Connecting Rod And Crankshaft

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 Connecting Rod End Play

Courtesy of KIA MOTORS AMERICA, INC.

• If out-of-tolerance, install a new connecting rod.
• 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 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 p in.
6. Reinstall the bearing half and cap, and torque the bolts.

   Tightening torque 

   19.6 N.m (2.0 kgf.m, 14.46 lb-ft) + 90°

   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 

   0.038-0.056 mm (0.0015-0.0022 in.)

   Fig 2: Measuring Plastigage At Its Widest Point

   Courtesy of KIA MOTORS AMERICA, INC.
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

    Courtesy of KIA MOTORS AMERICA, INC.

    DISCRIMINATION OF CONNECTING ROD 

    DISCRIMINATION OF CONNECTING ROD
    
    

    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 

    DISCRIMINATION OF CRANKSHAFT 

    Fig 4: Identifying Crankshaft Pin Mark Locations

    Courtesy of KIA MOTORS AMERICA, INC.

    DISCRIMINATION OF CRANKSHAFT 

    DISCRIMINATION OF CRANKSHAFT
    
    

    CLASS	MARK	OUTSIDE DIAMETER OF PIN
    1	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 5: Identifying Mark (Color) On Connecting Rod Bearing

    Courtesy of KIA MOTORS AMERICA, INC.

    DISCRIMINATION OF CONNECTING ROD BEARING 

    DISCRIMINATION OF CONNECTING ROD BEARING
    
    

    CLASS	MARK	THICKNESS OF BEARING
    E	BLUE	1.514-1.517 mm (0.0596-0.0597 in.)
    D	BLACK	1.511-1.514 mm (0.0595-0.0596 in.)
    C	BROWN	1.508-1.511 mm (0.0594-0.0595 in.)
    B	GREEN	1.505-1.508 mm (0.0593-0.0594 in.)
    A	YELLOW	1.502-1.505 mm (0.0591-0.0593 in.)

11. Selection

1. To check main bearing-to-journal oil clearance, remove the main bearing 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 

   49.00 N.m (5.0 kgf.m, 36.16 lb-ft) + 90°

   19.60 N.m (2.0 kgf.m, 14.46 lb-ft)+ 120°

   29.40-31.36 N.m (3.0-3.2 kgf.m, 21.70-23.14 lb-ft)

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

   Standard oil clearance

   0.022-0.040 mm (0.0009-0.0016 in.)

   Fig 6: Measuring Widest Part Of Plastigage

   Courtesy of KIA MOTORS AMERICA, INC.
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.

Crankshaft bore mark location 

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

Use them, and the numbers or bar stamped on the crank (marks for main journal size), to choose the correct bearings.

Fig 7: Identifying Crankshaft Bore Mark Location

Courtesy of KIA MOTORS AMERICA, INC.

DISCRIMINATION OF CYLINDER BLOCK 

CRANKSHAFT JOURNAL MARK LOCATION 

DISCRIMINATION OF CRANKSHAFT 

Fig 8: Identifying Crankshaft Journal Mark Location

Courtesy of KIA MOTORS AMERICA, INC.

DISCRIMINATION OF CRANKSHAFT 

PLACE OF IDENTIFICATION MARK (CRANKSHAFT BEARING) 

Fig 9: Identifying Mark (Color) On Crankshaft Bearing

Courtesy of KIA MOTORS AMERICA, INC.

DISCRIMINATION OF CRANKSHAFT BEARING 

SELECTION 

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

Standard end play

0.10-0.28 mm (0.0039-0.0110 in.)

Fig 10: Checking Crankshaft End Play

Courtesy of KIA MOTORS AMERICA, INC.

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

Thrust bearing thickness

2.41-2.45 mm (0.0949-0.0964 in.)

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

Main journal diameter: 68.942-68.960 mm (2.7142-2.7149 in.)

Crank pin diameter: 54.954-54.972 mm (2.1635-2.1642 in.)

Fig 11: Measuring Diameter Of Main Journal And Crank Pin

Courtesy of KIA MOTORS AMERICA, INC.