Repair Procedures: Inspection: Piston

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

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.
NOTE: 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:
  
  77.00 - 77.03 mm (3.0315 - 3.0327 in)
  
  Fig 1: Measuring Cylinder Bore Diameter
  Courtesy of KIA MOTORS AMERICA, INC.
2. Measure the piston outside diameter at 33.9 mm (1.5697 in) from top land of the piston.
  Piston outside diameter:
  
  76.97 - 77.00 mm (3.0303 - 3.0315 in)
  
  Fig 2: Measuring Piston Outside Diameter
  Courtesy of KIA MOTORS AMERICA, INC.

Select the piston matching with cylinder bore class.

Piston - to - cylinder clearance:

0.02 - 0.04 mm (0.0008 - 0.0016 in)

Check the cylinder bore size mark on the side of the cylinder block.

Fig 3: Checking Cylinder Bore Size Mark On Cylinder Block Side

Courtesy of KIA MOTORS AMERICA, INC.

CYLINDER BORE

Mark	Cylinder bore inner diameter
A	77.00 - 77.01 mm (3.0315 - 3.0319 in)
B	77.01 - 77.02 mm (3.0319 - 3.0323 in)
C	77.02 - 77.03 mm (3.0323 - 3.0327 in)

Check the piston size mark on the piston top face.

Fig 4: Checking Piston Size Mark On Piston Top Face

Courtesy of KIA MOTORS AMERICA, INC.

PISTON OUTER DIAMETER