ProductsLight VehiclePistons

Genuine MAHLE replacement pistons are ready for installation. The piston pins and circlips (if required) are protected against corrosion and by-packed to the pistons. Some pistons are supplied with rings.

The piston pins are selected according to the appropriate fit and are interchangeable within the piston type. In some cases, however, the pistons and pins are color-coded and these must not be replaced at all by differently marked parts.

Assembly of the piston and pin with a shrink fit in the con-rod calls for particular care. It is of particular importance that the pin floats in the pin bore after assembly.

The piston rings were fitted with the utmost care, sometimes by means of a ring fitting machine. Unnecessary removal and refitting with an excessive ring gap causes permanent deformation and impairs the running characteristic.

Before assembly, the con-rod bores must be checked for axial parallelism (deformation or distortion), and be aligned or replaced, if necessary. The engine components - cylinder block, crankshaft, con-rods and oil sump - must be carefully cleaned before assembly to remove machining residues and deposits.

The correct direction of installation must be observed when fitting the piston. The individual ring gaps should be distributed evenly around the circumference. The circlip must be fitted in such a way that the gap is at the top or bottom. The cylinder bore or piston and rings should be lubricated. Force must not be used (e.g. knocking the components into place).

Care should be taken that the cylinder head gasket, as well as air, fuel and oil filters are used according to the type of series production. In order to prevent cylinder distortion, the cylinder head bolts must be tightened to the torque or with the angle of rotation specified by the engine manufacturer.

After adding the coolant, vent the cooling system. Run the engine briefly and then check the oil pressure and oil level (Note: distribution of oil in filter and heat exchanger).

During the short running-in, the engine must operate solely under its own power without the aid of any external source. The speed should preferably be around 1.5 time idle speed. The engine should then be operated at no more than around 3/4 of its rated output and rated speed during its initial running period. It is preferred that RPM is not held constant, but varied from time to time. The prescribed oil and filter change intervals must be observed.

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