Bulletin #D3a - English

1. Use of Oversize Piston Rings

DSE9102 & GS93-02

The availability of oversize piston rings on all

DAIHATSU engines makes it economically
attractive for low to moderate levels of damage
on the piston ring grooves.

Any damage to the piston ring grooves should be

repaired in order to ensure good fit of the piston
ring in the groove and sufficient contact of the
piston ring with the cylinder liner.

Machining of piston ring grooves

a. Start from groove 1 (figure 1). The upper

surface of the first groove should be machined
as minimum. Then the lower surface is machined
to the required oversize dimensions as indicated
under column "A" on Table 1 on page 2.

b. Moving to groove 2 (figure 1), the upper

surface of the second groove is machined as
minimum followed by the lower surface which is
machined to the required size (refer to Table 1).

c. Any subsequent grooves are machined upper

surface first followed by lower surface to
standard size.
figure 1

Note:

Please note the maximum allowable oversize (OS) for each engine model as indicated on Table 1.
Since most of the wear and tear takes place on the lower groove surface, any larger oversize than
those recommended by DAIHATSU DIESEL MFG will weaken excessively the piston crown resulting to
damage. In situations like this the piston crown should be replaced immediately.

Machine radius R = 0.8mm

IMPORTANT: Please read the following service letter <<click here>> containing important
corrections on the oversize piston rings.

0.5 OVERSIZE 1.0 OVERSIZE 1.5 OVERSIZE 2.0 OVERSIZE

Groove Part Number A Part Number A Part Number A Part Number A

4.5 5.0
1st W157170011Z +0.02 W15710012Z +0.02 NIL NIL
+0.04 +0.04

4.5
DS-18 2nd W157170031Z 0 NIL NIL NIL
+0.02

4.5
3rd W1571700511 0 NIL NIL NIL
+0.02

DS-22 5.5 6.0 6.5 7.0

1st A579401091Z 0 A579401092Z 0 A579401093Z 0 A510910194AZ 0
(Cr)
+0.012 +0.012 +0.015 0.015
 2nd A510970231AZ 5.5 A5109TO232AZ 6.0 A510970233AZ 6.5 A510970234AZ 7.0
0 0 0 0
+0.012 +0.015 +0.015 +0.015

5.5 6.0 6.5 7.0

3rd A510970231AZ 0 A510970232AZ 0 A510970233AZ 0 A510970234AZ 0
+0.012 +0.012 +0.015 +0.015

1st NIL NIL NIL NIL

(Cr)
5.5 6.0 6.5 7.0
DSb-22 2nd A510970231A +0.025 A510970232A +0.025 A510970233A +0.025 A510970234A +0.025
0 0 0 0
5.5 6.0 6.5 7.0
3rd A510970231A +0.025 A510970232A +0.025 A510970233A +0.025 A510970234A +0.025
0 0 0 0

6.5 7.0 7.5 8.0

1st
A510970551Z 0 A510970552Z 0 A510970563Z 0 A510970554Z 0
(Cr)
+0.015 +0.015 +0.015 +0.015
DS-26
6.5 7.0 7.5 8.0
DV-26 2nd A510970591Z 0 A510970592Z 0 A510970593Z 0 A510970594Z 0
+0.015 +0.015 +0.015 +0.015

PS-26H 6.5 7.0 7.5 8.0

3rd A510970591Z 0 A5109TO592Z 0 A510970593Z 0 A510970594Z 0
+0.015 +0.015 +0.015 +0.015

7.5 8.0 8.5 9.0

1st A510970461AZ 0 A510970482AZ 0 A510970463AZ 0 A510970464A 0
(Cr) +0.015 +0.015 +0.015 +0.015

6.5 7.0 7.5 8.0

DS-28 2nd A510970501AZ 0 A510970502AZ 0 A510970503AZ 0 A510970504AZ 0
+0.015 +0.015 +0.015 +0.015

6.5 7.0 7.5 8.0

3rd A510970501AZ 0 A510970502AZ 0 A510970503AZ 0 A510970504AZ 0
+0.015 +0.015 +0.015 +0.015

1st 7.5 8.0 8.5 9.0

A510910281AZ 0 A510970282AZ 0 A510970283AZ 0 A510970284AZ 0
(Cr) +0.015 +0.015 +0.015 +0.015

7.5 8.0 8.5 9.0

DS-32 2nd A510970331AZ 0 A510970332AZ 0 A510970333A 0 A510970334AZ 0
+0.015 +0.015 +0.015 +0.015

7.5 8.0 8.5 9.0

3rd A510970331AZ 0 A510970332AZ 0 A510970333AZ 0 A510970334AZ 0
+0.015 +0.015 +0.015 +0.015

1st 5.5 6.0 6.5 7.0

A510970011Z +0.012 A510970012Z +0.012 A510970013Z +0.012 A510970014Z +0.012
PS-20 (Cr) 0 0 0 0
NOTE 2nd 5.5 6.0 6.5 7.0
& A510970051Z +0.012 A510970052Z +0.012 A510970053Z +0.012 A510970054Z +0.012
3rd 0 0 0 0
1st 6.5 7.0 7.5 8.0
PS-26 A510970101Z +0.015
0
A510970102Z +0.015 A510970103Z +0.015 A510970104Z +0.015
0 0 0
(Cr)
2nd 6.5 7.0 7.5 8.0
VS-26 & A510970151Z +0.015 A510970152Z +0.015 A510970153Z +0.015 A510970154Z +0.015
3rd 0 0 0 0
4.5 5.0
1st
A510970381Z +0.04 A510970381Z +0.04 NIL NIL
(Cr)
+0.02 +0.02
4.5 5.0
PK-16 2nd A510970401Z +0.04 A510970401Z +0.04 NIL NIL
+0.02 +0.02
4.5 5.0
3rd A510970421Z +0.04 A510970421Z +0.04 NIL NIL
+0.02 +0.02
1st 5.0 5.5 6.0 6.5
NIL +0.012 A510970191A +0.012 A510970192A +0.012 A510970193A +0.012
(Cr) 0 0 0 0
PS-22 2nd 5.0 5.5 6.0 6.5
& NIL +0.012 A510970231A +0.012 A510970232A +0.012 A510970233A +0.012
3rd 0 0 0 0

PS-30 1st A510970331A 7.5 A510970332A 7.5 A510970333A 8.5 A510970334A 9.0
+0.015 +0.015 +0.015 +0.015
 (Cr) 0 0 0 0
2nd 7.5 7.5 8.5 9.0
& NIL +0.015 NIL +0.015 NIL +0.015 NIL +0.015
3rd 0 0 0 0
5.5
1st A579401031Z +0.04 NIL NIL NIL
(Cr)
+0.02
DL-16 2nd
& NIL NIL NIL NIL
3rd
5.5 6.0
1st A579400071Z +0.055 A579400072Z +0.055 NIL NIL
DL-19 +0.035 +0.035
AL-PISTON 5.5 6.0
2nd A579400671Z +0.035 A579400672Z +0.035 NIL NIL
+0.015 +0.015
5.5 6.0 6.5 7.0
1st A579400191Z +0.055 A579400192Z +0.055 A579400193Z +0.055 A579400194Z +0.055
DL-19 (RN)
+0.025 +0.025 +0.025 +0.025
FCD- 5.5 6.0
PISTON 2nd
A579400791Z +0.035 A579400792Z +0.035 NIL NIL
(Cr)
+0.015 +0.015
5.5 6.0
1st A579400311Z +0.04 A579400312Z +0.04 NIL NIL
DL-20 +0.02 +0.02
AL-PISTON 5.5 6.0
2nd A579400571Z +0.02 A579400572Z +0.02 NIL NIL
0 0
5.5 6.0 6.5 7.0
1st A579400431Z +0.04 A579400432Z +0.04 A579400433Z +0.04 A579400434Z +0.04
DL-20 (RN) +0.02 +0.02 +0.02 +0.02
FCD- 5.5 6.0
PISTON 2nd A579400571Z +0.02 A579400572Z +0.035 NIL NIL
0 +0.015
5.5 6.0 6.5 7.0
1st
A579400911Z +0.035 A579400912Z +0.035 A579400913Z +0.035 A579400914Z +0.035
(RN)
+0.015 +0.015 +0.015 +0.015
DL-22 5.5 6.0 6.5 7.0
FCD- 2nd
A579401091Z +0.035 A579401092Z +0.035 A579401093Z +0.035 A579401094Z +0.035
PISTON (Cr) +0.015 +0.015 +0.015 +0.015
HFO Spec. 5.5 6.0 6.5 7.0
3rd A579401151Z +0.035 A579401152Z +0.035 A579401153Z +0.035 A579401154Z +0.035
+0.015 +0.015 +0.015 +0.015
6.5 7.0 7.5 8.0
1st A579401271Z +0.035 A579401272Z +0.035 A579401273Z +0.035 A579401274Z +0.035
(RN)
-0.015 -0.015 -0.015 -0.015
DL-24 6.5 7.0
FCD- 2nd
A579401371Z +0.035 A579401372Z +0.035 NIL NIL
PISTON (Cr)
-0.015 -0.015
HFO Spec. 6.5 7.0
3rd A579401411Z +0.035 A579401412Z +0.035 NIL NIL
-0.015 -0.015
7.5 8.0 8.5 9.0
1st
DL-32 (Cr)
A579401511Z +0.015
0
A579401512Z +0.015
0
A579401513Z +0.015 A579401514Z +0.015
0 0
FCD-
PISTON 2nd
& NIL NIL NIL NIL
HFO Spec.
3rd
7.5 8.0 8.5 9.0
1st
DK-32 (Cr)
A579401511Z +0.015
0
A579401512Z +0.015 A579401513Z +0.015 A579401514Z +0.015
0 0 0
FCD-
PISTON 2nd
& NIL NIL NIL NIL
HFO Spec.
3rd

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Updated 09.11.2004