How to choose piston rings for a VAZ 2109

How to understand when it's time to change piston rings

When the car's oil consumption increased significantly, compression in the cylinders dropped. Before quickly rushing to the garage, you need to measure the compression, first on dry cylinders and then fill the cap from a bottle of oil and measure again and compare the results. If dry cylinder performance is lower, the piston rings must be replaced.

If not, then the rings have nothing to do with it, and you should pay attention to the caps and valves. Also, if low-grade oil is used, the piston rings may become stuck. This phenomenon usually occurs in cars whose engines have not been used for a long time, or have been used for very short distances.

You can decarbonize the rings as follows: unscrew the spark plugs and pour kerosene into the cylinders overnight; this will save you from loosening the carbon deposits.

Compression measurement

So, if the car unit already has a significant mileage (manufacturers define 100 thousand km), then measuring compression in the engine cylinders is a prerequisite. If these same measurements turn out to be unsatisfactory, then not only the piston is replaced, but also a general overhaul of the engine.

Note. In most cases, if unsatisfactory compression is detected in the cylinders, in addition to replacing the piston and valve stem seals, the liners are also grooved, the timing belt is changed, as well as other parts.

Many car owners are in no hurry to go to a service station, even after the car has driven a long distance. The fear of huge costs deters motorists, but all this often leads to more serious consequences. This article was written specifically to help motorists change the piston themselves, thereby saving the family budget. So, the reasons influencing the replacement of the piston in the VAZ 2109 are as follows:

• Increased oil consumption;
• Increased compression in the engine cylinders (300-400 g per thousand kilometers);
• Decrease in engine power (especially noticeable on inclines, where the car barely drags).

Diagnostics or measurement of compression in cylinders

Superficial diagnostics can be carried out independently. To do this you need:

• Measure the value in cylinders;
• Remember the results;
• Pour some oil into the cylinders (using a bottle cap);
• Check compression again.

Attention: in this case, if the compression increases, then the probability of problems with the rings is almost one hundred percent. If the compression remains the same, the rings have nothing to do with it and the problem is most likely related to the valves or oil seals

Dimensions and markings of piston rings VAZ 2109 – 2115

I will now give you the main dimensions of the connecting rod and piston group below in the figure.

The piston is cast aluminum. According to the outer diameter, the pistons are divided into five classes (A, B, C, D, E) every 0.01 mm. The outer surface of the piston has a complex shape. Therefore, it is necessary to measure the piston diameter only in a plane perpendicular to the piston pin, at a distance of 55 mm from the piston bottom.

Main dimensions of the connecting rod VAZ 2109 – 2115

Based on the diameter of the hole for the piston pin, pistons are divided into three classes (1, 2, 3) every 0.004 mm.

The classes of piston diameters and holes for the piston pin are stamped on the bottom of the piston (Fig. 4).

The piston is cast aluminum. According to the outer diameter, the pistons are divided into five classes (A, B, C, D, E) every 0.01 mm. The outer surface of the piston has a complex shape. Therefore, it is necessary to measure the piston diameter only in a plane perpendicular to the piston pin, at a distance of 55 mm from the piston bottom.

Dimensions of piston rings VAZ 2109 – 2115

Based on the diameter of the hole for the piston pin, pistons are divided into three classes (1, 2, 3) every 0.004 mm.

The classes of piston diameters and piston pin holes are stamped on the piston crown.

Piston markings VAZ 2109 – 2115

We change piston rings on a VAZ 2109 with our own hands

When blue smoke comes out of the exhaust pipe of a car, fuel and oil consumption increases, this indicates wear of the piston group and replacement of its components. The article describes replacing the rings on a VAZ 2109 with your own hands, and also includes a video.

There are three piston rings on the VAZ 2109. They are not closed rims that are located on the outer wall of the cylinder in special grooves. These parts serve to seal the combustion chamber, regulate oil flow and improve heat transfer through the cylinder wall. Two compression valves prevent gases from the combustion chamber from entering the crankcase, and an oil scraper valve removes oil from the cylinder walls and prevents it from entering the combustion chamber.

Wear of piston group parts occurs after approximately 150 thousand kilometers due to the action of gases and friction of metal parts. They need to be changed if the following symptoms are present:

• compression drop;
• increased fuel consumption;
• the appearance of bluish smoke in the exhaust gases;
• increased oil consumption.

The cause of deterioration in engine performance may be coking of the piston and stuck rings. This happens when using low-quality fuels and lubricants that do not meet the manufacturers’ recommendations. During long-term operation, carbon deposits form, which covers the combustion chamber and its parts. Piston rings covered with carbon deposits “stick” and cannot perform their functions properly. In this case, they should be changed or decarbonized.

Coked piston with traces of carbon deposits

Step-by-step replacement instructions

Piston repair work must be performed on an inspection ditch, lift or overpass.

What will you need?

To repair a VAZ 2109 engine with your own hands, you need the following tools:

• a set of keys;
• set of heads;
• funnels;
• extension cords;
• torque wrench;
• set of probes;
  Set of gap gauges
• mandrel for pressing products on the piston;
• hammer;
• needle file;
• new repair kit.
  New consumables for piston VAZ 2109

When purchasing piston rings for the VAZ 2109, you should take into account the material of manufacture and their width. It is better to purchase original products to avoid fakes.

Stages

1. First of all, you need to dismantle the cylinder head with your own hands.
2. Then you need to remove the engine oil pan.
3. After rotating the crankshaft, install it so that the connecting rod mounting nuts extend as far as possible.
4. After unscrewing the fastening nuts, remove the connecting rod caps.
5. Using a hammer, tapping lightly, remove the piston with connecting rod from the cylinder.
6. Having opened the gap with your fingers, you need to remove all three products from the groove in turn and dismantle them from the piston.
   Together with the oil scraper, its expander is removed. Use your fingers to widen the gap
7. Using old products, you should clean the grooves from carbon deposits.
8. Removed products must be checked for suitability. To do this, they must be inserted into the cylinder and the gap measured using a feeler gauge. It should be in the range of 0.25 - 0.45 mm. A gap of up to 1 mm is allowed. If the value is greater, then the part must be urgently replaced. If the gap is larger, then the product needs to be sharpened using a needle file.
9. Before installing new products on VAZ 2109 pistons, they should be run in the grooves. If biting is detected, the part must be ground in using fine-grained sandpaper.

The table shows the maximum values ​​of the gaps between the part being replaced and the groove walls.

1. When installing, all parts should be thoroughly lubricated with oil.
2. Installation of products begins with the oil scraper. First, the expander is installed - a special spring with a lock. Then the product itself is put on her. The expander lock and the oil scraper ring gap must be opposite each other.
3. The lower compression ring has a groove and a tooth. When installed, they should be at the bottom of the part. On the upper surface there is usually an inscription “vas” or “tor”.
4. The upper compression ring is installed in the same way - with the lettering facing up.
5. The sequence of putting on the parts is as follows:

• first, the lock is released so that the part can easily fit onto the piston;
• then the lock itself starts;
• the remaining part is installed.

After installation on the piston, all parts need to be oriented. The installation axis of the piston pin should be 45 degrees with the lock of the upper compression ring. The lock of the next product should be at an angle of 180 degrees with respect to the previous one. Thus, the angle between the oil control valve and the upper compression valve will be 90 degrees. Then the pistons and rings are pressed out with a special mandrel and inserted into the cylinders from which they were removed. Next, we perform the reverse assembly with our own hands.

After replacement, the VAZ 2109 piston rings must be run-in. In this case, you should not load the engine, drive on roads with long ascents, and change gears correctly.

Video “Installing piston rings”

This video shows the process of installing piston parts: how to install and what to pay attention to.

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Table of nominal sizes of cylinders and pistons

By weight, pistons are sorted into three groups: normal, increased and decreased by 5 g. These groups correspond to markings on the bottom of the piston: “G”, “+” and “-”.

All pistons on the engine must be of the same mass group. Repair size pistons are manufactured with an outer diameter increased by 0.4 and 0.8 mm.

An increase of 0.4 mm corresponds to a marking in the form of a triangle, and an increase of 0.8 mm corresponds to a marking in the form of a square. The arrow on the piston crown shows how to properly orient the piston when installing it into the cylinder. It should be directed towards the camshaft drive.

Marking of the connecting rod: 1 – class of the connecting rod by weight and by the hole in the upper head. 2 – cylinder number

The piston pin is a hollow steel, floating type, which rotates freely in the piston bosses and connecting rod bushing. The pin is secured in the piston hole by two retaining rings. According to the outer diameter, the fingers are divided into three classes every 0.004 mm. The class is marked with paint on the end of the finger: a blue mark is the first class, a green mark is the second class, and a red mark is the third class.

Places where metal can be removed when adjusting connecting rod heads

The piston rings are made of cast iron. The upper compression ring has a chrome-plated barrel-shaped outer surface. The lower compression ring is scraper type. The oil scraper ring has chrome-plated working edges and an expansion coil spring. Repair size rings are marked digitally “40” or “80”, which corresponds to an increase in the outer diameter by 0.4 or 0.8 mm.

The connecting rod is steel, forged. The connecting rod is processed together with the cover and therefore they are individually non-interchangeable. To avoid mixing up the caps and connecting rods during assembly, they are marked with number 2 (Fig. 5) of the cylinder in which they are installed. A steel-bronze bushing is pressed into the upper head of the connecting rod.

Based on the diameter of the hole in this bushing, the connecting rods are divided into three classes every 0.004 mm. The class number 1 is stamped on the connecting rod cover. Based on the weight of the upper and lower heads, connecting rods are divided into classes, marked either with a letter or with paint on the connecting rod cover. Connecting rods of the same weight class must be installed on the engine.

The weight of the connecting rods can be adjusted by removing metal from the bosses on the upper head and on the cover to a minimum size of 33 and 32 mm (Fig. 6). After removing the metal from the connecting rod cap, it is necessary to mark the classes of the connecting rod on it by the hole for the piston pin and by weight.

Piston pin diameter VAZ 2101

Main dimensions of piston, connecting rod, piston pin and piston rings

The piston is made of aluminum alloy and coated with a layer of tin to improve run-in. The piston skirt is oval in cross section and conical in height. Therefore, it is necessary to measure the piston diameter only in a plane perpendicular to the piston pin and at a distance of 52.4 mm from the piston bottom.

The hole for the piston pin is shifted from the axis of symmetry by 2 mm to the right side of the engine. Therefore, for proper installation of the piston into the cylinder, there is a “P” mark near the hole for the piston pin, which should be facing towards the front of the engine.

Since 1986, repair size pistons for all engine models have been manufactured with an outer diameter increased by 0.4 and 0.8 mm. Until 1986, pistons of the following repair sizes were produced: for engines 2101 - with an increase of 0.2, 0.4 and 0.6 mm; for 21011 - with an increase of 0.4 and 0.7 mm.

The piston rings are made of cast iron. The outer surface of the upper compression ring is chrome plated and has a barrel shape. The lower compression ring is of the scraper type (with a groove along the outer surface), phosphated. The oil scraper ring has slots for oil removed from the cylinder and an internal coil spring (expander).

The piston pin is steel, tubular in cross-section, pressed into the upper head of the connecting rod and rotates freely in the piston bosses.

The connecting rod is steel, forged, with a split lower head in which the connecting rod bearing shells are installed. The connecting rod is processed together with the cover, so during assembly the numbers on the connecting rod and the cover must be the same.

The height of the cylinder block for a classic VAZ car (from the crankshaft axis to the plane of the cylinder head gasket): - 2101, 21011, 2105 = 207.1 tolerance -0.15, - 2103, 2106, 2121, 21033 (for 76 gasoline for China) , 2130 (1.8 liters OPP) = 215.9 tolerance -0.15, - 21213 (on motor 21214 block 21213) = 214.58 tolerance -0.15. The thickness of the cylinder walls usually allows the diameter to be increased by no more than 2 mm; if the water jacket, or rather the diameter of the cylinder, is shifted relative to the jacket, problems may arise.

Knee stroke 2101, 2103, 21213: stroke 2101 - 66mm (in everyday life called low) stroke 2103 - 80mm stroke 21213 - 80mm (more balanced due to more developed counterweights, apparently to the detriment of weight) stroke 2130 - 82mm There are Tyunen knees with a stroke of 84, 86.88 mm. But they cost from 10 thousand

The diameter of the pistons for the classic 2101 is 76mm 21011,2105 is 79mm 21213 is 82mm 2108 is 82mm (installed for driving on a 76 Benz, for export) There are many forged pistons of any stock diameter, and a maximum of 84mm. One of the main geometric characteristics of the piston is the compression height. It is determined by the distance from its bottom to the piston pin axis. For a classic VAZ engine it is 38 mm. There are pistons with a lower compression height, such as TPT pistons. The height is 31 mm.

Lengths of connecting rods for classic engines (what are there): All connecting rods 2101 are 136 mm long, but there is a connecting rod 213 that is the same length, but there the pin is pressed into the piston and not into the connecting rod. There are connecting rods shortened by 7mm (as an example: push the 80th knee into a low block) There are two types: shortened - produced immediately 7mm shorter (Lugansk, Ukraine, made: "Lugansk Crankshaft Plant"), and seated, then there is a stock connecting rod and it shrinks under heat, they did it with a scoop, but they are not very desirable, and in general opinion they are dangerous, since there will definitely be tension at the place of shrinkage, and the “hand of friendship” may appear

And so what we do:

We have an engine 2101 or 21011 with volumes of 1.2 and 1.3 respectively, what can we get? from 2101 blocks we can get volumes of 1.5 and 1.6 liters, from 21011 blocks 1.6 and 1.7. What is needed for this? 1. Crankshaft 2103 (if you hear a crankshaft 2106 or 2121, then keep in mind that the engine 2106 has a KV 2103, the Niva 2121(!) had a 2106 engine), or 21213 (it will be better) 2. Connecting rods Shortened, if we increase the volume connecting rods, then you can leave the original pistons, it all depends on the service life of the engine, if we sharpen then take new pistons) 3. Pistons (If we install original or 213 connecting rods)

Review of popular models of piston rings VAZ 2109 – 2115

There are many companies that produce piston rings, as well as many fakes, and there is simply not enough time to look through them all. Therefore, let's look at those manufacturers of piston rings that differ from others in normal quality and price. The first thing I want to recommend is SM piston rings.

Piston rings from SM

And

Piston rings from Mahle.

These companies produce piston rings for VAZ cars of various diameters and are perfect for us. They are most likely produced in China, because the original ones will cost much more. But this does not mean that everything is so bad, their quality is excellent. I still recommend rings from “SM”, because their price is much lower than that of “Mahle”, and the quality is the same, so why pay more and overpay for the brand.

The upper compression ring from these manufacturers is chrome-plated steel, but from the “SM” company it is copper-plated, this is clearly visible in the top photographs. The second compression ring is black and made of cast iron, but the ring from Mahle has a darker color. On the picture

The lower oil scraper rings are metal typesetting. The graphics on the left are “SM”, and on the right “Mahle”.

I recommend using metal oil scraper rings, because, unlike box-type rings, they fit perfectly in the cylinder, are resistant to overheating (they do not lose their spring properties) and their main advantage is that they work as two rings independent of each other. The rings are box-type, very afraid of overheating. When they overheat, they lose their spring properties and do their job poorly. And one more serious disadvantage: they require very careful running-in. At the slightest deviation from the running-in conditions, the working edges of the ring may break off in some places and allow oil to leak through.

Of course, there are other manufacturers of piston rings, but as usual they are complete fakes and sometimes it’s not possible to choose quality ones

VAZ 2109: when you need to replace the piston group

VAZ 2109 car engine

Plumes of bluish smoke coming from the exhaust pipe cause a lot of trouble for the driver. Often in this case it is necessary to repair the engine. This article suggests how to replace the entire piston on a VAZ 2109.

Features of the piston group of the VAZ 2109 car

Usually, after 150 thousand kilometers, visible wear occurs in the pistons group. It can be determined by some signs:

• Increased gas mileage.
• Reduction, less than 10 kgf/cm2, of engine compression.
• Increased oil consumption. 1000 kilometers are enough to reduce the oil level from maximum to minimum.
• Change in color of exhaust gases to a bluish tint.
• Oil consumption decreases slightly after replacing the oil seals. This suggests that diagnostics of the piston system and, if necessary, replacement of worn parts are necessary. The permissible wear of liners and pistons should not be more than 0.15 millimeters; in this case, you can only get by by replacing the piston rings.

You can replace the piston rings on a VAZ 2109 car without removing the engine from the car.

Tip: After installing other piston rings, the gasket located between the head and the cylinder block needs to be replaced. All other parts that fail are replaced with new ones during the assembly process.

How to disassemble the piston of a VAZ 2109 car

If the piston engine on a VAZ 2109 car fails, it must be replaced in an inspection pit or overpass. To work with your own hands you need: a set of keys, a special torque wrench, a mandrel with which the rings are crimped on the piston. Replacing a piston VAZ 2109, the video shows in detail the procedure for performing the work.

It is as follows:

• The battery, air filter for air purification, carburetor, ignition distribution sensor, and ventilation hose are pulled out.
• The lubricating fluid is drained from the engine sump.
• The sensor indicating the temperature of the cooling fluid is disconnected, the plug is unscrewed from the engine block and the antifreeze is drained.
• The “stove” is disconnected from the GB.
• The hose from the vacuum brake booster is removed from the intake manifold.
• The hoses are disconnected from the front pipes on the GB.
• The bolt holding the exhaust pipe to remove exhaust gases from the gearbox is unscrewed from the clamp, and the exhaust pipe is disconnected from the resonator pipe.
• The receiving pipe going to the manifold is disconnected from the engine.
• The upper and lower nuts securing the air intake are unscrewed. The latter also holds the front part of the shield, which protects the starter from the hot exhaust manifold.

Tip: You can simplify the removal and installation of the starter shield by removing the lower eye to secure it.

• The fasteners of the protective casing are unscrewed, it covers the camshaft drive belt.
• The belt tension is loosened. To do this, it is removed from the camshaft sprocket.
• The asterisk is removed.
• The back cover covering the belt is detached.
• The screws holding the head to the cylinder block are unscrewed.
• Having unscrewed all the bolts securing the cylinder head, the latter, after rocking, comes off from the cylinder head and is removed along with the gasket.
• The cover mounted on the clutch housing is released from the fastening and removed.
• The screws are unscrewed and the engine oil pan is removed.
• The oil receiver is pulled out from the pump housing to pump oil.
• The nuts of the connecting rod screws are unscrewed and the covers on the connecting rods are removed.
• With a light tap with the handle of a hammer, the piston with connecting rod and upper liner is pulled up.

Removing the piston and connecting rod from the cylinder

• In this way, all the engine pistons are pulled out.
• The connecting rod is clamped in a vice; the jaws on the vice are made of soft metal.
• Without applying much force, carefully use your fingers to open the locks on the piston rings, remove the compression rings, two in number, from the piston one by one.
• One oil scraper ring is removed.
• The oil scraper ring expander is pulled out.

Removing the Oil Ring Expander

How to change piston rings

Using old piston rings, the piston grooves are cleaned of carbon deposits. Before replacing the piston rings on a VAZ 2109, they need to be run in the piston grooves. If the rings bite, the parts must be ground in using fine-grain sandpaper. For convenience, it is placed on glass.

Tip: Pay special attention to the second compression ring. It is quite rigid, which means it is very fragile and can easily be broken.

You need to replace the VAZ 2109 piston rings after measuring the gap between the new piston ring and the groove wall with feeler gauges. The photo shows how this is done. There is a special instruction according to which the permissible gaps for rings in the piston grooves must be within the values ​​​​specified in the table.

Checking the gap

So:

• If the maximum permissible gap is exceeded, you will need to replace the piston rings on the VAZ 2109 yourself.
• The inscriptions “TOR” or “VAZ” should be at the top when installing the oil scraper and upper compression rings.
• The lower compression ring is oriented with the groove down.
• The rings are put on the piston in the following sequence:

1. the ring lock is moved apart to such an extent that the ring can be easily placed on the piston;
2. the ring lock is engaged on the piston;
3. The rear part of the part is installed.

Installation of new rings on the piston begins from the oil scraper ring expander. After installation, the expander lock ring must be rotated 180 degrees relative to the ring lock. After installing all the rings on the piston, they must be oriented so that the angle between the compression top ring lock and the piston pin installation axis is 45 degrees. The lock on the lower compression ring rotates 180 degrees, and the angle between the lock on the oil scraper ring and the lock on the upper compression ring should be 90 degrees.

So:

• If the ring installation technology is violated, the lubricating fluid can penetrate into the cylinder, which will lead to the formation of carbon deposits on the walls of the combustion chamber, smoke will come out of the muffler, and oil consumption will increase significantly. Rings can only be placed on the piston with special pliers or using a special device.
• When installing the unit, you need to lubricate the cylinder bore, rings and piston with high-quality motor oil.
• A mandrel is put on the piston, the rings are crimped with it, when self-installing the rings on the mandrel, you need to lightly tap the handle of a hammer.
• Inserts are installed in the bottom cover on the connecting rod. Before this, the beds in the connecting rod and in the cover for the liners are wiped dry.
• The crankshaft connecting rod journal and the surface inside the bearings are lubricated with high-quality engine oil.
• There is an arrow on the bottom of the piston, orienting it so that its direction is towards the crankshaft pulley, the piston is placed in the block sleeve.
• The piston must be recessed into the cylinder. The mandrel must be pressed against the block, and the bottom of the piston must be tapped with the handle of a hammer. At the same time, it is necessary to monitor the movement of the connecting rod towards the crankshaft journal.
• The cover is installed on the connecting rod, the nuts must be tightened with a torque of approximately 5 kgf/m.

How to break in a car after installing new piston rings:

• The car cannot be fully loaded.
• Change gears in a timely manner.
• Roads should not have long climbs.
• Constantly check the oil level.
• You can’t sit in traffic jams for a long time and accelerate sharply.
• The lubricating fluid and oil filter need to be changed after 1000 kilometers.

How to repair a piston VAZ 2109

If wear in the cylinders exceeds 0.15 millimeters, the cylinders need to be bored and the pistons and rings replaced to the following repair size:

• Replacement of a VAZ 2109 piston must be carried out taking into account the compliance of each piston class with a new piston ring.
• When choosing a ring, you need to pay attention to its markings:

1. if it is absent on the parts, then the product has nominal dimensions;
2. “40” - an increase of 0.4 millimeters in the diameter of the repair ring is marked;
3. “80” - corresponds to the marking of an increase in size by 0.8 millimeters.

Piston repairs in a BC are performed as follows:

• Cylinder wear is checked. Using a bore gauge, the diameter of the cylinder is measured in two directions—longitudinal and transverse—in four zones.

Measuring cylinder diameter with a bore gauge

• In the area of ​​the first belt there is practically no wear on the cylinder. Therefore, the amount of wear in the remaining belts of the part can be determined by the difference in diameters between this cylinder belt and the others.

Cylinder wear control belts

• If the amount of wear is more than 0.15 millimeters, the cylinders are bored to the closest repair size. It should be taken into account that the final operation for processing the cylinder is honing. Therefore, it is necessary to leave an allowance for processing of a diameter of 0.03 millimeters.
• After the final operation, the repair size of the piston and the diameter of the cylinder differed in the range of 0.025 - 0.045 millimeters.
• A new piston is installed.

Tip: The caps on the connecting rod are not interchangeable. The connecting rod cover and the part indicate the number of the cylinder where the connecting rod can be installed. When replacing a VAZ 2109 piston, the numbers on the connecting rod should be located on one side.

• In the same way, all remaining pistons on the VAZ 2109 are replaced.
• The engine is assembled in the reverse order of disassembly after the last piston is installed.

The replacement of VAZ 2109 pistons is well shown in the video.

How to properly break in an engine after replacing a piston

Proper running-in of the car is of great importance after the entire piston engine on the VAZ 2109 has been replaced. This must be treated very carefully, as well as repairs. Particular attention should be paid to those units in which the parts are connected to each other by friction, and the efficiency depends on the optimal clearances with which they should be adjacent to each other.

So:

• The speed of the car, after installing new pistons, should not exceed more than 60 kilometers in one hour per 1000 kilometers. This is necessary for grinding in parts that rub against each other.
• The main purpose of running in is to smooth out all micro-irregularities. This occurs by friction between the parts until their complete fit is ensured. Increased heating of engine parts occurs when there is high friction during “grinding in.”
• This indicates that the engine should operate with gentle, minimal loads.

Compliance with all these rules, after replacing the piston on a VAZ 2109, will ensure the use of the car in good condition for a long time.