Service Bulletin

Volvo Trucks North America, Inc.

Greensboro, NC USA Trucks
Date Group No. Page
11.2002 216 34 1(4)

Connecting Rod
D12D
Connecting Rod

T2019076

This information covers the proper handling and preparation of the connecting rod, be-
cause this “fractured” connecting rod must be separated prior to installation.

NOTE: For information about removing and installing the connecting rod, refer to Ser-
vice Information, group 21.

Contents
• “Connecting Rod” page 2

NOTE: Information is subject to change without notice.

Illustrations are used for reference only and may differ slightly from the actual vehi-
cle being serviced. However, key components addressed in this information are
represented as accurately as possible.

PV776-TSP180940 USA12617
Page 2

Design and Function

Connecting Rod
See also:

• “Connecting Rod” page 1

You must read and understand the precautions and

guidelines in Service Information, group 20, "General
Safety Practices, Engine" before performing this pro-
cedure. If you are not properly trained and certified in
this procedure, ask your supervisor for training before
you perform it.

The “fractured” connecting rod must be prepared for in-

stallation by first removing the screws and bearing cap.

The fracture line can be difficult to detect when the con-

necting rod is assembled. The side face of the trapezium
is not machined and the bushing for the wrist pin is nar-
rower than on previous versions.

NOTE: Old and new types of connecting rod can be

used together in the same engine. Either type should be
torque-tightened to 275 ± 15 Nm (205 ± 10 ft-lb).

Preparing the “fractured” connecting rod for installation:

The connecting rod and bearing cap are marked as

pairs using a 3-digit serial number. Be sure to always
use matched pairs.

T2019085

CAUTION
Use a vice with soft jaws. Otherwise, damage to the
connecting rod can occur.

Secure the connecting rod in a vice. Remove the

screws. Tap the bearing cap loose using a rubber mallet.

T2019077
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 11.2002 216 34 3(4)

CAUTION
Damaged connecting rods or caps must not be in-
stalled. Doing so may cause engine failure.

The connecting rod and the bearing cap must be han-

dled with care. Impact marks on the fracture surface can
weaken the material after torque tightening.

NOTE: Slight chipping may occur when the cap is sepa-

rated from the connecting rod. This does not affect the
function of the connecting rod.

T2019086

Bearing shells must be installed so they are flush with

the edge of the connecting rod and cap. This is to en-
sure that the mating surfaces align correctly.

T2019078

WARNING
Always wear appropriate eye protection to prevent the
risk of eye injury due to contact with debris or fluids.

Using compressed air, thorougly clean both mating sur-

faces before installing the bearing cap.

T2019318
Page 4

The serial numbers must be placed directly opposite

each other when the caps are reinstalled. The boss on
the cap must be aligned with the side of the connecting
rod.

T2019085

Carefully check that the mating surface of the bear-

ing cap is aligned to the mating surface of the
connecting rod.

T2019086

CAUTION
Do not use a pneumatic impact wrench to tighten the
bearing caps. Doing so can permanently damage the
mating surfaces.

Torque-tighten the bearing cap screws to 275 ± 15 Nm

(205 ± 10 ft-lb).

T2019080