NEXON BSVI MCE - SERVICE MANUAL

1.5L REVOTORQ BS VI 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 H7 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.