Fitting Pistons & Rings
- Measure cylinder bore .028" (.7 mm) from top of cylinder in line with crankshaft and again 90° from center line of crankshaft. Also measure bore at 1.18" (30 mm) on 1.6L engines and 1.319" (33.5 mm) on 1.8 engines.
- Measure piston 1.035" (26.3 mm) from bottom of skirt and 90° from piston pin hole. Determine cylinder-to-piston clearance. Clearance should be .010-.040" (.0004-.0016 mm). If clearance is incorrect, replace pistons or bore all cylinders to fit oversize pistons.
- After boring and honing, if cylinder bore diameter exceeds .0197" (.50 mm) more than standard bore of 3.6205-3.6216" (91.960-91.990 mm), replace crankcase.NOTE: Measurement of both pistons and cylinder bores should be performed at 68°F (20°C). All cylinders must be bored to same size and use same size pistons.
- Check ring end gap and piston groove clearance. Check end gap at bottom of cylinder bore. Position pistons with oil rail stopper pin to center of case. Install piston pin circlip, with dog ear facing out, on stopper pin side of piston. Fit piston rings with "R" or "N" facing up.