Section 03
ENGINE
Subsection 08
(CYLINDER AND HEAD)
VMR2003_012_03_08A.FM
03-08-19
Install cylinder head and the other parts in accor-
dance with the proper installation procedures.
PISTON
Removal
Remove:
– cylinder head (see CYLINDER HEAD
above)
– cylinder (see CYLINDER above).
Place a rag under piston.
Remove one piston circlip
no. 40
and discard it.
1. Piston circlip
NOTE:
The removal of both piston circlips is not
necessary to remove piston pin.
Push piston pin
no. 41
out of piston.
1. Piston
2. Piston pin
Detach piston
no. 42
from connecting rod.
Inspection
Piston
Inspect piston for scoring, cracking or other damages.
Replace piston and piston rings if necessary.
Using a micrometer, measure piston at 9 mm
(.354 in) perpendicularly (90°) to piston pin.
1. Measuring perpendicularly (90°) to piston pin
A. 9 mm (.354 in)
The measured dimension should be as described
in the following table. If not, replace piston.
Piston/Cylinder Clearance
Adjust and lock a micrometer to the piston dimension.
WARNING
Piston ring circlips are spring loaded.
R175motr99A
1
R175motr98A
2
1
PISTON MEASUREMENT
NEW NOMINAL
61.942 to 61.958 mm
(2.438 to 2.439 in)
SERVICE LIMIT
61.80 mm (2.433 in)
1
R610motr136A
A
Summary of Contents for RALLY 200 2003
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