Disassembly
1. Remove the cylinder head, toothed belt, front cover, flywheel, pistons and crankshaft.
Examination
1. Remove all gaskets, sealant, dirt, oil, grease and other foreign matter from the engine block. Visually check the cylinder block for rust, corrosion, cracks or any other defects.
2. Clear interfaced surfaces of a head of the block of cylinders and the block of cylinders of the laying remains. With a metal ruler and feeler gauge in six directions, check the flatness of the mating surface of the cylinder block.
- Flatness deviation: 0.05 mm
- Maximum deviation from flatness: 0.1 mm
3. Measure the diameters of the cylinders in diametrically opposite directions, in three planes along the height of the cylinders. If the cylinder diameters exceed the allowable values, are oval or tapered, or the surface of the cylinders is damaged or worn out, the cylinder block must be bored out and new oversize pistons and piston rings installed.
Nominal cylinder diameter:
- 1.3L engine: 71.5mm
- 1.1L engine: 67.0mm
Cylinder taper:
- 1.3 l engine: no more than 0.02 mm
- 1.1 l engine: no more than 0.05 mm
4. If there is a step on the top of the cylinder, cut it off with the special tool.
5. Four oversized piston sizes are available as spare parts: 0.25, 0.5, 0.75 and 1.00mm.
6. When boring cylinders to the nearest oversize, maintain clearance between the piston and cylinder and make sure the pistons are the same oversize.
Measure the outside diameter of each piston at a 90°angle to the piston pin, 47 mm from the piston crown.
Clearance between piston and cylinder: 0.02–0.04 mm.
7. When using new parts, a maximum clearance of no more than 85 microns is allowed.