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Section 1.18 Piston, Piston Ring, and Connecting Rod
The pistons are made of aluminum alloy with ring carriers and a shallow combustion chamber recess. The pistons are cooled by oil spray nozzles. See Figure "Piston Assembly (exploded view)" for an exploded view of the piston and connecting rod assembly.

1. Piston and Rings 2. Wrist Pin 3. Snap Ring

4. Connecting Rod 5. Bearing Cap 6. Connecting Rod Stretch Bolt

7. Bearing Shell

Figure 1. Piston Assembly (exploded view) The difference from the non-EGR engine cylinder liner to the EGR engine is a groove on the top part of the cylinder liner, which houses the carbon scraper ring. The EGR engine uses a new tool for piston installation; however, all other procedures are the same for the EGR and nonEGR engine. Section 1.18.1 Piston Removal Remove the piston assembly as follows: 1. Remove each cylinder head, as required. Refer to "1.2.1 Cylinder Head Removal" . Note: The MBE 4000 engine has individual heads for each cylinder. To remove one piston, do these procedures step by step. To remove all the pistons, repeat each step in these instructions, as applicable, for all six pistons. 2. Remove the oil pan.

NOTICE:
Do not damage the piston travel surface of the cylinder. 3. Using a plastic scraping tool, carefully scrape off any combustion residues from the combustion area in the cylinder in order to avoid damage to the piston rings when the piston is removed. 4. Install the engine barring tool (J–46392) . Refer to "1.16.1 Engine Barring Tool Installation" . 5. Be sure the connecting rods and the bearing caps are marked so that they can be matched for installation. See Figure "Checking Rod and Bearing Cap Markings" .

1. Bearing Cap

2. Connecting Rod

Figure 2. Checking Rod and Bearing Cap Markings 6. Remove and inspect the oil spray nozzles. Replace them if damaged. See Figure "Location of Oil Spray Nozzle" .

1. Oil Spray Nozzle Figure 3. Location of Oil Spray Nozzle

2. Cylinder Liner

7. Remove the connecting rod stretch bolts and bearing cap. See Figure "Removing the Bearing Caps" .

See Figure "Removing Carbon Scraper Ring" . Note: Step 9 only applies to EGR engines. Note: Piston removal in the EGR engine is performed with the engine facing upright – not turned on it's side. 9. Removing the Bearing Caps Note: If the bearing shell halves are removed from the rods and caps. 8. 11. the piston installation and removal must be carried out with the carbon scraper ring removed. therefore. 10. Remove the carbon scraper ring from the cylinder liner groove. . Remove the bearing shell halves from the bearing cap and connecting rod. go to step 10 . be sure to mark them so they can be matched for installation. For non-EGR engines.Figure 4. NOTICE: The carbon scraper ring has a smaller internal diameter than the piston skirt diameter.

Removing Carbon Scraper Ring 12. 14. Remove the piston rings from the piston. Push the wrist pin out and remove the piston from the connecting rod. Installed Piston 4. 15. Secure the connecting rod in a vise with protective jaws. Such surface damage could lead to later rod cracking or breaking. Cylinder Liner 2. Carbon Scraper Ring 3. . and remove them both from the cylinder block. Installed Carbon Scraper Ring Figure 5. 13. NOTICE: Be sure the vise jaws are adequately lined to prevent the rod surface from being nicked or marred in any way.18. Push the piston and connecting rod out of the cylinder. Remove the wrist-pin snap rings.1.3 Piston Ring Replacement" . Refer to "1.

1 Piston Inspection Inspect the piston as follows: 1. Connecting Rod 5. Snap Ring 4. Refer to "1. Bearing Shell Figure 6. Piston and Rings 2. Piston Assembly (exploded view) Description Piston Compression Height Wrist Pin Bore Diameter Wrist Pin Diameter Dimensions: mm (in. cracks in the piston wall.Section 1. Specifications are listed in Table "Piston Inspection Specifications" .132) 52.992-51.1.55 (3.18. or signs of seizing and/or erosion. Check the tolerance code on the piston and compare it to the tolerance code on the cylinder liner.03-52.04 (2. Piston Inspection Specifications 3. .130-3.998 (2. Replace any piston with damage to the snap ring grooves. Check the diameter of the wrist pin and the wrist pin bore. 1.18. See Figure "Tolerance Codes" .0488) 51. Remove the piston. See Figure "Piston Assembly (exploded view)" . Connecting Rod Stretch Bolt 7.0484-2. Bearing Cap 6.1 Piston Removal" .) 79. 4.0472) Table 9. Wrist Pin 3.0469-2. Inspect the cylinder liner and piston for damage and signs of wear.50-79. 2.

or chipped rings.1. Piston Figure 7.18. Replace any bolts that exceed the maximum length of 68. Refer to "1. 1.2 Connecting Rod End Play Measurement" . Check the length of the connecting rod stretch bolts.18.5 mm (2. Shank .70 in. Tolerance Codes 2. 7.). damaged. See Figure "Measuring a Stretch Bolt" . Replace any worn. 8. Refer to "1. 6. Measure the diameters of the bearing shell bore and crankshaft journals. Refer to "1.3 Connecting Rod Radial Play Measurement" for instructions.18. Check the connecting rod for any unusual condition.1. Check the condition of the piston rings.3 Piston Ring Replacement" . Cylinder Liner 5.1.

). Bearing Shell (2 halves) 6. Dial Gauge Holder 3. scoring. See Figure "Measuring Inside Diameters in the Connecting Rod" . 3. Use a quick-release caliper (internal measurement.2 Connecting Rod End Play Measurement Measure the connecting rod end play as follows: 1.) . 40 to 60 mm). Inspect the connecting rod for blue discoloration (indicates bearing damage). Measuring a Stretch Bolt Section 1. replace the connecting rod. Connecting Rod 5.07 mm (2. and cracks. Dial Gauge 2. If the value exceeds 52. Bearing Cap 7. with a dial gauge and holder.1 Piston Removal" . Remove the piston.18. 2. 1.1. Stretch Bolt (2 qty.18. notches.Figure 8. Refer to "1. Measure the inside diameter of the bushing in the small bore of the connecting rod. replace the connecting rod. If any of these conditions are found. Bushing 4.050 in.

970-256.370 (1. 4.) 255.75-1.89763.0775-10. Measuring Inside Diameters in the Connecting Rod Note: Checking the connecting rod for a twisted or bent condition in the next step requires machine shop equipment such as a caliper gauge with a round scale.7468) 44.022 (3.0012) 44. Inspect the connecting rod for twisting and dimensional tolerance. Figure 10. If any value exceeds those listed in Table "Connecting Rod Dimensional Tolerances" .030 (0. This could result in severe engine damage. see Figure "Connecting Rod Measurements" .0004) 0.6 (1.030 (10.01 (0.Figure 9. Connecting Rod Measurements Description Length of Connecting Rod Basic Bore Diameter for Connecting Rod Bearings Maximum Permissible Out-of-Round in Bearing Bore Maximum Permissible Out-of-Round in Bushing Bore Maximum Difference in Axial Parallelism Between Bearing Bore and Bushing Inner Surface Width of Connecting Rod (at big end) Width of Connecting Rod Journal Dimensions: mm (in.308-44. replace the connecting rod.5-44.000-99.8985) 0.0004) 0. NOTICE: Do not attempt to straighten the connecting rod.7441.0799) 99.01 (0.76) .

with the bearing shells removed. replace the connecting rod.01 mm (0. Measure the diameter of the connecting rod basic bore.0012 in. Install the piston.030 mm (10. Example: Wj —Wr = 0. 2.8985 in. 6. Example: Wj = 1.1.18. clean the bearing bores in both the connecting rod and the bearing cap.0775 to 10. On each side of the connecting rod.0115 in. Calculate the connecting rod end play. 5. 4. note the width (thickness) of the bearing journal. or more than 0.3 Connecting Rod Radial Play Measurement Measure the connecting rod radial play as follows: 1. 1. Section 1. subtract the value for the connecting rod width.0799 in. The diameter of the basic bore must be between 99.130 mm (0. . Using a chamois cloth.) from the connecting-rod centerline (Dimension C in figure "Connecting Rod Measurements" ).000 to 99.18. For each bearing journal.).970 to 256. From the value for the journal width. Measure the maximum permissible out-of-round in the bearing bore. Measure the difference in axial parallelism (Dimension B in figure "Connecting Rod Measurements" ): between the bearing bore and the inner surface of the bushing.0070 inch. (fore-to-aft movement) on the crankshaft.18.).).8976 to 3.). The maximum permissible is 0.Description Distance from Connecting Rod Center Line for Measuring Parallelism Table 14. note the width (thickness) of the rod.2 Piston Installation" .). 7.8050 inches.). Remove the piston. with the bearing shells removed.292 mm (0.) 50 (2) 1.022 mm (3. 2. This result is the end play. If the end play is less than 0. The measurement must be within 255. Refer to "1. Refer to "1. For each connecting rod. 2. or axial play.8120 inches. Example: Wr = 1. The maximum allowed difference is 0. listed in Table "Connecting Rod Dimensional Tolerances" . Remove the bolts and bearing cap when ready to install the piston.0004 in. 3. at 50 mm (2 in.1 Piston Removal" .0051 in.030 mm (0. 3. Connecting Rod Dimensional Tolerances Dimensions: mm (in. measure the length of the connecting rod (Dimension A in figure "Connecting Rod Measurements" ): the distance from the center bearing bore (big-end bore) to the center of the bushing (small-end bore).

Connecting Rod Bolt 4. Shaft Length: mm (in. Be sure the locking lugs on the bearing shells fit into the grooves in the rod and cap. pressing it on by hand. into the connecting rod and into the bearing cap. Bearing Shell Replacement 3. 5. listed in Table "Tightening Stages. Install the bearing cap on the connecting rod. as marked on removal. 6. Bearing Shell (2 halves) Figure 11. Tighten each one in turn to the first stage and then go on to the next stage. Connecting Rod 2. Lubricate the threads and the contact surface of the head of each stretch bolt with a light coating of engine oil. Max. Connecting Rod Stretch Bolts" . Install the two matched halves of the bearing shell. Bearing Cap 4. and tighten them alternately. Be sure that the marks on the cap and rod match. Install the stretch bolts in the connecting rod.3. 1.) Tightening Stage Torque Value: N·m (lb·ft) . See Figure "Bearing Shell Replacement" .

004) 93. Repair Stage: mm (in.5 (2. Calculate the average (nominal) bearing-journal diameter from these two measurements.7000-3. Bearing Journal Specifications 1.000 (3.480-93.6803-3.) 93.6705-3.730-93.0.) Standard Diameter: mm (in.500 (3.6606-3.7007) Undersize .6614) Table 17. Figure 12.1 (0.0. Table 16.70) Stage 1 Stage 2 108 (80) additional 90 degrees 7.980-93.0.25 (0. Using a micrometer. 3.50 (0. Shaft Length: mm (in.020) 93. 2.6968) Undersize .030) 93. Measure the bearing journal in the vertical plane and note the reading. and determine the current repair stage listed in Table "Bearing Bore Inside Diameter with Bearing Shells Installed" . measure the bearing journal on the crankshaft in both the vertical and horizontal plane and note the measurements.) Tightening Stage Torque Value: N·m (lb·ft) 68.1. See Figure "Measuring the Bearing Journal" to locate the measuring points and listed in Table "Bearing Journal Specifications" are the current repair stage specifications.) Diameter: mm (in. Measuring the Bearing Journal Repair Stage: mm (in.00 (0.6901-3.000 (3.900 (3.75 (0.250 (3.6712) Undersize .) .010) 93.6909) Undersize .750 (3.980-94.6811) Undersize . Connecting Rod Stretch Bolts 8. Measure the bearing journal in the horizontal plane and note the reading. Tightening Stages.0.230-93.880-93.040) 92.6960-3.Max.

Set the caliper (internal measurement 80 to 100 mm) to the nominal bearing-journal diameter calculated above.6931-3.596 (3. 9. Table 18. Preload the setting 5 mm (0.054-93.010) 93. Use a 75 to 100 mm micrometer for the setting.7046) Undersize .00 (0.6832-3.846 (3.6635-3.6652) 4.10 (0. Place the connecting rod in a vise with protective jaws.954-93.1.6990-3.75 (0.7029-3.6734-3.096 (3.804-93.020) 93.Repair Stage: mm (in. 10.0. Bearing Bore Inside Diameter with Bearing Shells Installed NOTICE: Be sure the vise jaws in the next step are adequately lined to prevent the connecting rod surface from being nicked or marred in any way.25 (0.0.6947) Undersize .6750) Undersize . To prevent the rod from twisting excessively.) 94.) Standard Diameter: mm (in.7006) Undersize .2 in.0. Such surface damage could lead to later cracking or breaking of the rod.554-93.096 (3.030) 93. See Figure "Setting the Caliper" .50 (0.040) 93.054-94.304-93. .004) 93.). position the rod in the vise as close as possible to the big-end bore.346 (3.6848) Undersize .0.996 (3.

See Figure "Measuring the Inside Diameter of the Bearing Shell" to locate the measuring points. Measure vertically and about 60 degrees each side of vertical. Using a quick-release caliper (internal measurement 80-120 mm). dial gauge.Figure 13. measure the inside diameter of the bearing bore (with the shells installed) at three points. and find the current specifications listed in Table "Bearing Bore Inside Diameter with Bearing Shells Installed" . Setting the Caliper 11. (A). (B) and (C). and holder. .

. Measuring the Inside Diameter of the Bearing Shell 1. and determine the current repair stage listed in Table "Bearing Bore Inside Diameter with Bearing Shells Installed" . 4. Calculate the average (nominal) bearing-journal diameter from these three measurements. replace the bearing shells. Mark off a point 60 degrees clockwise from vertical. Measure the bearing bore in this dimension and note the reading. 3. Bearing Cap Figure 14. Measure the bearing bore in this dimension and note the reading. Do not refinish them in any way. If any of the measurements are out of tolerance. Note: Connecting-rod bearings for all repair stages are delivered from the factory ready to install. Measure the bearing bore in the vertical dimension and note the reading. 2.1. Mark off a point 60 degrees counterclockwise from vertical. Bolt 2.

therefore. Install the piston. Connecting Rod Radial Play 1. Remove the bearing cap from the connecting rod.0030 inch.0021 . and arrow on piston points toward the front of the engine.). 15. Example: Dj = 3.116 (0. replace the connecting rod.5421 inches. Refer to "1.054 . 2. the piston installation and removal must be carried out with the carbon scraper ring un-installed or removed.1 mm. Position the connecting rod in the piston so that the longer end side is on the unit pump side (left side).054 mm (0. For each connecting rod.5391 inches. Note: In the above example.116 mm (0.0. the diameters of each bearing bore and its corresponding journal must belong to the same repair stage (both must be "standard. 2. Section 1. Example: Ds —Dj = 0. note the average value for the bearing journal diameter. If the radial play is less than 0. Example: Ds = 3. Description Dimensions: mm (in." "undersize 0. 1. as calculated. See Figure "Installing the Wrist Pin" ." etc. .0046 in." 14. subtract the value for the bearing journal diameter. Install the wrist pin in the piston.2 Piston Installation" .).).2 Piston Installation Install the piston as follows: NOTICE: The carbon scraper ring has a smaller internal diameter than the piston skirt diameter.1 mm.0046) 13.0021 in. Listed in Table "Connecting Rod Radial Play" is the radial play. as calculated. 3. Calculate the connecting rod radial play (up-and-down movement) at the bearing journal. From the value for the bearing bore diameter. 12. This result is the radial play.18. note the average value for the bearing bore diameter. Table 21.0. or more than 0.) Radial Play 0.18. both measurements belonged to repair stage "undersize 0. For each bearing journal.Note: To obtain a correct value for connecting-rod radial play.

Install the piston rings on the piston (1). Insert the wrist pin into the wrist pin bore. See Figure "Ring Gaps Offset 120 Degrees" . Installing the Wrist Pin 2. . 3.1. Lubricate the wrist pin with a light coating of clean engine oil.3 Piston Ring Replacement" . Wrist Pin 1. Orient the rings at 12 o'clock and 6 o'clock position. Refer to "1.18. 2. Piston Figure 15. Secure the wrist pin with the two snap rings. 3.

go to step 8.1. Position a ring compressor (J-45983) loosely over the piston. Install each piston ring in the appropriate groove on the piston. For non-EGR engines. Note: Steps 6 and 7 apply only to EGR engines. NOTICE: The carbon scraper ring has a smaller internal diameter than the piston skirt diameter. 4. the piston installation and removal must be carried out with the carbon scraper ring un-installed or removed. Tighten the ring compressor on the piston. Piston Figure 16. Lubricate the piston with a light coating of clean engine oil. Offset the ring gaps alternately by 120 degrees. 5. Ring Gaps Offset 120 Degrees 1. 2. therefore. .

. See Figure "Installation of Piston" . See Figure "Installing the Bearing Shells" . 6. thoroughly clean the carbon scraper ring seat. NOTICE: The half of the bearing shell installed in the connecting rod (rod half) has a speciallytreated friction surface that allows it to bear higher loads. If reusing a cylinder liner. Install sleeve (J-47710) to the cylinder block. 8. . it must point toward the front of the engine. Installation of Piston Note: If the replacement piston has a locating arrow. Figure 17. 7. It cannot be interchanged (swapped) with the other half of the bearing shell installed in the bearing cap (cap half). Install the rod half of the bearing shell in the connecting rod. as marked on removal.Note: Piston installation in the EGR engine is performed with the engine facing upright – not turned on its side.

12. This can lead to premature wear of the crankshaft. Be sure that the locking lug in the bearing shell is fully seated in the groove of the rod. See Figure "Installing a Piston" . NOTICE: Be careful not to scratch the crankshaft journals with the connecting rod. Push the piston into the cylinder until the rod bearing rests on the crankshaft journal. Bearing Shells 3. Bearing Cap 10. . Connecting Rod 2. Lubricate the bearing surface with a light coating of clean engine oil.9. Figure 18. 2. Installing the Bearing Shells 1. 1. Lubricate the cylinder liners with a light coating of clean engine oil. 11.

Remove sleeve (J-47110) and wipe the carbon scraper ring seat clean. Be sure that the locking lug in the bearing shell is fully seated in the groove of the cap. 15. Cylinder Block Note: Steps 11.1. 16. See Figure "Removing Carbon Scraper Ring" .). Installing a Piston 2. 13. 2. . See Figure "Installing the Bearing Shells" . 1. go to step 14.70 in. Piston 3. 14. Lubricate the stretch bolt threads with a light coating of engine oil. Measure the connecting rod stretch bolts. 17. Install carbon scraper ring in the cylinder liner groove. 12 and 13 apply only to EGR engines.5 mm (2. Replace any bolts that exceed the maximum length of 68. Install the cap half of the bearing shell in the bearing cap. For non-EGR engines. Lubricate the bearing surface with a light coating of clean engine oil. as marked on removal. Ring Compressor Figure 19. Check carbon scraper ring for correct fit after installation. See Figure "Measuring a Stretch Bolt" .

70) Stage 1 Stage 2 100-115 (74-85) additional 90-100° 20. Measuring a Stretch Bolt 18.18. Be sure that the marks on the cap and the rod match. 19. Install the bearing cap on the connecting rod and hand-tighten the stretch bolts. install the flywheel guide pins in the crankshaft gear. 23.1. measure the piston protrusion relative to crankcase top dead center at all the pistons.1. Listed in Table "Tightening Stages. Table 31. Shank Figure 20. Connecting Rod Bolts 21. Using a dial gauge and holder. Note: If it is necessary to turn the crankshaft and the flywheel has been removed. Check the connecting rod end play (axial play). Refer to "1. Max. Tighten the M16 x 1.5 (2. Rotate the crankshaft to make sure it turns freely. Shaft Length: mm (in. Connecting Rod Bolts" . See Figure "Piston Protrusion at Top Dead Center (TDC)" . Tighten each one in turn to the first stage and then go on to the next stage.5 connecting rod stretch bolts alternately.) Tightening Stage Torque Value: N·m (lb·ft) 68. Tightening Stages. See Figure "Checking Rod and Bearing Cap Markings" .2 Connecting Rod End Play Measurement" . . 22.

244 – 0.0261 in. repair as necessary. replace the piston.). Inspect crankshaft for damage to rod journal or for evidence of spun bearing. check if the block has been machined. If damaged. If damaged. 3. Damaged oil spray nozzles could result in a loss of oil pressure and cause engine damage. etc. Projection = 0.0281 in. repair as necessary. 2. If the components are within specification.0096 to 0. Description Specification: mm (in. Inspect piston.16.) Figure 21.) Piston Protrusion (at TDC) 0.0096 – 0. 4. Refer to "1. Inspect connecting rod for bent rod.1.2 Engine Barring Tool Removal" . If damaged. repair as necessary. NOTICE: Be careful not to damage the oil spray nozzles. or if a connecting rod is bent.715 mm (0. Piston Protrusion at Top Dead Center (TDC) 24.244 and 0. Piston 2. Cylinder Liner A. If the piston protrusion dimensions are not between 0. piston pin bushings and piston pin for wear or damage. Inspect rod bearings for wear or damage. Table 33. If damaged.244 to 0. Remove the engine barring tool (J–46392) . .0096 and 0. Piston Protrusion Specifications 25. Refer to piston protrusion specifications. listed in Table "Piston Protrusion Specifications" . pin bushing wear or damage.715 (0.0281) 5. 1.715 mm (0. repair as necessary.

Double Chamfered Oil Control Ring with I) Garter Spring (Groove III) 2. Remove the rings in order starting from the top of the piston down. Install the oil pan. as removed. Keystone Piston Ring (Groove 3. Piston Rings . Section 1. Install the oil spray nozzles. 1. Remove the piston rings using ring pliers (J-46072). Remove the piston. Taper Face Ring with Internal 4.3 Piston Ring Replacement Replace the piston ring as follows: 1.1 Piston Removal" .18. 27. 2.18. See Figure "Piston Rings"and Figure "Removing the Piston Rings" .26. Piston Angle (Groove II) Figure 22. Be sure they are seated and aligned correctly. Refer to "1.

018 to 0.60 1. Clean all the carbon from the ring grooves.024) 0. Removing the Piston Rings 3. The correct end-gap measurements are listed in Table "Piston Ring End-Gap Dimensions" . Be sure the grooves are not damaged and that there are no burrs or combustion residue in the grooves.) 0.) . Piston 2.022) Groove I (0.0 (.1.0 (. Ring Designation Keystone Taper-Faced with Internal Angle II (0. Before installing the new rings. check the end gap. Ring Pliers (J-46072) Figure 23.45 to 0.039) Maximum End Gap mm (in.40 to 0. 4.016 to 0.039) Gap When New mm (in.55 1.

Piston Ring End-Gap Dimensions 6. Measure its gap in the same way as the other two rings. See Figure "Checking the Ring End Gap" .) 0.55 Maximum End Gap mm (in.0 (. Measure the end gap using a feeler gauge. 1. . Place each ring squarely into the combustion area of a cylinder liner or cylinder.Ring Designation Double-Chamfered Oil Control with Garter Spring Groove III Gap When New mm (in. Note: Check the end gap of the upper two piston rings first. Figure 24.022) 5.) 1.016 to 0. Table 37. Checking the Ring End Gap 2.039) (0. Remove the spring garter from the third (lowest) ring. The garter spring must be removed from the third (lowest) piston ring before you can measure its end gap.40 to 0.

Piston Ring 3. Garter Spring Joint Figure 25. Be careful not to over-expand the rings during installation. Garter Spring 2. See Figure "Piston Ring Pliers (J-46072)" . set the maximum ring expansion stop on the piston ring pliers (J-46072) to the corresponding piston ring diameter. .3. Installing the Garter Spring 7. See Figure "Installing the Garter Spring" . 1. Install the garter spring into the ring. Using the knob. The garter spring joint should be positioned 180 degrees from the gap (A) in the piston ring.

Make sure the word "TOP" on each ring is facing toward the crown of the piston. Offset the ring gaps alternately by 120 degrees. Install the rings in the reverse order of their removal. . 9. Piston Ring Pliers (J-46072) 2. Ring Expansion Stop Knob Figure 26.1. Piston Diameter (mm) 8. from the bottom to the top of the piston. See Figure "Piston Rings Offset 120 Degrees" .

causing major engine repairs.1. Install the piston.4 Connecting Rod Bushing Replacement Replace the connecting rod bushing as follows: NOTICE: Be careful to avoid damaging the bushing bore when removing the bushing. Piston Rings Offset 120 Degrees 10. See Figure "Remove the Bushing" . Piston Figure 27. Refer to "1. Rest the connecting rod on a flat surface. press the bushing out of the connecting rod.18. Using an appropriate drift. 1. Section 1.18. . A damaged connecting rod can seize up suddenly.2 Piston Installation" .

080-57.100 (2. Remove the Bushing 2.050) 57. replace the connecting rod.000-57.) 52.2480) 57. replace the connecting rod.2 Connecting Rod End Play Measurement" .2472-2.019 (2. 3. Note: The inside diameter of the bushing bore and the outside diameter of the bushing must conform to the specifications listed in Table "Bushing Specifications" .2441-2.07 (2. Bushing 2. Connecting Rod Figure 28.1.2448 in.1.).05-52. Check the bushing bore in the connecting rod. Description Inside Diameter of Bushing Outside Diameter of Bushing Inside Diameter of Bushing Bore Dimensions: mm (in. Refer to "1.18.049-2. Measure the inside diameter of the bushing bore in the small bore of the connecting rod.2448) . If the measurement exceeds 57. This is necessary to obtain the required interference fit.019 mm (2. If surface material is missing from the bushing bore.

Measure the bushing bore in the connecting rod for deformation.0004 in. Bushing Specifications Dimensions: mm (in.Description Bushing Interference Fit Maximum Permissible Out-of-Round in Bushing Bore Table 43. Rest the connecting rod on a flat surface.100 mm (2. 7. Generated on 02-14-2012 . If the measurement is shorter than 52.0039) 0.061-0. 6.). Measure the outside diameter of the bushing.0024-0.).05 mm (2. If the measurement exceeds 57. machine the inside contact surface of the bushing until the measurement is correct.049 in. replace the connecting rod. Measure the inside diameter of the bushing.100 (0.01 mm (0. EPA04 MBE 4000 Workshop Manual (DDC-SVC-MAN0023) Printed Fri Mar 02 10:18:07 2012 Copyright © 2012 by Detroit Diesel Corporation. install the bushing in the connecting rod.) 0. replace the bushing. Using an appropriate drift. If the bushing bore is out-or-round by more than 0.01 (0. 5. All rights reserved.0004) 4.2480 in.).