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Repair procedures: Inspection: Notes

Connecting Rod And Crankshaft 

  1. Check the connecting rod end play.

    Using a feeler gauge, 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: Measuring End Play Connecting Rod Using Feeler Gauge
    G06862963Courtesy of HYUNDAI MOTOR CO.
    1. If out-of-tolerance, install a new connecting rod.
    2. If still out-of-tolerance, replace the crankshaft.
  2. Check the connecting road bearing oil clearance.
    1. Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
    2. Remove the 2 connecting rod cap nuts.
    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 nuts.

      Tightening torque 

      49.0 ~ 52.0 Nm (5.0 ~ 5.3kgf.m, 36.2 ~ 38.3lb-ft)

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

      Standard oil clearance 

      0.024 ~ 0.042mm (0.0009 ~ 0.0017in)

      Fig 2: Measuring Plastigage
      G06862964Courtesy 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.

      Connecting Rod Mark Location 

      Fig 3: Identifying Connecting Rod Mark Location
      G06862965Courtesy of HYUNDAI MOTOR CO.

      Discrimination Of Connecting Rod 

      DISCRIMINATION OF CONNECTING ROD

      Class Mark Inside Diameter
      A White 48.00 ~ 48.006mm (1.8896 ~ 1.8899in.)
      B None 48.006 ~ 48.012mm (1.8899 ~ 1.8902in.)
      C Yellow 48.012 ~ 48.018mm (1.8902 ~ 1.8904in.)

      Crankshaft Pin Mark Location 

      Fig 4: Identifying Crankshaft Pin Mark Location (1 Of 2)
      G06862966Courtesy of HYUNDAI MOTOR CO.
      Fig 5: Identifying Crankshaft Pin Mark Location (2 Of 2)
      G06862967Courtesy of HYUNDAI MOTOR CO.

      Discrimination Of Crankshaft 

      DISCRIMINATION OF CRANKSHAFT

      Class Mark Outside Diameter Of Pin
      I Yellow 44.960 ~ 44.966mm (1.7700 ~ 1.7703in.)
      II None 44.954 ~ 44.960mm (1.7698 ~ 1.7700in.)
      III White 44.948 ~ 44.954mm (1.7696 ~ 1.7698in.)

      Place Of Identification Mark (Connecting Rod Bearing) 

      Fig 6: Identifying Connecting Rod Bearing Identification Mark
      G06862968Courtesy of HYUNDAI MOTOR CO.

      Discrimination Of Connecting Rod Bearing 

      DISCRIMINATION OF CONNECTING ROD BEARING

      Class Mark Thickness Of Bearing
      AA Blue 1.514 ~ 1.517mm (0.0596 ~ 0.0597in.)
      A Black 1.511 ~ 1.514mm (0.0595 ~ 0.0596in.)
      B None 1.508 ~ 1.511mm (0.0594 ~ 0.0595in.)
      C Green 1.505 ~ 1.508mm (0.0593 ~ 0.0594in.)
      D Yellow 1.502 ~ 1.505mm (0.0591 ~ 0.0593in)
    11. Selection
      CRANKSHAFT IDENTIFICATION MARK REFERENCE

      Crankshaft Identification Mark Connecting Rod Identification Mark Assembling Classification Of Bearing
      I (Yellow) A (White) D (Yellow)
      B (None) C (Green)
      C (Yellow) B (None)
      II (None) A (White) C (Green)
      B (None) B (None)
      C (Yellow) A (Black)
      III (White) A (White) B (None)
      B (None) A (Black)
      C (Yellow) AA (Blue)
  3. Check the crankshaft bearing oil clearance.
    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: 

      27.5~31.4Nm (2.8~3.2kgf.m, 20.3~23.11lb-ft) + 60° ~ 64°

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

      Standard oil clearance: 

      0.028 ~ 0.046mm (0.0011 ~ 0.0018in)

      Fig 7: Measuring Widest Part Of Plastigage
      G06862969Courtesy 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.

    Connecting rods 

    1. When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at disassembly match. When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on the same side.
    2. Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a severely rough surface of the inside diameter of the small end is apparent, the rod must be replaced as well.
    3. Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is close to the repair limit, correct the rod by a press. Any connecting rod that has been severely bent or distorted should be replaced.

      Allowable bend of connecting rod: 

      0.05mm/100mm (0.0020 in./3.94 in) or less

      Allowable twist of connecting rod: 

      0.1mm/100mm (0.0039 in./3.94 in) or less

      Letters have been stamped on the end of the block as a mark for the size of each of the 5 main journal bores.

      Fig 8: Identifying No. 1 Crankshaft Bore Mark
      G06862970Courtesy of HYUNDAI MOTOR CO.

      Discrimination Of Cylinder Block 

      DISCRIMINATION OF CYLINDER BLOCK

      Class Mark Inside Diameter
      a A 59.000 ~ 59.006mm (2.3228 ~ 2.3230in.)
      b B 59.006 ~ 59.012mm (2.3230 ~ 2.3233in.)
      c C 59.012 ~ 59.018mm (2.3233 ~ 2.3235in.)

      Crankshaft Journal Mark Location 

      Fig 9: Identifying Crankshaft Journal Mark Location (1 Of 2)
      G06862971Courtesy of HYUNDAI MOTOR CO.
      Fig 10: Identifying Crankshaft Journal Mark Location (2 Of 2)
      G06862972Courtesy of HYUNDAI MOTOR CO.

      Discrimination Of Crankshaft 

      DISCRIMINATION OF CRANKSHAFT

      Class Mark Outside Diameter Of Journal
      I Yellow 54.956 ~ 54.962mm (2.1636 ~ 2.1638in.)
      II None 54.950 ~ 54.956mm (2.1633 ~ 2.1636in.)
      III White 54.944 ~ 54.950mm (2.1631 ~ 2.1633in.)

      Place Of Identification Mark (Crankshaft Bearing) 

      Fig 11: Identifying Crankshaft Bearing Identification Mark
      G06862973Courtesy of HYUNDAI MOTOR CO.

      Discrimination Of Crankshaft Bearing 

      DISCRIMINATION OF CRANKSHAFT BEARING

      Class Mark Thickness Of Bearing
      AA Blue 2.014 ~ 2.017mm (0.0793 ~ 0.0794in.)
      A Black 2.011 ~ 2.014mm (0.0791 ~ 0.0793in.)
      B None 2.008 ~ 2.011mm (0.0790 ~ 0.0791in.)
      C Green 2.005 ~ 2.008mm (0.0789 ~ 0.790in.)
      D Yellow 2.002 ~ 2.005mm (0.0788 ~ 0.0789in.)

      Selection 

      CRANKSHAFT IDENTIFICATION MARK REFERENCE

      Crankshaft Identification Mark Crankshaft Bore Identification Mark Assembling Classification Of Bearing
      I (Yellow) a (A) D (Yellow)
      b (B) C (Green)
      c (C) B (None)
      II (None) a (A) C (Green)
      b (B) B (None)
      c (C) A (Black)
      III (White) a (A) B (None)
      b (B) A (Black)
      c (C) AA (Blue)
  4. Check crankshaft end play.

    Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

    Standard end play: 

    0.06 ~ 0.26mm (0.0023 ~ 0.010in)

    Limit  : 0.30mm (0.0118in)

    Fig 12: Measuring Crankshaft End Play Dial Indicator
    G06862974Courtesy of HYUNDAI MOTOR CO.

    If the end play is greater than maximum, replace the thrust bearings as a set.

    Thrust bearing thickness: 

    2.44 ~ 2.47mm (0.096 ~ 0.097in)

  5. Inspect main journals and crank pins

    Using a micrometer, measure the diameter of each main journal and crank pin.

    Main journal diameter: 

    56.942 ~ 56.962mm (2.2418 ~ 2.2426in)

    Crank pin diameter: 

    44.946 ~ 44.966mm (1.7695 ~ 1.7703in)

    Fig 13: Measuring Main Journal Diameter Using Micrometer
    G06862975Courtesy of HYUNDAI MOTOR CO.
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