Engine Block: Inspection

1. Check the cylinder block for scores, rust and corrosion. Also check for cracks or any other defects. Replace the block if defective.
2. Measure the cylinder bore with a cylinder gauge at the three levels indicated and in the directions of A and B.

   Level 1: No. 1 piston ring position at TDC

   Level 2 : Center of cylinder

   Level 3 : Bottom of cylinder

   Fig 1: Measuring The Cylinder Bore

   Courtesy of HYUNDAI MOTOR CO.
3. If the cylinder bores show more than specified out-of-round or taper, or if the cylinder walls are badly scuffed or scored, the cylinder block should be rebored and honed. New oversize piston and rings should be installed.

   Standard value 

   Cylinder bore : 86.5 + 0.03 mm (3.41 + 0.0012 in.)

   Out - of - round and taper of cylinder bore :

   Max. 0.01 mm (0.0004 in.)

4. If a ridge exists at the top of the cylinder, cut it away with a ridge reamer.

   Piston service size and mark mm (in.) 

   Identification Mark : 25

   Size : 0.25 (0.010) O.S.

5. To rebore the cylinder bore to oversize, maintain the specified clearance between the oversize piston and the bore, and make sure that all pistons used are of the same oversize. The standard measurement of the piston outside diameter is taken at a level 16 mm (0.63 in.) from the center of pin hole and across the thrust faces.

   Piston - to - cylinder clearance 

   0.02 ~ 0.04 mm (0.0008 ~ 0.0016 in)

   Fig 2: Measuring Point On Piston Skirt

   Courtesy of HYUNDAI MOTOR CO.
6. Check for damage and cracks.
7. Check the top surface of the cylinder block for flatness. If the top surface exceeds limits, surface to minimum limit or replace.

Standard value 

Flatness of cylinder block : Max. 0.05mm (0.0020 in.)

Service limit 

Flatness of cylinder block: 0.1 mm (0.0039 in.)

Fig 3: Checking Top Surface Of Cylinder Block

Courtesy of HYUNDAI MOTOR CO.