Connecting Rod

Using filler 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)

1. If out-of-tolerance, install a new connecting rod.
2. If still out-of-tolerance after connecting rod replacement, replace the crankshaft.
   Fig 1: Checking Connecting Rod Bearing Oil Clearance

   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) + 88°~92°

   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:  0.018 ~ 0.36 mm (0.0007 ~ 0.0014 in)

   Fig 2: Checking Bearing Oil Clearance

   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 on 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 the selection table.
    CONNECTING ROD BEARING SELECTION CHART
    
    

    Connecting rod bearing		Connecting rod mark
    		A, 0	B, 00	C, 000
    Crank shaft pin journal mark	1	E (Pink)	D (Light Green)	C (White)
    	2	D (Light Green)	C (White)	B (Black)
    	3	C (White)	B (Black)	A (Light Blue)

    DISCRIMINATION OF CONNECTING ROD
    
    

    Mark	Connecting rod big-end inner diameter
    A, 0	45.000 ~ 45.006 mm (1.7717 ~ 1.7719 in)
    B, 00	45.006 ~ 45.012 mm (1.7719 ~ 1.7721 in)
    C, 000	45.012 ~ 45.018 mm (1.7721 ~ 1.7724 in)

    Fig 3: Discrimination Of Crankshaft Pin Journal Marks

    Courtesy of KIA MOTORS AMERICA, INC.
    DISCRIMINATION OF CRANKSHAFT PIN JOURNAL
    
    

    Mark	Crankshaft pin journal outer diameter
    1	41.966 ~ 41.972 mm (1.6522 ~ 1.6524 in)
    2	41.960 ~ 41.966 mm (1.6520 ~ 1.6522 in)
    3	41.954 ~ 41.960 mm (1.6517 ~ 1.6520 in)