KSPG Automotive Group

Installation of rings
Step by Step

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Information about our product range
can be found in our catalogue
"Piston Ring Sets".
Further information can be obtained directly
from your local Motor Service partner or at
www.ms-motor-service.com
The Motor Service Group is the sales organisation for the worldwide aftermarket activities of
Kolbenschmidt Pierburg. Under the premium brands KOLBENSCHMIDT, PIERBURG and
TRWEngine Components, we supply a comprehensive and tailored range of products
for inside and outside the engine.
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First clean the pistons thoroughly and
remove all carbon deposits from the ring
grooves. Use a twist drill and tap wrench to
remove the carbon deposit from the oil
drain holes. Replace cracked or deformed
and worn pistons.
If a clearance of 0.12 mm or more is measured
between a new, parallel-sided compression ring
and the associated groove wall, this means that
the piston is excessively worn and has to be
replaced.
Measure the piston ring grooves using a gauge.
KS Art. No. 50 009 824.
Remove carbon deposits from the top area of
the cylinder bore, above the ring travel zone.
F
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Feeler
gauge
0
,1
2
Groove clearance Piston usage
0.050.10 mm
Piston can be re-used
without restrictions
0.110.12 mm More caution necessary
> 0.12 mm
Fitment of new pistons
essential
If the cylinder wear exceeds
0.1 mm for SI engines and
0.15 mm for diesel engines, the
cylinder also has to be exchanged
(top ring reversal bore wear).
Check the ring set components
When tting the pistons with new rings, we recom-
mend in principle to exchange the complete set.
Check the ring height by means of a measuring
gauge. It is recommended to compare with our
catalogue data.
The diameter may be checked by means of
a measuring ring or of a reworked cylinder, the
ring gap on the basis of subjective assessment
or using a feeler gauge. When verifying the ring
diameter in worn cylinders/cylinder liners,
it should be remembered that the ring gap may
have larger values.
After tting the piston rings, make sure
that they can be freely moved.
Position the ring gaps with 120 oset
to the next ring.
Pistons for 2-stroke engines whose
rings are prevented from turning by a
small pin, must not be rotated when
being introduced into the cylinder. The
securing pin could otherwise slip under
the ring as it springs outwards into a
cylinder port. The ring would then break
o at the port edge.
Top ring reversal bore wear
Insert piston rings in the associated piston ring
groove using the right assembly tool!
Avoid excessive opening of the piston rings on
tting as this would cause permanent
deformation and impair the performance of the
piston rings.
The "TOP" marking must point to the base of the
piston so that the scraping eect is directed
towards the end of the shaft. Incorrectly tted
piston rings mean that the ring set unit will no
longer function properly. In severe cases, the
incorrectly tted piston rings cause the oil to be
pumped from the crankcase into the combustion
chamber.
Piston ring pliers.
KS Art. No. 50 009 815 for 50110 mm
KS Art. No. 50 009 829 for 110160 mm
When tting rings with spiral ex pan der the
spring ends should always be positioned
opposite the ring gap. Some spiral
expanders pass through a teon tube,
which is located opposite the spring ends
and therefore directly beneath the ring gap.
Oil the piston rings and the piston appropriately and
use a ring compressor or a conical KS assembly
sleeve in order to prevent damage to the piston rings.
KS No. Description
50 009 816 Piston ring compressor for 57 125 mm
50 009 828 Piston ring compressor for 90 175 mm
50 009 913 Piston ring case
Attention!
Chromium-plated piston rings must
not be tted to chromium-plated
cylinder liners.
!
Clean pistons Clean the cylinders Check piston ring grooves Check the cylinder wear
Fitting the piston rings Fitting oil scraper rings
Function test Fitting the piston
Please note:
In the case of certain three-piece oil control
rings the spring has a coloured dot at each
end. Each of these coloured dots must still be
visible after tting the ring to the piston. This
ensures that the spring ends butt up to each
other and do not overlap.
correct:
green colour mark red colour mark
assembly recommendation
incorrect:
joint overlapped
Segment
Expander spring
Segment