HKS 23004-AT001 Connecting Rod Set Installation Guide

HKS 23004-AT001 Connecting Rod Set

Important Information

Read this manual before installation.
Installation must be done by a professional.
Keep this manual after installation.

ZC6, 3BA-ZD8
ENGINE| FA20 FA24
MODEL YEAR| DBA-ZN6: 2012.04-
3BA-ZN8: 2021.10-
DBA-ZC6: 2012.04-
3BA-ZD8: 2021.09-
REMARKS| ※ This kit was developed on a JDM vehicle and has not yet been tested on vehicles for other markets.

• This product is cracked type connecting rod.
• In order to use this kit, the following parts are required:
• For FA20 equipped

Part Number 21003-AT003 High Comp Piston Kit for FA20 2.1L Kit Part Number 21003-AT004 Low Comp Piston Kit (86.0) for FA20 2.1L Kit
Part Number 21003-AT005 Low Comp Piston Kit (86.5) for FA20 2.1L Kit

Any one of the above piston kits

Part Number 23006-AT003 Crankshaft for FA20 2.1L/FA24 2.5L

Part Number SU003-09440 Bolt for Crankshaft Pully Set
Please check the HKS Website or CRANK Manual for tightening torque

• For FA24 equipped

Part Number 21003-AT007 Piston Kit for FA24 2.5L Kit

Part Number 23006-AT003 Crankshaft for FA20 2.1L/FA24 2.5L Connecting Rod Bearing for RB26&SR20. (NISMO bearing recommended)

REVISED HISTORY

Published in February, 2024 by HKS Co., Ltd. (Unauthorized reproduction is strictly prohibited.)

INTRODUCTION

• Thank you for purchasing the HKS CONROD SET FA20/FA24 I-BEAM STEP1.
• Installation must be done by a professional installer.
• After installation, follow the instruction in this manual.
• Please read this manual before installation.

NOTICE

• This manual assumes that you have and know to use the tools and equipment necessary to safely perform service operations on your vehicle.
• This manual assumes that you are familiar with typical automotive systems and basic service and repair procedures.
• Do not attempt to carry out the operations shown in this manual unless these assumptions are correct.
• Always have access to a factory repair manual.
• To avoid injury, follow the safety precautions contained in the factory repair manual.

PRODUCT FEATURES

• This product was developed for racing use and can increase in power of the engine. This product was developed to improve engine output to a higher range, and for race use on a closed course, where this kit is highly effective. However, when the power is increased, generally, the water temperature and/or the oil temperature tend to increase, and the oil pressure runs lower. Check the conditions of these to maintain the engine performance.
• To use this product on public roads, follow the necessary procedures and regulations for modified vehicles.

ATTENTION

• This manual indicates items you need to pay attention in order to install this product safely and lists precautions to avoid any possible damage and/or accidents.
• This product is an automobile part. Do not use for any other purposes.
• HKS will not be responsible for any damage caused by incorrect installation and/or use, or use after modification and/or dismantling of this product.
• This product was designed based on installation onto a specific factory vehicle.
• The specifications of this product are subject to change without notice.
• The instructions are subject to change without notice. Make sure to refer to the most recent instructions.

SAFETY PRECAUTIONS

The following precautions are preventing possible accidents and/or injuries and for your proper use.

WARNING Indicates risk of serious injury and/or possible death.

CAUTION Indicates risk of damage to people or large-scale damage to property. (Large-scale damage is the damage caused by a product defect. Ex. Damage to a vehicle, burnout, etc.)

WARNING

• To prevent explosion and/or fires, always:
  • Work on the vehicle in a well-ventilated area.
  • Handle any flammable objects with care.
• To prevent electrical damage/burns/fires, always:
  • Disconnect the negative terminal of the battery before beginning installation.
  • When disconnecting connectors, take extra care to avoid breaking the connectors.
• Before jacking up the vehicle, always use wheel blocks and position the jack correctly. Also, do not start working under the vehicle without using jack stands.
  • Positioning the jack incorrectly imbalances the vehicle and may damage the vehicle body.
  • Incorrect use of jack stands may result in the vehicle falling causing serious injury or possibly death.

CAUTION

• Do not misuse this product.
  • Misuse of this product may lead to engine damage.
  • Misuse of this product may lead to loss of its original function.
• Prior to installation, make sure the engine bay temperature has cooled to approximately 40°C/104°F.
  • Failure to let the engine cool down properly can lead to severe burns.
• Insert clean rags into open piping to prevent contaminants from entering the pipes.
  • If neglected, contaminants in the piping can lead to engine damage.
• Make sure that all of the parts listed in the Parts List are included in the kit.
• Reference the factory service manual when removing factory parts.
• Be careful when handling this product; avoid dropping or subjecting it to excessive impacts. Failure to do so may result in product damage or improper installation.
• Use the proper tools when tightening nuts and bolts. If over-tightened, the bolts may become damaged.
• Keep the removed factory parts in a safe place for ease of reinstallation at a later date (if necessary). It is recommended to mark the positions of the removed factory parts.
• When refilling oil, make sure to use the appropriate type of oil.

PARTS LIST

REPAIR PART

SPECIFICATIONS

| CONNECTING ROD
---|---
| FACTORY(FA20)| FACTORY(FA24)| HKS
Small End Diameter (mm)| 22| ←| ←
Big End Diameter (mm)| 53| 55| 51
Hole Center Distance (mm)| 129.3| ←| 129.5

IMPORTANT

Before taking measurements and assembling, make sure all parts are cleaned (including connecting rod bolts).
Without cleaning, accurate measurement and assembly cannot be performed.

INSTALLATION

1. Remove Factory Parts.
   Remove factory parts referring to the factory service manual.

2. Connecting Rod Bearing.
   In order to install this product, connecting rod bearing must be purchased separately.
   Determine a proper thickness of the bearing and select one from the following list of NISMO Connecting Rod Bearing for RB26 & SR20.PART NUMBER| Bearing thickness (mm)| Color code| Grade
   ---|---|---|---
   12110-RRR40| 1.500 ~ 1.503| None| STD 0
   12110-RRR41| 1.503 ~ 1.506| Brown| STD 1
   12110-RRR42| 1.506 ~ 1.509| Green| STD 2
   12110-RRR43| 1.541 ~ 1.549| Red| U/S

3. Clearance Verification for Connecting Rod Big End.
   

1. Assemble the Bearing to Connecting Rod Big End. Measure the inner diameter of the Bearing. (See figure 6.)
2. Measure the vertical direction of the large end inner diameter with connecting rod bearing as shown in Fig. 1 with a cylinder gauge etc. at two points in the front and back.  

(Use the smaller value for the calculation.)
  CAUTION
Make sure the connecting rod cap is in its proper position during fitting selection of the bearings.
Make sure to eliminate the level difference of the thrust side during assembly.
Improper position of the connecting rod cap may cause damage to the matching surface that results in connecting rod damage when tightening the bolt. At the final assembly, the thrust is supported by the crankshaft; therefore installation maybe easier than at the bearing’s fitting selection.

3. Confirm the outer diameter of the Crankshaft Pin. (See figure 2.) Or, measure the outer diameter of the Crankshaft Pin. (See figure 3 and 4)
4. Refer to Figure 2 when checking the classification code.  

SIZE No.| Pin DIA (mm)
---|---
A| 47.968 ~ 47.974
B| 47.961 ~ 47.968
5. When measuring the crankpin, refer to Figures 3 and 4 and measure the diameter of the crankshaft pin using a micrometer.
(Use a large value for calculation.)

6. Oil from the bearing inner diameter measured in 3.2 and crankpin diameter confirmed in 3.4 or 3.5 Calculate the clearance.  

Obtain the oil clearance from the following formula, and select the connecting rod bearing so that the oil clearance becomes the specified value.


Oil Clearance = “Inner dia of the Bearing”－“outer dia of the Crankshaft Pin”

7. Measure the thrust clearance with a thickness gauge. (See figure 5.)  

Thrust Clearance (mm)| 0.20 ~ 0.38
---|---
Limit (mm)| 0.45

CAUTION

  * The optimal performance cannot be guaranteed and oil film cannot function to prevent the engine from being damaged if the oil clearance is not within the designated range.
  * As exception, the oil clearance can be adjusted depending on the type of the race. Using this product for racing may shorten the product life.
  * For vehicles with much mileage or old model, please re-confirm the size by the measurement.

4. Installation of Connecting Rods

5. Assemble the bearings to the connecting rod big end.
   Before installing the Bearings, clean the back side of the bearings and inside of the connecting rod’s big end.
   Apply engine oil to the bearings.
   

6. Align and attach the bearing protrusion and the connecting rod’s locking notch.

7. Make sure that the protrusion on the connecting rod cap, #1, and #3 cylinder face to the front side, and #2 and #4 cylinder face to the rear side when installing. (See figure 7 and 8)
   
   

8. Apply engine oil on the threads and flange surface of the connecting rod bolts. Make sure that the assembly and direction of connecting rod are correct.

9. Apply molybdenum grease to the threads and bearing of the connecting rod bolt, and the inside diameter of the female thread of the rod, and attach it to the connecting rod. (Figure 6) After installing the bolts and tightening them with your fingers, tighten the bolts as in 4.6.

10. Tighten connecting rod bolts in the following order. Equally tighten at 5Nm (0.5kgfm) of torque. Equally tighten at 20Nm (2kgfm) of torque. Starting from “0”, equally tighten to a 150°angle. (See figure 9.).
    
    CAUTION

  * When the tightening angle is less than regulated value, the conclusion performance might not be able to be secured.
  * Including the Bearing alignment, if the Connecting rod bolts are re-tightened more than 4 times, then please replace the new bolt.
  * The connecting rod bolt that operated the engine is a non-reusable part. If the bolts are reused, the bolt may be broken.

CONFIRMATION AFTER INSTALLATION

1. Check the following before starting the engine:
   • Make sure pipes and hoses are routed and connected correctly.
   • Make sure hoses are not twisted or bent.
   • Make sure the negative cable terminal is securely attached to the battery.
   • Make sure the level gauge for the engine oil is between H (F) – L.
   • Make sure all bolts and nuts are tightened.
   • Make sure all installed components do not come in contact with other parts.
2. Start the engine and check the following:
   *Do not raise the engine RPM when the engine reaches the normal operation temperature. (Idling operation)
   • Make sure oil is not leaking.
   • Make sure air is not leaking.
   • Make sure fuel, traction oil, coolant, and air are not leaking after revving the engine 2 to 3 times while in neutral.
   • Make sure the installed parts are not interfere each other.
   • Make sure the level gauge for the engine oil is between H (F) to L.

MAINTENANCE

Proper maintenance of this product is necessary in order to maintenance the safety, reliability, and function of this product.

• Maintenance is the responsibility of the driver/owner.

• If work needs to be performed outside the scope of this manual, consult a professional.

• In order to maintain the performance of the kit, routine filter replacement is necessary.
  Recommended replacement intervals: Every 3,000 to 5,000km/2,000 to 3,200miles or every 3 to 6 months.

• When upgrading spark plugs, choose the appropriate heat range applicable to the engine. Consult a professional for more details.

• For optimal performance, it is recommended to replace the engine oil every 3,000km or every 6 months.

ATTENTION

• After replacement of crank bearings, do a break-in driving for approximately 1,000 to 3,000 km.
• Always warm up the engine.
• Before the engine warms up, rapid acceleration and/or revving the engine must be avoided.
• Even after the engine warms up, excessive revving should be avoided to protect the engine.

TROUBLESHOOTING

WARNING

• Do not start the engine when oil and/or water leakage is found.
• Stop driving if you feel an abnormal drop in oil pressure; oil may be leaking. Do not restart the engine if oil is leaking.
• Explain the source of the leakage to a professional and repairs must performed by a professional.
• If oil leakage is serious, ask a professional how to temporarily repair and conduct the repair by yourself to prevent further damage. In the case of serious oil leakage, please follow the professional advice or instruction of temporarily preventing further damage.
• Always follow the instructions given by a professional. If not, oil leakage can lead to a vehicle fire.
• If the vehicle gets damaged, repairs performed by a professional.
• If you hear or feel any abnormal noises, smell, or vibrations from the vehicle while driving, please take action following the instruction in factory service manual.

FOR SUBSEQUENT OWNERS

• If reselling or transfer this product to a new owner, please give this Installation Manual to the new owner.
• Consult a professional when removing this product from the vehicle.

Customer Support

HKS Co., Ltd.
7181 Kitayama, Fujinomiya, Shizuoka 418-0192, Japan
https://www.hks-power.co.jp/en/

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