Kia Carnival (2007 year). Manual — part 418

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

Cylinder bore inner diameter mark location

Discrimination of cylinder bore inner diameter

Mark

Cylinder bore inner diameter

Y

101.513~101.526mm

(3.9966~3.9971in)

X

101.500~101.513mm

(3.9961~3.9966in)

Cylinder liner classifying mark location

The outer discrimination mark of the cylinder liner is on the outer surface of the liner and the inner mark is on
the top surface of it.

Discrimination of cylinder liner

Mark

Outer diameter (mm)

Mark

Inner diameter (mm)

3Y

101.493~101.506mm(3.9958~3.9963in)

Yellow

97.113~97.126mm(3.8233 ~ 3.8239in)

3Y

101.493~101.506mm(3.9958~3.9963in)

Blue

97.100~97.113mm(3.8228~ 3.8233in)

3X

101.480~101.493mm(3.9953 ~ 3.9958in)

Yellow

97.113~97.126mm(3.8233~3.8239in)

3X

101.480~101.493mm(3.9953 ~ 3.9958in)

Blue

97.100~97.113mm(3.8228~ 3.8233in)

Piston Outer diameter mark location

Discrimination of piston outer diameter

Mark

Piston outer diameter

A

97.015~97.030mm(3.8195~3.8201in)

B

97.030~97.045mm(3.8201~3.8207in)

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

Cylinder liner selection table

Cylinder bore mark

Cylinder liner mark

Oil clearance

Y

3Y- Yellow

0.007~0.033mm(0.0003~0.0013in)

Y

3Y- Blue

0.007~0.033mm(0.0003~0.0013in)

X

3X- Yellow

0.007~0.033mm(0.0003~0.0013in)

X

3X- Blue

0.007~0.033mm(0.0003~0.0013in)

Piston

Cylinder liner mark

Piston outer diameter

mark

Oil clearance

Yellow

B

0.068~0.096mm(0.0027~0.0038in)

Blue

A

0.070~0.098mm(0.0028~0.0039in)

PISTON AND PISTON RINGS

1. Clean the 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 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)