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Old 08-15-2013, 04:20 PM   #1 (permalink)
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Default Piston Ring End Gap setting

Hey everyone,

I'm rebuilding the bottom section of my G13a engine in my 1986 Samurai. Currently, I've gotten to the stage of installing the new piston rings but I'm at a stand still because I don't know what the correct end gap measurement should be.

I will be grateful for any assistance on the issue. Thanks in advance.

Slick
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Old 08-15-2013, 04:52 PM   #2 (permalink)
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Ring end gap...

Top ring - 0.20~0.30mm
2nd ring - 0.20~0.30mm
Oil ring - 0.20~0.70mm
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Old 08-15-2013, 05:56 PM   #3 (permalink)
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Wow...that's fast...thanks alot fordem.

A few other things:

Honing - is it recommended to hone the cylinders before installing the pistons?? The reason I ask is because there seems to be a lot of mixed feelings about honing cylinders.

Break in procedures - same as honing, there are a lot of different and opposing ideas about properly breaking in an engine with new piston rings.

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Dill
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Old 08-16-2013, 07:11 AM   #4 (permalink)
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Factory service manuals don't have any recommendations on honing, or break-in, although I believe break-in is covered in the owner's manual (which I don't have) - if you want my personal recommendations, I would bore very slightly undersized and then hone to the required dimensions, honing gives a better surface finish and a cross hatch pattern that supposedly holds oil and improves the break-in.

Manufacturer's break-in is usually nothing more that a warning to limit speeds for the first thousand miles or so, and not to allow the engine to lug, my preference is to limit engine rpm and load for the first few hundred miles, and to raise the rpm limit gradually, brief higher rpm runs are permitted and in fact encouraged, as long as they are not sustained or repeated.

Accelerating briskly through the lower gears allows the combustion pressures to "load" the rings against the wall, helping them to seat.

Don't forget to retorque the head bolts at the first service.

Question for you - is this a re-bore (oversize piston & rings) or a re-ring job - my suggestion on honing does not work for a re-ring job, but, if you're not boring, honing is even more important because it breaks the glaze on the cylinder walls, and so allows the new rings to seat properly - the issue becomes how much can you hone without developing excessive clearance.
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Old 08-16-2013, 10:28 AM   #5 (permalink)
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Thanks for the advice.

I'm only actually doing a re-ring job along with changing my valve seals. I just got the service manual for the jeep so i will search for the break in process. I can't seem to find any mention about honing the cylinders in the section that deals with installing new rings but I will take your advice about deglazing. There seems to be some brown / goldish marks on some of the cylinder walls to. Will try and take some pictures and post them in a few minutes.

A friend of mine reminded me about re-torquing with first servicing a few days ago .

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Old 08-16-2013, 12:48 PM   #6 (permalink)
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Here are the photos of the cylinders I promised. What do you think?

[IMG][/IMG]






Last edited by Slick; 08-16-2013 at 12:53 PM.
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Old 08-16-2013, 01:39 PM   #7 (permalink)
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A "Flex Hone" may better serve your glaze breaking needs.



I can't attest to the fitness of your bore and pistons though with regard to being concentric, having excessive wear (size) nor cylinder taper. IF that is an issue now, it won't get any better, with new rings.
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Old 08-16-2013, 01:57 PM   #8 (permalink)
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Ok but what are those brown marks from??
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Old 08-16-2013, 02:44 PM   #9 (permalink)
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How long has the engine been open to the atmosphere? Looks like just a light surface rusting to me, is all.
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Old 08-16-2013, 02:45 PM   #10 (permalink)
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My suspicion is rust - I would also suspect you have quite a bit of wear on those bores - notice there appears to be a "ring" at the top edge? If you have enough of a ridge to catch your finger nail on, you may need more than just a hone & "re-ring" - have a machinist check those bores for concentricity and piston to wall clearance, anything over 0.004 piston to wall is out of tolerance.
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