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1.5L REVOTORQ ENGINE
68
L. CONNECTING ROD
1. Inspect connecting rod small end bush and if
necessary, replace it.
2. Check connecting rod small end parent bore
dimension.
Connecting Rod – Small end Dimensions
Stage
Parent Bore
Diameter (mm)
Bush – outer
Diameter (mm)
Press fit in
0.075-0.125
Standard
30.025
30.000 –
30.025
3. If necessary machine connecting rod small end
parent bore to next over size.
4. Ensure that connecting rod big end and small
end axis are parallel to each other and are
within specified limits.
5. Ensure that the centre distance between small
end to big end is maintained within specified
limit.
6. Smear oil on parent bore of connecting rod.
7. Install new bush in such a way that slits are
symmetrically positioned approximately in the
vertical axis.
NOTE
If required Machine the side faces of bush to
match the taper faces of connecting rod.
8. Finish connecting rod small end bush bore on
a connecting rod boring machine.
9. Alternately connecting rod small end bush may
be reamed. The end edges to be chamfered /
deburred manually.
10. Install connecting rod bearing caps without
bearing shells on connecting rod.
11. Tighten connecting rod bearing cap mounting
bolts to specified torque.
12. Ensure that identification numbers for
connecting rod and connecting rod bearing cap
are matched and notches for bearing shells are
on the same side.
13. Check twist and bend of connecting rod by
using new piston pin in connecting rod small
end bush.
14. Measure twist and bend of connecting rod with
feeler gauge with respect to vertical face of the
connecting rod alignment gauge in vertical and
horizontal plane at a distance of 50 mm from
line joining centers of connecting rod small end
and big end bosses.
15. Check connecting rod big end parent bore
dimension.
16. If connecting rod big end parent bore is slightly
more than maximum permissible limits, it is
possible to reclaim the connecting rod provided
the wear is confined only to connecting rod
bearing cap. In such cases the connecting rod
bearing cap mating surface can be slightly
faced. The parent bore should then be finished
on a connecting rod boring machine.
17. Ensure that the connecting rod big end and
small end axis are parallel to each other within
the specified limits. Centre to centre distance
between connecting rod small end and big end
is maintained within specified limits.
18. If one or more connecting rods are to be
replaced, ensure that difference in weight of
connecting rod in one engine is within
permissible limits.
19. Install new pair of connecting rod bearing shell
according to size of crank pin journal diameter,
making sure that securing lugs of bearing
shells are properly seated in grooves of
connecting rod and its bearing cap.
NOTE
Lower and Upper bearings are not
interchangeable.
20. Install connecting rod bearing cap with bearing
shell on connecting rod. Tighten connecting
rod bearing cap mtg. bolts to specified torque.
21. Measure connecting rod bearing bore. Record
the readings in the format given in this manual.