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 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 0.05mm (0.0020in)

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

If deep scratches are present, replace the cylinder block.
Inspect the cylinder bore diameter.
Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial direction.

Standard diameter :

1.6 CVVT : 76.50 ~ 76.53mm (3.0118 ~ 3.0130in)

1.4 DOHC : 75.50 ~ 75.53mm (2.9724 ~ 2.9736in)

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

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 KIA MOTORS AMERICA, INC.

Identification of cylinder bore size

CYLINDER BORE SIZE IDENTIFICATION REFERENCE

Mark	Cylinder bore inner diameter
A	76.50 ~ 76.51mm (3.0118 ~ 3.0122in)
B	76.51 ~ 76.52mm (3.0122 ~ 3.0126in)
C	76.52 ~ 76.53mm (3.0126 ~ 3.0130in)

Check the piston size mark (A) on the piston top face.

Fig 4: Identifying Piston Size Mark On Piston Top Face

Courtesy of KIA MOTORS AMERICA, INC.

Discrimination of piston outer diameter

PISTON OUTER DIAMETER

Select the piston related to cylinder bore class.
Piston-to-cylinder clearance :

0.02 ~ 0.04mm (0.0008 ~ 0.0016in)