Repair Procedures: Inspection: Piston

WARNING: This page is about a different variant/trim than selected.

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.
Information

Do not use a wire brush.
Check the piston-to-cylinder clearance by calculating the difference between the cylinder bore inner diameter and the piston outer diameter.
Piston-To-Cylinder Clearance:

0.02 - 0.04 mm (0.0008 - 0.0016 in.)
1. Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial direction.
  Cylinder Bore Diameter:
  
  81.00 - 81.03 mm (3.1890 - 3.1902 in.)
  
  Fig 1: Measuring Cylinder Bore Diameter At Position In Thrust And Axial Direction
  Courtesy of KIA MOTORS AMERICA, INC.
  
  Information
  
  Measure position points (from the top of the cylinder block):
  
  30 mm (1.1811 in.)/60 mm (2.3622 in.)/90 mm (3.5433 in.)
2. Measure the piston outside diameter at 35 mm (1.3780 in) from top land of the piston.
  Piston Outside Diameter:
  
  80.97 - 81.00 mm (3.1878 - 3.1890 in.)
Fig 2: Measuring Piston Outside Diameter
Courtesy of KIA MOTORS AMERICA, INC.

Select the piston matching with cylinder bore class.

Check the cylinder bore size code on the cylinder block side surface.

Fig 3: Checking Cylinder Bore Size Code On Cylinder Block Side Surface
Courtesy of KIA MOTORS AMERICA, INC.

CYLINDER BORE INNER DIAMETER

Size Code	Cylinder Bore Inner Diameter
A	81.00 - 81.01 mm (3.1890 - 3.1894 in.)
B	81.01 - 81.02 mm (3.1894 - 3.1898 in.)
C	81.02 - 81.03 mm (3.1898 - 3.1902 in.)

Check the piston size mark on the piston top face.

Fig 4: Checking Piston Size Mark On Piston Top Face

G12162868

Courtesy of KIA MOTORS AMERICA, INC.

PISTON OUTER DIAMETER

Size Code	Piston Outer Diameter
A	80.97 - 80.98 mm (3.1878 - 3.1882 in.)
B	80.98 - 80.99 mm (3.1882 - 3.1886 in.)
C	80.99 - 81.00 mm (3.1886 - 3.1890 in.)