- Service Bulletin - Pistons.
Normal combustion: is smooth and even from the spark
plug through the top of the chamber.
1 2 3
Spark occurs Combustion moves Combustion and
smoothly across power completed
chamber
- Service Bulletin - Pistons.
Pre-Ignition: occurs
when the fuel/air mixture is 1 2
ignited early by hot carbon
deposits. Advanced ignition
timing is also a cause of pre-
ignition and will result
engine component damage.
Ignition occurs from Spark plug ignites
hot deposit.
3
Flame fronts collide
- Service Bulletin - Pistons.
Detonation- occurs
1 2
when a second flame front
moves across the cylinder.
This generally occurs after
the spark plug fires and
when the piston is not in Combustion begins at
Spark occurs
the correct position for spark plug, spontaneous
maximum power. combustion begins
elsewhere.
Flame fronts
collide
- Service Bulletin - Pistons.
Diagonal Skirt Contact:
Appearance:
Non-symmetric contact/wear pattern on
piston skirt.
Cause:
Bent connecting rod.
Misaligned small end bush.
Excessive crankshaft end float.
Symptom:
Oil consumption/noise.
Remedy:
Check connecting rod and small end
for misalignment & rectify fault.
Check crankshaft end float & rectify.
- Service Bulletin - Pistons.
Gudgeon Pin Seizure:
Appearance:
Seized gudgeon pin.
Surface of pin and pin hole surface
Cause:
Lack of lubrication, possibly during
initial start-up (after re-build).
Tight small end bush
Symptom:
Engine noise
Remedy:
Replace damaged components. Ensure
gudgeon pin has correct clearance in the small
end bush, or if the pin is anchored in the
connecting rod, ensure that the piston is free
to articulate about the gudgeon pin. Ensure
adequate lubrication of piston and pin. Avoid
lengthy periods of low engine speed in the
running in period.
- Service Bulletin - Pistons.
Hole burned through crown:
Findings:
Hole in piston crown. Crown edge locally
burnt or molten.
Cause:
Detonation. Pre-ignition. Incorrect combustion
Symptom:
Engine noise. „Pinking“. Loss of power
Remedy:
Check spark plugs and ignition setting.
Ensure correct carburation or fuel injection.
Ensure that no air leaks exist in the induction
system. Use only correct fuel as specified
by the engine manufacturer
- Service Bulletin - Pistons.
Indentations on piston crown
Appearance:
Indentations on piston crown. Possible
fracture and/or distorted and seized top land.
Cause:
Foreign matter entering combustion chamber
and becoming trapped between piston and
cylinder head
Symptom:
Engine noise.
Remedy:
Ensure no other matter trapped in induction
system. Check and correct any damage to
cylinder head, valves, connecting rod and
bearings. Check induction and air filtration
system for leaks and correct any damage.
Replace damaged components.
- Service Bulletin - Pistons.
Abrasive Particle Damage:
Appearance:
Vertical scratching or scuffing of piston
skirt.
Piston rings and cylinder bore may also be
damaged by vertical scratching.
Cause:
Abrasive matter in engine
Symptom:
Oil consumption
Remedy:
Clean and inspect all engine components.
Clean all oil-ways.Ensure that air and oil
filters are clean and fitted with correct
filter elements.
Check integrity of all connection between
air filter and engine. All damaged components
should be replaced.
- Service Bulletin - Pistons.
Piston - Ring Land Fracture:
Cause - petrol engines: excessive combustion
chamber pressure, Over-advanced ignition setting,
Increased compression ratio, Detonation.
Cause - diesel engines: Irregular combustion
pressure due to: Start of delivery too early,
Injector nozzle defective / broken, fuel Cetane value
too low, causing extreme delay of start of ignition,
Compression ratio too high,
excessive use of aerosol
starting aid.
Symptoms:
Oil consumption, loss of power,
engine noise, excessive blow-by
Remedy:
Establish cause and correct.
Replace damaged components.
- Service Bulletin - Pistons.
Skirt Erosion at Gudgeon Pin Hole:
Appearance:
Erosion of piston skirt adjacent to piston pin
hole. The material sometimes appears to
have melted. Damage to cylinder bore.
Cause:
Foreign matter assembled with piston in pin
bore. Used circlips refitted. Incorrect fitting of
circlips. End thrust transmitted via the piston
pin from misaligned connecting rod or
crankshaft end float.
Symptom:
Engine noise. Oil consumption
Remedy:
Correct any cylinder bore damage. Check for
and correct any connecting rod misalignment
or excessive crankshaft end float. Replace
piston assembly ensuring that all circlips are
correctly located.
- Service Bulletin - Pistons.
Skirt Cracked or Broken
Appearance:
Cracks / break-outs on piston skirt.
Cause:
Mechanic impact prior to installation.
Contact to crankshaft balancer.
Cylinder bore distorsion.
Foreign object in crank drive.
Symptom:
Engine noise.
Remedy:
Check functional length of connecting rod.
Check dimensions of crankshaft.
Check piston skirt length.
Check cylinder bore.
Inspect engine for foreign objects.
Replace all damaged components.
- Service Bulletin - Pistons.
Overheated Piston Crown:
Appearance:
Top land seized. Consequential seizure
down to skirt possible.
Piston rings damaged, trapped in ring grooves
Cause:
Overheating of piston crown due to:
Exceptionally high combustion temperatures,
Malfunction of piston cooling system.
Symptom:
Oil consumption, Engine noise, Loss of power
Remedy:
Check adjustment of fuel injection equipment
and correct as necessary.
Check piston cooling system.
Rectify or replace all damaged cylinder
components.
- Service Bulletin - Pistons.
Skirt Seizure on Thrust - Side:
Appearance:
Seizure or scuffing on piston skirt thrust face.
Non-thrust face remains relatively undamaged.
Cause:
Oil starvation, possibly during initial use.
Oil dilution by fuel or water. Oil spray nozzle
on connecting rod clocked or misaligned.
BE bearing shell without oil hole installed.
Symptom:
Engine noise. Some power loss.
Remedy:
Check lubrication system and cylinder bore
and correct as necessary. Replace damaged
components. Check function and alignment of
spray nozzles on connecting rods.
Check engine for internal coolant leakage.
Check injection and timing.
Ensure all components of the engine lubrication
system are fully primed before starting the engine.
- Service Bulletin - Pistons.
Skirt Seizure on Thrust & Non-Thrust Sides:
Appearance: seizure or scuffing on thrust side and
anti-thrust side of piston skirt.
Cause: progression of damage caused by lack of
lubrication.
Insufficient piston to cylinder clearance.
Cylinder bore distorsion.
In cases where all pistons in the engine are
affected the cause is usually: General engine
overheating.
Symptoms: engine noise. Loss of power.
Fumes from engine breather.
Remedy: check cylinder bore and coolant circulation
and correct as necessary.
Replace damaged cylinder components.
- Service Bulletin - Pistons.
Erosion of Piston Material from Crown:
Appearance: crown or bowl edges locally
burnt/eroded.
Extreme: Hole in pston crown.
Cause: irregular „knocking“ combustion due to:
Start of delivery too early / too late.
Injector nozzle defective / broken.
Fuel Cetane value too low.
Compression ratio too low.
Symptom: engine noise. „Knocking“ under load.
Loss of power.
Remedy: check setting of injection system.
Inspect injector nozzles.
Replace all damaged components.
Use only correct fuel as specified by the
engine manufacturer
- Service Bulletin - Pistons.
Piston Rings Trapped in their Grooves:
Appearance:
Piston rings trapped in their grooves by
carbon build-up.
Scuffing/wear of piston ring outer surface.
Symptoms:
Oil consumption, Loss of power,
piston & ring seizure.
Cause:
Excessive combustion temperatures.
Oil in combustion chamber.
Remedy:
Ensure valves, valve guides and valve stem oil
seals (where fitted) are in good order and
free from wear. Check engine oil quality &
quantity and replace damaged components.
- Service Bulletin - Pistons.
Burnt Piston Ring Surfaces:
Appearance: running surfaces of piston rings
scuffed or burnt.
Scuffing or seizure marks on ring lands.
Cause: lack of lubrication on liner surface.
Oil level in engine too low..
Oil spray nozzles not aligned, blocked or
missing.
Oil controlling of ring set too aggressive.
Injector nozzle defective or broken.
Fuel delivery too early or too late.
Symptom: loss of power. Oil consumption.
Remedy: check lubrication of liner.
Ensure correct oil volume in the engine.
Check correctness of ring set type and correct
positioning of the individual piston rings.
Check injector nozzles/setting of injection
system. Replace damaged components.
