Failure of connecting rod in automotive engine may cause catastrophic situation. The corner radius at small end has an effect on stress raising. To investigate the stress distribution in connecting rod during operation, the finite element analysis was used by giving possible maximum tension and compression. Excessive sizing after forging connecting rod may result in the tensile residual stress which lower the fatigue life and cause premature failures. It was shown that when the sizing amount is too large, the location of high tensile residual stress coincide with that of high stress amplitude during operation through the elastic-plastic finite element analysis. The endurance limit moves down due to the surface finish and decarburization, which combines with the movement of resultant stress points to dangerous range. It was concluded that the precise control of sizing and enough corner radius are necessary to a reliability of connecting rod.