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

ENGINES 601, 602, 603 (except, 602.98) 

Fig 1: Checking Connecting Rod

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 2: Identifying Connecting Rod Specification

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

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

Fig 3: Identifying Connecting Rod Specification

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

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 as of 09/88: 2 holes for piston pin lubrication

	Removing/installing
1	Remove pistons		AR03.10-P-7021AW
	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 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	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
			*BA03.10-P-1001-01C
			*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
			Fig 4
			*WH58.30-Z-1001-12A
			*WH58.30-Z-1002-12A
5	Inspect connecting rod bush inner diameter		*BE03.10-P-1006-01C
			Fig 4
			*WH58.30-Z-1001-12A
			*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
			*WH58.30-Z-1008-05A
			*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

Number	Designation			Engine 601.921 up to 09/84	Engine 601.921 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

Number	Designation			Engine 601 up to 09/84 except 601.921	Engine 601 as of 10/84 except 601.921 , 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

CONNECTING ROD

Fig 4: Identifying Dial Indicator (001 589 32 21 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.