Bulletin #D2 - English

INSPECTION AND RECONDITIONING OF CONNECTING ROD

DSE9002 (Revised)

1. INSPECTION

a. Cracks on the serration surface

Check serration surfaces, bolt holes and knock pin holes

by Magna-Flux spray. Fine cracks should be repaired by
hand grinding as necessary. However, if the extent of the
crack exceeds the limits set on table A, then such a
connecting rod is condemned (see figure 1).
figure 1
Limits of the crack (all models)

Length: 20mm on one tooth

20mm in total n next two teeth
30mm in total on all teeth
Depth: 2.0mm maximum

Removal of the crack

figure 2
All cracks should be ground off by hand grinder to their
full length and maximum depth, making sure to smooth
out any sharp edges (see figure 2).

b. Deformation of the big end bore

Install large end cap on connecting rod and tighten crank

pin bolts to the recommended value without the bearing
metal in position. Measure connecting rod big end bore at
two points (see figure 3). Any deformation exceeding the
limits set below should be rectified by grinding.

ALLOWABLE LIMIT (1/100mm)

ENGINE MODEL
A B
PS-20 -5 -10
PS-26 -5 -10

figure 3 PS-30 -5 -10

DS-18 -5 -10
DS-22 -5 -10
DSD-22 -5 -10
DS-26 -7 -12
DS-28 -7 -12
DS-32 -7 -12
VS-22 -5 -10
VS-26 -5 -10
DV-26 -7 -12
DV-28 -7 -12
DV-32 -7 -12
PL-24 -7 -12
DL-20 -5 -10
DL-19 -5 -10
DL-20 -5 -10
DL-22 -5 -10
 DL-24 -7 -12
DL-26 -7 -12
DL-28 -7 -12
DL-32 -7 -12

2. RECONDITIONING

a. Serrated surfaces

Apply fine Carborundum on matching serrated surfaces.

Rub serrated surfaces against each other to get good fit.
Wipe clean and check for sufficient touching of the
teethed area using blue dubbing agent.

Minimum contact area should be 75% of total contact

area of the serrated surfaces.

b. Big end bore

Any deformation or damage to the big end bore bearing

surface should be repaired by grinding (see figure 4).

Engine model Big end bore diameter

PS-18 132 mm
PS-20 143 mm
PS-22 163 mm
PS-26D & VS-26D 205 mm
PS-26H & VS-26H 205 mm
PK-14 96 mm
PK-16 116 mm
PS-30 230 mm
DS-18 153 mm
figure 4
DS-22 175 mm
DS-26 & DS-26A 210 mm
DS-28 230 mm
DS-32 260 mm
DL-19 153 mm
DL-20 165 mm
DL-22 175 mm
DL-24 195 mm
DL-26 215 mm
DL-28 230 mm
DL-32 260 mm
DL-40 340 mm
DV-22 & DV-22A 185 mm
DV-26 210 mm
DV-32 260 mm
figure 5
VS-20 143 mm
PL-24 205 mm

c. Bolt seat flange

Visually inspect bolt seat flange of big end bore. Any

excessive damage (dents, deep scratches) should be
repaired by machining (see figure 5).
 figure 6 d. Connecting rod bolts

Any repairs done as described above (sections a, b, c) will

affect the clearance between bolt and root of female
thread (see figure 6). If necessary re-tap the thread as
indicated below:

Engine model Thread Size

PS-26D W32 x Td12
PS-26H W32 x Td12
DS-22 M22 x 1.5
DS-26 M24 x 2.0
M27 x 2.0 or
DS-28
M30 x 2.0
DS-32 M30 x 2.0
DL-22 M24 x 2.0

It is suggested that crank pin bolts are replaced every 20,000 hours of operation (consult Bulletin
#D1 for more information on crank pin bolt replacement).

Note:

When installing large end cap, bearing metal and connecting rod in engine, tighten
crank pin bolts by the "Rotating Angle Confirmation Method" as described in
Bulletin #D1, to ensure deformation and clearances remain within limits.

Legal Notice
Copyright 2000 by marine industrial concerns s.a..
All rights reserved. E-mail comments to Webmaster
Updated 09.11.2004