Fitting Pistons & Rings
- Measure cylinder bore .028" (.70 mm) from top of cylinder in-line with crankshaft and again 90 degrees from center line of crankshaft. Also measure down bore at 1.18" (30.0 mm) on 1.6L engines and 1.32" (33.5 mm) on 1.8L engines.
- Measure piston 1.04" (26.3 mm) from bottom of skirt and 90 degrees from piston pin hole. Determine cylinder-to-piston clearance. See PISTONS, PINS & RINGS SPECIFICATIONS table. If clearance is incorrect, replace pistons or bore all cylinders to fit oversize pistons.
- If cylinder bore diameter exceeds 3.641-3.642" (92.48-92.51 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 ring groove clearance. See PISTONS, PINS & RINGS SPECIFICATIONS table. 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" marking facing up. When installing piston rings, ensure that ring end gaps are staggered around piston ring and not in-line with piston pin hole. See Fig 1 .