Connecting Rod And Crankshaft: Notes

Using a dial indicator, measure the end play while moving the connecting rod back and forth.

Standard end play: 0.1 ~ 0.25mm (0.004 ~ 0.010in.)

Maximum end play: 0.4mm (0.016in.)

Fig 1: Checking Connecting Rod End Play

Courtesy of HYUNDAI MOTOR CO.

• If out-of-tolerance, replace the connecting rod assembly.
• If still out-of-tolerance, replace the crankshaft.

1. Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
2. Remove the 2 connecting rod cap bolts.
3. Remove the connecting rod cap and bearing half.
4. Clean the crank pin and bearing.
5. Place plastigage across the crank pin.
6. Reinstall the bearing half and cap, and torque the bolts.

   Tightening torque 

   16 ~ 20 Nm (160 ~ 200 kgf.cm, 12 ~ 15 lbf.ft) + 90°

   NOTE: Do not turn the crankshaft.
7. Remove the 2 bolts, connecting rod cap and bearing half.
8. Measure the plastigage at its widest point.

   Standard oil clearance 

   0.018 ~ 0.036mm (0.0007 ~ 0.0014in.)

   Fig 2: Measuring Plastigage

   Courtesy of HYUNDAI MOTOR CO.
9. If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same color mark (select the color as shown in the next column), and recheck the clearance.
   CAUTION: Do not file, shim, or scrape the bearings or the caps to adjust clearance.
10. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that one), and check clearance again.
    NOTE: If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over.
    CAUTION: If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent.
    Fig 3: Identifying Connecting Rod Mark Location

    Courtesy of HYUNDAI MOTOR CO.
    CONNECTING ROD DIAMETER SPECIFICATIONS
    
    

    CLASS	MARK	INSIDE DIAMETER
    0	A	51.000 ~ 51.006mm (2.0079 ~ 2.0081 in.)
    1	B	51.006 ~ 51.012mm (2.0081 ~ 2.0083in.)
    2	C	51.012 ~ 51.018mm (2.0083 ~ 2.0086in.)

    Fig 4: Identifying Crankshaft Pin Mark

    Courtesy of HYUNDAI MOTOR CO.
    CRANKSHAFT DIAMETER SPECIFICATION
    
    

    CLASS	MARK	OUTSIDE DIAMETER OF PIN
    I	A	47.994 ~ 48.000mm (1.8895 ~ 1.8898in.)
    II	B	47.988 ~ 47.994mm (1.8893 ~ 1.8895in.)
    III	C	47.982 ~ 47.988mm (1.8890 ~ 1.8893in.)

    Fig 5: Identifying Connecting Rod Bearing Mark

    Courtesy of HYUNDAI MOTOR CO.
    CONNECTING ROD BEARING THICKNESS SPECIFICATIONS
    
    

    CLASS	MARK	THICKNESS OF BEARING
    A	BLUE	1.500 ~ 1.503mm (0.0590 ~ 0.0591 in.)
    B	BLACK	1.497 ~ 1.500mm (0.0589 ~ 0.0590in.)
    C	NONE	1.494 ~ 1.497mm (0.0588 ~ 0.0589in.)
    D	GREEN	1.491 ~ 1.494mm (0.0587 ~ 0.0588in.)
    E	YELLOW	1.488 ~ 1.491 mm (0.0586 ~ 0.0587in.)

11. Selection
    CRANKSHAFT IDENTIFICATION MARKS
    
    

    CRANKSHAFT IDENTIFICATION MARK	CONNECTING ROD IDENTIFICATION MARK	ASSEMBLING CLASSIFICATION OF BEARING
    I (A)	0 (A)	E (YELLOW)
    	1 (B)	D (GREEN)
    	2(C)	C (NONE)
    II (B)	0 (A)	D (GREEN)
    	1 (B)	C (NONE)
    	2(C)	B (BLACK)
    III (C)	0 (A)	C (NONE)
    	1 (B)	B (BLACK)
    	2 (C)	A (BLUE)

1. To check main bearing-to-journal oil clearance, remove the main caps and bearing halves.
2. Clean each main journal and bearing half with a clean shop tower.
3. Place one strip of plastigage across each main journal.
4. Reinstall the bearings and caps, then torque the bolts.

   Tightening torque 

   M8

   13 ~ 19 Nm (130 ~ 190 kgf.cm, 10 ~ 14 lbf.ft) + 90°

   M10

   27 ~ 33 Nm (270 ~ 330 kgf.cm, 19.5 ~ 24 lbf.ft) + 90°

   NOTE: Do not turn the crankshaft.
5. Remove the cap and bearing again, and measure the widest part of the plastigage.

   Standard oil clearance 

   0.004 ~ 0.022mm (0.00016 ~ 0.00087in.)

   Fig 6: Measuring Plastigage

   Courtesy of HYUNDAI MOTOR CO.
6. If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same color mark (select the color as shown in the next column), and recheck the clearance.
   CAUTION: Do not file, shim, or scrape the bearings or the caps to adjust clearance.
7. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that one), and check clearance again.
   NOTE: If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over.
   CAUTION: If the marks are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent.