Item 1: Power Cylinder Assembly
Item 2: Cylinder Sleeve O-rings
Item 3: Engine Block

Ensure Piston, Connecting Rods, Piston Pin Retainer, and Connecting Rod
Bearings ORIENTATION is correct prior to assembly

6A. TORQUE DATA

(PSET 1) Target Torque: 22.0 ft/lb (30 Nm), Minimum Torque: 22.0 ft/Ib (30 Nm), Maximum Torque: 23.0 ft/lb (31.1 Nm),
batch (2).

¢ If results are above 25 ft/lb, loosen both of the rod bolts and retorque within the proper range

(PSET 2) Target Torque: 77.0 ft/lb (105 Nm), Minimum Torque: 77.0 ft/lb (104.3 Nm), Maximum Torque: 78 ft/lb (105.7 Nm),
batch (2).

« If torque results are above 80 ft/lb, replace both of the rod bolts and start at step 1
(PSET 3) Target Angle: 90 degrees, Minimum Angle: 90 degrees, Maximum Angle: 91 degrees, batch (2).

« If torque results are 93 degrees or higher, replace both of the rod bolts and start at step 1

* Verify the final torque value is within a minimum of 95 ft/lb to a maximum of 150 ft/lb. If any are out of range, replace both of
the rod bolts and start at step 1. Typically the final torque values for all 6 rods will be fairly consistant if done correctly

« Maximum torque variance on a single rod is 20 ft/lb. If that value is exceeded, replace both of the rod bolts and start at step
1

7. Install Cylinder Head 0000870980 2017 A26 Engine Service Manual

8. Follow Engine Assembly procedures (Oil priming, fluid levels, MAF calibration, break-in procedure)
9. Install ECM Template

NOTE: A parameter template must be installed in the engine ECM via SDS after the repair is complete. This must be done
before the truck is returned to service. IK1201473 - Recall 22518 SDS Template to Enable Con-Rod can be followed for basic

template programming instructions, but the template within the article SHOULD NOT be installed if connecting rod
replacement has occurred. The template from this article will ENABLE knock detection, while the goal after repairs, is to
DISABLE knock detection.

i. Download Template - Knock Detection Template
NOTE: Template is currently a zip file. Open the zip file and extract the template to your desktop before trying to load it into SDS.
ii. ApplyTemplate
iii. Look up parameter 3900 and verify it is set to "Knock Detection Disabled". A fresh health report can also be
pulled, and verified similar to the IKNOW article listed above (IK1201473), but it should read "EBP
Knock Detection Disabled"

=
W ALL PARAMETERS Dock (ers)

Knock detection disabled Edit

Connecting Rod Strategy Enable

Parameter 3900- Connecting Rod Strategy Enable

BEST REPAIR PRACTICES

Shop Environment:

e Work area must be clean. Contamination to following components can lead to premature engine failure:
eo Crankshaft, Cylinder Sleeve
o Engine Lubrication and High-Pressure Fuel Systems
o Front and Rear Gear-Train

Steam Clean Engine and Engine Compartment: IF REQUIRED

e Prior to engine disassembly, remove contaminates that are built up around the EGR Cooler, Exhaust Manifold, Cylinder Head,
Fuel System, and Oil Pan
e Properly cover electronics and open entrances

Engine Block and Cylinder Head Preparation for Assembly:

e Do NOT use an abrasive disc or wire wheel

e Utilize recommended tools to clean cylinder head, block deck surface, liner flanges, and counterbores
e 3M Roloc Bristle cleaning disc “Green” or “Yellow” to clean surfaces
© 3M Scotch Brite “Maroon” pads

Engine Preparation and Assembly:

e Clean components with brake cleaner or solvent
ce Do NOT use brake cleaner or solvents to clean NEW Connecting Rod Bearings
e Air or blow dry components
¢ Clean all oil and residue from the backside of the connecting rod bearings and saddle surfaces of the connecting rods
e lf required, store cleaned components in plastic bags to reduce contamination
e Utilize the proper lubrication
© Utilize P-80 LUBRICANT to lubricate Cylinder Sleeve and new Cylinder Sleeve O-rings
© Utilize LUBRIPLATE 105 to lubricate new Connecting Rod Bearings

Connecting Rod Cap Installation:

Ensure proper torque wrench settings are programmed prior to use. Reference 1K1201391
Add clean engine oil to the first 3 to 4 threads and washer surface of each new connecting rod bolt

Initially seat the connecting rod cap and install bolts by hand. Alternate back and forth to seat the cap flush prior to torqueing
Alternate back and forth starting with: 2x each 22 (ft-lb), 77 (ft-lb), 90 degrees
Anytime connecting rod bolts are replaced the connecting rod cap needs to be removed and ensure the connecting rod cap are
centered

Torque Wrench Operation:

e Ensure your torque wrench has been calibrated by an authorized Snap-On repair facility. Reference 1K1201391
e Torque wrench calibration / Snap-On repair center. Reference TL2900164

Torque Wrench Data Review (Connecting Rod Bolts):

e Ensure (36) lines of data is recorded. Reference IK1201391> Section Viewing Torque Wrench Data

e If an over-torque occurs at 22 or 77 ft-lb both Connecting Rod Bolts can be backed off and retorqued
o Ensure retorque process begins at 22 ft-lb

e If an over-torque occurs at 90 degrees both Connecting Rod Bolts need to be replaced

e Connecting Rod Bolts are torque to yield. DO NOT REUSE

Post Repair & Road-test:
Ensure knock calibration has been disabled
Prior to engine start-up perform Engine Oil Priming Procedure listed within A26 engine service manual
Vacuum test cooling system prior to fill
Fill cooling and engine oil to proper levels
Monitor oil pressure gauge for the first minute
Idle engine for 30 minutes, no excessive RPM changes
Listen for unusual noises
Prior to road-test inspect engine for coolant and oil leaks
Road-test vehicle for 60 minutes
After proper engine operation has been verified, inspect engine for leaks
Perform post repair Health Report

FAQ

1. Will this repair be exempted from the Repair Velocity metrics?
a. The repair is being handled the same as engine replacement, which are not removed. The Repair Velocity target was set
with engine replacement volume included.
2. How are parts orders managed for the connecting rods?
a. Once the repair path is determined, the parts will be sent automatically, no need to order connecting rods.
b. Our parts expediters use a Child Case File and the PO for the parts shipment is the Connecting Rod replacement Case
File.
3. Is the oil replacement covered through the warranty claim?
a. Yes, oil is covered.
4. Can you change the connecting rods from the bottom of the engine without removing the cylinders?
a. No, there is not enough room to remove the wrist pin.

WARRANTY INFORMATION

© As of 11/7/22 - International will discontinue Blue Tag returns for A26 Connecting Rods and transition
to the International Product Review Center (PRC) Warranty part return process

« ALL connecting rods and bearings may be called back under appropriate Return Authorization (RA)
form within the Warranty Claim Processing Portal (currently iClaim)

e Refer to WPL2800136 for Digital Torque Wrench policy
o Issues with wrench, reference TL2900164

Inspections should be included within the claim as T-time

2517649C93 - 0.2Hr
2517649094 - 0.1Hr

Standard Repair Time(s):

Labor Op Labor Description HRs Elemental Steps |Notes

LT12-1146UV-20 Connecting Rod, Replace 23.4

c.
5
z

e Utilizing CYL KIT PULLER

e Utilizing Reduced PWR CYL
KIT

e Torque Data Upload

¢ Includes packaging Blue Tag
parts

RH12-1146UV-20 Connecting Rod, Replace 23.4

c.
—
~~
e

Utilizing CYL KIT PULLER

© Utilizing Reduced PWR CYL
KIT

e Torque Data Upload

e Includes packaging Blue Tag

parts

cr.
5
x

Complete Power Cylinder 21.7
Assembly, Replace e Utilizing CYL KIT PULLER

LT12-1146UV-22 e Utilizing Assembled PWR CYL
KIT

e Torque Data Upload

* Includes packaging Blue Tag
parts

RH12-1146UV-22 Complete Power Cylinder 21.7
Assembly, Replace

c.
5
x

e Utilizing CYL KIT PULLER

e Utilizing Assembled PWR CYL
KIT

* Torque Data Upload

e Includes packaging Blue Tag
parts

HX12-1146UV-20 Connecting Rod, Replace 93.4

c.
5
x

e Utilizing CYL KIT PULLER

© Utilizing Reduced PWR CYL
KIT

e Torque Data Upload

e Includes packaging Blue Tag
parts

HX12-1146UV-22 Complete Power Cylinder 21.7
Assembly, Replace

r.
5
x

e Utilizing CYL KIT PULLER

¢ Utilizing Assembled PWR CYL
KIT

* Torque Data Upload

e Includes packaging Blue Tag
parts

HH12-1146UV-20 Connecting Rod, Replace 93.4

C.
EI
x

e Utilizing CYL KIT PULLER

e Utilizing Reduced PWR CYL
KIT

¢ Torque Data Upload

e Includes packaging Blue Tag
parts

HH12-1146UV-22 Complete Power Cylinder 21.7
Assembly, Replace

c.
5
x

e Utilizing CYL KIT PULLER

e Utilizing Assembled PWR CYL
KIT

e Torque Data Upload

© Includes packaging Blue Tag
parts

ECM Template 0.5 Only if required

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