Installing Piston and Cylinder Assemblies: A Step-by-Step Guide

With your short block complete and ARP head studs installed, the next step is assembling and installing your pistons and cylinders. This process is critical for ensuring proper deck height and a reliable engine build. Our latest YouTube video walks you through this procedure. Below is a detailed guide to help you achieve success.

Step 1: Check and Adjust Deck Height

Deck height—the distance from the piston crown to the top of the cylinder—is a crucial measurement. Follow these steps to check and adjust it:

1. Temporary Assembly:

   • Install one piston and cylinder assembly without sealant, base shims, or gaskets.
   • Push the piston through the cylinder to expose the wrist pin bore.
   • Optionally, pre-install the wrist pin into one piston boss for easier alignment.

2. Align with the Connecting Rod:

   • Slide the assembly onto the engine and line up the piston with the connecting rod.
   • Lubricate and insert the wrist pin through the rod, but do not install the wrist pin clip yet. This assembly will be removed later.

3. Measure Deck Height:

   • Rotate the engine to bring the piston to top dead center (TDC). Hand-feed the timing chains to prevent them from binding.
   • Measure the deck height using a specialized deck height tool or a dial/digital caliper.
   • Target Deck Height: 1 to 1.5 mm. If it is less than 1 mm, base shims will be required.

4. Select Base Shims:

• LN Engineering offers copper base shims in 0.25 mm, 0.5 mm, 0.75 mm, and 1 mm thicknesses. Choose the correct thickness to achieve the desired deck height.

Step 2: Prepare for Final Assembly

1. Disassemble and Clean:

   • Remove the piston and cylinder assembly.
   • Clean the cylinder base and case deck using denatured alcohol and Kimwipes to ensure a spotless surface.

2. Apply Sealant:

• Use a non-hardening sealant on the cylinder base. If using base shims or gaskets, apply sealant to both sides.
• Recommended Sealants:
• Elring Curil T (used in this guide)
• Curil K2
• Dow Corning 730 (top pick by most engine builders, but $$$)

Step 3: Final Assembly

1. Install the Assembly:

   • Slide the cleaned Porsche piston and cylinder assembly back onto the engine, aligning the wrist pin bore with the connecting rod.
   • Insert the wrist pin into place and install the second wrist pin clip.

2. Secure the Clips:

   • Before installing the second clip, cover all openings in the engine case to prevent accidental loss of the clip inside the engine.
   • Verify that both sides of the piston have wrist pin clips installed securely.

3. Seat the Cylinder:

• Push the cylinder firmly onto the engine case. Use a Porsche cylinder hold-down nut to secure the assembly until the heads are fitted.

Step 4: Repeat for Remaining Assemblies

Repeat the process for all remaining piston and cylinder assemblies before proceeding to install your Porsche cylinder heads.

Tips for Success

• Take Accurate Measurements: Proper deck height ensures optimal engine performance and prevents damage.
• Handle Clips Carefully: Wrist pin clips can easily eject during installation. Always work with caution and keep spares on hand.
• Use High-Quality Tools and Materials: Proper tools and sealants make the process smoother and more reliable.

For a detailed demonstration of this process, check out our video: Installing Piston and Cylinder Assemblies. If you have any questions or need further guidance, leave a comment—we’re here to help.

Watch the Video Now!