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 

   Standard : Less than 0.03mm (0.0012 in)

   Limit: 0.05 mm (0.0020 in)

   Fig 1: Measuring Surface Contacting Cylinder Head Gasket For Warpage

   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: 

   82.00 ~ 82.03mm (3.2283 ~ 3.2295in)

   Fig 2: Measuring Cylinder Bore Diameter At Position In Thrust And Axial Directions

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

   Courtesy of HYUNDAI MOTOR CO.
   CYLINDER BORE INNER DIAMETER CHART
   
   

   Class	Cylinder Bore Inner Diameter	Size code
   A	82.00 ~ 82.01mm (3.228 ~ 3.2287in)	A
   B	82.01 ~ 82.02mm (3.2287 ~ 3.2291in)	B
   C	82.02 ~ 82.03mm (3.2291 ~ 3.2295in.)	C

7. Check the piston size code on the piston top face.
   Fig 4: Identifying 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 CHART
   
   

   Class	Piston Outer Diameter	Size Code
   A	81.97 ~ 81.98mm (3.2271 ~ 3.2275in)	A
   -	81.98 ~ 81.99mm (3.2275 ~ 3.2279in)	-
   C	81.99 ~ 82.00mm (3.2279 ~ 3.2283in)	C

8. Select the piston related to cylinder bore class.

Clearance 

0.02 ~ 0.04mm (0.00078 ~ 0.00157in.)