Cylinder Block

1. Remove gasket material.

   Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.

2. Clean cylinder block

   Using a soft brush and solvent, thoroughly clean the cylinder block.

3. Inspect top surface of cylinder block for flatness.

   Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage.

   Flatness of cylinder block gasket surface 

   1. Standard: Less than 0.03mm (0.0012 in.)
   2. Limit: 0.05 mm (0.0020 in.)
      Fig 1: Checking Cylinder Block Top Surface For Flatness

      Courtesy of HYUNDAI MOTOR CO.
4. Inspect cylinder bore diameter

   Visually check the cylinder for vertical scratches. If deep scratches are present, replace the cylinder block.

5. Inspect cylinder bore diameter

   Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial directions.

   Standard diameter 

   1. 82.00~82.03mm (3.2283~3.2295in.)
      Fig 2: Measuring Cylinder Bore

      Courtesy of HYUNDAI MOTOR CO.
6. Check the cylinder bore size code on the cylinder block bottom face.
   Fig 3: Locating Cylinder Bore Size Code

   Courtesy of HYUNDAI MOTOR CO.
   Fig 4: Cylinder Bore Size Code Table

   Courtesy of HYUNDAI MOTOR CO.
7. Check the piston size code (A) on the piston top face
   Fig 5: Locating Piston Size Code

   Courtesy of HYUNDAI MOTOR CO.
   NOTE: Stamp the grade mark of basic diameter with rubber stamp
   Fig 6: Piston Size Code Table

   Courtesy of HYUNDAI MOTOR CO.
8. Select the piston related to cylinder bore class.

Clearance 

1. 0.02~0.04mm (0.00078~0.00157in.)

Boring cylinder 

1. Oversize pistons should be selected according to the largest bore cylinder.
   Fig 7: Oversized Piston Identification Table

   Courtesy of HYUNDAI MOTOR CO.
   NOTE: The size of piston is stamped on top of the piston.
2. Measure the outside diameter of the piston to be used.
3. According to the measured O.D., calculate the new bore size.
   1. New bore size = Piston O.D + 0.02 to 0.04 mm
   2. (0.0008 to 0.0016 in.) (clearance between piston and cylinder) - 0.01 mm (0.0004 in.) (honing margin.)
4. Bore each of the cylinders to the calculated size.
   CAUTION: To prevent distortion that may result from temperature rise during honing, bore the cylinder holes in the firing order.
5. Hone the cylinders, finishing them to the proper dimension (piston outside diameter + gap with cylinder).
6. Check the clearance between the piston and cylinder.

1. Standard: 0.02-0.04 mm (0.0008-0.0016 in.)