Connecting Rod

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

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

Fig 1: Measuring End Play Using Feeler Gauge

Courtesy of HYUNDAI MOTOR AMERICA

1. If out-of-tolerance, install a new connecting rod.
2. If still out-of-tolerance after connecting rod replacement, replace the crankshaft.

1. Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.
2. Remove 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: 

   [27.5 ~ 31.4 N.m (2.8 ~ 3.2 kgf.m, 20.3 ~ 23.1 lb-ft)] + [68 ~ 72°]

   Fig 2: Tightening Bearing Half And Cap

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

   Standard oil clearance: 

   0.040 ~ 0.062 mm (0.0016 ~ 0.0024 in.)

   Fig 3: Measuring Standard Oil Clearance

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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 4: Connecting Rod Mark

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    CONNECTING ROD INSIDE DIAMETER SPECIFICATION
    
    

    Class	Mark	Inside Diameter
    0	a	58.000 ~ 58.006 mm (2.2834 ~ 2.2837 in.)
    1	b	58.006 ~ 58.012 mm (2.2837 ~ 2.2839 in.)
    2	c	58.012 ~ 58.018 mm (2.2839 ~ 2.2842 in.)

    Crankshaft Pin Mark Location 

    Identification Of Crankshaft 

    Fig 5: Crankshaft Pink Mark

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    CRANKSHAFT PIN OUTSIDE DIAMETER SPECIFICATIONS
    
    

    Class	Mark	Outside Diameter Of Pin
    I	1 or A	54.966 ~ 54.972 mm (2.1640 ~ 2.1642 in.)
    II	2 or B	54.960 ~ 54.966 mm (2.1638 ~ 2.1640 in.)
    III	3 or C	54.954 ~ 54.960 mm (2.1635 ~ 2.1638 in.)

    Place Of Identification Mark (Connecting Rod Bearing) 

    Fig 6: Connecting Rod Bearing Identification Mark

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    CONNECTING ROD BEARING THICKNESS SPECIFICATION
    
    

    Class	Mark	Thickness Of Bearing
    E	Blue	1.509 ~ 1.512 mm (0.0594 ~ 0.0595 in.)
    D	Black	1.506 ~ 1.509 mm (0.0592 ~ 0.0594 in.)
    C	Red	1.503 ~ 1.506 mm (0.0591 ~ 0.0592 in.)
    B	Green	1.500 ~ 1.503 mm (0.0590 ~ 0.0591 in.)
    A	Yellow	1.497 ~ 1.500 mm (0.0589 ~ 0.0590 in.)

11. Selection

    		Connecting Rod Identification Mark
    		0(a)	1(b)	2(c)
    Crankshaft Identification Mark	1 or A	A (Yellow)	B (Green)	C (Red)
    	2 or B	B (Green)	C (Red)	D (Black)
    	3 or C	C (Red)	D (Black)	E (Blue)

1. When reinstalling, check the cylinder numbers on the connecting rods and the caps. When installing a new connecting rod, the notches for bearing fixing on the connecting rods and caps should face the same direction.
2. If one or both edge of the connecting rod thrust surface is damaged, replace the rod. If the inner surface of the rod is damaged or rough, also replace it.
3. Using a connecting rod aligner, measure the bent or torsion of the rod. If the measurement is near the specification, adjust the rod with a press. If the rod is bent or twisted excessively, replace it.

   Allowable bend of connecting rod: 

   0.05 mm/100 mm (0.0020 in./3.9370 in.)

   Allowable twist of connecting rod: 

   0.1 mm/100 mm (0.0039 in./3.9370 in.)

   NOTE: When assembling the rod without a bearing, there should be no difference.