Cylinder Block: Notes

Remove gasket material.
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
Clean cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder block.
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

Standard: Less than 0.03mm (0.0012 in.)

Limit: 0.05 mm (0.0020 in.)

Fig 1: Inspecting Top Cylinder Block Surface For Flatness
Courtesy of HYUNDAI MOTOR CO.
Inspect cylinder bore diameter
Visually check the cylinder for vertical scratch.

If deep scratches are present, replace the cylinder block.
Inspect cylinder bore diameter
Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial directions.

Standard diameter

82.00 ~ 82.03mm (3.2283 ~ 3.2295in.)

Fig 2: Inspecting Cylinder Bore Diameter
Courtesy of HYUNDAI MOTOR CO.

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

Fig 3: Checking Cylinder Bore Size Code

Courtesy of HYUNDAI MOTOR CO.

CYLINDER BORE INNER DIAMETER

Class	Cylinder bore inner diameter	Size code
A	82.00 ~ 82.01mm (3.228 ~ 3.2287in.)	A
B	82.01 ~ 82.02mm (3.2287 ~ 3.2291 in.)	B
C	82.02 ~ 82.03mm (3.2291 ~ 3.2295in.)	C

Check the piston size code on the piston top face.

Fig 4: Checking Piston Size Code On Piston Top Face

Courtesy of HYUNDAI MOTOR CO.

NOTE: Stamp the grade mark of basic diameter with rubber stamp.

PISTON OUTER DIAMETER

Select the piston related to cylinder bore class.
Clearance: 0.02 ~ 0.04mm (0.00078 ~ 0.00157in.)