BE03.10-P-1003-01C Dimension permissible twist of connecting rod bearing bore to connecting rod bush bore over a length of 100 mm mm 0.1 0.1
BE03.10-P-1004-01C Dimension Permissible variation of axial parallelism of connecting rod bearing bore to connecting rod bush bore over a length of 100 mm mm 0.045 0.045
BE03.10-P-1005-01C Dimension Permissible weight difference between complete connecting rods in the same engine g 2 2
BE03.10-P-1006-01C Dimension Connecting rod bush inner Ø (d) mm 28.012...28.024 28.018...28.024
See picture in   AR03.10-P-6111AW  AR03.10-P-6111AW 
BE03.10-P-1007-01C Dimension Connecting rod bush outside dia. mm 30.575...30.600 30.575...30.600
BE03.10-P-1008-01C Dimension Connecting rod bush basic bore Ø (d1) mm 30.500...30.525 30.500...30.525
See picture in   AR03.10-P-6111AW  AR03.10-P-6111AW 
BE03.10-P-1009-01C Dimension Piston pin play in connecting rod bush mm 0.007...0.018 0.007...0.018
BE03.10-P-1010-01C Dimension Peak-to-valley height (Rz ) inside connecting rod bush μ M 5 5
TORQUE SPECIFICATION CONNECTING ROD

Number Designation Engines 601, 602 except 602.98, 603 except 603.970 up to 11/90 603.970 up to 8/90 Engines 601, 602 except 602.98, 603 except 603.970 as of 12/90 - 10/92 603.970 as of 9/90 - 10/92 Engines 601, 602 except 602.98, 603 as of 11/92
BA03.10-P-1001-01C Connecting rod bolt (stretch shank) 1st stage new Nm - 45 40
used Nm - 40 -
Step 2   ∠ ° - 90 90
See picture in     - AR03.10-P-6111-01AW  AR03.10-P-6111-01AW 
BA03.10-P-1002-01C Connecting rod bolt (stretch bolt) 1st stage   Nm 30 - -
Step 2   ∠ ° 90 - -
See picture in     AR03.10-P-6111-01AW     
Fig 4: Identifying Dial Indicator (001 589 32 21 00)
G05438225Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
COMMERCIALLY AVAILABLE TOOLS

Number Designation
WH58.30-Z-1008-05A Connecting rod tester
WH58.30-Z-1009-05A Conrod straightening equipment
WH58.30-Z-1001-12A Quick calipers for internal measurements
WH58.30-Z-1002-12A Micrometer
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