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

ENGINES 604, 605, 606 

Fig 1: Checking Connecting Rod Dimensions

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	Removing/installing
1	Remove pistons		AR03.10-P-7021B
	Checking
2	Inspect 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 the connecting rod, grinding off the specified area to balance the weights between the individual rods, refer to ↓	*BE03.10-P-1005-01C
		connecting rod as-built configuration description	GF03.10-P-0800B
3	Bolt connecting rod bearing cap to connecting rod	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-6111-02A
			*BA03.10-P-1001-01B
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
			Figure
			*WH58.30-Z-1001-12A
			*WH58.30-Z-1012-12A
5	Inspect connecting rod bush inner diameter		*BE03.10-P-1006-01C
			Figure
			*WH58.30-Z-1001-12A
		If excessive wear is present ↓	*WH58.30-Z-1012-12A
		Press in the new connecting rod bush	AR03.10-P-6111-03HA
		Connecting rod bush inner diameter	*BE03.10-P-1006-01C
		Connecting rod bush outside dia.	*BE03.10-P-1007-01C
		Connecting rod bush basic bore dia. (d1)	*BE03.10-P-1008-01C
		Piston pin play in connecting rod bush	*BE03.10-P-1009-01C
		Peak-to-valley height (Rz ) inside connecting rod bush	*BE03.10-P-1010-01C
6	Align connecting rod		AR03.10-P-6111-04HA
			*WH58.30-Z-1008-05A
			*WH58.30-Z-1009-05A  *BE03.10-P-1003-01C  *BE03.10-P-1004-01C
7	Install in reverse order

Inspection data for connecting rod

Number	Designation			Engines 604, 605.910/911/912, 606.910/912	Engines 605.960/962, 606.961/962/964
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	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) 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	26.012...26.018	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	28.575...28.600	30.575...30.600
BE03.10-P-1008-01C	Dimension	Connecting rod bush basic bore ø(d1)	mm	28.500...28.521	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	μM	5	5

Connecting rod

Number	Designation			Engines 604, 605, 606
BA03.10-P-1001-01B	Connecting rod bolt (stretch shank)	1st stage	Nm	40
		2nd stage	∠°	90

Fig 2: Identifying Dial Indicator (001 589 53 21 00)

Courtesy 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-1012-12A	Setting gage for micrometer

Connecting rods

Number	Designation			Engine 604, 605, 606
BA03.10-P-1001-01B	Conrod bolt (stretch shank)	1st stage	Nm	40
		2nd stage	∠°	90