A1 - DDCSN
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1. Reusing a connecting rod with a damaged or loose bushing may result in severe cylinder kit damage 1 Inspect the piston pin bushing for indications of scoring If scoring is found replace the rod 2 Inspect the piston pin bushing for indications of overheating A bushing that has overheated may become loose If a loose bushing is found the rod must be replaced 1 19 4 Assembly of Connecting Rod Assemble connecting rod as follows 1 Install the connecting rod cap with the numbers on the same oil cooler side on the connecting rod 2 Lubricate the bolt threads with clean engine oil NOTICE Do not over torque the connecting rod bolt nuts Over torque may permanently distort the connecting rod cap NOTICE Be sure the connecting rod bolt has not turned in the connecting rod before torque is applied to the nut 3 Torque the bolt nuts to 160 185 N m 118 137 lb ft All information subject to change without notice Rev 01 04 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 20 60 03Rev 1 373 1 19 CONNECTING ROD 1 19 4 1 Inspection of Assembled Connecting Rod Measure the connecting rod bearing diameter at five locations See Figure 1 307 E2 CENTER DISTANCE ______ ROD LENGTH OPEN END ROD CLOSED END ROD Figure 1 307 Dimensional Inspection of Connecting Rods 1 Calculate size of2. The current connecting rods bearings and crankshafts must be used together to ensure interchangeability Former parts cannot be mixed with new parts in the same engine The former connecting rods will continue to be available for engines built prior to the unit serial numbers as listed in Table 1 7 The connecting rod bearing shells are precision made and are of the replaceable type The upper bearing shell is seated in the connecting rod and a lower bearing shell is seated in the connecting rod cap These bearings are not identical The upper and lower bearing shells are located in the connecting rod by a tang at the parting line at one end of each bearing shell See Figure 1 299 The tri metal bearing wear surfaces use a steel backing First an optimum composition copper tin and lead lining is bonded to the steel back A nickel barrier above the lining and the overlay serves to prevent tin migration A soft lead overlay 0 025 mm 0 001 in thick provides run in protection and an initial wear surface A flash tin plate front and back is for added corrosion protection and resistance during shipping and handling These bearings are identified by the satin silver sheen of the tin when new and a dull gray of the overlay after being in service All information subject to change without notice Rev 01 04 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 20 60 03Rev 1 365 1 19 CONNECTING ROD The oil hole through th
3. information subject to change without notice Rev 01 04 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 20 60 03Rev 1 367 1 19 CONNECTING ROD 33498 1 Connecting Rod Nut 2 4 Connecting Rod Bearing Cap 2 Notched Bolt 2 5 Bearing Shells 3 Connecting Rod Figure 1 302 Connecting Rod and Bearing Shells Closed end Rod The upper end of the rod has a pressed in machined bushing with two scallops 180 degrees apart Spray oil entering these scallops lubricates the piston pin and bushing during engine operation The piston pin floats in the bushings of both the piston and the connecting rod The lower bearing cap is secured to the connecting rod by two specially machined bolts and nuts See Figure 1 302 The two special bolts locate the cap relative to the upper end The assembly is machined as a unit and must not be used in the engine with any other cap or upper end Orientation of the cap to the upper end is identified by stamped numbers Rev 01 04 All information subject to change without notice 1 368 From Bulletin 20 60 03Rev 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL Closed end connecting rods prior to model year 2000 have no center drilled lubricating oil passage See Figure 1 303 see Figure 1 304 and see Figure 1 305 N LOCATING LOCATING TANG TANG Figure 1 303 Connecting Rod Bearing Detail C
4. All information subject to change without notice 1 378 From Bulletin 20 60 03Rev 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION
5. IESEL CORPORATION SERIES 60 SERVICE MANUAL b If the connecting rod bearing to journal clearance exceeds 0 152 mm 0 006 in with used parts replace with a new bearing NOTE The current bearing shells for 14 L engines and 12 7 L engines for model year 2000 have an oil hole in them to allow oil to flow into the connecting rod See Figure 1 308 OIL HOLE CURRENT 12 7L AND 14L FORMER 12 7L PRIOR TO MODEL YEAR 2000 MODEL YEAR 2000 Figure 1 308 Connecting Rod Bearings for 14 L and 12 7 L Engines NOTE Before installing the bearings inspect the crankshaft journals Refer to section 1 7 2 4 Do NOT replace one connecting rod bearing shell alone If one bearing shell requires replacement install both new upper and lower bearing shells Also if a new or reground crankshaft is to be used install all new bearing shells NOTE Bearing shells are NOT reworkable from one undersize to another under any circumstances Bearing shells are available in 0 254 0 508 and 0 762 mm approximately 0 010 0 020 and 0 030 in undersize for service with reground crankshafts The bearing size specifications are listed in Table 1 24 All information subject to change without notice Rev 01 04 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 20 60 03Rev 1 377 1 19 CONNECTING ROD 1 19 5 Installation of Connecting Rod Refer to section 1 18 5 to install the piston and connecting rod assembly Rev 01 04
6. SERIES 60 SERVICE MANUAL This page intentionally left blank All information subject to change without notice Rev 0 04 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 20 60 03Rev 1 364c 1 19 CONNECTING ROD 1 19 CONNECTING ROD Two types of connecting rod are used in Series 60 engines The open end or saddle type connecting rod is used with cast iron pistons which have bolt on style piston pins The closed end or trunk type connecting rod is used with forged steel pistons which have floating trunk style piston pins NOTICE Do not mix forged steel pistons used with closed end connecting rods and cast iron pistons used with open end connecting rods in the same engine This will cause severe engine damage OPEN END CONNECTING ROD The open end connecting rod is forged to an I section with an open or saddle type contour at the upper end and a bearing cap at the lower end The surface of the connecting rod is shot peened for added strength Therefore no grinding is permitted since it will remove the benefits of shot peening The upper end of the connecting rod is machined to match the contour of the piston pin The piston pin is secured to the connecting rod with two special bolts and spacers The lower bearing cap is secured to the connecting rod by two specially machined bolts and nuts See Figure 1 299 1 Connecting Rod Nut 2 5 Piston Pin Bolt 2 2 Notched Bolt 2 6 Connecting R
7. diameter at split line W W A B 2 2 Calculate the average bore out of round X X W C X must be between 0 012 and 0 012 mm 0 0005 and 0 0005 in 3 Calculate the average connecting rod bearing bore size Y Y W X 2 Y must be between a For 12 7 and 11 1 L 91 288 and 91 313 mm 3 594 and 3 595 in b For 14L and 12 7 EGR On Highway 101 288 and 101 3133 mm 3 988 and 3 989 in Rev 01 04 All information subject to change without notice 1 374 From Bulletin 20 60 03Rev 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL 4 Determine taper Z Z D2 D1 Z must be between 0 012 and 0 012 mm 0 0005 and 0 0005 in 5 Determine the rod length by finding the distance between E1 and E2 See Figure 1 307 a The acceptable rod length specification for 11 1 Liter connecting is 281 95 282 05 mm 11 1004 11 1043 in b The acceptable rod length specification for both 12 7 Liter and 14 Liter connecting rods is 269 25 269 35 mm 10 6004 10 6043 in c The acceptable rod length specification for Series 60G Engines is 262 90 263 00 mm 10 3504 10 3543 in d If the connecting rod bore is not to specifications the rod must be scrapped and cannot be machined 6 If anew connecting rod is required stamp the cylinder number on the connecting rod and cap Refer to section 1 18 3 1 19 4 2 Inspection of Connecting Rod Bearings and Bearing Bores Inspect the con
8. e unit serial numbers as listed in Table 1 7 Rev 01 04 All information subject to change without notice 1 366 From Bulletin 20 60 03Rev 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL CLOSED END CONNECTING ROD Each connecting rod is forged to an I section with a closed hub at the upper end and a bearing cap at the lower end See Figure 1 302 Unlike the open end connecting rod the closed end rod is not drilled prior to model year 2000 Lubrication for the piston and piston pin is supplied by a spray nozzle bolted to the block at the base of each cylinder bore Current blocks are drilled and tapped for installation of the cooling nozzles into the main oil gallery These nozzles spray crankcase oil upwards onto the piston and piston pin during engine operation providing the required lubrication and cooling NOTE The current connecting rod for 14 L engines and model year 2000 12 7 L engines use a drilled passage way through the rod to lubricate the piston pin bushing These connecting rods can be mixed within an engine with the former non drilled connecting rod See Figure 1 301 OIL PASSAGE CURRENT 12 7L AND 14L FORMER 12 7L PRIOR TO MODEL YEAR 2000 MODEL YEAR 2000 Figure 1 301 Current and Former Closed End Connecting Rods All
9. e stamped with their correct cylinder location If not marked stamp location 1 6 on the tang side cooler side of the rod and cap Refer to section 1 18 2 for piston and connecting rod assembly removal procedure 1 19 3 Disassembly of Connecting Rod Disassemble the connecting rod as follows NOTE It is best to disassemble inspect and assemble each connecting rod separately It is very important to keep the connecting rod cap and the upper and lower bearing shells to the original connecting rod 1 Loosen and remove the two connecting rod nuts See Figure 1 299 2 Remove connecting rod cap and bearings shells See Figure 1 299 1 19 3 1 Inspection of Connecting Rod Clean the bearings prior to inspection as follows 1 Clean the bearings with fuel oil To avoid injury from flying debris when using compressed air wear adequate eye protection face shield or safety goggles and do not exceed 40 psi 276 kPa air pressure 2 Dry the bearings with compressed air Inspect the open end connecting rod as follows 1 Inspect the connecting rod saddle at the piston pin contact surface for traces of fretting and corrosion 2 To repair wet with fuel oil and smooth with crocus cloth Rev 01 04 All information subject to change without notice 1 372 From Bulletin 20 60 03Rev 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL Inspect the closed end connecting rod as follows NOTICE
10. e upper bearing shell supplies oil to the oil passage in the connecting rod thereby providing a supply of lubricating oil from the crankshaft to the connecting rod bearings piston pin bushing and underside of the piston dome The upper shell is grooved from one edge to the oil hole The lower shell has a full length 180 degree groove See Figure 1 300 OIL HOLE LOCATING LOCATING TANG TANG Figure 1 300 Connecting Rod Bearing Detail Open End Rod The connecting rods bearing caps are numbered according to the cylinder position with matching numbers stamped on the connecting rod tang side The current wider connecting rod bearings replaced the former connecting rod bearings as listed in Table 1 24 This change was made to improve oil film thickness and reduce bearing pressures The current bearings are 47 44 47 14 mm 1 868 1 856 in wide The former bearings were 43 44 43 13 mm 1 710 1 698 in wide To provide full support for the wider bearings new connecting rods with smaller rod chamfers and current crankshafts with smaller fillet radii were also released Refer to section 1 7 for information on the current crankshafts NOTE The current connecting rod bearings connecting rods and crankshafts must be used together to ensure interchangeability Former parts cannot be mixed with new parts in the same engine The former bearing shells will be available for engines built prior to th
11. eventative a Check large end bore for burrs or foreign particles If possible use an emery cloth to smooth bore surface otherwise replace part To avoid injury from flying debris when using compressed air wear adequate eye protection face shield or safety goggles and do not exceed 40 psi 276 kPa air pressure b Blow compressed air through the drilled oil passage to ensure the passage is clean of obstructions Make sure the split line cap to rod is throughly clean c On a closed end rod inspect the piston pin bearing for wear scoring surface defects dents scratches or out of round condition Refer to section Specifications Inspect the bearings shells a Measure the thickness of the bearing shells using a micrometer and ball attachment J 4757 Refer to section 1 9 2 2 The minimum thickness of a worn standard connecting rod bearing shell should not be less than 3 086 mm 0 1215 in b If either bearing shell is thinner than this dimension replace both bearing shells Inspect the bearing shells and the crankshaft journals a Check the clearance between the connecting rod bearing shells and the crankshaft journals using a soft plastic measuring strip which is squeezed between the journal and the bearing Refer to section 1 A Checking Bearing Clearances in Shop Notes section Rev 01 04 All information subject to change without notice From Bulletin 20 60 03Rev 6SE483 0303 Copyright 2003 DETROIT D
12. losed End Rod Without a Drilled Passage LOCATING LOCATING TANG TANG Figure 1 304 Connecting Rod Bearing Detail for Pleasure Craft Marine Closed End Rod Without a Drilled Passage All information subject to change without notice Rev 01 04 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 20 60 03Rev 1 369 1 19 CONNECTING ROD OIL HOLE CURRENT 12 7L AND 14L FORMER 12 7L PRIOR TO MODEL YEAR 2000 MODEL YEAR 2000 Figure 1 305 Connecting Rod Bearings for 14 L and 12 7 L Engines The connecting rod bearing caps are numbered according to the cylinder position with matching numbers stamped on the connecting rod tang side The connecting rod bearing shells are precision made and are of the replaceable type The upper bearing shell is seated in the connecting rod and a lower bearing shell is seated in the connecting rod cap The upper and lower bearings are identical except for marine applications see Figure 1 304 The upper and lower bearing shells are located in the connecting rod by a tang at the parting line at one end of each bearing shell The tri metal bearing wear surfaces use a steel backing First an optimum composition copper tin and lead lining is bonded to the steel back A nickel barrier above the lining and the overlay serves to prevent tin migration A soft lead overlay 0 025 mm 0 001 in thick provides run in protection and an initial wear s
13. necting rod bearing as follows To avoid injury from flying debris when using compressed air wear adequate eye protection face shield or safety goggles and do not exceed 40 psi 276 kPa air pressure 1 Check connecting rod bearing wear surfaces for scoring pitting flaking chipping cracking loss of overlay or signs of overheating a Overlay plated bearings may develop very small cracks or small isolated cavities checking on the bearing surface during engine operation These are characteristics of and are NOT detrimental to this type of bearing The bearings should not be replaced for these minor surface imperfections The upper bearing shells which carry most of the load will normally show signs of distress before the lower bearing shells do If the overlay is worn through to the copper across the bearing shell all the bearing shells must be replaced b If any of these conditions are detected replace the bearings All information subject to change without notice Rev 01 04 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 20 60 03Rev 1 375 1 19 2 1 376 CONNECTING ROD Inspect the backs of the connecting rod bearing shells a Check for bright spots that indicate shells have been shifting in their bores b If bright spots are evident replace the bearings shells Inspect the connecting rod bearing bores if using a service replacement connecting rod clean rod to remove rust pr
14. od Bearing Cap 3 Connecting Rod 7 Bearing Shells 4 Spacer Washer 2 Figure 1 299 Connecting Rod and Bearing Shells Open End Rod Rev 01 04 All information subject to change without notice 1 364d From Bulletin 20 60 03Rev 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL The two special bolts locate the cap relative to the upper end The assembly is machined as a unit and must not be used in the engine with any other cap or upper end Orientation of the cap to the upper end is identified by stamped numbers NOTE The Series 60G engine connecting rod is shorter in length and identified by Natural Gas on the side The current connecting rods with smaller rod chamfers replaced the former connecting rods effective with the following engine serial numbers listed in Table 1 7 Engine Model Engine Serial Number 6067WK60 11 1L 6R184522 6067GK60 12 7L 6R188251 Table 1 7 New Connecting Rod Replacements This change was made to allow installation of new wider connecting rod bearings that provide improved oil film thickness and reduced bearing pressures The rod chamfers on the current connecting rods are smaller than those on the former rods This has been done to provide proper support for the wider bearings To conform with this change new crankshafts with smaller fillet radii have been released Refer to section 1 7 for information on the new crankshafts NOTE
15. urface A flash tin plate front and back is for added corrosion protection and resistance during shipping and handling These bearings are identified by the satin silver sheen of the tin when new and a dull gray of the overlay after being in service Rev 01 04 All information subject to change without notice 1 370 From Bulletin 20 60 03Rev 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL 1 19 1 Repair or Replacement of Connecting Rod To determine if repair is possible or replacement is necessary perform the following procedure See Figure 1 306 INSPECT REMOVE DISASSEMBLE CONNECTING ROD CONNECTING CONNECTING BEAR SHELLS amp BURRED OR CRANK JOUR FOREIGN PARTICLES ON OF CLEAR REPLACE l INSPECT CONNECTING ROD BRIGHT SCORED INSPECT SPOTS ON CHIPPED CRANKSHAFT BEARING SEED ane SHELLS BEARING REPLACE REPLACE REPLACE ASSEMBLE INSTALL Figure 1 306 Flowchart for Repair or Replacement of Connecting Rod All information subject to change without notice Rev 01 04 6SE483 0303 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 20 60 03Rev 1 371 1 19 CONNECTING ROD 1 19 2 Removal and Cleaning of the Connecting Rod Before removal make sure the connecting rods and caps ar
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