Repair Procedures: Inspection

Connecting Rod And Crankshaft 

1. Check the connecting rod end play.

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

   Standard end play:  0.1~ 0.25mm (0.004 ~ 0.010in.)

   Maximum end play:  0.35mm (0.0138in.)

   Fig 1: Measuring Connecting Rod End Play

   Courtesy of KIA MOTORS AMERICA, INC.
   1. If out-of-tolerance, install a new connecting rod.
   2. If still out-of-tolerance, replace the crankshaft.
2. Check the connecting road bearing oil clearance.
   1. Check that 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 bearing half.
   4. Clean the crank pin and bearing.
   5. Place plastigage across the crank pin.
   6. Reinstall the bearing half and cap, and torque 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.
   7. Remove 2 bolts, connecting rod cap and bearing half.
   8. Measure the plastigage at its widest point.

      Standard oil clearance 

      0.027 ~ 0.045mm (0.0010 ~ 0.0017in.)

      Fig 2: Measuring Plastigage At Widest Point

      Courtesy of KIA MOTORS AMERICA, INC.
   9. If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same color mark (select the color as shown in CONNECTING ROD BEARING DISCRIMINATION ), and recheck the clearance.
      CAUTION: Do not file, shim, or 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 (the color listed above or below that one), and check clearance again.
       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.

       Connecting Rod Mark Location 

       Fig 3: Identifying Connecting Rod Mark

       Courtesy of KIA MOTORS AMERICA, INC.

       Discrimination Of Connecting Rod 

       CONNECTING ROD DISCRIMINATION
       
       

       Class	Mark	Inside Diameter
       a	A	51.000 ~ 51.006mm (2.0079 ~ 2.0081in.)
       b	B	51.006 ~ 51.012mm (2.0081 ~ 2.0083in.)
       c	C	51.012 ~ 51.018mm (2.0083 ~ 2.0085in.)

       Crankshaft Pin Mark Location Discrimination Of Crankshaft 

       Fig 4: Identifying Crankshaft Pin Mark

       Courtesy of KIA MOTORS AMERICA, INC.
       NOTE: Conform to read stamping order as shown by arrow direction from #1 in Fig 4.

       Discrimination Of Crankshaft 

       CRANKSHAFT DISCRIMINATION
       
       

       Class	Mark	Outside Diameter Of Pin
       I	1	47.966 ~ 47.972mm (1.8884 ~ 1.8886in.)
       II	2	47.960 ~ 47.966mm (1.8881 ~ 1.8884in.)
       III	3	47.954 ~ 47.960mm (1.8879 ~ 1.8881in.)

       Place Of Identification Mark (Connecting Rod Bearing) Discrimination Of Connecting Rod Bearing 

       Fig 5: Identifying Connecting Rod Bearing Color

       Courtesy of KIA MOTORS AMERICA, INC.

       Discrimination Of Connecting Rod Bearing 

       CONNECTING ROD BEARING DISCRIMINATION
       
       

       Class	Mark	Thickness Of Bearing
       AA	Blue	1.517 ~ 1.520mm (0.0597 ~ 0.0598in.)
       A	Black	1.514 ~ 1.517mm (0.0596 ~ 0.0597in.)
       B	None	1.511 ~ 1.514mm (0.0595 ~ 0.0596in.)
       C	Green	1.508 ~ 1.511mm (0.0594 ~ 0.0595in.)
       D	Yellow	1.505 ~ 1.508mm (0.0593 ~ 0.0594in.)

   11. Selection
       CRANKSHAFT AND CONNECTING ROD IDENTIFICATION MARK REFERENCE
       
       

       Crankshaft Identification Mark	Connecting Rod Identification Mark	Assembling Classification Of Bearing
       I (1)	a (A)	D (Yellow)
       	b (B)	C (Green)
       	c (C)	B (None)
       II (2)	a (A)	C (Green)
       	b (B)	B (None)
       	c (C)	A (Black)
       III (3)	a (A)	B (None)
       	b (B)	A (Black)
       	c (C)	AA (Blue)

3. Check the crankshaft bearing oil clearance.
   1. To check main bearing-to-journal oil clearance, remove the main caps and bearing halves.
   2. Clean each main journal and bearing half with a clean shop tower.
   3. Place one strip of plastigage across each main journal.
   4. Reinstall the bearings and caps, then torque the bolts.

      Tightening torque 

      14.7Nm (1.5kgf.m, 10.8lb-ft) + 27.5~31.4Nm (2.8~3.2kgf.m, 20.3~23.1lb-ft) + 120~125°

      NOTE: Do not turn the crankshaft.
   5. Remove the cap and bearing again, and measure the widest part of the plastigage.

      Standard oil clearance 

      0.020 ~ 0.038mm (0.0008 ~ 0.0015in.)

      Fig 6: Measuring Widest Part Of Plastigage

      Courtesy of KIA MOTORS AMERICA, INC.
   6. If the plastigage measures too wide or too narrow, remove the upper half of the bearing, install a new, complete bearing with the same color mark (select the color as shown in CONNECTING ROD BEARING DISCRIMINATION ), and recheck the clearance.
      CAUTION: Do not file, shim, or scrape the bearings or the caps to adjust clearance.
   7. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that one), and check clearance again.
      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.