3. Subtract piston diameter measurement from cylinder bore diameter measurement. Standard piston to bore clearance is 0.20-0.046mm (0.0008-0.0018 inch).
Service limit: 0.070mm MAX (0.0028 inch MAX)

NOTE: The actual piston diameter is indicated on the top of all oversize pistons. If piston to bore clearance exceeds service limit, refinish cylinder to provide proper clearance for piston.

4. Insert piston ring into cylinder bore. Using a piston, push piston ring slightly beyond bottom of ring travel, 115mm (4.5 inch) from cylinder block deck face. Use caution to avoid damage to ring or cylinder bore.

5. Measure end gap of all piston rings with a feeler gauge.

Ring end gap:
Top ring: 0.23-0.49mm (0.009-0.019 inch)
2nd ring: 0.23-0.49mm (0.009-0.019 inch)
Oil ring rail: 0.25-0.77mm (0.010-0.030 inch)

Service limit:
Top ring: 1.00mm max (0.039 inch max)
2nd ring: 1.00mm max (0.039 inch max)
Oil ring rail: 1.25mm max (0.049 inch max)

If end gap is greater than service limit, replace piston ring. If end gap exceeds service limit, even with a new piston ring, rebore cylinder block.

Owner caption January 2005 · Photo 101 of 980