Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2002 Freightliner Sprinter 3500 L5-2.7L DSL TurboFACTORY OEM SERVICE PROCEDURE
Connecting Rod, Engine
Connecting rod
Distance between middle connecting rod bore to connecting rod bushing bore 148.970 mm to 149.030 mm
Width of connecting rod bearing bore at connecting rod bushing bore 21.940 mm to 22 mm
Connecting rod bearing shell basic bore 51.600 mm to 51.614 mm
Allowable out-of-roundness and taper of basic bore .020 mm
Allowable twist of connecting rod bearing bore to connecting rod bushing bore over a length of 100 mm .100 mm
Allowable variation of axial parallelism of connecting rod bearing bore to connecting rod bushing bore over a length of 100 mm .045 mm
Allowable difference in weight of complete connecting rod of an engine 2g
Connecting rod inner bushing 30.018 to 30.024 mm
Connecting rod outer bushing 32.575 mm to 32.600 mm
Connecting rod basic bore 32.500 mm to 32.525 mm
Piston pin play in connecting rod .018 mm to .024 mm
Peak-to-Valley height (Rz) of connecting rod bushing on inside 5
Connecting rod bolt thread M8 x 1 (1)
Connecting Rod
Bolt-Connecting Rod Cap to Connecting Rod (3 stage, 1&2 torque, 3 torque angle) 5, 25 Nm (44, 221 in lbs.), plus 90°
Distance between middle connecting rod bore to connecting rod bushing bore 148.970 mm to 149.030 mm
Width of connecting rod bearing bore at connecting rod bushing bore 21.940 mm to 22 mm
Connecting rod bearing shell basic bore 51.600 mm to 51.614 mm
Allowable out-of-roundness and taper of basic bore .020 mm
Allowable twist of connecting rod bearing bore to connecting rod bushing bore over a length of 100 mm .100 mm
Allowable variation of axial parallelism of connecting rod bearing bore to connecting rod bushing bore over a length of 100 mm .045 mm
Allowable difference in weight of complete connecting rod of an engine 2g
Connecting rod inner bushing 30.018 to 30.024 mm
Connecting rod outer bushing 32.575 mm to 32.600 mm
Connecting rod basic bore 32.500 mm to 32.525 mm
Piston pin play in connecting rod .018 mm to .024 mm
Peak-to-Valley height (Rz) of connecting rod bushing on inside 5
Connecting rod bolt thread M8 x 1 (1)
Connecting Rod
Bolt-Connecting Rod Cap to Connecting Rod (3 stage, 1&2 torque, 3 torque angle) 5, 25 Nm (44, 221 in lbs.), plus 90°
Factory Service Tools
Use the Manual With the Right Hardware
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.