CYLINDER AND PISTON
3. Measure:
• Piston ring end gap
Out of specification
→
Replace the piston
ring.
TIP
The oil ring expander end gap cannot be mea-
sured. If the oil ring rail gap is excessive, replace
all three piston rings.
EAS24440
CHECKING THE PISTON PIN
1. Check:
• Piston pin
Blue discoloration/grooves
→
Replace the
piston pin, and then check the lubrication sys-
tem.
2. Measure:
• Piston pin outside diameter “a”
Out of specification
→
Replace the piston pin.
3. Measure:
• Piston pin bore inside diameter “b”
Out of specification
→
Replace the piston.
4. Calculate:
• Piston-pin-to-piston-pin-bore clearance
Out of specification
→
Replace the piston pin
and piston as a set.
EAS24450
INSTALLING THE PISTON AND CYLINDER
1. Install:
• Top ring “1”
• 2nd ring “2”
• Oil ring expander “3”
• Lower oil ring rail “4”
• Upper oil ring rail “5”
TIP
Be sure to install the piston rings so that the
manufacturer marks or numbers face up.
Piston ring
Top ring
End gap (installed)
0.10
–
0.25 mm (0.0039
–
0.0098
in)
Limit
0.50 mm (0.0197 in)
2nd ring
End gap (installed)
0.10
–
0.25 mm (0.0039
–
0.0098
in)
Limit
0.60 mm (0.0236 in)
Oil ring
End gap (installed)
0.20
–
0.70 mm (0.0079
–
0.0276
in)
Piston pin outside diameter
13.995
–
14.000 mm (0.5510
–
0.5512 in)
Limit
13.975 mm (0.5502 in)
Piston pin bore inside diameter
14.002
–
14.013 mm (0.5513
–
0.5517 in)
Limit
14.043 mm (0.5529 in)
• Piston-pin-to-piston-pin-bore clearance =
Piston pin bore inside diameter “b” -
Piston pin outside diameter “a”
Piston-pin-to-piston-pin-bore
clearance
0.002
–
0.018 mm (0.0001
–
0.0007
in)
Limit
0.068 mm (0.0027 in)
