Cylinder Block

Remove the gasket material.
Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
Clean the cylinder block
Using a soft brush and solvent, thoroughly clean the cylinder block.
Inspect the top surface of the 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 0.05 mm (0.0020 in.),

Less than 0.02 mm (0.0008 in.) / 150 x 150

Fig 1: Inspecting Surface Of Cylinder Block For Flatness
Courtesy of KIA MOTORS AMERICA, INC.
Inspect cylinder bore diameter
Visually check the cylinder for vertical scratches.

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

92.00 ~ 92.03 mm (3.6220 ~ 3.6232 in.)

Fig 2: Inspecting Cylinder Bore Diameter
Courtesy of KIA MOTORS AMERICA, INC.

Check the cylinder bore size code on the cylinder block.

Fig 3: Identifying Cylinder Bore Size Code On Cylinder Block

Courtesy of KIA MOTORS AMERICA, INC.

CYLINDER BORE INNER DIAMETER

Class	Size code	Cylinder bore inner diameter
A	A	92.00 ~ 92.01 mm (3.6220 ~ 3.6224 in.)
B	B	92.01 ~ 92.02 mm (3.6224 ~ 3.6228 in.)
C	C	92.02 ~ 92.03 mm (3.6228 ~ 3.6232 in.)

Check the piston size code (A) and the front mark (B) on the piston top face.

Fig 4: Identifying Piston Size Code On Piston

Courtesy of KIA MOTORS AMERICA, INC.

PISTON OUTER DIAMETER

Select the piston related to cylinder bore class.
Clearance : 0.03 ~ 0.05 mm (0.0012 ~ 0.0020 in.)