Fitting Pistons & Rings

Visually inspect cylinder block for cracks or flaws. Using bore gauge, measure cylinder bore for out-of-round or excessive taper. If out-of-round or taper exceeds .0008" (.020 mm), refinish bore. When one cylinder is bored, all must be bored.
NOTE: Before block machining operations, ensure main bearing caps are installed and tightened to specification. Bore cylinders in the order of No. 2-4-1-3 to prevent distortion.

Determine piston oversize according to amount of wear in cylinder. See PISTON DIAMETER SPECIFICATIONS table. By measuring piston at thrust face and adding mean of piston-to-cylinder clearance, finish hone of cylinder may be determined. Measure bore halfway down cylinder and 90° to crankshaft center line.

PISTON DIAMETER SPECIFICATIONS

Application		In. (mm)
1.8L
Standard		3.2663-3.2683 (82.965-83.015)
0.5 mm O/S		3.2860-3.2880 (83.465-83.515)
1 mm O/S		3.3057-3.3077 (83.965-84.015)
2.0L
Standard		3.3254-3.3274 (84.465-84.515)
0.5 mm O/S		3.3451-3.3470 (84.965-85.015)
1 mm O/S		3.3648-3.3667 (85.465-85.515)

After honing cylinder to final fit, measure piston-to-cylinder clearance using pull scale and feeler gauge. Extracting force to pull scale should be .44-3.31 lbs. (.2-1.5 kg) using .0016" (.040 mm) feeler gauge.
NOTE: Pistons and rings are available in .5 mm and 1 mm oversize for service. Ensure piston and cylinder are at 68°F (20°C) when checking piston fit.
If pistons are reused, de-carbon ring grooves with scraper and piston groove cleaner tool. Clean oil slots in bottom land of oil ring groove. Check for scratches, wear, or damage.
Measure piston ring end gap. For all models, end gap limit is .04" (1 mm). Replace rings if beyond limit. Measure side clearance of rings in grooves as each ring is installed.
Side clearance limit is .004" (.10 mm) for all rings. If side clearance exceeds limits, replace piston and rings. When installing rings, ensure stamped mark on each ring faces up.