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: If the gap is too small, check to see if you have the proper rings for your engine. If the gap is too large, recheck the cylinder bore diameter against the wear limits. If the bore is beyond the service limit, the engine block must be rebored. 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.)