Repair Procedures: Inspection: Notes

Connecting Rod 

1. Check the connecting rod side clearance.

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

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

   Side clearance 

   Standard: 0.10~ 0.25 mm (0.0039 ~ 0.0098 in.)

   Fig 1: Inspecting Connecting Rod Side Clearance

   Courtesy of KIA MOTORS AMERICA, INC.
2. Check the connecting road bearing oil clearance.
   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 lower bearing.
   4. Clean the crank pin and bearing.
   5. Place a plastigage across the crankshaft pin journal.
   6. Reinstall the lower bearing and cap, and torque the bolts.

      Tightening torque 

      1st step:

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

      2nd step: 88 ~ 92°

      NOTE:

      • Do not turn the crankshaft.
      • Always use new connecting rod cap bolts. Connecting rod cap bolts are torque-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 width of the plastigage at its widest point.

      Oil clearance: 

      0.028 ~ 0.046 mm (0.00110 ~ 0.00181 in.)

      Fig 2: Measuring Width Of Plastigage

      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 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 repeat the check procedure.
       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.

       Connecting Rod Identification Mark 

       Fig 3: Identifying Connecting Rod Identification Mark

       Courtesy of KIA MOTORS AMERICA, INC.
       CONNECTING ROD SPECIFICATIONS
       
       

       Class	Mark	Inside Diameter
       0	A	48.000 ~ 48.006 mm (1.88976 ~ 1.89000 in.)
       1	B	48.006 ~ 48.012 mm (1.89000 ~ 1.89023 in.)
       2	C	48.012 ~ 48.018 mm (1.89023 ~ 1.89047 in.)

       Crankshaft Pin Identification Mark 

       Fig 4: Identifying Crankshaft Pin Identification Mark

       Courtesy of KIA MOTORS AMERICA, INC.
       NOTE: Conform to read stamping order as shown in illustration with arrow direction from #1.
       CRANKSHAFT SPECIFICATIONS
       
       

       Class	Mark	Outside Diameter Of Pin
       I	1	44.966 ~ 44.972 mm (1.77031 ~ 1.77055 in.)
       II	2	44.960 ~ 44.966 mm (1.77008 ~ 1.77031 in.)
       III	3	44.954 ~ 44.960 mm (1.76984 ~ 1.77008 in.)

       Connecting Rod Bearing Identification Mark 

       Fig 5: Identifying Connecting Rod Bearing Identification Mark

       Courtesy of KIA MOTORS AMERICA, INC.
       CONNECTING ROD BEARING SPECIFICATIONS
       
       

       Class	Mark	Thickness Of Bearing
       A	Blue	1.509 ~ 1.512 mm (0.05941 ~ 0.05953 in.)
       B	Black	1.506 ~ 1.509 mm (0.05929 ~ 0.05941 in.)
       C	None	1.503 ~ 1.506 mm (0.05917 ~ 0.05929 in.)
       D	Green	1.500 ~ 1.503 mm (0.05906 ~ 0.05917 in.)
       E	Yellow	1.497 ~ 1.500 mm (0.05894 ~ 0.05906 in.)

   11. Select a connecting rod bearing using selection chart.
       CONNECTING ROD BEARINGS SELECTION CHART
       
       

       Assembling Classification Of Bearing		Connecting Rod Identification Mark
       		0 (A)	1 (B)	2 (C)
       Crankshaft Identification Mark	I (1)	E (Yellow)	D (Green)	C (None)
       	II (2)	D (Green)	C (None)	B (Black)
       	III (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: 

      0.05 mm (0.0020 in.) or less for 100 mm (3.94 in.)

      Allowable twist of connecting rod: 

      0.10 mm (0.0039 in.) or less for 100 mm (3.94 in.)

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