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Repair Procedures: Inspection: Notes

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~ 0.25 mm (0.004 ~ 0.010 in.)

    Fig 1: Measuring Connecting Rod End Play
    G10367042Courtesy of HYUNDAI MOTOR AMERICA
    1. If out-of-tolerance, install a new connecting rod.
    2. If still out-of-tolerance, replace the crankshaft.
  2. Check the connecting rod 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 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: 

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

      Fig 2: Removing Connecting Rod Cap And Bearing Half
      G10367043Courtesy of HYUNDAI MOTOR AMERICA
      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: 

      0.044 ~ 0.062 mm (0.0017 ~ 0.0024 in.)

      Fig 3: Checking Standard Oil Clearance
      G10367044Courtesy of HYUNDAI MOTOR AMERICA
    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 the next column), 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 4: Connecting Rod Mark Location
      G10367045Courtesy of HYUNDAI MOTOR AMERICA
      CONNECTING ROD DIAMETER SPECIFICATION

      Class Mark Inside Diameter
      0 a 58.000 ~ 58.006 mm
      (2.2834 ~ 2.2837 in.)
      1 b 58.006 ~ 58.012 mm
      (2.2837 ~ 2.2839 in.)
      2 c 58.012 ~ 58.018 mm
      (2.2839 ~ 2.2842 in.)

      Crankshaft Pin Mark Location 

      Identification Of Crankshaft 

      Fig 5: Crankshaft Pin Mark Location
      G10367046Courtesy of HYUNDAI MOTOR AMERICA
      CRANKSHAFT SPECIFICATION

      Class Mark Outside Diameter Of Pin
      I 1 or A 54.966 ~ 54.972 mm
      (2.1640 ~ 2.1642 in.)
      II 2 or B 54.960 ~ 54.966 mm
      (2.1638 ~ 2.1640 in.)
      III 3 or C 54.954 ~ 54.960 mm
      (2.1635 ~ 2.1638 in.)

      Place Of Identification Mark (Connecting Rod Bearing) 

      Fig 6: Identifying Connecting Rod Bearing Identification Mark
      G10367047Courtesy of HYUNDAI MOTOR AMERICA
      CONNECTING ROD BEARING SPECIFICATION

      Class Mark Thickness Of Bearing
      E Blue 1.511 ~ 1.514 mm
      (0.0595 ~ 0.0597 in.)
      D Black 1.508 ~ 1.511 mm
      (0.0594 ~ 0.0595 in.)
      C Red 1.505 ~ 1.508 mm
      (0.0593 ~ 0.0594 in.)
      B Green 1.502 ~ 1.505 mm
      (0.0591 ~ 0.0593 in.)
      A Yellow 1.499 ~ 1.502 mm
      (0.0590 ~ 0.0591 in.)
    11. Selection
        Connecting Rod Identification Mark 
      0(a) 1(b) 2(c)
      Crankshaft Identification Mark  1 or A A
      (Yellow)      		 B
      (Green)      		 C
      (Red)
      2 or B B
      (Green)      		 C
      (Red)      		 D
      (Black)
      3 or C C
      (Red)      		 D
      (Black)      		 E
      (Blue)
  3. Check the connecting rod.
    1. When reinstalling, check the cylinder numbers on the connecting rods and the caps. When installing a new connecting rod, the notches for bearing fixing on the connecting rods and caps should face the same direction.
    2. If one or both edge of the connecting rod thrust surface is damaged, replace the rod. If the inner surface of the rod is damaged or rough, also replace it.
    3. Using a connecting rod aligner, measure the bent or torsion of the rod. If the measurement is near the specification, adjust the rod with a press. If the rod is bent or twisted excessively, replace it.

      Allowable bend of connecting rod 

      0.05 mm/100 mm (0.0020 in./3.9370 in.)

      Allowable twist of connecting rod 

      0.1 mm/100 mm (0.0039 in./3.9370 in.)

      NOTE: When assembling the rod without a bearing, there should be no difference.
  4. Check the crankshaft bearing oil clearance.
    1. To check main bearing-to-journal oil clearance, remove the main bearing caps and bearing halves.
    2. Clean each main journal and bearing half with a clean shop towel.
    3. Place one strip of plastigage across each main journal.
    4. Reinstall the bearings and caps, then torque the bolts.

      Tightening torque: 

      49.0 Nm (5.0 kgf.m, 36.2 lb-ft) + 90°

      19.6 Nm (2.0 kgf.m, 14.5 lb-ft)+ 120°

      29.4 ~ 31.4 Nm (3.0 ~ 3.2 kgf.m, 21.7 ~ 23.1 lb-ft)

      Fig 7: Main Bearing Caps Tightening
      G10367048Courtesy of HYUNDAI MOTOR AMERICA
      NOTE: Do not turn the crankshaft.
    5. Remove the cap and bearing again, and measure the widest part of the plastigage.

      Standard oil clearance: 

      0.022 ~ 0.040 mm (0.0009 ~ 0.0016 in.)

      Fig 8: Checking Standard Oil Clearance
      G10367049Courtesy of HYUNDAI MOTOR AMERICA
    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 the next column), 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.

      Crankshaft bore mark location 

      Letters have been stamped on the block as a mark for the size of each of the 4 main journal bores.

      Use them, and the numbers or bar stamped on the crank (marks for main journal size), to choose the correct bearings.

      Fig 9: Crankshaft Bore Mark Location
      G10367050Courtesy of HYUNDAI MOTOR AMERICA
    CYLINDER BLOCK SPECIFICATION

    Class Mark Inside Diameter
    a A 73.500 ~ 73.506 mm
    (2.8937 ~ 2.8939 in.)
    b B 73.506 ~ 73.512 mm
    (2.8939 ~ 2.8942 in.)
    c C 73.512 ~ 73.518 mm
    (2.8942 ~ 2.8944 in.)

    Crankshaft Journal Mark Location 

    Discrimination Of Crankshaft 

    Fig 10: Crankshaft Journal Mark Location
    G10367051Courtesy of HYUNDAI MOTOR AMERICA
    CRANKSHAFT SPECIFICATION

    Class Mark Outside Diameter Of Journal
    I 1 or A 68.954 ~ 68.960 mm
    (2.7147 ~ 2.7150 in.)
    II 2 or B 68.948 ~ 68.954 mm
    (2.7145 ~ 2.7147 in.)
    III 3 or C 68.942 ~ 68.948 mm
    (2.7142 ~ 2.7145 in.)

    Place Of Identification Mark (Crankshaft Bearing) 

    Fig 11: Identifying Crankshaft Bearing Identification Mark
    G10367052Courtesy of HYUNDAI MOTOR AMERICA
    CRANKSHAFT BEARING SPECIFICATION

    Class Mark Thickness Of Bearing
    E Blue 2.277 ~ 2.280 mm
    (0.0896 ~ 0.0897 in.)
    D Black 2.274 ~ 2.277 mm
    (0.0895 ~ 0.0896 in.)
    C Red 2.271 ~ 2.274 mm
    (0.0894 ~ 0.0895 in.)
    B Green 2.268 ~ 2.271 mm
    (0.0893 ~ 0.0894 in.)
    A Yellow 2.265 ~ 2.268 mm
    (0.0892 ~ 0.0893 in.)
    CRANKSHAFT DESCRIPTION

      Crankshaft Bore Identification Mark 
    a(A) b(B) c(C)
    Crankshaft Identification Mark  1 or A A
    (Yellow)    		 B
    (Green)    		 C
    (Red)
    2 or B B
    (Green)    		 C
    (Red)    		 D
    (Black)
    3 or C C
    (Red)    		 D
    (Black)    		 E
    (Blue)
  5. Check crankshaft end play.

    Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

    Standard end play: 

    0.10 ~ 0.28 mm (0.0039 ~ 0.0110 in.)

    Fig 12: Checking Crankshaft End Play
    G10367053Courtesy of HYUNDAI MOTOR AMERICA

    If the end play is greater than maximum, replace the thrust bearings as a set.

    Thrust bearing thickness: 

    2.41 ~ 2.45 mm (0.0949 ~ 0.0964 in.)

  6. Inspect main journals and crank pins

    Using a micrometer, measure the diameter of each main journal and crank pin.

    Main journal diameter: 

    68.942 ~ 68.960 mm (2.7142 ~ 2.7149 in.)

    Crank pin diameter: 

    54.954 ~ 54.972 mm (2.1635 ~ 2.1642 in.)

    Fig 13: Measuring Main Journal Diameter
    G10367054Courtesy of HYUNDAI MOTOR AMERICA
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