Drive system

TCD 2013 4V - Truck I 02-03-03

Removing and installing small end bush

Commercial available tools: Danger!
– Press or threaded spindle
Danger of injury, do not touch hot parts!
Special tools: Danger of injury, do not touch supercooled
– Base plate. . . . . . . . . . . . . . . . . . 131200 components or the liquid nitrogen!
– Assembly tool kit. . . . . . . . . . . . . 131240
Wear protective gloves and glasses!
– Nitrogen (liquid)
– Degreasing agent/cleaning
Attention!
The press-in process must be carried out
agent
without interruption as a result of the tem-
– Compressed air
perature difference between the small end
– Heating oven
bush and the connecting rod.
The necessary work steps must be practi-
sed before pressing in. 6
The pressing out of the small end bush is
shown with hydraulic press.
A threaded spilndle can also be used alter-
natively.

Removing the small end bush

Attention! 3
Never hammer out the small end bush!

z Insert big end bearing holder (3) in base plate (2). 1

z Insert removal gauge (1) in base plate.
Attention!
Do not confuse the removal gauge with the
installation gauge!

The groove (arrow) must face the big end

bearing holder.
Make sure the removal gauge is inserted
flush! 2

© 40404-0

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 Drive system
I 02-03-03 TCD 2013 4V - Truck

z Insert the bottom part of the assembly tool (3) into the
removal gauge from below. 1
z Place the connecting rod (1) on the base plate. 2
The flat side (arrow) of the connecting rod
must face down.

z Turn the bottom part (3) into the top part (2) of the as-
sembly tool.

6
© 40403-0

z Align the top part (1) of the assembly tool and remov-
al gauge (2).
The top part of the assembly tool and the
removal gauge are level with the angled
surfaces (arrows) of the big end bearing.

© 40401-0

z Screw the top part (1) and bottom part (2) of the as-
sembly tool together.

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 Drive system
TCD 2013 4V - Truck I 02-03-03

z Align the hydraulic press horizontally on the base

plate.
The press-out die is in the centre above
the top of the assembly tool.

6
© 36284-2

z Press out the small end bush with slight pressure.

z Clean the bush bore.
The bush bore must be free from grease
and dirt.

© 36285-2

Installing small end bush

z Insert big end bearing holder (3) in base plate (2). 3
z Insert installation gauge (1) in base plate.
The groove (arrow) must face the big end
bearing holder.
1
Make sure the installation gauge is inser-
ted flush.

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I 02-03-03 TCD 2013 4V - Truck

z Heat up the connecting rod (1).

 max. 200°C
z Place the connecting rod on the base plate (2). 1
The flat side (arrow) of the connecting rod
must face down.

2
6
© 40406-0

z Cool down the small end bush (1) in liquid nitrogen.

 approx. -40 °C

© 36288-2

z Place supercooled small end bush (1) on installation

mandrel (3).
The index pin (2) is sitting correctly in the
groove (arrow) of the small end bush. 1

2
3

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 Drive system
TCD 2013 4V - Truck I 02-03-03

z Insert installation mandrel (1) with small end bush (2)

in con rod bore.
The small end bush must be insertable in
the connecting rod bore with little force.
Note installation position of the small end
1
bush.
z Pull out the installation mandrel.
The small end bush may not slip. 2

6
© 36290-3

z Check installation position.

Position of the bush joint (arrow) looking at
the flat side of the connecting rod shank.

© 40968-1

Mechanical machining of the small end

bush is necessary after assembly work.

z Spindle small end bush to dimension A .

Maximum Minimum
Dimensions
dimension dimension
Bore of small
end bush 45,050 mm 45,040 mm
dimension A
Piston pin dia-
45,000 mm 44,994 mm
meter
Theoretical
0,056 mm 0,040 mm
clearance

© 39730-2

© 04/2009 5/6 20044-001

 Drive system
I 02-03-03 TCD 2013 4V - Truck

© 04/2009 6/6 20044-001