Kia Carnival (2009+). Manual — part 25

2. The standard measurement of the piston outside diameter is taken 47mm (1.85in) from top land of the piston.

Standard diameter :
97.015~97.045mm (3.8195 ~ 3.8207in)

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

Piston-to-cylinder clearance :
0.070 ~ 0.098mm (0.0028 ~ 0.0039in)

4. Inspect the piston ring side clearance.

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

Piston ring side clearance
No. 2 : 0.06 ~ 0.10mm (0.0024 ~ 0.0039in)
Oil ring : 0.03 ~ 0.07mm (0.0012 ~ 0.0028in)

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

5. Inspect the 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 rings. If the gap is too large, recheck the cylinder bore inner diameter. If the
bore is over the service limit, the cylinder block must be rebored.

Piston ring end gap
Standard
No.1 : 0.25~ 0.40mm (0.0098 ~ 0.0157in)
No.2 : 0.40 ~ 0.55mm (0.0157 ~ 0.0217in)
Oil ring : 0.20 ~ 0.40mm(0.0079 ~ 0.0157in)

PISTON PINS

1. Measure the outer diameter of piston pin.

Piston pin diameter :
31.994~32.000mm (1.2596 ~ 1.2598in)

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

Piston pin hole inner diameter:
32.015~32.025 mm (1.2604~1.2608 in)
0.015~0.031 mm(0.0003~0.0012 in)

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

Inside diameter of connecting rod small end bore:
32.012~32.033mm (1.2603~1.2611 in)
0.012~0.039 mm(0.0005~0.0015 in)

4. Apply oil on the piston pin when assembling.

LADDER FRAME AND BALANCE SHAFT

1. Measure the ladder frame inner diameter.

Ladder frame inner diameter

LH1

25.000 ~ 25.021 mm(0.9843~0.9851in)

LH2

54.000 ~ 54.030 mm(2.1260~2.1272in)

LH3

56.000 ~ 56.030 mm(2.2047~2.2059in)

RH1

35.000 ~ 35.025 mm(1.3780~1.3789in)

RH2

54.000 ~ 54.030 mm(2.1260~2.1272in)

RH3

56.000 ~ 56.030 mm(2.2047~2.2059in)

2. Measure the balance shaft outer diameter.

Balance shaft outer diameter

LH1

24.939 ~ 24.960 mm(0.9818~0.9827in)

LH2

53.910 ~ 53.940 mm(2.1224~2.1236in)

LH3

55.910 ~ 55.940 mm(2.2012~2.2024in)

RH1

34.925 ~ 34.950 mm(1.3750~1.3760in)

RH2

53.910 ~ 53.940 mm(2.1224~2.1236in)

RH3

55.910 ~ 55.940 mm(2.2012~2.2024in)

3. Measure the end play of the balance shaft.

0.10~0.25mm (0.0036~0.0098in)

OIL PRESSURE SWITCH

1. Check the continuity between the terminal and the body with an ohmmeter. If there is no continuity, replace the oil

pressure switch.

2. Check the continuity between the terminal and the body when the oil hole is blocked with a fine stick. If there is

continuity with a fine stick is pushed, replace the switch.

continuity with a fine stick is pushed, replace the switch.

3. If there is no continuity when a 49.0kpa (0.5kg/cm", 7.1psi) is applied through the oil hole, the switch is operating

properly.
Check for air leakage. If air leaks, the diaphragm is broken. Replace it.

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 the piston and connecting rod.

(1) Insert the piston pin and fix the piston pin clip.

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

2. Install the piston rings.

(1) Install the oil ring expander and two side rails by hand.

(2) Using a piston ring expander, install the two compression rings with the code mark facing upward.

(3) Position the piston rings so that the ring ends are as shown.