Cylinder Block

Check cylinder block for following conditions and repair or replace cylinder block as needed.
1. Leakage damage
2. Cracks
3. Scoring of cylinders
Check distortion of cylinder head mating surface (block deck) in six directions shown in figure. See Fig 2.
Distortion: 0.006 in (0.15 mm) maximum

Fig 1: Checking Distortion Of Cylinder Head Mating Surface
Courtesy of KIA MOTORS AMERICA, INC.
Repair block deck by surface grinding block, or in extreme cases replace cylinder block.
Maximum resurface amount: 0.008 in (0.20 mm)

Fig 2: Measuring Cylinder Block Distortion
Courtesy of KIA MOTORS AMERICA, INC.
If deck is at or below this specification, replace cylinder block.
NOTE: Before surfacing cylinder block, check deck height from center line of crankshaft to deck surface.
Measure cylinder bore with a dial bore gauge at X and Y vectors shown in figure. See Fig 3.
1. Cylinder bore size
  1. Standard: 3.1892~3.1897 in (81.006~81.019 mm)
  2. Bore + 0.010 in (0.25 mm): 3.1990~3.1996 in (81.256~81.269 mm):
  3. Bore + 0.020 in. (0.50 mm): 3.2089~3.2094 in (81.506~81.519 mm)
Fig 3: Measuring Cylinder Bore With A Dial Bore Gauge
Courtesy of KIA MOTORS AMERICA, INC.
Take cylinder measurements at top, center and bottom of cylinder to check for cylinder diameter, taper and out-of-round.
1. Taper: 0.0007 in (0.019 mm)
2. Maximum Out-of-round: 0.0007 in (0.019 mm) Maximum
NOTE: Boring cylinders should be based on maximum oversized piston that can be installed without exceeding maximum overbore.

Fig 4: Measuring Cylinder Bore Taper
Courtesy of KIA MOTORS AMERICA, INC.