Engine News

4000 Series 130 Issue 1

Connecting Rod and Bolts for Earlier Engines November 2022

This engine news article applies to the following 4000 Series engines:
4006TAG1, 4006-23TAG2 (A), 4006TWG, 4006TEG, 4008TAG, 4008TAG1 (A), 4008-30TAG1, 4008-
30TAG3, 4008TWG2, 4012TAG, 4012/4012-46TAG1 (A), 4012-46TAG3 (A), 4012-46TAG0A, 4012 TWG,
4012-46TWG3 (A), 4012-46TWG4 (A), 4012TEG, 4012TEG2, 4016TAG, 4016TAG1 (A), 4016TAG2 (A),
4016TWG2, 4016TEG1/2 (A), 4016-61 TRG1 (A), 4006TESI, 4008TESI, 4012TESI, 4016TESI and for certain
engines up to the engine serial numbers that are listed in Table 1.
Table 1
Engines Serial Number for UK Serial Number for India
4006-23TAG3 (A) DGDF1421U17638H DGDF1392S22617H
4008TAG2/4008-30TAG2 (A) DGBH1057U17740H DGBH1444S20019H
4012/4012-46TAG2 (A) DGBM1522U17737H DGBM1019S22964H
4012/4012-46TWG2 DGKM1413U17605H -
4016-61 TRG2 (A) DGWR1086U17700H -
4016-61 TRG3 (A) DGXR1098U17608H DGXR1181S22771H

A B
Existing connecting rods bolts have a 2 mm (0.08 inch) thread pitch. New connecting rods bolts have a 1.5 mm
(0.06 inch) thread pitch. The new connecting rods bolts have three ‘F’ marks (A1) stamped on the head of the
connecting rod bolt and have a depression (B1) on the bottom of the connecting rod bolt.
Note: The existing connecting rods bolts do not have three ‘F’ marks stamped on the head of the connecting
rod bolt and do not have a depression on the bottom of the connecting rod bolt.

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The information is correct at the time of print.

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Engine News - 4000 Series 130 Issue 1 November 2022

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1

C D
Existing connecting rods have ‘1DD’ (C1) stamped on the face of the connecting rod. New connecting rods
have ‘5AA’ (D1) stamped on the face of the connecting rod.
Existing connecting rod bolt (Perkins part number 363/48) has been replaced with new connecting rod bolt
(Perkins part number T435662).
For 4006 engines, existing connecting rod kit (Perkins part number 6SE92D) has been replaced with new
connecting rod kit (Perkins part number T435679).
For 4008 engines, existing connecting rod kit (Perkins part number 8SE920D) has been replaced with new
connecting rod kit (Perkins part number T435681).
For 4012 engines, use existing connecting rod kit (Perkins part number 12SE920D) has been replaced with
new connecting rod kit (Perkins part number T435859).
For 4016 engines, use existing connecting rod kit (Perkins part number 12SE920D) has been replaced with
new connecting rod kit (Perkins part number T435860).

Notes:
New and existing connecting rods and bolts are not interchangeable. Existing connecting rod bolts cannot
be installed in new connecting rods or new connecting rod bolts in existing connecting rods. This will
damage the threads of the connecting rod and the bolt.
New and existing connecting rod assemblies should not be used in the same engine. Complete sets of
connecting rod assemblies should be changed to avoid a mix of connecting rod assemblies in an engine.
Existing connecting rod bolts will be available for servicing the existing connecting rod assemblies where
required.
The connecting rod bolts are single use only and should be discarded after use.
Before the connecting rod bearings are installed, apply clean engine oil on the front face of the connecting
rod bearing shells. Do not lubricate the back face of the connecting rod bearing shells. The back face of the
connecting rod bearings should be installed dry. The bearing face of the connecting rod and the bearing
face of the cap should be installed dry.

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The information is correct at the time of print.

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Engine News - 4000 Series 130 Issue 1 November 2022

Tightening Procedure for Existing Connecting Rod Bolts

Follow the procedure below:

Notes:
Ensure that the engine is cold, i.e. local engine room ambient temperature.
Use a suitable degreaser to clean oil from the connecting rod bolt holes in the connecting rod.
Inspect all relevant components for wear and for distortion before the components are installed. Pay
particular attention to the connecting rod bolting faces that are part of the connecting rod and cap. Look for
evidence of heavy scoring or material rolling. If there is excessive wear or damage to the bolting faces,
contact the Service Engineering department at Stafford, U.K. or the Distributor Solution Network (DSN).
1 Lubricate the first 2 to 4 threads of the new connecting rod bolts with clean engine oil.
Note: Do not lubricate the underside of the head of the connecting rod bolts during installation.
2 Install the connecting rod bolts to the connecting rod cap hand tight.
3 Tighten the connecting rod bolts to a pull-up torque of 60 Nm (44 lbf/ft) 6 kgf/m.
4 Tighten the connecting rod bolts to a snug torque of 112 N·m (83 lb ft) 11 kgf/m.
Note: To complete the operation, for existing connecting rod bolts, a further 65 degree tightening is required.
Due to a restricted access this can be carried out in more than one step. To perform this procedure two people
are required to ensure that the socket remains in contact with the connecting rod bolt during the tightening
steps.
5 Obtain a suitable, calibrated torque wrench. An example would be a digital ratchet torque wrench that has
the capability to accurately record a torque angle. If a suitable digital ratchet torque wrench cannot be obtained,
an alternative would be an angle gauge with a suitable 3/4" drive socket.
6 Install the socket to the connecting rod bolt. Apply light pressure to the torque wrench. Set the leading edge
of the socket in line with the centre of the connecting rod. Turn connecting rod bolt through an initial angle. The
trailing edge of the socket is now in line with the centre of the connecting rod.
Note: Ensure that the socket remains in contact with the connecting rod bolt during steps 6 and 7.
7 Reposition the torque wrench so that the leading edge of the socket is in line with the centre of the
connecting rod. Turn connecting rod bolt through a final angle. The trailing edge of the socket is now in line
with the centre of the connecting rod.
Note: For existing connecting rod bolts, the angles that the connecting rod bolt has been tightened to in steps
6 and 7 should add up to a total angle of 65 degrees. Minimize the attempts required in order to achieve the
correct torque angle.
8 Record the final torque and angle that is applied to each connecting rod bolt.

Confidential Yellow. © 2022 Perkins Engines Company Limited. All rights reserved.

The information is correct at the time of print.