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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: 0.10 ~ 0.25mm (0.0039 ~ 0.0098in)

    Maximum: 0.35mm (0.0138in)

    Fig 1: Checking Connecting Rod End Play Using Feeler Gauge
    G08321098Courtesy of KIA MOTORS AMERICA, INC.
    1. If out-of-tolerance, install a new connecting rod.
    2. If still out-of-tolerance after connecting rod replacement, 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 bolts.
    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 bolts. Do not reuse the bolts.

      Tightening torque: 

      17.7 ~ 21.6N.m (1.8 ~ 2.2kgf.m, 13.0 ~ 15.9lb-ft) + 88 ~ 92°

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

      Standard oil clearance 

      0.032 ~ 0.052mm (0.0013 ~ 0.0020in)

      Fig 2: Measuring Crankshaft Plastigage
      G08321099Courtesy of KIA MOTORS AMERICA, INC.
    9. If the measurement from the plastigage is too wide or too narrow, remove the upper and lower bearing and then install a new bearings with the same color mark.

      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. Recheck the oil clearance.
      NOTE: If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and restart 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: Connecting Rod Mark Location
      G08321100Courtesy of KIA MOTORS AMERICA, INC.
      DISCRIMINATION OF CONNECTING ROD

      Mark Connecting rod big-end inner diameter
      A, 0 45.000 ~ 45.006mm (1.7717 ~ 1.7719in)
      B, 00 45.006 ~ 45.012mm (1.7719 ~ 1.7721in)
      C, 000 45.012 ~ 45.018mm (1.7721 ~ 1.7724in)

      Crankshaft Pin Diameter Mark Location 

      Fig 4: Crankshaft Pin Diameter Mark Location
      G08321101Courtesy of KIA MOTORS AMERICA, INC.
      DISCRIMINATION OF CRANKSHAFT PIN DIAMETER

      Mark Crankshaft pin outer diameter
      1 41.972 ~ 41.966mm (1.6524 ~ 1.6522in)
      2 41.966 ~ 41.960mm (1.6522 ~ 1.6520in)
      3 41.960 ~ 41.954mm (1.6520 ~ 1.6517in)

      Connecting Rod Bearing Color Location 

      Fig 5: Connecting Rod Bearing Color Location
      G08321102Courtesy of KIA MOTORS AMERICA, INC.
      DISCRIMINATION OF CONNECTING ROD BEARING

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

      Connecting rod mark
    A, 0 B, 00 C, 000
    Crank shaft pin journal mark  1 E (Red) D (Green) C (None)
    2 D (Green) C (None) B (Black)
    3 C (None) B (Black) A (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: 

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

      Allowable twist of connecting rod: 

      0.10mm/100mm (0.0039in/3.94in) or less

    NOTE: When the connecting rods installed without bearings, there should be no difference on side surface.
  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: 

      17.7~21.6Nm (1.8~2.2kgf.m, 13.0~15.9lb-ft) + 88~92°

      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, 3, 4, 5: 0.021 ~ 0.042mm (0.0008 ~ 0.0017in)

      Fig 6: Measuring Crankshaft Plastigage
      G08321103Courtesy of KIA MOTORS AMERICA, INC.
    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 DISCRIMINATION OF CRANKSHAFT MAIN BEARING  crankshaft main bearing selection table in this Group).

      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  crankshaft main bearing selection table in this Group).

      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 side surface 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: Cylinder Block Crankshaft Journal Bore Mark Location
      G08321104Courtesy of KIA MOTORS AMERICA, INC.
      DISCRIMINATION OF CYLINDER BLOCK CRANKSHAFT JOURNAL BORE

      Mark Cylinder block crankshaft journal bore inner diameter
      A 52.000 ~ 52.006mm (2.0472 ~ 2.0475in)
      B 52.006 ~ 52.012mm (2.0475 ~ 2.0477in)
      C 52.012 ~ 52.018mm (2.0477 ~ 2.0479in)

      Crankshaft Main Journal Mark Location 

      Fig 8: Crankshaft Main Journal Mark Location
      G08321105Courtesy of KIA MOTORS AMERICA, INC.
      DISCRIMINATION OF CRANKSHAFT MAIN JOURNAL

      Mark Crankshaft main journal outer diameter
      1 47.960 ~ 47.954mm (1.8882 ~ 1.8879in)
      2 47.954 ~ 47.948mm (1.8879 ~ 1.8877in)
      3 47.948 ~ 47.942mm (1.8877 ~ 1.8875in)

      Crankshaft Main Bearing Color Location 

      Fig 9: Crankshaft Main Bearing Color Location
      G08321106Courtesy of KIA MOTORS AMERICA, INC.
      DISCRIMINATION OF CRANKSHAFT MAIN BEARING

      Mark Color Crankshaft main bearing thickness
      No. 1, 2, 3, 4, 5
      A Blue 2.026 ~ 2.029mm (0.0798 ~ 0.0799in)
      B Black 2.023 ~ 2.026mm (0.0796 ~ 0.0798in)
      C None 2.020 ~ 2.023mm (0.0795 ~ 0.0796in)
      D Green 2.017 ~ 2.020mm (0.0794 ~ 0.0795in)
      E Red 2.014 ~ 2.017mm (0.0793 ~ 0.0794in)
    8. Select the bearing by using selection table.
    CRANKSHAFT MAIN BEARING SELECTION TABLE

      Cylinder block crankshaft journal bore mark
    A B C
    Crank shaft main journal mark 1 E (Red) D (Green) C (None)
    2 D (Green) C (None) B (Black)
    3 C (None) B (Black) A (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 ~ 0.25mm (0.0020 ~ 0.0098in)

    Limit: 0.30mm (0.0118in)

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

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