Bulletin #D1 - English

TIGHTENING OF CONNECTING ROD BOLT

ROTATING ANGLE CONFIRMATION METHOD
TNO8506 & TNO8504 & TNO8502

Be sure to tighten connecting rod bolts firmly. Poor

tightening may result in damage to the bearing metal or
to the serrated portion at the large end, or to a
catastrophic accident such as bolt breakage.

A. Handle parts carefully so as not to cause scratches,

dents or the deposition of dirt on screw portion of the
bolts and connecting rod contact surface.

B. Roughness or scratches on bolt threads or seat surface

may result in poor tightening. To ensure firm tightening
use anti-seizure agent (MOLYKOTE 1000 spray type) over
these surfaces. Roughness or scratches on surface, if any,
should be repaired by machining or otherwise.

C. Screw the bolt into the original hole from which it was
removed.
figure 1
D. At first screw bolts by hand and check if they turn
easily by hand.

E. Tighten bolts using the following procedure.

Four bolts connecting rod

1. Without bearing metal, tighten bolts to torque A (table

1) using a torque wrench.

figure 2 Tightening sequence:

bolt 1 - 4 - 2 - 3 - 1 (figure 1)

2. Set the template on the large end cap and mark point B
as indicated by the hole on the template. (figure 2)

3. Punch a tally mark on the bolt head next to the line on

the template indicating point A. (figure 3)

4. Attach the bearing metal and large end cap and install
in the engine. Tighten bolts with a torque wrench of the
specified capacity. Be sure to tighten in two steps.

figure 3 Tightening sequence:

1st step: At torque A (table 1)

bolt 1 - 4 - 2 - 3 - 1 (figure 1)

2nd step: Tighten bolt until tally mark rotates to point B.

bolt 1 - 4 - 2 - 3 - 1 (figure 1)

5. After tightening to mark B check tally mark on bolt to

have moved to position B on the large end cap or has
gone slightly beyond it (figure 4). Finally set lock washer
figure 4 in place.
 Two bolts connecting rod

1. Place template on large end cap and punch points A

and B as indicated by the line and hole on the template
(figure 5).

2. Attach large end cap without bearing metal and tighten

bolts using torque wrench. Tighten bolts to torque A (table
1).

Tightening sequence:

figure 5 bolt 1 - 2 - 1 (figure 6)

3. Punch tally mark on bolt heads next to point A on large

end cap.

4. Attach bearing metal and install in the engine. Tighten

bolts with torque wrench of the specified capacity. Be sure
to tighten bolts in two steps.

Tightening sequence:

1st step: At torque A (table 1)

bolt 1 - 2 - 1 (figure 6)

2nd step: Tighten bolt until tally mark rotates to point B.

bolt 1 - 2 - 1 (figure 6)
figure 6
5. After tightening to mark B check tally mark on bolt to
have moved to position B on the large end cap or has
gone slightly beyond it (figure 7). Finally set lock washer
in place.

Note:
After several hours of operation, each part is run-in,
resulting in some deflection of the relative positions of the
bolt and large end cap. Therefore, bolt tally marks cannot
be reused after an extended operating period. Thus, when
tightening bolts, punch new marks and distinguish them
from previous markings.
figure 7
F. After installation check free side motion of connecting rod and clearances between bearing
metal and crank pin. After test running, thoroughly check by hand touching for abnormalities,
then start normal operation.

During running-in of new parts, check for appropriate tightening of connecting rod bolts within the
first 3000 hours of operation. Thereafter, check every 6000 hours.

For easy maintenance procedure use the following:

Removing inspection doors, tighten bolts to proper torque B as indicated in table 1,

using a torque wrench with the appropriate setting. Bolts that do NOT move are
tightened correctly. In case of a bolt moving during inspection tightening, then
remove bolt and tighten again using the Angle Tightening Method.

G. Notes on bolt replacement

1. It is recommended that connecting rod bolts are

replaced, irrespective of their condition, every 20,000
hours of operation to ensure proper and safe operation of
the engine.
 2. Check for proper fit of bolt head seat surfaces with
large end cap using blue dubbing agent. Bolts with
inadequate fit should be repaired to obtain good fit.

3. Spray anti-seizure agent MOLYKOTE 1000 to both screw

and large end cap surfaces that come in contact with each
other. Tighten bolt to proper torque B as indicated on
table 1, and repeat tightening and loosening two or three
times to get initial running-in. Check that bolts can be
easily screwed by hand.

4. Mark bolt head with engine identification number,

cylinder number and bolt number (figure 8).

figure 8

H. Troubleshooting

If you are uncertain as to how many hours bolts have logged in, then examine the shape of the
bolt. Unless you identify the latest parkerized black color type bolt (figure 9c) then you should
replace the bolt.

more than 10 years old 7 to 8 years old NEW parkerized black color type

figure 9a figure 9b figure 9c

Table of Rotated Angle of Connecting Rod Bolt

Revised September 1985

Four bolts connecting rod Two bolts connecting rod

Angle of Angle of
Engine A torque B torque Engine A torque B torque
rotation rotation
model (kg m) (kg m) model (kg m) (kg m)
(degrees) (degrees)

DL-22 25 45 65 DL-19 25 40 65
DL-24 25 55 70 DL-20 35 50 95
DL-26 25 50 65 DS-18A 25 40 65
DL-28 35 65 95 DS-19A 25 40 65
DL-32 35 70 95 PS-26 35 50 95
DSK-22 25 45 50 PS-26H 35 50 95
DS-22 25 45 50 VS-26H 35 50 95
PL-24 25 55 50 DV-22A 35 55 135
DS-26 25 45 45 Note:
1. Anti-seizure MOLYKOTE 1000 Spray
DS-26A 25 50 65 type should be used on bolt seats and threads
before tightening.
DS-28 35 65 95
 DS-32 35 70 95 2. On connecting rod bolts, A torque and
rotation angle should be the first concern.
DV-26 25 45 45 B torque is for reference only.

DV-26A 25 50 65
DV-32 35 70 95
table 1

Daihatsu Connecting Rod Bolt Tightening Templates can be supplied free of charge to all owners
and managers of vessels fitted with an applicable engine model. To order your free bolt template
click here.

Some engine models may not require a tightening template. To find out more check the Frequently
Asked Questions section.

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Updated 09.11.2004