General

231 Issue 1

Piston Pin Bushing - Remove and Install

January 2012

This engine news article applies to 1000, 1100 and 1200 Series 3, 4 and 6 cylinder engines.
Caution: Specialist equipment and personnel with the correct training are needed to carry out the procedure
in this article.

Types of Connecting Rods

There are five types of connecting rods that can possibly be found in the above engines.
(A) Flat butt face connecting rod
(B) Serrated connecting rod
(C1) Fracture split connecting rod that have locating tags.
(D1) Fracture split connecting rod without locating tags.
(E) Angled fracture split connecting rod that have locating tags

A0072

A0073

Engine News - General 231 Issue 1

January 2012

C
E
Piston Pin Bushing - Remove and Install
Prior to removing the piston pin bushing and machining procedure the connecting rod bolts/nuts should be
tightened to 20Nm (15 lb ft).
Before removing the original piston pin bushing from the connecting rod the connecting rod should be fully
inspected to ensure that the connecting rod is serviceable. The correct grade of the connecting rod should be
established to enable the connecting rod to be machined to the connecting rod original specifications. Refer to
Table 4 for full specification.
Fabrication of a suitable tooling jig in order to remove and install the piston pin bushing will be required. The
tooling must be capable of supporting the connecting rod at both ends as the connecting rod is of an offset
design.
Fabricate the suitable jig tools, made of steel and soft type material as required, in order to press the original
piston pin bushing out of the connecting rod and the new piston pin bushing into the connecting rod. Refer to
Table 1, Table 2, illustration (A) and illustration (B) for the correct dimensions.

1
2
3
4
5
7

Engine News - General 231 Issue 1

January 2012

Table 1
Dimension

Connecting Rod Number

Values

4115C331
4115C334
4115C335
4115C336
4115C337
4115C321

67mm (2.638 inch)

4115C322

A1

4115C311
4115C312
4115C313
4115C314
4115C315
4115C316
A1

4115C341

76mm (2.99 inch)

A2

3mm (0.118 inch)*

A3

10 Degrees

A4

As Required

A5

8mm (0.315 inch)*

A6

44mm (1.73 inch)

A7

As Required

Notes:
A soft type of material should be used for dimension A2* in order to prevent damage to the
connecting rod surface.
A soft type of material should be used for dimension A5* in order to prevent damage to the
connecting rod surface. The thickness of A5* will vary from connecting rod to connecting rod.
Ensure that the size of A5* is adjusted in order to ensure that connecting rod is fully supported.
Ensure that the connecting rod assembly is securely clamped to the tooling jig.
7

10
11

12

Engine News - General 231 Issue 1

January 2012

Table 2
Dimension

Values

B7

As Required

B8

50mm (1.97 inch)

B9

37.5mm (1.48 inch)

B10

As Required

B11

43mm (1.69 inch)

B12

10 Degrees

1 Position the connecting rod onto the fabricated tooling jig. Ensure that the connecting rod is well supported
at both ends. Install the assembly onto a suitable press.

L
1
2
3

D
2 Using the fabricated mandrel (C1) in order to remove piston pin bushing from the connecting rod.
3 Inspect the bore (D2) for the piston pin bushing in the connecting rod for wear or damage. If necessary,
remove any burrs in the bore for the piston pin bushing in the connecting rod.
4 Position the new piston pin bushing on top of the bore (D2) of the connecting rod.
5 Ensure that the lubrication hole (D1) in piston pin bushing is aligned to the with the oil hole in connecting rod
(D3).
Note: Some connecting rods have no lubrication hole (D3).
6 Position the fabricated tooling onto a suitable press in order to press the new piston pin bushing into the
connecting rod. Ensure that the lubrication hole in the piston pin bushing (D1) is still aligned with the hole in
the connecting rod (D3).
7 Using the fabricated mandrel (C1) in order to install the piston pin bushing to the connecting rod.

Engine News - General 231 Issue 1

January 2012

8 Machine the profile of the parallel piston pin bushing (Perkins part number 3112E041) to the connecting rod
profile of 10 degrees. This machining procedure is required prior the machining of the finished bore of the
piston pin bushing.
9 Machine the partially finished bushing to the correct diameter. Obtain the correct grade of connecting rod.
Refer to Table 3 and Table 4 for the correct information.
10 Obtain the correct clearance and surface finish between the piston pin and piston pin bushing. Refer to
Table 3 and Table 4 for the correct information.
11 Ensure that the distance between the parent bores of the connecting rod is still within tolerance. Refer to
the relevant Workshop Manual or Service Manual for the correct dimensions.
Caution: Do not stamp the connecting rod.
12 Check that the grade letter on the connecting rod is correct. If necessary, delete the letter and etch a new
letter on the side of the connecting rod.
Table 3
Connecting Rod
Assembly Part Number

Bushing Part Number

Finished Inside Diameter

(mm/inch)

Roundness

Surface Finish

3112E041 or 3112A005

39.723-39.738 (1.5631.564)

0.006

0.8

3112A006

38.117-38.136 (1.5001.501)

0.006

0.8

3112E031

39.723-39.738 (1.5631.564)

0.006

0.8

4115C311
4115C312
4115C313
4115C314
4115C315
4115C316
4115C321
4115C322
4115C341
4115C342
4115C343
Table 4
Connecting Rod
Assembly Part
Number

Bushing Part
Number

Connecting Rod
Grade Lengths L
(mm)

Grade Code

Colour Code

4115C311

165.761 to 165.728

Red

4115C312

165.715 to 165.682

Orange

4115C313

165.670 to 165.637

White

165.624 to 165.591

Green

4115C315

165.578 to 165.545

Purple

4115C316

165.532 to 165.499

Blue

166.425 to 166.392

Brown

166.562 to 166.529

Pink

219.100 to 219.050

White

161.2.92 to 161.259

Red

161.216 to 161.183

Green

161.140 to 161.107

Blue

4115C314

4115C321
4115C322
4115C334

3112E041 or
3112A005

3112A006
3112E041 or
3112A005

4115C341
4115C342
4115C343

3112E031

Notes:
Bushing (Perkins part number 3112E041) is installed on 1004 engines and bushing (Perkins part number
3112A005) on 1104 engines.
Bushing (Perkins part number 3112E011) has been replaced with bushing (Perkins part number
3112E041)
5

Engine News - General 231 Issue 1

January 2012
End

Perkins Confidential Yellow. Issued by Perkins Engines Company Ltd, Peterborough PE1 5NA, England. Proprietary information of
Perkins Engines Company Ltd 2012, all rights reserved. The information is correct at the time of print. This Engine News article is for
technical information only and cannot be used as a basis for any claim including but not limited to warranty.
To enable the distribution lists for engine news articles to be maintained, If you currently receive engine news articles, but no
longer require them, please contact Matthew OHare by email at o_hare_matthew@perkins.com