AR03.

20-W-4291-04A Determine connecting rod bearing radial play

Modification notes
22.2.07 Connecting rod bearing inside dia. for an engaged Engine 541.9, from engine end no. 054766 *BE03.10-N-1001-01C
connecting rod bearing shell, standard Engine 542.9 from engine end no. 054766
22.2.07 Connecting rod journal dia. connecting rod journal width, Engine 541.9 EURO standardII as of engine *BE03.20-N-1004-02C
dia. standard width no. 098132 engine 541.9 EURO standard III
Engine 542.9 EURO standard II as of engine
no. 098132 engine 542.9 EURO standard III
Engine 542.9 EURO IV standard with code
MS4 EURO V standard with code MS5

Test specifications for connecting rod

Number Designation Engine Engine Engine

541.9, 542.9 541.9, 542.9
up to engine from engine from engine
end no. 054765 end no. 054766 end no. 054766

BE03.10-N-1001-01C Connecting rod bearing inside dia. Default mm 94.054 to 94.096 94.064 to 94.110 94.064 to 94.110
for connecting rod bearing shells
inserted

Deviation 0.10 mm 93.954 to 93.996 93.964 to 94.010 93.964 to 94.010

Deviation 0.25 mm 93.804 to 93.846 93.814 to 93.860 93.814 to 93.860

Deviation 0.50 mm 93.554 to 93.596 93.564 to 93.610 93.564 to 93.610

Deviation 0.75 mm 93.304 to 93.346 93.314 to 93.360 93.314 to 93.360

Oversize 1.00 mm 93.054 to 93.096 93.064 to 93.110 93.064 to 93.110

BE03.10-N-1005-01C Bolt, connecting rod bearing cap to Thread dia. M 16 1.5 16 1.5 16 1.5
connecting rod

Permissible shank mm 74.5 74.5 74.5

length

BE03.10-N-1006-01C Connecting rod bearing radial play mm 0.064 to 0.126 0.064 to 0.126 0.064 to 0.126

Check values for a crankshaft

Number Designation Engine 541.9 Engine 542.9

EURO standard II EURO standardII
up to engine no. up to engine no.
098131 098131

BE03.20-N-1004-02C Connecting rod journal Dia. standard mm 93.980...94.000 93.980 - 94.000

dia., connecting rod width mm 37.000...37.100 81.000 - 81.140
journal width

Dia. deviation 0.10 mm 93.880 - 93.900 93.880 - 93.900

width mm 37.000 - 37.100 81.000 - 81.140

Dia. deviation 0.25, mm 93.730 - 93.750 93.730 - 93.750

width mm 37.000 - 37.100 81.000 - 81.140

Dia. deviation 0.50 mm 93.480 - 93.500 93.480 - 93.500

width mm 37.000 - 37.100 81.000 - 81.140

Dia. deviation 0.75 mm 93.230 - 93.250 93.230 - 93.250

width mm 37.000 - 37.100 81.000 - 81.140

Dia. deviation 1.00 mm 92.980 - 93.000 92.980 - 93.000

Check values for a crankshaft

Number Designation Engine 541.9 Engine 542.9

EURO standardII EURO standard II
As of engine no. as of engine no.
098132 098132
Motor 541.9 Engine 542.9
Norm EURO III EURO standard III

BE03.20-N-1004-02C Connecting rod journal Dia. standard mm 93.980 - 94.000 93.980 - 94.000
dia., connecting rod width mm 37.000 - 37.130 81.000 - 81.140
journal width

Dia. deviation 0.10 mm 93.880 - 93.900 93.880 - 93.900

width mm 37.000 - 37.130 81.000 - 81.140

Dia. deviation 0.25, mm 93.730 - 93.750 93.730 - 93.750

width mm 37.000 - 37.330 81.000 - 81.340

Dia. deviation 0.50 mm 93.480 - 93.500 93.480 - 93.500

width mm 37.000 - 37.330 81.000 - 81.340

Dia. deviation 0.75 mm 93.230 - 93.250 93.230 - 93.250

width mm 37.000 - 37.330 81.000 - 81.340

Dia. deviation 1.00 mm 92.980 - 93.000 92.980 - 93.000

width mm 37.000 - 37.330 81.000 - 81.340

Check values for a crankshaft

Number Designation Engine 541.9 Engine 542.9

EURO IV standard EURO IV standard
with with
code MS4 code MS4
EURO V standard EURO V standard
with with
code MS5 code MS5

BE03.20-N-1004-02C Connecting rod journal Dia. standard mm 93.980 - 94.000 93.980 - 94.000
dia., connecting rod width mm 37.000 - 37.130 81.000 - 81.140
journal width

Dia. deviation 0.10 mm 93.880 - 93.900 93.880 - 93.900

width mm 37.000 - 37.130 81.000 - 81.140

Dia. deviation 0.25, mm 93.730 - 93.750 93.730 - 93.750

width mm 37.200 - 37.330 81.200 - 81.340

Dia. deviation 0.50 mm 93.480 - 93.500 93.480 - 93.500

width mm 37.200 - 37.330 81.200 - 81.340

Dia. deviation 0.75 mm 93.230 - 93.250 93.230 - 93.250

width mm 37.200 - 37.330 81.200 - 81.340

Dia. deviation 1.00 mm 92.980 - 93.000 92.980 - 93.000

width mm 37.200 - 37.330 81.200 - 81.340

Connecting rod

Number Designation Engine 541.9,

BA03.10-N-1001-01C Bolt of connecting rod bearing Stage 1 Nm 110
cap to connecting rod

Stage 2 ° 90

001 589 53 21 00
Dial indicator

1 Clean connecting rod journals on crankshaft (1) with a

chamois leather.

2 Measure connecting rod journal dia. of crankshaft (1) using

the micrometer in three measuring directions (D, E, F) offset
by about 60°. Calculate a mean value using the three
measured values.
The crankshaft (1) must be machined or installed if one
measurement of connecting rod journal dia. is outside the
tolerance.

3 Assign connecting rod bearing shells according to the mean

value of the connecting rod journal dia..
Observe machining stage (standard or deviation and
corresponding width). All connecting rod journal dia. must have
the same machining stage; machine or replace the crankshaft
(1) as required.

W03.20-1076-11

4 Clean connecting rod bearing shells (3, 4), and their mounts in connecting rod (2) and
connecting rod bearing cap (6) with a chamois leather and check for wear and damage.
In cases of wear, the connecting rod bearing shells (3, 4) must be replaced if all
connecting rod journal Ø on crankshaft are within tolerance.

5 Assign marked connecting rod bearing shell (3, 4) on connecting rod (2) and connecting
rod bearing cap (6) and insert.
The locking lugs on connecting rod bearing shells (3, 4) must be located in foreseen
grooves (arrows) in connecting rod (2) and connecting rod bearing cap (6). The
connecting rod bearing cap (6) and the connecting rod (2) are marked by numbers (e.g.
4185) for pairing and must not get mixed up with each other (cracked separating
surfaces). They must be assigned according to marked installation position of connecting
rod journal on crankshaft.

6 Measure connecting rod bolts (5).

Replace corresponding connecting rod bolt (5) if the shank length is exceeded.

7 Tighten connecting rod bearing cap (6) with connecting rod bolt (5) on connecting rod
(2).
The connecting rod (2) and connecting rod bearing cap (6) must only be tightened
using engaged connecting rod bearing shells (3, 4). Observe tightening torque stage.

W03.10-1032-03
8 Set dial indicator and quick connect calipers for inside measurements using the
outside micrometer to dimension 92.0 mm (note pretension 5 mm) and set the scale of
the dial indicator to "0".

9 Measure connecting rod bearing inside dia. in assembled connecting rod (2) using quick
calipers for inside measurements in the measurement directions (A, B, C). Begin with
measuring direction (A) 90° offset from separation point (arrows) and measure each
remaining measuring direction (B, C) offset by about 60°.
The preset dimension 92.0 mm plus one read off measurement value gives in each
case one measured connecting rod bearing inside Ø. If one of the three connecting rod
bearing inside Ø lies outside tolerance then repeat the measurement procedure with
new connecting rod bearing shells. Replace connecting rod (2) with connecting rod
bearing cap (6) if necessary. Take mean value of three connecting rod bearing inside Ø.

10 Taking mean value of connecting rod journal Ø from mean value of connecting rod
bearing inside Ø gives the connecting rod bearing play.
Example: 94.062 mm - 93.99 mm = 0.072 mm

11 Take off connecting rod bearing cap (6) again.

The connecting rod bearing inside dia. and connecting rod journal must have the same
machining stage (standard or deviation) in order to achieve the correct connecting rod bearing
play. The connecting rod bearing shells are delivered ready-to-install ex works and for repair
purposes, also in oversizes. No reworking is permissible.

W03.10-1036-03