Standard Procedure - Piston Ring Fitting

Before reinstalling used rings or installing new rings, the ring clearances must be checked.

1. Wipe the cylinder bore clean.
2. Insert the ring in the cylinder bore.
   Fig 1: Checking Ring End Gap

   Courtesy of CHRYSLER LLC

   1 - FEELER GAUGE

   NOTE: The ring gap measurement must be made with the ring positioned at least 12 mm (0.50 inch.) from bottom of cylinder bore.
3. Using a piston, to ensure that the ring is squared in the cylinder bore, slide the ring downward into the cylinder.
4. Using a feeler gauge check the ring end gap. See Fig 1. Replace any rings not within specification.

   PISTON RING SIDE CLEARANCE 

   NOTE: Make sure the piston ring grooves are clean and free of nicks and burrs.
   Fig 2: Measuring Piston Ring Side Clearance

   Courtesy of CHRYSLER LLC

   1 - FEELER GAUGE

5. Measure the ring side clearance as shown in illustration. See Fig 2. Make sure the feeler gauge fits snugly between the ring land and the ring. Replace any ring not within specification.
6. Rotate the ring around the piston, The ring must rotate in the groove with out binding.
   PISTON RING SPECIFICATION CHART
   
   

   Ring Position	Ring/Groove	Maximum
   	Side Clearance	Clearance
   Upper Ring	0.02-0.07 mm	0.11 mm
   	(0.0008-0.0028 in.)	(0.004 in.)
   Intermediate Ring	0.02-0.06 mm	0.10 mm
   	(0.0008-0.0023 in.)	(0.004 in.)
   Ring Position	Ring Gap	Wear Limit
   Upper Ring	0.30-0.40 mm	0.45 mm
   -	(0.0118-0.0157 in.)	(0.0177 in.)
   Intermediate Ring	0.35-0.60 mm	0.74 mm
   -	(0.0137-0.0236 in.)	(0.029 in.)
   Oil Control Ring	0.020-0.71 mm	0.76 mm
   (Steel Rail)	(0.0078- 0.0279 in.)	(0.030 in.)

7. The No. 1 and No. 2 piston rings have a different cross section. Ensure No. 1 ring is installed with manufacturers I.D. mark (Dot) facing up, towards top of the piston.
   NOTE: Piston rings are installed in the following order:

   1. Oil ring expander.
   2. Lower oil ring side rail.
   3. Upper oil ring side rail.
   4. No. 2 Intermediate piston ring.
   5. No. 1 Upper piston ring.
   Fig 3: Side Rail - Installation

   Courtesy of CHRYSLER LLC

   1 - SIDE RAIL END

8. Install the oil ring expander as shown in illustration.
9. Install upper side rail by placing one end between the piston ring groove and the expander ring. Hold end firmly and press down the portion to be installed until side rail is in position. Repeat this step for the lower side rail. See Fig 3.
   Fig 4: Upper And Intermediate Rings

   Courtesy of CHRYSLER LLC
10. Install No. 2 intermediate piston ring using a piston ring installer. See Fig 4.
11. Install No. 1 upper piston ring using a piston ring installer. See Fig 4.
    Fig 5: Piston Ring End Gap Position

    Courtesy of CHRYSLER LLC

    1 - SIDE RAIL UPPER

    2 - NO. 1 RING GAP

    3 - PISTON PIN

    4 - SIDE RAIL LOWER

    5 - NO. 2 RING GAP AND SPACER EXPANDER GAP

12. Position piston ring end gaps as shown in Fig 5. It is important that expander ring gap is at least 45° from the side rail gaps, but not on the piston pin center or on the thrust direction.