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Fitting Pistons

  1. With piston removed and disassembled from connecting rod, measure diameter of piston. Measure with micrometer positioned at correct distance down from bottom of skirt on piston (see Fig 1). Distance A is different, depending on manufacturer.
    Fig 1: Piston Diameter Measurement
    G09325560Courtesy of BMW OF NORTH AMERICA, INC.
    PISTON MEASURING DISTANCE

    Application 2500 cc Engine In. (mm) 2800 cc Engine In. (mm)
    Mahle Pistons 81 (20.5) .58 (14.7)
    KS Pistons 1.03 (26.25) .95 (24.05)
  2. Measure inside diameter of bore in crankcase. If clearance exceeds specification, crankcase bore must be bored for next oversize piston. Pistons are available in 0.010" and 0.020" oversize.
  3. Check piston ring side clearance and end gap. If new rings are installed, install with word "TOP" stamped in ring toward top of piston.
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