Hyundai Tucson Quiz
Engine Mechanical System

connecting rods

In this manual: Engine Mechanical System
General Information — 17Engine Mechanical System — 51Engine Electrical System — 26Emission Control System — 23Engine/Fuel Control System — 44Clutch System — 12MANUAL TRANSMISSION SYSTEM — 12AUTOMATIC TRANSMISSION SYSTEM — 42Four-Wheel Drive (4WD) System — 14Drive Shaft and Axle — 22Suspension System — 30Steering System — 16Restraint — 21Braking System — 47Body Work (Interior and Exterior) — 145Body Electrical System — 162Heating, Ventilation and Air Conditioning — 39
40steps
~245min
5/5difficulty
1special tools
0102030405021.616N·mlb·ft
Tightening torque found on this page
Done 0 of 40

Components and Component Location

COMPONENTS

1. Piston Ring
2. Expander Ring
3. Piston Pin
4. Plunger		 5. Connecting Rod
6. Connecting Rod Upper Bearing
7. Connecting Rod Lower Bearing
8. Connecting Rod Bearing Cap

Repair Procedures

DISASSEMBLY

Engine removal is required for this procedure.
  1. Remove the engine assembly from the vehicle. (See Engine and Transaxle - Engine and Transaxle)
  2. Remove the transaxle assembly from the engine assembly. Automatic Transaxle (Refer to Automatic Transaxle System - "Automatic Transaxle")
  3. Automatic Transaxle: Remove the drive plate. (Refer to Cylinder Block - "Drive Plate")
  4. Remove the rear oil seal. (Refer to Cylinder Block - "Rear Oil Seal")
  5. Install the engine on an engine stand for disassembly.
  6. Remove the timing chain. (Refer to Valve Timing System - Timing Chain)
  7. Remove the water pump. (Refer to Cooling System - "Water Pump".)
  8. Remove the water inlet pipe and thermostat. Refer to Cooling System - "Thermostat".
  9. Remove the intake manifold. (Refer to Exhaust and Intake System - "Intake Manifold")
  10. Remove the A/C compressor. (Refer to Heating, Ventilation and Air Conditioning - Compressor)
  11. Remove the exhaust manifold. (Refer to Intake and Exhaust System - "Exhaust Manifold")
  12. Remove the cylinder head assembly. (See Cylinder Head - Cylinder Head)
  13. Remove the oil filter. (Refer to Lubrication System - "Engine Oil")
  14. Remove the oil filter. (Refer to Lubrication System - "Oil Pan")
  15. Remove the knock sensor (A).
  16. Remove the OPS (Oil Pressure Switch) (B).
  17. Remove the CKPS (Crankshaft Position Sensor) (C).
  18. Inspect the connecting rod side clearance.
  19. Check the connecting rod bearing oil clearance.
  20. Remove the piston and connecting rod assembly.
    1. Using a scraper, remove carbon deposits from the top of the cylinder bore.
    2. Remove the connecting rod bearing caps (A).
    3. Push the piston, connecting rod assembly and upper bearing into the cylinder block.
  21. Check whether the piston fits the piston pin. Try to move the piston back and forth relative to the piston pin. If movement is noticeable, replace the piston and pin assembly.
  22. Remove the piston rings.
    1. Using a piston ring remover, remove the 2 compression rings.
    2. Remove the two side rails and the oil ring by hand.
  23. Remove the connecting rod from the piston.
    1. Remove the snap ring (A) from the piston.
    2. Remove the piston pin (B) from the piston.
    3. Remove the piston (C) and connecting rod (D).

Inspection

CONNECTING ROD
  1. Check the connecting rod side clearance. Using a feeler gauge, measure the clearance while moving the connecting rod back and forth.
    • If the connecting rod axial play is not within the specified value, install a new connecting rod.
    • If the value is still out of the specified range, replace the crankshaft.

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

  2. Check the connecting rod bearing oil clearance.
    1. Make sure the marks on the connecting rod and cap are aligned to ensure correct assembly.
    2. Remove the 2 connecting rod cap bolts.
    3. Remove the connecting rod cap and lower bearing.
    4. Clean the crankpin and bearing.
    5. Place Plastigage across the crankshaft journal.
    6. Install the lower bearing and cap, then tighten the bolts. Tightening torque: Step 1: 17.7 ~ 22 N·m Step 2: 88 ~ 92°
    7. Remove the connecting rod cap and lower bearing.
    8. Measure the width of the Plastigage at its widest point.

      Oil clearance: 0.024 ~ 0.042 mm (0.00094 ~ 0.00165 in.)

    9. If the Plastigage width is too wide or too narrow, remove the upper bearing and lower bearing, then install new bearings with the same color code. Recheck the oil clearance.
    10. If the Plastigage indicates the clearance is still incorrect, immediately use bearings of a smaller or larger size. Recheck the oil clearance. CONNECTING ROD IDENTIFICATION MARK
      Connecting Rod Specifications
      GRADE Mark Inside diameter
      0 B 48.000 ~ 48.006 mm
      (1.88976 ~ 1.89000 in.)
      1 B 48.006 ~ 48.012 mm
      (1.89000 ~ 1.89023 in.)
      2 AGAINST 48.012 ~ 48.018 mm
      (1.89023 ~ 1.89047 in.)

      Crankshaft Pin Identification Mark
      Crankshaft Specifications
      GRADE Mark BUSHING OUTER DIAMETER
      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
      Connecting Rod Bearing Specifications
      GRADE Mark BEARING THICKNESS
      B Light Blue 1.511 ~ 1.514 mm
      (0.05948 ~ 0.05960 in.)
      B BLACK 1.508 ~ 1.511 mm
      (0.05937 ~ 0.05948 in.)
      AGAINST WHITE 1.505 ~ 1.508 mm
      (0.05925 ~ 0.05937 in.)
      D Light Green 1.502 ~ 1.505 mm
      (0.05913 ~ 0.05925 in.)
      E PINK 1.499 ~ 1.502 mm
      (0.05901 ~ 0.05913 in.)
    11. Select the connecting rod bearing using the selection table. Connecting Rod Bearing Selection Table
      BEARING ASSEMBLY CLASSIFICATION CONNECTING ROD IDENTIFICATION MARK
      0 (A) 1 (B) 2 (c)
      CRANKSHAFT IDENTIFICATION MARK I (1) E
      (Pink)      		 D (Light Green) C (WHITE)
      II (2) D (Light Green) C (WHITE) B (BLACK)
      III (3) C (WHITE) B (BLACK) A (Blue)
  3. Inspect the connecting rods.
    1. When assembling, be sure to mark the cylinder numbers on the connecting rod and the corresponding cap. When installing a new connecting rod, make sure the locating notches are on the same side.
    2. Replace the connecting rod if it is damaged at either end of the mating surface. Also, if the inner diameter surface of the small end is worn or rough, replace the rod as well.
    3. Using a connecting rod aligner, make sure the rod is not bent or twisted. If the measured value is close to the repair limit, correct the rod by pressing it. Replace any heavily bent or twisted rods. Allowable connecting rod bend: 0.05 mm (0.0020 in.) or less per 100 mm (3.94 in.). Allowable connecting rod twist: 0.10 mm (0.0039 in.) or less per 100 mm (3.94 in.).
  4. Clean the piston.
    1. Using a scraper, remove carbon deposits from the piston top.
    2. Using a suitable tool or a broken ring, clean the piston ring grooves.
    3. Using solvent and a brush, thoroughly clean the piston.
  5. Check the clearance between the piston and cylinder by calculating the difference between the cylinder bore inner diameter and the piston outer diameter.

    Piston-to-cylinder clearance: 0.02–0.04 mm (0.0008–0.0016 in.)

    1. Using a cylinder bore gauge, measure the cylinder bore diameter in the thrust and axial directions.

      Cylinder bore diameter: 81.00 ~ 81.03 mm (3.1890 ~ 3.1902 in.)

    2. Measure the piston outer diameter at 35 mm (1.3780 in.) from the top of the piston.

      Piston outer diameter: 80.97 ~ 81.00 mm (3.1878 ~ 3.1890 in.)

  6. Select a piston that matches the cylinder bore size class.
    1. Check the cylinder bore size code on the side surface of the cylinder block.
      Cylinder bore inner diameter
      Size code Cylinder bore inner diameter
      B 81.00 - 81.01 mm (3.1890 - 3.1894 in.)
      B 81.01 ~ 81.02 mm (3.1894 ~ 3.1898 in.)
      AGAINST 81.02 ~ 81.03 mm (3.1898 ~ 3.1902 in.)
    2. Check the piston size mark on the top side of the piston.
      Piston Outer Diameter
      Size code Piston Outer Diameter
      B 80.97 ~ 80.98 mm (3.1878 ~ 3.1882 in.)
      B 80.98 - 80.99 mm (3.1882 - 3.1886 in.)
      AGAINST 80.99~81.00 mm (3.1886~3.1890 in.)
  7. Inspect the piston ring side clearance. Using a feeler gauge, measure the clearance between a new piston ring and the piston ring groove. If the clearance is greater than the maximum value, replace the piston.

    Piston Ring Side Clearance [STANDARD]
    No. 1 Ring: 0.040 ~ 0.080 mm (0.00157 ~ 0.00315 in.)
    No. 2 Ring: 0.040 ~ 0.080 mm (0.00157 ~ 0.00315 in.)
    Oil Ring: 0.020 ~ 0.060 mm (0.00079 ~ 0.00236 in.)
    If the clearance exceeds the maximum value, replace the piston.
  8. Inspect the piston ring end gap. To measure the piston ring end gap, insert the piston ring into the cylinder bore. Position the ring at a right angle to the cylinder wall, lightly pressing it in with the piston. Measure the gap using a feeler gauge.

    Piston Ring End Gap [STANDARD]
    No. 1 Ring: 0.15 ~ 0.30 mm (0.0059 ~ 0.0118 in.)
    No. 2 Ring: 0.30 ~ 0.45 mm (0.0118 ~ 0.0177 in.)
    Oil Ring: 0.20 ~ 0.50 mm (0.0079 ~ 0.0197 in.)
    If the clearance exceeds the maximum allowable limit, replace the piston ring. If the clearance is still excessive, check the cylinder bore inside diameter. If the bore diameter exceeds the maximum allowable limit, replace the cylinder block.
  9. Measure the piston pin diameter.

    Piston Pin Diameter: 19.997 ~ 20.000 mm (0.78728 ~ 0.78740 in.)

  10. Measure the piston pin-to-piston clearance.

    Piston Pin to Piston Clearance: 0.004 ~ 0.016 mm (0.00016 ~ 0.00063 in.)

  11. Inspect the clearance between the outer diameter of the piston pin and the inner diameter of the small end bore of the connecting rod.

    Piston Pin to Connecting Rod Clearance: 0.007 ~ 0.016 mm (0.00028 ~ 0.00063 in.)

PISTON, PISTON RINGS, PISTON PIN

Installation

  1. Install the piston and connecting rod.
    1. Install a snap ring (A) on one side of the piston pin bore.
    2. Align the front mark on the piston with the mark on the connecting rod.
    3. Insert the piston pin (B) through the piston pin bore and the small end bore of the connecting rod.
    4. After inserting the piston pin, install a snap ring (C) on the other side.
  2. Install the piston rings.
    1. Install the oil ring expander and the two side rails by hand.
    2. Using a piston ring expander, install the two compression rings with the manufacturer's mark facing up.
    3. Position the piston rings so that the ring end gaps are as shown. (No. 1 ring should be positioned opposite the No. 2 ring.)
      EXAMPLE:
  3. Install the connecting rod bearings.
    1. Align the tang of the bearing with the groove of the connecting rod or connecting rod cap.
    2. Install the bearings (A) in the connecting rod and the connecting rod cap (B).
  4. Install the piston and connecting rod assembly.
    • Before installing the piston, apply a coat of engine oil to the piston ring grooves and the cylinder bores.
    • Install the piston and connecting rod so that the front marks face the front of the engine.
    1. Install the ring compressor, make sure the rings are in the correct position, then insert the piston into the cylinder. Tap it in with the wooden handle of a hammer.
    2. Stop as soon as the ring compressor is released, and check the alignment of the connecting rod and bearing before pressing the piston onto the crankshaft.
    3. Apply engine oil to the bolt threads. Install the connecting rod caps with bearings and tighten the bolts.
      Torque:
      Step 1: 17.7 ~ 22 N·m
      Step 2: 88 ~ 92°
      Using the special service tool (09221-4A000), tighten the connecting rod cap bolts.
  5. Check the connecting rod side clearance.
  6. Install the remaining parts in the reverse order of removal.

Test yourself

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