Piston Installation Process


Tools Required

  1. Locating Clamp
  2. Sealing Device
  3. Guide Tube/Extension Tube
  4. Piston ring inserting bush
  5. Lifting tool
  6. Protection cap
  7. Screw tap M16
  8. Lifting gear with rope and shackle

Starting positions

Piston has been cleaned, inspected, overhauled if necessary, assembled with conrod head. Protection cap have been fitted over the cylinder head studs. Cylinder liner has been cleaned, connecting rod is in exactly BDC position.
thrust ring attachment process
piston installation process
Sequence of operation


  1. Screw lifting tool into the piston and secure it with rope to the lifting gear.
  2. Oil the piston ring and the running surface of the piston with clear lubricaging oil.
  3. Arrange positions of piston rung end gaps for rings Nos.1-4 to be towards the control/timing side (ST) and in accordance with the draft.
  4. Oil instrument bush on inside and place it on the cylinder liner (remove covering beforehand).
  5. Screw guide and extension tubes onto the two central connecting rod bolts.
  6. Move piston, suspended from lifting gear, over the cylinder and lower it cautiously into the cylinder liner, guiding the piston until the piston skirt enters the liner.
    Note: Turn the piston until the marking (ST) on the piston upper surface comes to lie on the control/timing side of engine.
  7. Carefully continue in lowering the piston while the piston rings are sliding from through the insertion bush into the cylinder liner. Align the conrod head in the time to that the extens-tubes are pointing to the corresponding boreholes in the connecting rod.
  8. Detach guide tubes before they completely enter the boreholes in the connecting rod, and carefully resume lowering the piston until it is seated. When doing so, pay attention to the locating pins (2 pins) in the joint face. In order to ease insertion, the locating clamp may be slightly slackened.
  9. Fit thrust ring (2-parts) and nuts over the connecting rod bolts.
  10. Detach locating clamp and preload the connecting rod bolts.
  11. Turn piston to TDC position and remove insertion bush and lifting tool.

Note: Seal up lube oil passage bore in the conrod shank against ingression of dirty, using suitable means.

Incase switching-on the lube oil pump is required, the lube oil passage bore is to be sealed up by means of the sealing device.

VIEW WHOLE PROCESS IN PHOTOS



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