Piston Ring Replacement

1.	Remove the piston from the cylinder block.

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

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 ( K20A6 engine), 2.5 mm (0.10 in.) wide (K24A3 engine).
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, push a new ring (A) into the cylinder bore 15-20 mm (0.6-0.8 in.) from the bottom. 15-20 mm (0.6-0.8 in. )AB

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 over the service limit, the cylinder 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
K20A6 engine
Standard (New):	0.40-0.55 mm (0.016-0.022 in.)
Service Limit:	0.70 mm (0.028 in.)

K24A3 engine
Standard (New):	0.50-0.65 mm (0.020-0.026 in.)
Service Limit:	0.75 mm (0.030 in.)

Oil Ring
K20A6 engine
Standard (New):	0.25-0.65 mm (0.010-0.026 in.)
Service Limit:	0.75 mm (0.030 in.)

K24A3 engine
Standard (New):	0.20-0.70 mm (0.008-0.028 in.)
Service Limit:	0.80 mm (0.031 in.)

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

ABCABTop Ring (Standard):
A: 3.1 mm (0.12 in.)
B: 1.2 mm (0.05 in.)Second Ring (Standard):
A: 3.4 mm (0.13 in.)
B: 1.2 mm (0.05 in.)Piston Ring Dimensions:K20A6
engineABK20A6
engineK24A3
engineK24A3
engineC

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

8.	Position the ring end gaps as shown: OIL RING GAPAbout 90°SECOND RING GAPPISTON PINOIL RING GAPAbout 45°TOP RING GAP and SPACER RING GAP

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

**Top Ring Clearance**
Standard (New):
K20A6 engine:	0.035-0.060 mm (0.0014-0.0024 in.)
K24A3 engine:	0.045-0.070 mm (0.0018-0.0005 in.)
Service Limit:	0.13 mm (0.005 in.)

**Second Ring Clearance**
Standard (New):
K20A6 engine:	0.030-0.055 mm (0.0012-0.0022 in.)
K24A3 engine:	0.040-0.065 mm (0.0016-0.0026 in.)
Service Limit:	0.13 mm (0.005 in.)