MAHLE Motorsport

Technically The Best Pistons

& Rings In Racing

Customer & Technical Service 1-888-255-1942

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Website
MAHLEMotorsports.com

Contact Email
Customer Service motorsport@mahle.com
Sales motorsport.sales@mahle.com
Technical Support motorsport.tech@mahle.com

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It's astounding to consider that MAHLE has only been partici­pating in U.S. Motorsport since early
2000. Because we have built on success in NASCAR, American Le Mans, and other top series,
MAHLE continues to demonstrate why we are the first name in high performance racing pistons.

In recent years, MAHLE Motorsport powered vehicles have won multiple championships in
everything from NASCAR, IRL, American Le Mans, World of Outlaws, SCORE Offroad, to local
circle track and drag strip championships across the country and everything else in between,
not to mention cap­turing world records in the quarter mile, and at the Bonneville Salt Flats.

Whether you're competing professionally, running a street/strip car, time attack, diesel drag
or pulling, race on dirt or asphalt, be a part of the winning tradition of MAHLE Motor­sport.
Porsche Piston Sets
The Highest Quality In Racing

Phosphate Coated To Reduce

Light Weight Slipper Micro-Welding & Pin Galling
Skirt Forging
Fully Machined Crown GRAFAL®
Anti-Friction Skirt Coating

Machine Finished High Strength, Light Weight

Pin Bores Low Drag Ring Pack
German Steel Pins
Proven To Make More
Horsepower & Torque
 Table Of Contents
Page
Water-Cooled 1
356 Air Cooled 2
2.0L, 2.2L, 2.4L, 2.7L Air Cooled 3
3.0L, 3.2L, 3.3L Air Cooled 4
3.6L Air Cooled 5
Rings & Components 6
Tech & Ring Gap Instructions 6-7

Motorsport Piston Sets

MAHLE’s relationship with Porsche dates back to Porsche’s beginning. Together we have developed
some of the best competition and sports car engines available throughout the last nine decades.

MAHLE Motorsports North America has taken the extensive experience gained from its relationship
with Porsche to develop a series of performance and racing piston and cylinder kits. These kits were
designed for high performance applications and are modern adaptations of the original or aftermarket
kits; therefore there may be visual differences that are intentional and beneficial to the performance,
durability and longevity of the components.

The pistons are machined from forgings with narrower and shorter skirts to reduce weight and friction. They
are then dual coated, with Phosphate and MAHLE’s proprietary GRAFAL® skirt coating. The phosphate
is a dry film lubricant designed to help protect the pin bores from galling and ring grooves from micro-
welding. The GRAFAL® anti-friction skirt coating is designed to reduce drag, wear and noise.

The kits are supplied with modern ring sets made from stronger more durable materials that are dimensionally
narrower and shorter to be more conformable providing more consistent contact with the cylinders resulting in
increased sealing and oil control.
 PORSCHE WATER-COOLED
Bore Stroke Rod Comp Pin Crown Wght Compression Alloy Clearance Guide
Height Diam. Vol G Ratio Meas. Min Max Part No.
NOTE: All Water-cooled CR calculated at zero deck clearance and 1mm head gasket thickness

PORSCHE 944 TURBO 2.5L for use in factory aluminum bores only
1.2, 1.5, 3.0mm Performance Ring Set Included 54cc
100.5mm 78.9mm 150mm 40.8mm 24mm -21cc 473 8.6 2618 0.500 0.0020 0.0028 930070756 *
101.0mm 479 8.6 930070776 *
*2618 Alloy & Hard Anodized Top Ring Groove For Extreme Duty Applications

PORSCHE 968 TURBO 3.0L for use in factory aluminum bores only
1.2, 1.5, 3.0mm Performance Ring Set Included 56cc
104.5mm 87.8mm 150mm 36mm 24mm -32cc 501 8.8 2618 0.400 0.0020 0.0028 930130214 *
*2618 Alloy & Hard Anodized Top Ring Groove For Extreme Duty Applications

PORSCHE Cayman 3.4L for use with replacement cast iron cylinder liner
1.2, 1.5, 2.0mm Performance Ring Set Included 39cc
96.0mm 78mm 144.98mm 32.35mm 22mm -9.6cc 405 11.1 4032 0.500 0.0008 0.0016 197848980 *
*Hard Anodized Top Ring Groove

PORSCHE Cayman 3.4L for use with replacement Nikasil cylinder liner
1.2, 1.5, 2.0mm Performance Ring Set Included 39cc
96.0mm 78mm 144.98mm 32.35mm 22mm -9.6cc 405 11.1 4032 0.500 0.0008 0.0016 197849080 *
*Hard Anodized Top Ring Groove

PORSCHE 996 3.6L for use with replacement cast iron cylinder liner
1.2, 1.5, 2.0mm Performance Ring Set Included 38cc
96.0mm 82.8mm 141.99mm 32.95mm 22mm -13.3cc 407 11.3 4032 0.500 0.0008 0.0016 197849180 *
*Hard Anodized Top Ring Groove

PORSCHE 996 3.6L for use with replacement Nikasil cylinder liner
1.2, 1.5, 2.0mm Performance Ring Set Included 38cc
96.0mm 82.8mm 141.99mm 32.95mm 22mm -13.3cc 407 11.3 4032 0.500 0.0008 0.0016 197849280 *
*Hard Anodized Top Ring Groove

PORSCHE 997 3.8L for use with replacement cast iron cylinder liner
1.0, 1.0, 2.0mm Performance Ring Set Included 38cc
99.0mm 82.8mm 141.99mm 32.95mm 22mm -13.2cc 416 11.8 4032 0.500 0.0008 0.0016 197837098 *
100.0mm 423 12.0 197837037 *
*Hard Anodized Top Ring Groove

PORSCHE 997 3.8L for use with replacement Nikasil cylinder liner
1.0, 1.0, 2.0mm Performance Ring Set Included 38cc
99.0mm 82.8mm 141.99mm 32.95mm 22mm -13.2cc 416 11.8 4032 0.500 0.0008 0.0016 197846098 *
100.0mm 423 12.0 197846037 *
*Hard Anodized Top Ring Groove

Porsche 991 3.8L Turbo (2014-2019) Box in Box

1.2, 1.2, 3.0mm Performance Ring Set included 63cc
102mm 77.5mm 138mm 33.95mm 23mm -7.6cc 485 9.0 2618 0.550 0.0046 0.0054 197976416 *
*Hard Anodized Top Ring Groove

888-255-1942 MAHLEMotorsport.com 1
 PORSCHE 356 AIR-COOLED
Bore Stroke Rod Comp Pin Crown Wght Compression Alloy Clearance Guide
Height Diam. Vol G Ratio Meas. Min Max Part No.
NOTE: All Air-cooled CR calculated at 1mm below deck

PORSCHE 356 - Slip-in cylinder case register (30° cylinder heads)

1.2, 1.2, 2.8mm Performance Ring Set Included 57.5cc 60.5cc
86.0mm 74mm 135.95mm 27.05mm 22mm 15.8cc 301 10.0 9.5 2618 0.250 0.0004 0.0012 PP86-003N Piston (set)
*LN cylinders sold through LN distributors; Kit PN shown for reference only LN 102-86 * Cylinder (ea)
PS86-003N * Kit (set)

PORSCHE 356 - Slip-in cylinder case register (30° cylinder heads)

1.2, 1.2, 2.8mm Performance Ring Set Included 60.5cc 63.5cc
86.0mm 74mm 135.95mm 27.05mm 22mm 18.7cc 305 10.0 9.5 2618 0.250 0.0004 0.0012 PP86-004N Piston (set)
*LN cylinders sold through LN distributors; Kit PN shown for reference only LN 102-86 * Cylinder (ea)
PS86-004N * Kit (set)

PORSCHE 356 - Slip-in cylinder case register (30° cylinder heads)

1.2, 1.2, 2.8mm Performance Ring Set Included 63.5cc 66.5cc
86.0mm 74mm 135.95mm 27.05mm 22mm 21.8cc 307 10.0 9.5 2618 0.250 0.0004 0.0012 PP86-005N Piston (set)
*LN cylinders sold through LN distributors; Kit PN shown for reference only LN 102-86 * Cylinder (ea)
PS86-005N * Kit (set)

PORSCHE 356 - Machine-in 94.5mm cylinder case register (30° cylinder heads)
1.2, 1.2, 2.8mm Performance Ring Set Included 57.5cc 60.5cc
91.0mm 74mm 135.95mm 27.05mm 22mm 10.6cc 321 10.0 9.5 2618 0.250 0.0006 0.0014 PP91-001N Piston (set)
*LN cylinders sold through LN distributors; Kit PN shown for reference only LN 102-91 * Cylinder (ea)
PS91-001N * Kit (set)

PORSCHE 356 - Machine-in 94.5mm cylinder case register (30° cylinder heads)
1.2, 1.2, 2.8mm Performance Ring Set Included 60.5cc 63.5cc
91.0mm 74mm 135.95mm 27.05mm 22mm 13.6cc 324 10.0 9.5 2618 0.250 0.0006 0.0014 PP91-002N Piston (set)
*LN cylinders sold through LN distributors; Kit PN shown for reference only LN 102-91 * Cylinder (ea)
PS91-002N * Kit (set)

PORSCHE 356 - Machine-in 94.5mm cylinder case register (30° cylinder heads)
1.2, 1.2, 2.8mm Performance Ring Set Included 63.5cc 66.5cc
91.0mm 74mm 135.95mm 27.05mm 22mm 16.6cc 332 10.0 9.5 2618 0.250 0.0006 0.0014 PP91-003N Piston (set)
*LN cylinders sold through LN distributors; Kit PN shown for reference only LN 102-91 * Cylinder (ea)

Motorsport Air-Cooled Cylinders

The cylinders included in Motorsports air-cooled kits are produced and machined to original
equipment tolerances, designed to provide increased performance, durability and longevity.
Some applications are available as either a slip-in or machine-in design. The slip-in
cylinders are simply a larger internal bore replacement. The machine-in cylinders require the
engine cases be machined to a larger bore diameter to accept their larger spigot diameter.
The larger spigot diameter is preferable for extreme applications as with highly boosted
turbo or competition use engines.

MAHLE Motorsport has partnered with LN Engineering to broaden the range of available
Porsche applications. The LN “Nickies” cyinders are manufactured from a different
aluminum alloy than MAHLE cylinders. The MAHLE Motorsport pistons designed to work
with LN liners are manufactured from the compatible alloy and designed specifically for
use with LN liners, offering the same performance, durability and longevity.

2 MAHLEMotorsports.com 888-255-1942
 PORSCHE 2.0L / 2.2L / 2.4L / 2.7L AIR-COOLED
Bore Stroke Rod Comp Pin Crown Wght Compression Alloy Clearance Guide
Height Diam. Vol G Ratio Meas. Min Max Part No.
NOTE: All Air-cooled CR calculated at 1mm below deck

PORSCHE 911 and 911S 2.0L (1964-1969)

1.2, 1.2, 2.0mm Performance Ring Set Included 70.5cc
80.0mm 66mm 130mm 34mm 22mm 38.8cc 334 10.0 4032 0.250 0.0010 0.0018 PP80-001 Piston (set)
PC80-001 Cylinder (ea)
PS80-001 Kit (set)

PORSCHE 911 2.0L Cup

1.2, 1.2, 2.0mm Performance Ring Set included 70.5cc
80.0mm 66mm 130mm 34mm 22mm 40cc 337 10.3 4032 0.250 0.0010 0.0018 PP80-002 Piston (set)
PC80-001 Cylinder (ea)
PS80-002 Kit (set)

PORSCHE 911 and 911S 2.2L (1970-1971)

1.2, 1.2, 2.0mm Performance Ring Set Included 70.5cc
84.0mm 66mm 130mm 34mm 22mm 27.2cc 371 8.5 4032 0.250 0.0010 0.0018 PP84-001 Piston (set)
PC84-001 Cylinder (ea)
PS84-001 Kit (set)

PORSCHE 911 and 911S 2.4L (1972-1973)

1.2, 1.2, 2.0mm Performance Ring Set Included 70.5cc
84.0mm 70.4mm 130mm 34mm 22mm 27.2cc 371 9.0 4032 0.250 0.0010 0.0018 PP84-001 Piston (set)
PC84-001 Cylinder (ea)
PS84-001 Kit (set)

PORSCHE 911S 2.5L Long Stroke

1.2, 1.2, 2.0mm Performance Ring Set Included 70.5cc
86.7mm 70.4mm 127.8mm 34mm 22mm 25.9cc 401 9.3 4032 0.250 0.0010 0.0018 PP86-002 Piston (set)
PC86-002 Cylinder (ea)
PS86-002 Kit (set)

PORSCHE 911S 2.5L Short Stroke

1.2, 1.5, 3.0mm Performance Ring Set included 68cc
89.0mm 66mm 130mm 33.9mm 22mm 30.2cc 420 10.2 2618 0.250 0.0009 0.0017 PP89-002N Piston (set)
*LN cylinders sold through LN distributors; Kit PN shown for reference only LN 103-89 * Cylinder (ea)
PS89-002N * Kit (set)

PORSCHE 911 2.7L (1973-1977) Carb or Mechanical Injection

1.2, 1.5, 3.0mm Performance Ring Set included 68cc
90.0mm 70.4mm 127.8mm 34mm 22mm 26.1cc 402 10.3 2618 0.500 0.0009 0.0017 PP90-003N Piston (set)
*LN cylinders sold through LN distributors; Kit PN shown for reference only LN 103-90 * Cylinder (ea)
PS90-003N * Kit (set)

PORSCHE 911 2.7L to 2.8L (1973-1977) Carb or Mechanical Injection

1.2, 1.5, 3.0mm Performance Ring Set Included 68cc
92.0mm 70.4mm 127.8mm 33.9mm 22mm 21.5cc 425 9.8 2618 0.400 0.0009 0.0017 PP92-004N Piston (set)
*LN cylinders sold through LN distributors; Kit PN shown for reference only LN 103-92 * Cylinder (ea)
PS92-004N * Kit (set)

PORSCHE 911 2.7L to 2.9L (1973-1977) Carb or Mechanical Injection

1.2, 1.5, 3.0mm Performance Ring Set Included 68cc
93.0mm 70.4mm 127.8mm 33.9mm 22mm 23.4cc 440 10.3 2618 0.400 0.0010 0.0018 PP93-004N Piston (set)
*LN cylinders sold through LN distributors; Kit PN shown for reference only LN 103-93 * Cylinder (ea)
PS93-004N * Kit (set)

888-255-1942 MAHLEMotorsport.com 3
 PORSCHE 3.0L / 3.2L / 3.3L AIR-COOLED
Bore Stroke Rod Comp Pin Crown Wght Compression Alloy Clearance Guide
Height Diam. Vol G Ratio Meas. Min Max Part No.
NOTE: All Air-cooled CR calculated at 1mm below deck

PORSCHE 930 TURBO 3.3L to 3.4L (1978-1992)

1.2, 1.2, 3.0mm Performance Ring Set Included 90cc
98.0mm 74.4mm 127mm 32.8mm 23mm 14.2cc 432 7.7 4032 0.250 0.0010 0.0018 PP98-012 Piston (set)
PC98-001 Cylinder (ea)
PS98-009 Kit (set)

PORSCHE 911 CARRERA 3.2L to 3.4L (1984-1989) Motronic Inj

1.2, 1.2, 3.0mm Performance Ring Set Included 90cc
98.0mm 74.4mm 127mm 32.8mm 23mm 35.8cc 507 10.1 2618 0.250 0.0006 0.0014 PP98-013 Piston (set)
PC98-001 Cylinder (ea)
PS98-010 Kit (set)

PORSCHE 911 3.0L to 3.2L (1976-1983) Carb or Mechanical Injection

1.2, 1.2, 3.0mm Performance Ring Set Included 90cc
98.0mm 70.4mm 127.8mm 33.7mm 22mm 40cc 500 10.2 2618 0.250 0.0006 0.0014 PP98-014 Piston (set)
PC98-001 Cylinder (ea)
PS98-014 Kit (set)

PORSCHE 911 3.0L to 3.2L (1976-1983) Motronic Inj.

1.2, 1.2, 3.0mm Performance Ring Set Included 90cc
98.0mm 70.4mm 127.8mm 34mm 22mm 38.5cc 494 10.0 2618 0.250 0.0006 0.0014 PP98-015 Piston (set)
PC98-001 Cylinder (ea)
PS98-015 Kit (set)

PORSCHE 930 TURBO 3.0L to 3.2L (1975-1977)

1.2, 1.2, 3.0mm Performance Ring Set Included 90cc
98.0mm 70.4mm 127.8mm 33.7mm 22mm 15.8cc 419 7.5 4032 0.250 0.0010 0.0018 PP98-016 Piston (set)
PC98-001 Cylinder (ea)
PS98-016 Kit (set)

PORSCHE 911 CARRERA 3.2L to 3.4L (1984-1989)

1.2, 1.2, 3.0mm Performance Ring Set Included
Compatible with dual plug cylinder heads and high lift cams (DC80) 92cc
98.00mm 74.4mm 127mm 32.8mm 23mm 43.2cc 457 11.0 2618 0.250 0.0006 0.0014 PP98-017 Piston (set)
PC98-001 Cylinder (ea)
PS98-017 Kit (set)

PORSCHE 911 3.2L to 3.5L (1984-1989) - Machine-in 105mm cylinder case register
1.2, 1.5, 3.0mm Performance Ring Set Included 90cc
100.0mm 74.4mm 127mm 32.8mm 23mm 35cc 473 10.3 2618 0.500 0.0010 0.0018 PP100-009N Piston (set)
*LN cylinders sold through LN distributors; Kit PN shown for reference only LN 103-100/105 * Cylinder (ea)
PS100-009N * Kit (set)

PORSCHE 911 3.3L to 3.5L 930T (1978-1992) - Machine-in Ø105mm cylinder case register
1.2, 1.5, 3.0mm Performance Ring Set Included 90cc
100.0mm 74.4mm 127mm 32.8mm 23mm 0.5cc 428 7.0 2618 0.250 0.0010 0.0018 PP100-010N ** Piston (set)
*LN cylinders sold through LN distributors; Kit PN shown for reference only LN 103-100/105 * Cylinder (ea)
**Hard Anodized Top Ring Groove For Extreme Duty Applications PS100-010N * Kit (set)

PORSCHE 911 3.0L to 3.3L CIS Inj. (1976-1983) - Machine-in Ø105mm cylinder case register
1.2, 1.5, 3.0mm Performance Ring Set Included 90cc
100.0mm 70.4mm 127.8mm 34mm 22mm 35cc 474 9.8 2618 0.250 0.0010 0.0018 PP100-011N Piston (set)
*LN cylinders sold through LN distributors; Kit PN shown for reference only LN 103-100/105 * Cylinder (ea)
PS100-010N * Kit (set)

4 MAHLEMotorsports.com 888-255-1942
 PORSCHE 3.6L AIR-COOLED
Bore Stroke Rod Comp Pin Crown Wght Compression Alloy Clearance Guide
Height Diam. Vol G Ratio Meas. Min Max Part No.
NOTE: All Air-cooled CR calculated at 1mm below deck

PORSCHE 964 NA 3.6L to 3.8L (also fits 993) (1989-1998) - Slip-in Ø107mm cylinder case register
1.2, 1.2, 3.0mm Performance Ring Set Included 90cc
102.0mm 76.4mm 127mm 31.5mm 23mm 44.5cc 474 12.6 4032 0.450 0.0010 0.0018 PP102-011 Piston (set)
PC102-002 Cylinder (ea)
PS102-017 Kit (set)

PORSCHE 964 NA 3.6L to 3.8L (also fits 993) (1989-1998) - Machine-in Ø109mm cylinder case register
1.2, 1.2, 3.0mm Performance Ring Set Included 90cc
102.0mm 76.4mm 127mm 31.5mm 23mm 44.5cc 474 12.6 4032 0.450 0.0010 0.0018 PP102-011 Piston (set)
PC102-001 Cylinder (ea)
PS102-018 Kit (set)

PORSCHE 993 TURBO 3.6L to 3.8L - Machine-in Ø109mm cylinder case register, shorter 114.5mm tall cylinder
1.2, 1.2, 3.0mm Performance Ring Set Included 90cc
102.0mm 76.4mm 127mm 31.8mm 23mm 9.7cc 437 8.1 4032 0.590 0.0010 0.0018 PP102-012 Piston (set)
PC102-003 Cylinder (ea)
PS102-019 Kit (set)

PORSCHE 964 TURBO (& 993 Carerra to Turbo conversion) 3.6L to 3.8L - Slip-in Ø107mm cylinder case register
1.2, 1.2, 3.0mm Performance Ring Set Included 90cc
102.0mm 76.4mm 127mm 31.8mm 23mm 22.6cc 453 9.3 4032 0.470 0.0010 0.0018 PP102-013 Piston (set)
PC102-002 Cylinder (ea)
PS102-020 Kit (set)

PORSCHE 964 TURBO (& 993 Carrera to Turbo conversion) 3.6L to 3.8L - Machine-in Ø109mm cylinder case register
1.2, 1.2, 3.0mm Performance Ring Set Included 90cc
102.0mm 76.4mm 127mm 31.8mm 23mm 22.6cc 453 9.3 4032 0.470 0.0010 0.0018 PP102-013 Piston (set)
PC102-001 Cylinder (ea)
PS102-021 Kit (set)

PORSCHE 993 RSR style 3.6L to 3.8L (also fits 964) (1989-1998) - Slip-in Ø107mm cylinder case register
1.2, 1.2, 3.0mm Performance Ring Set Included 90cc
102.0mm 76.4mm 127mm 31.5mm 23mm 38.1cc 489 11.4 4032 0.315 0.0010 0.0018 PP102-014 Piston (set)
PC102-002 Cylinder (ea)
PS102-022 Kit (set)

PORSCHE 993 RSR style 3.6L to 3.8L (also fits 964) (1989-1998) - Machine-in Ø109mm cylinder case register
1.2, 1.2, 3.0mm Performance Ring Set Included 90cc
102.0mm 76.4mm 127mm 31.5mm 23mm 38.1cc 489 11.4 4032 0.315 0.0010 0.0018 PP102-014 Piston (set)
PC102-001 Cylinder (ea)
PS102-023 Kit (set)

PORSCHE 964 / 993 Stroker 3.6L to 3.9L - Slip-in Ø107mm cylinder case register
1.2, 1.2, 3.0mm Performance Ring Set Included 90cc
102.0mm 80.4mm 127mm 29.5mm 23mm 35.0cc 480 11.4 4032 0.500 0.0010 0.0018 PP102-015 Piston (set)
PC102-002 Cylinder (ea)
PS102-024 Kit (set)

PORSCHE 964 / 993 Stroker 3.6L to 3.9L - Machine-in Ø109mm cylinder case register
1.2, 1.2, 3.0mm Performance Ring Set Included 90cc
102.0mm 80.4mm 127mm 29.5mm 23mm 35.0cc 480 11.4 4032 0.500 0.0010 0.0018 PP102-015 Piston (set)
PC102-001 Cylinder (ea)
PS102-025 Kit (set)

PORSCHE 964 / 993 3.6L to 3.9L (1989-1998) - Machine-in Ø109mm cylinder case register
1.2, 1.5, 3.0mm Performance Ring Set Included 90cc
104.0mm 76.4mm 127mm 31.8mm 23mm 36.2cc 528 11.4 2618 0.500 0.0011 0.0019 PP104-001N Piston (set)
*LN cylinders sold through LN distributors; Kit PN shown for reference only LN 104-104 * Cylinder (ea)
PS104-001N * Kit (set)

888-255-1942 MAHLEMotorsport.com 5
 Porsche Ring Sets, Pins, & Clips
Finish Set Set
Bore Description Part Number Description Part Number
Porsche Ring Sets Piston Pins
80.00 mm 1.2, 1.2, 2.0mm File Fit (6cyl) PR80MS-12 22 x 12/15.7 x 52mm Taper CH 101g 9894428
84.00 mm 1.2, 1.2, 2.0mm File Fit (6cyl) PR84MS-12 22 x 13 x 58.11mm CH 112g 9900106
86.70 mm 1.2, 1.2, 2.0mm File Fit (6cyl) PR86MS-12 23 x 13 x 50mm Taper R 98g 4394409
89.00 mm 1.2, 1.5, 3.0mm File Fit (6cyl) PR89MS 22 x 13 x 52mm CH 101g 1979122
90.00 mm 1.2, 1.5, 3.0mm File Fit (6cyl) PR90MS 23 x 13.5 x 55.6mm CH 119g 9299621
92.00 mm 1.2, 1.5, 3.0mm File Fit (6cyl) PR92MS 23 x 13.5 x 57.404mm R 124g 9298392
93.00 mm 1.2, 1.5, 3.0mm File Fit (6cyl) PR93MS 23 x 13.9 x 63.5mm CH 131g 9301712
95.00 mm 1.2, 1.5, 3.0mm File Fit (6cyl) PR95MS 24 x 15 x 58.1mm CH 125g 9900079
98.00 mm 1.2, 1.5, 3.0mm File Fit (6cyl) PR98MS
98.00 mm 1.2, 1.2, 3.0mm File Fit (6cyl) PR98MS-12 Clips (each) w/o tang
100.00 mm 1.2, 1.5, 3.0mm File Fit (6cyl) PR100MS 22mm x 1.6mm Round Wire Lock 2042968
102.00 mm 1.2, 1.2, 3.0mm File Fit (6cyl) PR102MS-12 23mm x 1.6mm Round Wire Lock 9315805
102.00 mm 1.46, 1.46, 2.99mm File Fit (6cyl) PR102MS-15 24mm x 1.6mm Round Wire Lock 9900539
104.00 mm 1.2, 1.5, 3.0mm File Fit (6cyl) PR104MS

86.00 mm 1.2, 1.2, 2.8mm Drop In (4cyl) 8600MS-12

91.00 mm 1.2, 1.2, 2.8mm File Fit (4cyl) 1978643
96.00 mm 1.2, 1.5, 2.0mm File Fit (6cyl) NIKASIL 1978504
96.00 mm 1.2, 1.5, 2.0mm File Fit (6cyl) 1978505
99.00 mm 1.0, 1.0, 2.0mm File Fit (1cyl) 3903MS-112-1
100.00 mm 1.0, 1.0, 2.0mm File Fit (1cyl) 3942MS-112-1
101.00 mm 1.2, 1.5, 3.0mm File Fit (4cyl) 9300402
100.50 mm 1.2, 1.5, 3.0mm File Fit (1cyl) ALUSIL 1977212
104.50 mm 1.2, 1.5, 3.0mm File Fit (4cyl) 9300400

Final Assembly Tech Tips

Compression Ratio
The compression ratio shown in the application guide is calculated at 1mm (0.040”) deck clearance for Air-Cooled applications. For Water-Cooled
at zero deck clearance and a 1mm head gasket thickness. The compression ratio of your specific application will vary depending on the deck
clearance that the engine is built with.
Piston Ring Gaps
The rings should be checked in the cylinder to ensure that the end gaps are sufficient. Recommendations and additional information is provided in
the ring instructions located on page 7. Should you require additional ring end gap, the rings should be gapped before installation on the piston.

Piston Orientation In Engine

For pistons that have an arrow laser etched on the crown, the pistons are installed so that the arrow points toward the flywheel.
For pistons with slanted dome and symmetric valve pockets, the pistons are installed so that the short end of the dome is located under the spark
plug.
Piston to Valve Clearance
Valve to piston clearance depends on many factors; including the piston crown configuration, valve train and camshaft characteristics, and cylinder
head design. The camshaft manufacturer can supply the minimum recommended valve to piston clearance for your specific camshaft/valve train
combination. After the camshaft is “degreed” correctly you may check the valve clearance using either modeling clay or light spring method.
Minimum recommended clearance for valve face to valve pocket floor of the piston is 0.080” for the intake valve, and 0.100” for the exhaust valve.
Minimum radial clearance is 0.050” radially for all valves.

NOTICE: Be sure to check the clearances of MAHLE pistons in relation to other engine com¬ponents such as valves, connecting rods, and oil
squirters BEFORE running the engine. These components may need adjustment in order to function properly with MAHLE pistons.

Piston to Cylinder Wall Clearance

MAHLE machines the proper piston to cylinder wall clearance into every piston and cylinder kit.

The recommended piston to cylinder wall measurement and location is listed on the outside label of the box. The piston measurement location is
measured up from the bottom of the piston skirt. For the cylinder, the measurement location is measured down from the top of the cylinder. The
cylinder should be measured in the same axis as the pistons (thrust / anti-thrust). It is worth noting that the piston to wall clearance value specified
is measured over the Grafal® skirt coating.
Tech Note
Prior to final engine assembly, the top, bottom, and face of each ring plus the cylinder bore should be lightly coated with clean, light-weight,
conventional motor oil. DO NOT dip the entire piston as this may lead to improper seating of the rings.

Additional tech information and informative technical videos covering the above points are located on our website as well as the
MAHLE Motorsport YouTube channel.

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 Ring Gap Instructions
Top Ring Second Ring 4.000 Bore Example

Application (minimum) (minimum) Oil Ring Rail Top, 2nd, Oil Rails

High Performance Street - NA Bore x 0.0045" Bore x 0.0050" Min 0.015" 0.018", 0.020", Min 0.015"

Circle Track, Drag Racing - NA Bore x 0.0050" Bore x 0.0060" Min 0.015" 0.020", 0.024", Min 0.015"

Nitrous up to 200hp (25HP/cyl) Bore x 0.0060" Bore x 0.0060" Min 0.015" 0.024", 0.024", Min 0.015"

Nitrous Race 200hp+ (25HP/cyl) Bore x 0.0070" Bore x 0.0070" Min 0.015" 0.028", 0.028", Min 0.015"

Turbo / Supercharger Bore x 0.0060" Bore x 0.0060" Min 0.015" 0.024", 0.024", Min 0.015"

Turbo / Supercharger Race Bore x 0.0070" Bore x 0.0070" Min 0.015" 0.028", 0.028", Min 0.015"

NOTE: The second ring gap recommendations have continued to change over the years. Current recommendations are such that the 2nd ring gap
is larger than the top rings for most applications. Testing has proven that a larger second ring gap increases the top ring’s stability allowing for a better
seal. This larger “escape” path prevents inter-ring pressure from building up and lifting the top ring off the piston allowing combustion to get by. Many
engine builders have reported lower blow-by and horsepower gains at the upper RPM ranges with the wider second ring gaps. Also, almost every new
car made is using this inter-ring pressure reduction method to lower blow-by and emissions and to increase engine output. Additionally, and for these
reasons , these ring gap recommendations are to be considered minimums, and some kits will come with larger gaps than the minimum listed in the
table directly out of the box.

PROPER RING INSTALLATION Top Compression

Top ring: If there is a dot (pip mark) or a laser etching (commonly etched as “TOP” Ring Gap
or the MAHLE logo, or a number designator) on one of the flats of the top ring, this
marking is indicating the top of the ring. Typically, if there is a bevel on the ID of the
top ring, the bevel should be facing up toward the top of the piston.

Oil Ring
Wrist Pin Expander
Engine Front Gap Range
Centerline

2nd Ring: I If there is a dot (pip mark) or a laser etching (commonly etched as
“TOP” or the MAHLE logo, or a number designator) on one of the flats of the top
ring, this marking is indicating the top of the ring. Typically, if there is a bevel on
the ID of the 2nd ring, the bevel should be facing down toward the bottom of the Bottom Oil Top Oil
Ring Rail Gap Ring Rail Gap
piston. Any marking indicating the top of the piston ring supersedes the location of
the ID bevel of the ring.
2nd Compression
Ring Gap

Oil Ring - may be either 2 piece or 3 piece design:

2 Piece Instructions: Remove the coil spring from the oil ring and place the coil spring in the groove, noting the location of the coil
spring joint. Install the oil ring in the ring groove; the oil ring gap must be assembled opposite (180 degrees) to coil spring joint.
3 Piece Instructions: Place the expander in the groove, ensure the ends are butted against each other. Position the expander ends
in the desired orientation on the piston, an image of the recommended installation location is provided in the Proper Ring Alignment
section. Install the lower steel ring, the ring end gap must be approximately 90° to 120° left from the expander edges. Install the upper
steel ring observing the same distance for the right side. After ring installation, check if oil ring set can move freely without binding.
Important: expander ends must not overlap.

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