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Repair procedures: Inspection: Notes

Connecting Rod And Crankshaft 

  1. Check the connecting rod end play.

    Using feeler gauge, measure the end play while moving the connecting rod back and forth.

    End play 

    Standard : 0.1 ~ 0.25 mm (0.0039 ~ 0.0098 in)

    Maximum : 0.4 mm (0.0157 in)

    Fig 1: Measuring End Play While Moving Connecting Rod Back And Forth
    G06879150Courtesy 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 rod bearing oil clearance.
    1. Check the match marks 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 lower bearing.
    4. Clean the crankshaft pin journal and bearing.
    5. Place a plastigage across the crankshaft pin journal.
    6. Reinstall the lower bearing and cap, and tighten the nuts.

      Tightening torque: 

      31.4 ~ 34.3 N.m (3.2 ~ 3.5 kgf.m, 23.1 ~ 25.3 lb-ft)

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

      Standard oil clearance 

      0.018 ~ 0.036 mm (0.0007 ~ 0.0014 in)

      Fig 2: Measuring Plastigage At Its Widest Point
      G06879151Courtesy of HYUNDAI MOTOR CO.
    9. If the plastigage measures too wide or too narrow, remove the upper and lower bearing and then install a new bearings with the same color mark. (Refer to CONNECTING ROD BEARING SELECTION TABLE ).

      Recheck the oil clearance.

      CAUTION: Do not file, shim, of 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. (Refer to CONNECTING ROD BEARING SELECTION TABLE ).

      Recheck the oil clearance.

      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
      G06879152Courtesy of HYUNDAI MOTOR CO.

      Identification Of Connecting Rod 

      CONNECTING ROD BIG-END INNER DIAMETER REFERENCE CHART

      Mark Connecting rod big-end inner diameter
      ^ 48.000 ~ 48.006 mm (1.8898 ~ 1.8900 in)
      b 48.006 ~ 48.012 mm (1.8900 ~ 1.8902 in)
      c 48.012 ~ 48.018 mm (1.8902 ~ 1.8905 in)

      Crankshaft Pin Journal Mark Location 

      Fig 4: Identifying Crankshaft Pin Journal Mark Location
      G06879153Courtesy of HYUNDAI MOTOR CO.

      Identification Of Crankshaft Pin Journal 

      CRANKSHAFT PIN JOURNAL OUTER DIAMETER REFERENCE CHART

      Mark Crankshaft pin journal outer diameter
      ^ 44.966 ~ 44.972 mm (1.7703 ~ 1.7705 in)
      b 44.960 ~ 44.966 mm (1.7701 ~ 1.7703 in)
      c 44.954 ~ 44.960 mm (1.7698 ~ 1.7701 in)

      Connecting Rod Bearing Mark Location 

      Fig 5: Identifying Connecting Rod Bearing Mark Location
      G06879154Courtesy of HYUNDAI MOTOR CO.

      Identification Of Connecting Rod Bearing 

      CONNECTING ROD BEARING THICKNESS REFERENCE CHART

      Mark Color Connecting rod bearing thickness
      AA Blue 1.514 ~ 1.517 mm (0.0596 ~ 0.0597 in)
      A Black 1.511 ~ 1.514 mm (0.0595 ~ 0.0596 in)
      B None 1.508 ~ 1.511 mm (0.0594 ~ 0.0595 in)
      C Green 1.505 ~ 1.508 mm (0.0593 ~ 0.0594 in)
      D Yellow 1.502 ~ 1.505 mm (0.0591 ~ 0.0593 in)
    11. Select the bearing by using selection table.

      Connecting Rod Bearing Selection Table 

      CONNECTING ROD BEARING SELECTION CHART

        Connecting rod mark
      ^ b c
      Crank shaft pin journal mark  ^ D (Yellow) C (Green) B (None)
      b C (Green) B (None) A (Black)
      c B (None) A (Black) AA (Blue)
  3. Check the 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: 

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

      Allowable twist of connecting rod: 

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

  4. Check the crankshaft bearing oil clearance.
    1. To check main bearing-to-journal oil clearance, remove the main bearing caps and lower bearings.
    2. Clean each main journal and lower bearing with a clean shop towel.
    3. Place one strip of plastigage across each main journal.
    4. Reinstall the lower bearings and caps, then tighten the bolts.

      Tightening torque: 

      53.9 ~ 58.8 N.m (5.5 ~ 6.0 kgf.m, 39.8 ~ 43.4 lb-ft)

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

      Standard oil clearance: 

      No. 1, 2, 4, 5 : 0.022 ~ 0.040 mm (0.0009 ~ 0.0016 in)

      Fig 6: Measuring Widest Part Of Plastigage
      G06879155Courtesy of HYUNDAI MOTOR CO.
    6. If the plastigage measures too wide or too narrow, remove the upper and lower bearing and then install a new bearings with the same color mark. (Refer to CRANKSHAFT MAIN BEARING SELECTION TABLE ).

      Recheck the oil clearance.

      CAUTION: Do not file, shim, or scrape the bearings or the cap to adjust clearance.
    7. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing. (Refer to CRANKSHAFT MAIN BEARING SELECTION TABLE ).

      Recheck the oil clearance.

      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.

      Cylinder block crankshaft journal bore mark location 

      Letters have been stamped on the end of the block as a mark for the size of each of the 5 main journal bores. Use them, and the numbers or letters stamped on the crank (marks for main journal size), to choose the correct bearings.

      Fig 7: Identifying Cylinder Block Crankshaft Journal Bore Mark Location
      G06879156Courtesy of HYUNDAI MOTOR CO.

      Identification Of Cylinder Block Crankshaft Journal Bore 

      CYLINDER BLOCK CRANKSHAFT JOURNAL BORE INNER DIAMETER REFERENCE CHART

      Mark Cylinder block crankshaft journal bore inner diameter
      ^ 54.000 ~ 54.006 mm (2.1260 ~ 2.1262 in)
      b 54.006 ~ 54.012 mm (2.1262 ~ 2.1265 in)
      c 54.012 ~ 54.018 mm (2.1265 ~ 2.1267 in)

      Crankshaft main journal mark location 

      Fig 8: Identifying Crankshaft Main Journal Mark Location
      G06879157Courtesy of HYUNDAI MOTOR CO.

      Identification of crankshaft main journal 

      CRANKSHAFT MAIN JOURNAL OUTER DIAMETER REFERENCE CHART

      Mark Crankshaft main journal outer diameter
      ^ 49.962 ~ 49.968 mm (1.9670 ~ 1.9672 in)
      b 49.956 ~ 49.962 mm (1.9668 ~ 1.9670 in)
      c 49.950 ~ 49.956 mm (1.9665 ~ 1.9668 in)

      Crankshaft main bearing mark location 

      Fig 9: Identifying Crankshaft Main Bearing Mark Location
      G06879158Courtesy of HYUNDAI MOTOR CO.

      Identification of crankshaft main bearing 

      CRANKSHAFT MAIN BEARING THICKNESS REFERENCE CHART

      Mark Color Crankshaft main bearing thickness
      No. 1, 2, 4, 5 No. 3
      AA Blue 2.014 ~ 2.017 (0.0793 ~ 0.0794) 2.011 ~ 2.014 (0.0792 ~ 0.0793)
      A Black 2.011 ~ 2.014 (0.0792 ~ 0.0793) 2.008 ~ 2.011 (0.0791 ~ 0.0792)
      B None 2.008 ~ 2.011 (0.0791 ~ 0.0792) 2.005 ~ 2.008 (0.0789 ~ 0.0791)
      C Green 2.005 ~ 2.008 (0.0789 ~ 0.0791) 2.002 ~ 2.005 (0.0788 ~ 0.0789)
      D Yellow 2.002 ~ 2.005 (0.0788 ~ 0.0789) 1.999 ~ 2.002 (0.0787 ~ 0.0788)
    8. Select the bearing by using selection table.

      Crankshaft main bearing selection table 

      CRANKSHAFT MAIN BEARING SELECTION CHART

        Cylinder block crankshaft journal bore mark
      ^ b c
      Crank shaft main journal mark  ^ D (Yellow) C (Green) B (None)
      b C (Green) B (None) A (Black)
      c B (None) A (Black) AA (Blue)
  5. Check the crankshaft end play.

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

    End play 

    Standard: 0.05 ~ 0.175 mm (0.0020 ~ 0.0069 in)

    Limit : 0.20 mm (0.0079 in)

    Fig 10: Measuring Thrust Clearance While Prying Crankshaft Back And Forth With Screwdriver
    G06879159Courtesy of HYUNDAI MOTOR CO.

    If the end play is greater than maximum, replace the center bearing.

  6. Inspect the crankshaft main journals and pin journals.

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

    Main journal diameter: 

    49.950 ~ 49.968 mm (1.9665 ~ 1.9672 in)

    Pin journal diameter: 

    44.954 ~ 44.972 mm (1.7698 ~ 1.7705 in)

    Fig 11: Measuring Diameter Of Each Main Journal And Pin Journal
    G06879160Courtesy of HYUNDAI MOTOR CO.
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