What is the most likely cause of misalignment wear on connecting rod bearings during an engine overhaul?

Misalignment wear on connecting rod bearings is most commonly attributed to a bent connecting rod. When a connecting rod is bent, it creates an angle that does not align properly with the crankshaft and the other components involved in the motion of the engine. This misalignment leads to uneven distribution of load across the bearing surfaces, resulting in increased friction and wear in specific areas of the bearing. Over time, this can lead to significant bearing failure, as the compromised alignment affects the overall performance and durability of the engine.

Other options, while they can lead to various types of wear or failure, do not directly cause misalignment in the same way a bent connecting rod does. Proper finishing of the bearing bore surfaces ensures a good fit and smooth operation but does not inherently relate to alignment issues. Excessive bearing-to-crankshaft clearance can lead to wearing but typically manifests itself through other symptoms, such as noise or loss of oil pressure, rather than direct misalignment. Lastly, improper torquing of connecting rod bolts can cause a myriad of issues, including bearing wear, but typically does not directly lead to the alignment issues associated with a bent connecting rod. Thus, the most direct and probable cause of misalignment wear is indeed a bent connecting rod.