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Piston Inspection

WARNING: This page does not describe the selected car, but rather 22 other vehicles, including the 2009 Mazda B2300, 2009 Mazda 5, 2008 Mazda Tribute, 2008 Mazda B2300, and 2008 Mazda 5. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION:
  • The piston, piston ring and connecting rod cannot be disassembled.
  • When replacing the piston, piston pin, piston ring and connecting rod, replace them together as a single unit.
  1. Measure the outer diameter of each piston at right angle 90° to the piston pin, 10.0 mm {0.40 in}  above the under of the piston.
    • If not within the specification, replace the piston, piston pin, piston ring and connecting rod as a single unit.

    Piston Diameter 

    1. 87.465-87.495 mm {3.4435-3.4446 in} 
      Fig 1: Measuring Piston Diameter
      G02831605Courtesy of MAZDA MOTORS CORP.

  2. Measure the piston-to-cylinder clearance.
    • If not within the specification, replace the piston, piston pin, piston ring and connecting rod as a single unit.

    Standard Clearance 

    1. 0.025-0.045 mm {0.0010-0.0017 in} 

    Maximum Clearance 

    1. 0.11 mm {0.0043 in} 

  3. Measure the piston ring-to-ring groove clearance around the entire circumference.
    • If it exceeds the specification, replace the piston, piston pin, piston ring and connecting rod as a single unit.

    Standard Clearance 

    1. Top: 0.03-0.08 mm {0.0012-0.0031 in} 
    2. Second: 0.03-0.07 mm {0.0012-0.0027 in} 
    3. Oil: 0.03-0.07 mm {0.0012-0.0027 in} 

    Maximum Clearance 

    1. Top: 0.17 mm {0.0067 in} 
    2. Second, Oil: 0.15 mm {0.0059 in} 
      3. Fig 2: Measuring Piston Ring-To-Ring Groove Clearance
      G02831606Courtesy of MAZDA MOTORS CORP.

  4. Insert the piston ring into the cylinder by hand and use the piston to push it to the bottom of the ring travel.
  5. Measure each piston ring end gap with a feeler gauge.
    • If it exceeds the specification, replace the piston, piston pin, piston ring and connecting rod as a single unit.

    Standard End Gap 

    1. Top: 0.16-0.31 mm {0.0063-0.0122 in} 
    2. Second: 0.33-0.48 mm {0.0130-0.0189 in} 
    3. Oil (Rail): 0.20-0.70 mm {0.0079-0.0275 in} 
      Fig 3: Measuring Piston Ring End Gap
      G02831607Courtesy of MAZDA MOTORS CORP.

    Maximum End Gap 

    1. 1.0 mm {0.0393 in} 

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