Engine Block: Inspection

Check the engine block for scores, rust and corrosion. Also check for cracks or any other defects. Replace the block if defective.
Using a straight edge and feeler gauge, check the top surface of the block for warpage. Make sure that the surface is free from gasket chips or other foreign material.
Standard : 0.03 mm (0.0012 in.) or less

Limit : 0.06 mm (0.0024 in.) or less

Fig 1: Checking Top Surface Of Block For Warpage
Courtesy of HYUNDAI MOTOR CO.
Measure the cylinder bore with a cylinder gauge at three levels in the direction of A and B. If the cylinder bores show more than the specified out-of-round or taper or if the cylinder walls are badly scuffed or scored, the cylinder block should be rebored and honed. Oversize pistons and rings must be fitted.
Cylinder I.D:76.5 ~ 76.53 mm(3.0118 ~ 3.0130 in.)

Cylinder I.D taper : 0.01 mm (0.0004 in.) or less

Fig 2: Checking Cylinder Bores For Out-Of-Round Or Taper
Courtesy of HYUNDAI MOTOR CO.
If a cylinder ridge exists, cut away with a ridge reamer.
Oversize pistons are available in four sizes.
Piston service size and mark mm (in.)

0.25 (0.010) O.S. : 0.25
When boring the cylinder to the oversize, maintain the specified clearance between the oversize piston and the bore, and make sure that all pistons used are the same oversize.
The standard measurement of the piston's outside diameter is taken 39.35 mm (1.55 in.) from the top land of the piston.

Piston - to - cylinder clearance

0.025 ~ 0.045 mm (0.0010 ~ 0.0018 in.)

Fig 3: Measuring Piston Outside Diameter
Courtesy of HYUNDAI MOTOR CO.