Kia Carnival (2009+). Manual — part 114

4. Inspect cylinder bore diameter

Visually check the cylinder for vertical scratchs.
If deep scratches are present, replace the cylinder block.

5. Inspect cylinder bore diameter

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

Standard diameter
96.00 ~ 96.03mm (3.7795 ~ 3.7807in.)

6. Check the cylinder bore size code on the cylinder block.

Class

Size code

Cylinder bore inner diameter

A

A

96.00~96.01mm

(3.7795 ~ 3.7799in.)

B

B

96.01~96.02mm

(3.7799 ~ 3.7803in.)

C

C

96.02~96.03mm

(3.7803 ~ 3.7807in.)

7. Check the piston size code on the piston top face.

Class

Size code

Piston outer diameter

A

A

95.96~95.97mm

(3.7779 ~ 3.7783in.)

B

B

95.97~95.98mm

(3.7783 ~ 3.7787in.)

C

C

95.98~95.99mm

(3.7787 ~ 3.7791in.)

8. Select the piston related to cylinder bore class.

Clearance : 0.03 ~ 0.05mm(0.0012 ~ 0.0020in.)

PISTON AND RINGS

1. Clean piston

(1) Using a gasket scraper, remove the carbon from the piston top.

(2) Using a groove cleaning tool or broken ring, clean the piston ring grooves.

(3) Using solvent and a brush, thoroughly clean the piston.

Do not use a wire brush.

2. The standard measurement of the piston outside diameter is taken 14 mm (0.5512 in.) from the bottom of the

piston.

Standard diameter
95.96 ~ 95.99mm (3.7779~ 3.7791in.)

3. Calculate the difference between the cylinder bore diameter and the piston diameter.

Piston-to-cylinder clearance
0.03 ~ 0.05mm(0.0012 ~ 0.0020in.)

4. Inspect the piston ring side clearance.

Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove.

Piston ring side clearance
Standard
No.1 : 0.03 ~ 0.07mm (0.0012 ~ 0.0027in.)
No.2 : 0.03 ~ 0.07mm (0.0012 ~ 0.0027in.)
Oil ring : 0.06 ~ 0.15mm (0.0024 ~ 0.0059in.)
Limit
No.1 : 0.1mm (0.004in.)
No.2 : 0.1mm (0.004in.)
Oil ring : 0.2mm (0.008in.)

If the clearance is greater than maximum, replace the piston.

5. Inspect piston ring end gap.

To measure the piston ring end gap, insert a piston ring into the cylinder bore. Position the ring at right angles to
the cylinder wall by gently pressing it down with a piston. Measure the gap with a feeler gauge. If the gap exceeds
the service limit, replace the piston ring. If the gap is too large, recheck the cylinder bore diameter. If the bore is
over the service limit, the cylinder block must be replaced.

Piston ring end gap
Standard
No.1 : 0.17 ~ 0.32mm (0.0067 ~ 0.0126in.)
No.2 : 0.32 ~ 0.47m (0.0126 ~ 0.0185in.)
Oil ring : 0.20 ~ 0.70mm (0.0079 ~ 0.0275in.)
Limit
No.1 : 0.6mm (0.0236in.)
No.2 : 0.7mm (0.0275in.)
Oil ring : 0.8mm (0.0315in.)

PISTON PINS

1. Measure the diameter of the piston pin.

Piston pin diameter
23.002 ~ 23.006mm (0.9056 ~ 0.9057in.)

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

Piston pin-to-piston clearance
0.009 ~ 0.017mm (0.0004 ~ 0.0007in.)

3. Check the difference between the piston pin diameter and the connecting rod small end diameter.

Piston pin-to-connecting rod interference
-0.032 ~ -0.017mm (-0.0012 ~ -0.0007in.)

REASSEMBLY

• Thoroughly clean all parts to assembled.
• Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
• Replace all gaskets, O-rings and oil seals with new parts.

1. Assemble piston and connecting rod.

(1) Use a hydraulic press for installation.

(2) The piston front mark and the connecting rod front mark must face the timing belt side of the engine.