Cylinder Block

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 0.05 mm (0.0020 in.), Less than 0.02 mm (0.0008 in.) / 150 x 150

Fig 1: Measuring Surface Contacting Cylinder Head Gasket
Courtesy of HYUNDAI MOTOR CO.
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

96.00 ~ 96.03 mm (3.7795 ~ 3.7807 in.)

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

Check the cylinder bore size code on the cylinder block.

Fig 3: Identifying Cylinder Bore Size Code On Cylinder Block

Courtesy of HYUNDAI MOTOR CO.

CYLINDER BORE INNER DIAMETER SPECIFICATIONS

Class	Size code	Cylinder bore inner diameter
A	A	96.00~96.01 mm (3.7795 ~ 3.7799 in.)
B	B	96.01~96.02 mm (3.7799 ~ 3.7803 in.)
C	C	96.02~96.03 mm (3.7803 ~ 3.7807 in.)

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.

PISTON OUTER DIAMETER SPECIFICATION

Select the piston related to cylinder bore class.
Clearance:

0.03 ~ 0.05 mm (0.0012 ~ 0.0020 in.)