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Subaru Manley - Piston and Ring Installation

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The document provides instructions for installing pistons and rings in Subaru EJ20, EJ25 and FA20 engines. It includes details on piston sizing, wrist pin orientation, ring end gap recommendations based on boost levels, and ensuring proper ring installation and seating.

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Subaru Manley - Piston and Ring Installation

Uploaded by

greg monroe
926 views2 pages
The document provides instructions for installing pistons and rings in Subaru EJ20, EJ25 and FA20 engines. It includes details on piston sizing, wrist pin orientation, ring end gap recommendations based on boost levels, and ensuring proper ring installation and seating.

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Subaru-Manley_Piston-and-Ring-Installation

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The document provides instructions for installing pistons and rings in Subaru EJ20, EJ25 and FA20 engines. It includes details on piston sizing, wrist pin orientation, ring end gap recommendations based on boost levels, and ensuring proper ring installation and seating.

Copyright:

© All Rights Reserved
Download as PDF, TXT or read online from Scribd
Download as pdf or txt
926 views2 pages

Subaru Manley - Piston and Ring Installation

Uploaded by

greg monroe
The document provides instructions for installing pistons and rings in Subaru EJ20, EJ25 and FA20 engines. It includes details on piston sizing, wrist pin orientation, ring end gap recommendations based on boost levels, and ensuring proper ring installation and seating.

Copyright:

© All Rights Reserved
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09/21/16

PISTON AND RING


PERFORMANCE PRODUCTS, INC. INSTALLATION INSTRUCTIONS
SUBARU EJ20, EJ25, FA20
PISTON INSTALLATION INSTRUCTIONS
Important - Before balancing, please check to make sure that you have the correct components. Used or altered parts are
non-returnable.
PISTON TO CYLINDER WALL CLEARANCE
Although piston to wall clearance preferences vary somewhat among engine builders, we recommend the following:
Gauge Point
Distance Uncoated Skirt Coated Skirt

Subaru 75mm Stroke (Mild Boost) 1.100” .0035” .003”


Subaru 75mm Stroke (High Boost) 1.100” .004” .0035”
Subaru 79/83mm Stroke (Mild Boost) .850” .0035” .003”
Subaru 79/83mm Stroke (High Boost) .850” .004” .0035”
Subaru 86mm/FA20 (Mild Boost) .850” .0035” .003”
Subaru 86mm/FA20 (High Boost) .850” .004” .0035”

Piston diameter must be measured at a gauge point, which is measured from the bottom of the oil ring. (See Fig. 1)
Clearance is built into the piston based upon the finished bore size of the cylinder.

Fig. 1

Installation instructions for Subaru Grade A and B Platinum Series pistons


PISTON SIZING
Manley Subaru bore graded pistons are manufactured to provide DROP-IN installation and correspond to the OEM Grade
Range A or B bore sizes. Select the appropriate mix of grade range pistons for your block’s requirements. The proper
clearance is designed into each grade range. Do not attempt to modify the piston to wall clearance by mis-matching the
grade ranges. Corresponding Grade A and B pistons will have a piston to wall clearance range of .0023”- .0031”. The
piston to wall clearance gauge point for all Subaru graded pistons is 0.850” from the bottom of the oil ring.
CYLINDER WALL PREP
Depending upon the mileage of your engine and the condition of the cylinder walls, you may elect to leave the bores in
their current condition or introduce some crosshatch with an abrasive-ball brush hone or polish with Scotchbrite®. For
factory honed (new blocks) we recommend a flex hone with 240-320 grit. This won’t alter bore size and creates a better
surface finish for performance ring sets.
PISTON WRIST PIN OFFSET
Manley Subaru pistons are designed with offset wrist pins to reduce connecting rod angularity. Please note the arrow on
the top of each piston. This arrow MUST point to the front of the block.
ROUND WIRE LOCKS
Manley pistons are designed to retain the wrist pin with round wire locks (2 per piston). Proper intallation of locks is critical!
Please consult a professional engine builder or contact Manley Performance if you have any questions.
RECOMMENDED RINGS
DUE TO DISCREPANCIES IN RADIAL DEPTHS OF PISTON RINGS IN THE FIELD FROM VARIOUS MANUFACTURERS, WE ADVISE
USING MANLEY PERFORMANCE PISTON RINGS ON ALL MANLEY PERFORMANCE PISTONS ENSURING MAXIMUM PERFORMANCE.
SEE REVERSE SIDE FOR SUBARU PISTON RING INSTALLATION INSTRUCTIONS
PISTON RING
INSTALLATION INSTRUCTIONS
SUBARU EJ20, EJ25, FA2O
GENERAL GAPPING RECOMMENDATIONS

APPLICATION FUEL TOP RING SECOND RING OIL RING RAIL


Mild Boost up to 15lb Gas, Alky, E85 Bore x .005” Bore x .005” Min. .015”
Medium Boost 16-25lb Gas, Alky, E85 Bore x .006” Bore x .006” Min. .015”
High Boost 26-35lb+ Gas, Alky, E85 Bore x .0065” Bore x .0065” Min. .015”
Extreme Boost 35lb+ Gas, Alky, E85 Bore x .0075” Bore x .0075” Min. .015”

Disclaimer: These are general gapping recommendations and are not to be considered absolute. State of engine tune, operating environment
and personal experience must also be considered.
1. File fit ring sets require filing of the top and 2nd
rings to achieve the correct end gap. To properly
measure the ring gap, the ring should be square in the
bore 1” down from the deck. Measure the ring end gap
with a feeler gauge or equivalent device. Calculate the
recommended ring end gap from the chart above. (Bore
size measured in inches)
2. A proper ring gap filing tool must be used. Ring
filing should be done in an inward direction and square
to the sides of the ring. Must de-burr all edges after
filing.
3. Correct ring installation is critical. The top ring
will have a shiny gray edge. When the top and 2nd ring
has a dot, install dot side up. Unmarked top rings with
an inner bevel install with bevel up. Unmarked 2nd
rings with inner bevel install with bevel down. Narrow
rings (1.0/1.2mm) that aren’t marked or beveled can be
installed with either side up. Do not overlap the ends of
the oil ring expander. See orientation diagram.
4. Ring to piston groove back clearance should be
a minimum of .005” deeper than the radial wall
dimension of the piston ring. The piston ring should
not stick out of the groove by any amount. Ring
groove side clearance should be a minimum of .0015”
to a maximum of .0030”.
Subaru EJ20/EJ25/FA20 Ring Sets
Containing Oil Rails with Tab Insert tab in this location. Insert tab in this location.

When installed in a horizontally opposed engine, rail gaps


should be installed as shown to the right.
The top and bottom rails are tabbed to prevent rotation and to
block oil migration at the bottom of the cylinders. These tabs
should be installed into the tab receiver grooves located above
and below the oil ring groove in line with the wrist pin.
Ring Seating
When first starting your engine to ensure proper ring seating, do not allow the engine to idle for long periods at a time. It is a good idea
to mildly load the engine as soon as you can. Highway driving is a good way to properly seat the rings quickly. Do not idle the engine as
idling does not break in any engine. Manley DOES NOT recommend the use of synthetic oils during break-in. After 2000-3000 miles on
the street, or one night racing on the track, the rings should be adequately seated so that any oil you prefer can then be used.

Engine Preparation - Iron Cylinders


Finish hone cylinder walls with torque plates installed if available. Recommended hone grit specification: Chrome face top ring: 280 grit.
Followed by light plato hone. Finished hone with a 30 degree cross-hatch pattern off horizontal axis; resulting in a 60 degree included
angle.

Manley Performance Products 732-905-3366 Fax 732-905-3010 www.manleyperformance.com

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