03-33 Reconditioning, aligning and mounting conrod in bearings Operation No. of operation texts and operation values or standard texts and flat rates 03-6 P03-582-5 2 Marking 6 Upper conrod bearing shell 3 Bottom balancing weight 7 Lower conrod bearing shell 4 M9 conrod bolt 8 Bearing shell locating lugs 5 Dowel sleeve Arrow Direction of travel Data Center of conrod bearing bore to 44.995-45.005 center of conrod bush bore (L) 48.995-49.005 ) Width of conrod at conrod bearing bore (B) 2.948-22.000 Width of conrod at conrod bush bore (b) 2.948-22.000 Conrod basic bore (D) 5.600-5.69 5.600-5.64 ) Conrod bush basic bore (d) 24.500-24.52 Conrod bush inner (d) 22.007-22.03 Piston pin clearance in conrod bush 0.03-0.08 Inner peak-to-valley height of conrod bush 0.005 Permissible axial twist of conrod bearing bore 0.5 to conrod bush bore Permissible variation of axial parallelism of 0.07 conrod bearing bore to conrod bush bore Copyright Daimler AG /20/0 G/0/08. This WIS printout will not be recorded by the update service. Page
Permissible variation in concentricity of 0.0 conrod bearing bore Permissible difference in weight of complete conrod within an engine ) Engines 02.9 4 g Crankshaft machining dimensions Crankshaft Size Color code Machining dimensions ) Conrod bearing journal Standard none 47.955-47.965 at crankshaft Standard orange 47.945-47.955 Standard 2 blue 47.935-47.945 st repair size - 47.700-47.75 2nd repair size - 47.450-47.465 3rd repair size - 47.200-47.25 4th repair size - 46.950-46.965 Conrod bearing journal Standard 27.958-28.042 width Repair sizes to 28.300 ) The crankshaft should be machined so that the specified bearing play is maintained with the existing bearing shells. Test data Conrod bearing play radial 0.02-0.04 Conrod bearing shells axial Piston guided Color code red yellow blue Wall thickness in mm Standard.806 -.80.80 -.84.84 -.88 Standard ).8 -.85.85 -.89.89 -.823 Standard 2 ).86 -.820.820 -.824.824 -.828 st repair size -.935 -.999-2nd repair size - 2.060-2.064-3rd repair size - 2.85-2.89-4th repair size - 2.30-2.34 - ) Standard and standard 2 wall thicknesses are not supplied as replacement parts. Copyright Daimler AG /20/0 G/0/08. This WIS printout will not be recorded by the update service. Page 2
Special tools 00 589 66 2 00 00 589 53 2 00 Commercially available tools Conrod inspection tool e. g. Model BC 50 KWT D-6328 Dietzenbach Conrod aligning tool e. g. Model BC 503 KWT Quick-calipers for internal measurements 20-40 mm 40-60 mm Micrometer screw 0-25 mm 50-75 mm Notes Conrod and conrod caps are marked together (arrow). Conrods which have been overheated as a result of bearing damage (blue discoloration), must not be re-used. The conrod shaft must not have any cross scores and notches. D-6328 Dietzenbach Conrods are supplied as replacement parts with a machined small end bush. P03-205-3 The conrod and the conrod cap are fixed to each other with dowel sleeves. Pay attention to difference in weight of conrods when replacing. Copyright Daimler AG /20/0 G/0/08. This WIS printout will not be recorded by the update service. Page 3
The end play of the conrod is limited at the piston pin bosses (piston-guided conrod, arrows). Reconditioning P03-039-7 Check conrod bolts, replace if necessary (03-30). 2 Fit on conrod bearing cap, oil thread and head contact surface of bolt and tighten to 20 Nm. 3 Measure conrod bearing basic bore. If the basic bore exceeds 5.69 mm or is conical, dress contact face of bearing cap on a dressing plate to max. 0.02 mm. Machine conrod cap together with conrod. P03-200-3 Copyright Daimler AG /20/0 G/0/08. This WIS printout will not be recorded by the update service. Page 4
4 Press in new small end bush so that the oil bores are aligned (arrows). Insertion pressure 2500 N. 5 Hollow out small end bush by turning or reaming. 6 Dress side contact surfaces of conrod on the dressing plate. P03-585-3 Aligning 7 Check angles of conrod with conrod inspection tool with bearing shells and piston pins installed. 8 Align conrod with a conrod aligning tool. 9 Align the parallelism of the conrod bearing bore to the conrod bush bore. P03-2096-3 Copyright Daimler AG /20/0 G/0/08. This WIS printout will not be recorded by the update service. Page 5
0 Align the axial twist of the conrod bearing bore to the conrod bush bore. P03-2095-3 Mounting in bearings Measure conrod basic bore and note. P03-200-3 2 Measure conrod bearing journal and note. 3 Calculate radial conrod bearing play. 4 Match up conrod bearing shell. 5 Mount conrod on pistons (03-36). P03-2022-3 Copyright Daimler AG /20/0 G/0/08. This WIS printout will not be recorded by the update service. Page 6