Piston Ring Replacement

1.Remove the piston from the engine block.

2.Using a ring expander (A), remove the old piston rings (B).

 

3.Clean all ring grooves thoroughly with a squared-off broken ring or ring groove cleaner with a blade to fit the piston grooves.
The top and 2nd ring grooves are 1.2 mm (0.05 in.) wide. The oil ring groove is 2.0 mm (0.08 in.) wide.
File down a blade if necessary.
Do not use a wire brush to clean the ring grooves, or cut the ring grooves deeper with the cleaning tools.

NOTE: If the piston is to be separated from the connecting rod, do not install new rings yet.

4.Using a piston that has its rings removed, push a new ring (A) into the cylinder bore 15-20 mm
(0.6-0.8 in.) from the bottom.

 

5.Measure the piston ring end-gap (B) with a feeler gauge:


Piston Ring End-Gap
 
Top Ring: 
Standard (New): 0.20-0.35 mm
(0.008-0.014 in.)
 
Service Limit: 0.60 mm (0.024 in.) 

Second Ring: 
Standard (New): 0.40-0.55 mm
(0.016-0.022 in.)
 
Service Limit: 0.70 mm (0.028 in.) 

Oil Ring: 
Standard (New): 0.20-0.70 mm
(0.008-0.028 in.)
 
Service Limit: 0.80 mm (0.031 in.) 

6.Install the top ring and the second ring as shown. The top ring (A) has a 1R mark, and the second ring (B) has a 2R mark. The manufacturing marks (C) must be facing upward.

 

7.Rotate the rings in their grooves to make sure they do not bind.

8.Position the ring end gaps as shown:

 

9.After installing a new set of rings, measure the ring-to-groove clearances:

Top Ring Clearance
Standard (New): 0.035-0.060 mm
(0.0014-0.0024 in.)
 
Service Limit: 0.13 mm (0.005 in.) 

Second Ring Clearance
Standard (New): 0.030-0.055 mm
(0.0012-0.0022 in.)
 
Service Limit: 0.13 mm (0.005 in.)