Connecting Rod

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

Side clearance 

Standard: 0.1 - 0.25 mm (0.0039 - 0.0098 in.)

Maximum: 0.35 mm (0.0138 in.)

Courtesy of HYUNDAI MOTOR AMERICA

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

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 connecting rod cap, and torque 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.
7. Remove the connecting rod cap.
8. Measure the plastigage at its widest point.

   Bearing oil clearance: 

   0.037 - 0.055 mm (0.0015 - 0.0022 in.)

   Courtesy of HYUNDAI MOTOR AMERICA

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.
    • 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 Identification Mark 

    Courtesy of HYUNDAI MOTOR AMERICA

    Identification Of Connecting Rod 

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

    Crankshaft Pin Outside Diameter Identification Mark 

    Courtesy of HYUNDAI MOTOR AMERICA

    Identification Of Crankshaft Pin Outside Diameter 

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

    Connecting Rod Bearing Identification Mark 

    Courtesy of HYUNDAI MOTOR AMERICA

    Discrimination of Connecting Rod Bearing 

    Class	Color	Connecting rod bearing thickness
    A	Blue	1.510 - 1.513 mm (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.)

11. Use the bearing selection table below to select a suitable connecting rod bearing.

    Connecting Rod Bearing Selection Table 

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.)/100 mm (3.94 in.)

Allowable twist of connecting rod: 

0.1 mm (0.0039 in.)/100 mm (3.94 in.)