ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and QSL9 Engines – 001-014   Connecting Rod

The connecting rod configuration can change, depending on the engine configuration. Some engines use straight split connecting rods. Other engines use angle split connecting rods. The connecting rod can also have a fracture split surface or a serrated surface.

Connecting rods with a fracture split or serrated surface must be treated with caution. The two pieces of the connecting rod can not be rubbed together, as this will damage the mating surfaces. Use care to not drop either piece of the connecting rod.

1. C connecting rods are straight, with a smooth machined surface.
2. L fracture split connecting rods are angled, with a fractured surface at the crankshaft end.
3. L serrated connecting rods are angled with a serrated machined surface at the crankshaft end.

These connecting rods can not be mixed in the same engine.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

WARNING  Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.

WARNING  Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

WARNING  To reduce the possibility of personal injury, avoid direct contact of hot oil with your skin.

WARNING  Some state and federal agencies have determined that used engine oil can be carcinogenic and cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil. If not reused, dispose of in accordance with local environmental regulations.

• Disconnect the batteries. Refer to the OEM service manual.
• Drain the cooling system. Refer to Procedure 008-018 in Section 8.
• Drain the lubricating oil. Refer to Procedure 007-037 in Section 7.
• Remove the cylinder head. Refer to Procedure 002-004 in Section 2.
• Remove the lubricating oil pan and gasket. Refer to Procedure 007-025 in Section 7.
• Remove the lubricating oil suction tube. Refer to Procedure 007-035 in Section 7.
• Remove the piston and connecting rod, and disassemble. Refer to Procedure 001-054 in Section 1.

WARNING  When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam can cause serious personal injury.

WARNING  When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.

WARNING  Some solvents are flammable and toxic. Read the manufacturer’s instructions before using.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Use a nylon bristle brush to clean the oil drillings.

Use steam or solvent to clean the connecting rods.

Dry with compressed air.

Inspect the connecting rods and connecting rod caps for damage.

Otherwise, replace the connecting rod if the “I-beam” is nicked or otherwise damaged.

Inspect the piston pin bore for damage or misalignment of the oil passage and bushing.

Measure the connecting rod piston pin bushing inside diameter.

Connecting Rod Piston Pin Bushing Diameter

Measure the connecting rod crankshaft bore with the bearing shells removed and the caps tightened to the proper torque value. Refer to Procedure 001-054 in Section 1.

Connecting Rod Crank Bore Diameter (Bearings Removed)

Measure the diameter of the rod journal on the crankshaft.

Out-of-Roundness

Taper

NOTE: If the crankshaft rod journals are not within the given specifications, the crankshaft must be replaced.

Bearing Clearance

Bearing clearance: rod inside diameter (with bearing) minus crankshaft journal diameter.

Bearing clearance can also be determined with a plastigauge during engine assembly.

Use a connecting rod checking fixture, Part Number ST-561, and a connecting rod mandrel set, Part Number 3823286, to inspect the bend and twist of the rods.

Calibrate the checking fixture with a new rod that has been measured for correct center to center length, 215.975 to 216.025 mm [8.5029 to 8.5040 in].

Assemble the connecting rod cap to the rod, as described previously in this procedure.

Install the piston pin mandrel from the mandrel set, Part Number 3823286, into the piston pin bore.

NOTE: Use a mandrel, Part Number 3823283, if a piston bushing has been removed or mandrel, Part Number 3823284, if the bushing is still in place.

Install the mandrel, Part Number 3823303, into the crankshaft bore and expand the mandrel.

NOTE: Make sure the pin on the mandrel is down and locked in position in the center of the connecting rod.

Install the connecting rod into the fixture.

Move the dial holder to position the contact points of the indicators on the mandrel in the piston pin bore.

Tighten the bracket to hold the indicators in position.

Set the dial indicators to zero.

Remove the connecting rod from the fixture.

Turn the rod 180 degrees horizontally and install the rod into the fixture again.

Check the dial indicators for zero position again.

If the dial indicators show any change from zero adjust the dials to half the indicated reading.

The fixture is now calibrated to allow the connecting rod to be installed into the fixture in either direction and the dials will indicate an equal defection on either side or zero.

Install the mandrel and arbor into the connecting rod to be inspected.

Install the connecting rod into the fixture.

Measure the connecting rod length and bend (alignment).

Straight Split Connecting Rod Length

Angle Split Connecting Rod Length

Connecting Rod Bend (Alignment)

Install a feeler gauge between the mandrel and the dial indicator holding plate, as shown in illustration.

Connecting Rod Twist

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

• Assemble and install the pistons and connecting rod assemblies. Refer to Procedure 001-054 in Section 1.
• Install the lubricating oil suction tube. Refer to Procedure 007-035 in Section 7.
• Install the lubricating oil pan and gasket. Refer to Procedure 007-025 in Section 7.
• Install the cylinder head. Refer to Procedure 002-004 in Section 2.
• Fill the lubricating oil pan. Refer to Procedure 007-037 in Section 7.
• Fill the cooling system. Refer to Procedure 008-018 in Section 8.
• Connect the batteries. Refer to the OEM service manual.
• Operate the engine and check for leaks.