CRANKCASE SERVICING

Table 3.05-1. Connecting Rod Specifications

CONNECTING ROD, BUSHING AND BEARING
ROD MATERIAL - Heat treated steel forging
ALLOWABLE WEIGHT VARIATION - 90 grams (3 oz.)

Measurement Wear Limit mm (in.) New Minimum mm (in.) New Maximum mm (in.)
(A) Rod Length, Center To Center 259.96 (10.234) 259.96 (10.234) 260.04 (10.237)

(B) Rod Small End Finish Size -

53.848 (2.120) 53.800 (2.118) 53.830 (2.119)
w/o bushing

(C) Bushing Bore Diameter 1 50.076 (1.9715) 50.030 (1.969) 50.043 (1.970)
(D) Rod Large End Finish Size -
88.519 (3.485) 88.483 (3.483) 88.505 (3.484)
w/o bushing

(E) Rod - w/bearing-Inside Diameter - New 84.302 (3.319) 84.233 (3.316) 84.255 (3.317)

Bushing Press Fit In Rod

0.043 (0.0017) 0.069 (0.0027) 0.150 (0.0059)
(Interference Fit Between Rod And Bushing)

Rod Large End Width - 58.75 (2.312) 58.80 (2.314)

Rod Side Clearance - 0.20 (0.008) 0.35 (0.013)

Bearing Running Clearance 0.213 (0.0084) 0.05 (0.0019) 0.112 (0.0044)

Connecting Rod Maximum Twist 0.02 (0.0007) - -

Small End Maximum Taper 0.018 (0.0007) - -
Big End Maximum Taper 0.014 (0.0005) - -
NOTE: 1 Connecting rod surface quality must be 0.6 micrometers (23.6 microinches) roughness average.

CONNECTING ROD, INSPECTING 5. Lubricate the bolt threads and washer faces with
r: clean engine oil.

A WARNING 6. Torque connecting rod bolts in two steps to a torque

Use only non-flammable cleaning solvent. Do not of 110 N·m (81 ft-Ib).
use gasoline, paint thinners or other volatile fluids
for cleaning. Comply with the solvent manufactur-
er's recommendations for proper use and handling
I A
••
CAUTION Connecting I rod
can be tightened
bolts
three
of solvents. Improper handling or misuse could times before they must be replaced.
result in severe personal injury or death.

7. Check the inside diameter of the connecting rod

1. Clean the connecting rod threads and the mating bore, without the bearing insert, using a dial bore gauge
surface between the rod and the cap with an approved (see Figure 3.05-8).
cleaning solvent.

2. Clean the oil hole at the top of the rod.

3. Clean all bolts thoroughly and inspect for nicks or

thread damage.

4. Lubricate the bolts with SAE 30 oil and screw into the
rod face by hand.

NOTE: If bolts cannot be installed by hand, clean the

threads of the rod again and try a new bolt. If a new bolt
does not screw in freely, discard the rod and install a
new one (PIN 351043).

A CAUTION I
I....;
••
==- .
~onotretaPtheconnect-
mg rod or bolt threads as
Figure 3.05-8. Measuring Connecting Rod Bore
they are a special rolled thread.
FORM 6259 First Edition 3.05 - 3
CRANKCASE SERVICING

8. With rod cap torqued to specification, measure and CHECKING CONNECTING ROD
record the three inside diameters of each connecting STRAIGHTNESS
rod at points A, B, and C (see Figure 3.05-9).

CONNECTING ROD TWIST

DIAMETER
B
NOTE: This procedure should be performed after
piston pin bushings have been checked, rod caps
installed with markings aligned and bolts have been
torqued to 110 N·m (81.ft-lb).

DIAMETER
A
1. Attach the connecting rod to an alignment fixture and
install the piston pin into the piston pin bushing (see
Figure 3.05-1 0).

Figure 3.05-9. Measuring Connecting Rod

9. If the difference between points A and C is over

0.05 mm (0.002 in.), the rod should be discarded.
{
10. If the difference between point B and the average of
A and C (A and C divided by 2) exceeds 0.05mm (0.002 r
in.), the rod should be discarded.

11. Check the inside diameter of the connecting rod INDICATOR VSG159

piston pin bore. Replace the bushing if worn beyond

dimensional limits. Refer to Section 1.05 General Figure 3.05-10. Connecting Rod Twist Gap
Information for dimensions.

A CAUTION I
I'-== Spe~ial attention should
....1 be given to all aspects of 2. Place the indicator on the piston pin.
the connecting rods and bolts. Lack of attention
during an overhaul could result in rod bearing 3. With the indicator studs horizontal, use a feeler
failure. gauge to measure the gap between the studs and the
fixture.
NOTE: Always check the connecting rod if the
cylinder has been water filled, a piston has seized or
a valve is broken. NOTE: Connecting rod allowable maximum twist is
0.02 mm (0.0007 in.).

CAUTION I
I'-.A
==-
be replaced.
---'.
Never s~raighten a bent
connectmg rod. It must 4. If the connecting rod does not meet specifications it
must be replaced.

3.05 - 4 FORM 6259 First Edition


CONNECTING ROD BENDING
1. With the connecting rod still mounted in the align-
ment fixture proceed as follows:
• With indicator studs vertical, use a feeler gauge to
measure gap between the studs and the fixture (see
Figure 3.05-11).
VSG158
INDICATOR
Figure 3.05-11. Connecting Rod Bend Gap
• The maximum gap between either indicator stud and
the fixture is 0.1 mm (0.004 in.).
2. If connecting rod does not meet specifications it must
be replaced.
PISTON, INSPECTING
1. Visually check pistons for scuffed or scored skirts
and cracked or worn piston ring lands. Replace the
piston if this type of damage is found.
2. Check the piston tops for evidence of burning,
etching or melting caused by detonation or preignition.
3. Check for imprints caused by contact with valves. If
imprints can be seen the engine has been assembled
out of time. Retime the engine.
FORM 6259 First Edition
CRANKCASE SERVICING
4. Inspect the piston pins for wear or damage. Replace
if necessary.
PISTON, CLEANING
A WARNING
Use only a non-flammable cleaning solvent. Do not
use gasoline paint thinners or other highly volatile
fluids for cleaning. Comply with the solvent
manufacturer's recommendations for proper use
and handling of solvents. Improper handling or
misuse could result in severe personal injury or
death.
NEW PISTONS
1. Make sure that the piston is clean.
2. Coat the pistons with clean engine oil and assemble
into the engine.
USED PISTONS
1. Use an approved cleaning solvent and a soft bristle
brush to degrease the pistons.
2. To remove carbon deposits, immerse the pistons in a
concentrated solution of liquid cleaner heated to 50° C
(122° F) for a minimum of twenty four hours.
3. If stubborn deposits remain, brush the pistons using
a hard brass brush.
4. Dry with moisture-free compressed air.
NOTE: After piston cleaning has been performed,
reinspect to determine usability of pistons. Refer to
Table 3.05-2.
5. Coat with clean engine oil and assemble into the
engine immediately. See Section 4.00 Crankcase
Assembly, for piston installation.
3.05 - 5