Connecting Rod

Measure the side clearance of connecting rod big end using a feeler gauge.

Side clearance 

Specified value: 0.1 - 0.25 mm (0.00394 - 0.00984 in.)

Courtesy of HYUNDAI MOTOR AMERICA

• If the side clearance is out of the limit value, replace the connecting rod.
• If the side clearance is still out of the limit value even after replacing the connecting rod, replace the crankshaft.

1. Check the alignment marks of connecting rod and connecting rod cap for correct installation.
2. Loosen the 2 connecting rod cap bolts.
3. Remove the connecting rod cap and lower bearing.
4. Clean the crankshaft pin journals and bearings.
5. Place the plastic gauge in axial direction.
6. Reinstall the lower bearing and connecting rod cap and then tighten the bolts to the specified torque.

   Tightening torque: 

   27.5 - 31.4 N.m (2.8 - 3.2 kgf.m, 20.3 - 23.1 lb.ft) + 68 - 72°

   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 again.
8. Measure the widest part of the plastic gauge.

   Standard oil clearance: 

   0.042 - 0.060 mm (0.00165 - 0.00236 in.)

   Courtesy of HYUNDAI MOTOR AMERICA

9. If the measured value of plastic gauge is out of the specified value, replace the bearing with a new one having the same classification color and then remeasure the oil clearance. (Refer to classification table for connecting rod bearing below)
   NOTE:

   • Do not adjust the clearance by machining the bearing or cap.
10. If the remeasured value is still out of the specified value, install the next larger or smaller bearing and then remeasure the oil clearance. (Refer to classification table for connecting rod bearing below)
    NOTE:

    • If the proper oil clearance is not obtained even after assembling the next larger or smaller bearing, replace the crankshaft and then inspect again from step 1.
    • If the classification marks are indecipherable because of the accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent.

    Classification mark position for connecting rod 

    Courtesy of HYUNDAI MOTOR AMERICA

    CONNECTING ROD INNER DIAMETER SPECIFICATIONS
    
    

    Class	Mark	Connecting rod big end inner diameter
    0	a	56.000 - 56.006 mm (2.2047 - 2.2050 in.)
    1	b	56.006 - 56.012 mm (2.2050 - 2.2052 in.)
    2	c	56.012 - 56.018 mm (2.2052 - 2.2054 in.)

    Classification mark position for crankshaft pin journal 

    Courtesy of HYUNDAI MOTOR AMERICA

    CRANKSHAFT PIN JOURNAL OUTER DIAMETER SPECIFICATIONS
    
    

    Class	Mark	Crankshaft pin journal outer diameter
    I	A or 1	52.966 - 52.972 mm (2.0853 - 2.0855 in.)
    II	B or 2	52.960 - 52.966 mm (2.0850 - 2.0853 in.)
    III	C or 3	52.954 - 52.960 mm (2.0848 - 2.0850 in.)

    Classification color and mark position for connecting rod bearing 

    [Connecting rod upper bearing] 

    Courtesy of HYUNDAI MOTOR AMERICA

    [Connecting rod lower bearing] 

    Courtesy of HYUNDAI MOTOR AMERICA

    CONNECTING ROD BEARING THICKNESS SPECIFICATIONS
    
    

    Class	Color	Connecting rod bearing thickness
    E	Blue	1.509 - 1.512 mm (0.0594 - 0.0595 in.)
    D	Black	1.506 - 1.509 mm (0.0592 - 0.0594 in.)
    C	Red	1.503 - 1.506 mm (0.0591 - 0.0592 in.)
    B	Green	1.500 - 1.503 mm (0.0590 - 0.0591 in.)
    A	Yellow	1.497 - 1.500 mm (0.0589 - 0.0590 in.)

11. Select the proper connecting rod bearing using the below bearing selection table.

1. When reinstalling, check the cylinder numbers on the connecting rods and the caps. When installing a new connecting rod, the bearing fixing notches on the connecting rods and caps should face the same direction.
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 connecting rod must be replaced as well.
3. Using a connecting rod aligning tool, measure the bend/twist of connecting rod and if the measured value is close to the allowable value, modify the connecting rod using the press machine. If the bend/twist is excessive, replace the connecting rod.

   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.)