Connecting Rod

Using feeler gauge, measure the side clearance while moving the connecting rod back and forth.

Side clearance: 

0.1 - 0.25 mm (0.0039 - 0.0098 in)

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

Courtesy of KIA MOTORS AMERICA, INC.

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.

   Tightening torque: 

   17.7-21.6 N.m (1.8-2.2 kgf.m, 13.0-15.9 lb.ft) + 68°-72°

   NOTE:

   • Do not turn the crankshaft.
   • Always use new connecting rod cap bolts. Connecting rod cap bolts are toque-to-yield bolts designed to be permanently elongated beyond the state of elasticity when torqued, so if the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force.
7. Remove the connecting rod cap and lower bearing.
8. Measure the plastigage at its widest point.

   Bearing oil clearance: 

   0.037 - 0.055 mm (0.0015 - 0.0022 in)

   Courtesy 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.

   NOTE: 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 start over.
    NOTE: 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.
11. Select the bearing by using selection table.
    CONNECTING ROD BEARING SELECTION DESCRIPTION
    
    

    Connecting rod bearing		Connecting rod mark
    		A	B	C
    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)

    CONNECTING ROD INNER DIAMETER SPECIFICATION
    
    

    Class	Mark	Connecting rod big-end inner diameter
    0	A	45.000 - 45.006 mm (1.7717 - 1.7719 in)
    1	B	45.006 - 45.012 mm (1.7719 - 1.7721 in)
    2	C	45.012 - 45.018 mm (1.7721 - 1.7724 in)

    Courtesy of KIA MOTORS AMERICA, INC.

    CRANKSHAFT PIN JOURNAL OUTER DIAMETER SPECIFICATION
    
    

    Class	Mark	Crankshaft pin journal outer diameter
    I	1	41.966 - 41.972 mm (1.6522 - 1.6524 in)
    II	2	41.960 - 41.966 mm (1.6520 - 1.6522 in)
    III	3	41.954 - 41.960 mm (1.6517 - 1.6520 in)

    Courtesy of KIA MOTORS AMERICA, INC.

    CONNECTING ROD BEARING THICKNESS SPECIFICATION
    
    

    Class	Color	Connecting rod bearing thickness
    A	Blue	1.510 - 1.513mm (0.0594 - 0.0596 in)
    B	Black	1.507 - 1.510 mm (0.0593 - 0.0594 in)
    C	None	1.504 - 1.507 mm (0.0592 - 0.0593 in)
    D	Green	1.501 - 1.504 mm (0.0591 - 0.0592 in)
    E	Red	1.498 - 1.501 mm (0.0590 - 0.0591 in)

    Courtesy of KIA MOTORS AMERICA, INC.

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

   Allowable twist of connecting rod: 

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

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