NUMBER: 07 EPA04 MBE 4000-5 S.M. REF.: 1.18.1.3, 1.18.2 and 1.

A ENGINE:
MBE 4000 DATE: October 2007

SUBJECT: REVISED CONNECTING ROD TORQUE

PUBLICATION: 6SE412
MBE Engineering has revised the specification for the connecting rod bolt torque for all EPA04
MBE 4000 engines. The connecting rod bolt torque specifications listed in 6SE412 are 100–115
N·m (74–85 lb·ft) with an additional 90–100 degree rotation. The revised connecting rod bolt torque
specification is 108 N·m (80 lb·ft) with an additional 90 degree rotation. Listed in Table 1 are the
updates for Sections 1.18.2, 1.18.1.3, and 1.A.
Section Change
Connecting rod bolt torque values for Table 1-27
1.18.1.3
have been updated.
Connecting rod bolt torque values for Table 1-31
1.18.2
have been updated.
Connecting rod bolt torque values for Table 1-80
1.A
have been updated.

Table 1 Connecting Rod Bolt Torque Change

1.18.1.3 CONNECTING ROD RADIAL PLAY MEASUREMENT
Measure the connecting rod radial play as follows:
1. Remove the piston. Refer to section 1.18.1.
2. Using a chamois cloth, clean the bearing bores in both the connecting rod and the bearing cap.
3. Install the two matched halves of the bearing shell, as marked on removal, into the connecting
rod and into the bearing cap. Be sure the locking lugs on the bearing shells fit into the grooves
in the rod and cap. See Figure 1–104.

1. Connecting Rod 3. Bearing Cap

2. Bearing Shell (2 halves) 4. Connecting Rod Bolt

Figure 1–104 Bearing Shell Replacement

4. Install the bearing cap on the connecting rod, pressing it on by hand. Be sure that the marks
on the cap and rod match.
5. Lubricate the threads and the contact surface of the head of each stretch bolt with a light
coating of engine oil.
6. Install the stretch bolts in the connecting rod, and tighten them alternately. Tighten each one in
turn to the first stage and then go on to the next stage, listed in Table 1–27.
Max. Shaft Length: mm (in.) Tightening Stage Torque Value: N·m ( lb·ft)
68.5 (2.70) Stage 1 108 (80)
68.5 (2.70) Stage 2 additional 90 degree rotation

Table 1–27 Connecting Rod Stretch Bolts Tightening Stages

 7. Using a micrometer, measure the bearing journal on the crankshaft in both the vertical and
horizontal plane and note the measurements. See Figure 1–105 to locate the measuring points
and listed in Table 1–28 are the current repair stage specifications.

Figure 1–105 Measuring the Bearing Journal

Repair Stage: mm (in.) Diameter: mm (in.)
Standard 93.980-94.000 (3.7000-3.7007)
Undersize - 0.1 (0.004) 93.880-93.900 (3.6960-3.6968)
Undersize - 0.25 (0.010) 93.730-93.750 (3.6901-3.6909)
Undersize - 0.50 (0.020) 93.480-93.500 (3.6803-3.6811)
Undersize - 0.75 (0.030) 93.230-93.250 (3.6705-3.6712)
Undersize - 1.00 (0.040) 92.980-93.000 (3.6606-3.6614)

Table 1–28 Bearing Journal Specifications

[a] Measure the bearing journal in the vertical plane and note the reading.
[b] Measure the bearing journal in the horizontal plane and note the reading.
 [c] Calculate the average (nominal) bearing-journal diameter from these two measurements,
and determine the current repair stage listed in Table 1–29.
Repair Stage: mm (in.) Diameter: mm (in.)
Standard 94.054-94.096 (3.7029-3.7046)
Undersize - 0.10 (0.004) 93.954-93.996 (3.6990-3.7006)
Undersize - 0.25 (0.010) 93.804-93.846 (3.6931-3.6947)
Undersize - 0.50 (0.020) 93.554-93.596 (3.6832-3.6848)
Undersize - 0.75 (0.030) 93.304-93.346 (3.6734-3.6750)
Undersize - 1.00 (0.040) 93.054-93.096 (3.6635-3.6652)

Table 1–29 Bearing Bore Inside Diameter with Bearing Shells Installed
NOTICE:
Be sure the vise jaws in the next step are adequately lined
to prevent the connecting rod surface from being nicked or
marred in any way. Such surface damage could lead to later
cracking or breaking of the rod.

8. Place the connecting rod in a vise with protective jaws. To prevent the rod from twisting
excessively, position the rod in the vise as close as possible to the big-end bore.
9. Set the caliper (internal measurement 80 to 100 mm) to the nominal bearing-journal diameter
calculated above. Use a 75 to 100 mm micrometer for the setting. Preload the setting 5 mm
(0.2 in.). See Figure 1–106.

Figure 1–106 Setting the Caliper

 10. Using a quick-release caliper (internal measurement 80-120 mm), dial gauge, and holder,
measure the inside diameter of the bearing bore (with the shells installed) at three points.
Measure vertically and about 60 degrees each side of vertical. See Figure 1–107 to locate the
measuring points, and find the current specifications listed in Table 1–29.

1. Bolt 2. Bearing Cap

Figure 1–107 Measuring the Inside Diameter of the Bearing Shell

[a] Measure the bearing bore in the vertical dimension and note the reading.
[b] Mark off a point 60 degrees counterclockwise from vertical. Measure the bearing bore in
this dimension and note the reading.
[c] Mark off a point 60 degrees clockwise from vertical. Measure the bearing bore in this
dimension and note the reading.
[d] Calculate the average (nominal) bearing-journal diameter from these three measurements,
and determine the current repair stage listed in Table 1–29. If any of the measurements are
out of tolerance, replace the bearing shells.

NOTE:
Connecting-rod bearings for all repair stages are delivered from the factory ready to install. Do
not refinish them in any way.

NOTE:
To obtain a correct value for connecting-rod radial play, the diameters of each bearing bore and its
corresponding journal must belong to the same repair stage (both must be "standard," "undersize
0.1 mm," etc.).
 11. Calculate the connecting rod radial play (up-and-down movement) at the bearing journal. If the
radial play is less than 0.054 mm (0.0021 in.), or more than 0.116 mm (0.0046 in.), replace
the connecting rod. Listed in Table 1–30 is the radial play.
Description Dimensions: mm (in.)
Radial Play 0.054 - 0.116 (0.0021 - 0.0046)

Table 1–30 Connecting Rod Radial Play

[a] For each connecting rod, note the average value for the bearing bore diameter, as
calculated. Example: Ds = 3.5421 inches.
[b] For each bearing journal, note the average value for the bearing journal diameter, as
calculated. Example: Dj= 3.5391 inches.
[c] From the value for the bearing bore diameter, subtract the value for the bearing journal
diameter. This result is the radial play. Example: Ds—Dj = 0.0030 inch.

NOTE:
In the above example, both measurements belonged to repair stage "undersize 0.1 mm."

12. Remove the bearing cap from the connecting rod.

13. Install the piston. refer to section 1.18.2.
1.18.2 PISTON INSTALLATION
Installation steps are as follows:
1. Position the connecting rod in the piston so that the longer end side is on the unit pump side.
2. Install the wrist pin in the piston. See Figure 1–108.

1. Piston 2. Wrist Pin

Figure 1–108 Installing the Wrist Pin

[a] Lubricate the wrist pin with a light coating of clean engine oil.
[b] Insert the wrist pin into the wrist pin bore.
[c] Secure the wrist pin with the two snap rings.
3. Install the piston rings on the piston. See Figure 1–109. Refer to section 1.18.3.

1. Piston

Figure 1–109 Ring Gaps Offset 120 Degrees

[a] Lubricate the piston with a light coating of clean engine oil.
[b] Install each piston ring in the appropriate groove on the piston.
4. Offset the ring gaps alternately by 120 degrees.
5. Position a ring compressor loosely over the piston. Tighten the ring compressor on the piston.
NOTICE:
The half of the bearing shell installed in the connecting rod
(rod half) has a specially-treated friction surface that allows
it to bear higher loads. It cannot be interchanged (swapped)
with the other half of the bearing shell installed in the bearing
cap (cap half).
6. Install the rod half of the bearing shell in the connecting rod, as marked on removal. See
Figure 1–110.

1. Connecting Rod 2. Bearing Shells 3. Bearing Cap

Figure 1–110 Installing the Bearing Shells

[a] Be sure that the locking lug in the bearing shell is fully seated in the groove of the rod.
[b] Lubricate the bearing surface with a light coating of clean engine oil.
7. Lubricate the cylinder liners with a light coating of clean engine oil.
NOTICE:
Be careful not to scratch the crankshaft journals with the
connecting rod. This can lead to premature wear of the
crankshaft.

8. Push the piston into the cylinder until the rod bearing rests on the crankshaft journal. See
Figure 1–111.

1. Ring Compressor 2. Piston 3. Cylinder Block

Figure 1–111 Installing a Piston

9. Install the cap half of the bearing shell in the bearing cap, as marked on removal. See Figure
1–110.
[a] Be sure that the locking lug in the bearing shell is fully seated in the groove of the cap.
[b] Lubricate the bearing surface with a light coating of clean engine oil.
 10. Measure the connecting rod stretch bolts. Replace any bolts that exceed the maximum length
of 68.5 mm (2.70 in.). See Figure 1–112. Lubricate the stretch bolt threads with a light
coating of engine oil.

1. Shank

Figure 1–112 Measuring a Stretch Bolt

11. Install the bearing cap on the connecting rod and hand-tighten the stretch bolts. Ensure that the
marks on the cap and the rod match.
12. Tighten the M16 x 1.5 connecting rod stretch bolts alternately. Tighten each one in turn to the
first stage and then go on to the next stage. Listed in Table 1–31.
Max. Shaft Length: mm (in.) Tightening Stage Torque Value: N·m (lb-ft)
Stage 1 108 (80)
68.5 (2.70)
Stage 2 additional 90 degree rotation

Table 1–31 Connecting Rod Bolts Tightening Stages

13. Check the connecting rod end play (axial play). Refer to section 1.18.1.2.
14. Rotate the crankshaft to make sure it turns freely.

NOTE:
If it is necessary to turn the crankshaft and the flywheel has been removed, install the flywheel guide
pins in the crankshaft gear.
 15. Using a dial gauge and holder, measure the piston projection relative to crankcase top dead
center at all the pistons. See Figure 1–113.

1. Piston 2. Cylinder Liner

Figure 1–113 Piston Projection at Top Dead Center (TDC)

16. If the piston projection dimensions are not between 0.244 and 0.715 mm (0.0096 and 0.0281
in.), replace the piston. Listed in Table 1–32.
Description Specification: mm (in.)
Piston Projection (at TDC) 0.244 – 0.715 (0.0096 – 0.0281)

Table 1–32 Piston Projection Specifications

17. Remove the engine barring tool J-46392. Refer to section 1.16.2.
NOTICE:
Be careful not to damage the oil spray nozzles. Damaged oil
spray nozzles could result in a loss of oil pressure and cause
engine damage.

18. Install the oil spray nozzles, as removed. Be sure they are seated and aligned correctly.
19. Install the oil pan.
1.A ADDITIONAL INFORMATION
Piston, Piston Ring and Connecting Rod
Listed in Table 1–80 are the connection rod bolt torque stages.
Max. Shaft Length: mm (in.) Tightening Stage Torque Value: N·m (lb·ft)
Stage 1 108 (80)
68.5 (2.70)
Stage 2 additional 90 degree rotation

Table 1–80 Connecting Rod Bolts Torque Stages

ADDITIONAL SERVICE INFORMATION
Additional service information is available in the Detroit Diesel EPA04 MBE 4000 Service Manual
(6SE412). The next revision to this manual will include the revised information.

Detroit Diesel®, DDC® and the spinning arrows design are registered trademarks of Detroit Diesel Corporation.
© Copyright 2002 Detroit Diesel Corporation. All rights reserved. Printed in U.S.A.