| Engine 1.1 | |
| I group | 68.65...68.66 mm |
| II group | 68.66...68.67 mm |
| III group | 68.67...68.68 mm |
| Piston clearance in cylinder | 0.015...0.050 mm |
| Engine 1.4i | |
| I group | 77.19...77.20 mm |
| II group | 77.20...77.21 mm |
| III group | 77.21...77.22 mm |
| IV group | 71.22...77.23 mm |
| Piston clearance in cylinder | 0.020...0.045 mm |
| Engine 1.6i | |
| I group | 79.91...79.92 mm |
| II group | 79.92...79.93 mm |
| III group | 79.93...79.94 mm |
| IV group | 79.94...79.95 mm |
| Piston clearance in cylinder | 0.010...0.040 mm |
| Diesel engine 1.8 | |
| Group A | 82.46...82.47 mm |
| Group B | 82.47...82.48 mm |
| Group C | 82.49...82.50 mm |
| Group D | 82.51...82.52 mm |
| Piston clearance in cylinder | 0.020...0.055 mm |
| Permissible piston protrusion from the cylinder | 0.500...0.840 mm |
The wear limit is 0.15 mm of the total gap resulting from the wear of the piston and cylinder liner.
Burning on the bottoms or obvious signs of wear on the piston skirts indicate the need to replace the entire set of pistons. Replacement of the piston set is also necessary when only one piston is damaged. In diesel engines, the pistons can be separated from the connecting rods after the circlips have been removed. In engines 1.1, as well as 1.4i, the piston pins are installed in the pistons with an interference fit. If necessary, they can only be removed under pressure. After this operation, the pistons are no longer usable, they cannot be reinstalled and must be replaced as a set.
Installation of pistons with connecting rods can only be done by professionals, as this is a technically very difficult task and special tools are required to complete it.
Piston rings must be inserted into the corresponding grooves of the piston and the gaps measured with a feeler gauge (pic. 2.76). Inserting the piston rings in turn into the cylinder bores, measure the gaps in the locks with a feeler gauge. Permissible values for these gaps are given in section 1.1. If the piston ring lock gap is larger than allowed, the measurement must be repeated using a new piston ring. If it turns out that in this case the gap is too large, this means that the cylinder liner is worn out. In this case, it is necessary to bore the engine cylinder liners to the next repair size and use new oversized pistons. If the gaps in the locks turn out to be too small, cut the locks to the required lock gaps. To do this, hold a flat file in a vise and cut the ring lock, simultaneously moving both its surfaces on both sides of the file. To install the rings on the pistons, use special tongs. Designation "TOR" on the rings should be visible from above.
The pistons are mounted with the connecting rods in such a way that the arrows located on the bottoms of the pistons are directed towards the transmission of the gas distribution drive.
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