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Service

information
SI 0010
 1/4

Pistons with Reduced Compression Height


What Does Compression
Height Mean?
The compression height is the
dimension between the piston
head and the centreline of the
piston pin (Fig. 1). This is a significant measurement when overhauling engines as it ensures that
the piston is positioned at the correct distance from the cylinder
head at the top dead centre, so
optimising the combustion process.
MSI have an extensive range of
pistons with reduced compression
height to facilitate professional
engine reconditioning. A table of
the fast moving parts is shown on
pages 3 and 4. Details are provided in the latest KS Catalogue
Pistons/Cylinders/Kit Sets.

Fig. 1

Why Pistons with Reduced


Compression Height?

MSI Motor Service International GmbH -0705-EN

Compression and Piston


Protrusion
Diesel engines have a much higher
compression than petrol engines
due to their structure. In order to
achieve this high compression, the
clearance - i.e. the distance between the cylinder head and the
piston top dead centre - should be
as small as possible. When designing the engines, the desired compression is achieved by allowing
the piston to protrude a certain
distance beyond the face of the
engine block in the top dead centre. This is then referred to as piston protrusion (dimension C in

Fig. 3

Fig. 2). In spite of this protrusion,


the piston does not hit against the
cylinder head because the cylinder
head gasket also has a specific
material thickness and the clearance between the piston and the
cylinder head is still maintained.
Figure 3 shows how the piston
protrusion is measured.

Pistons with reduced compression


height are always necessary
whenever the sealing surface of
the cylinder block on diesel
engines, especially truck engines,
is refinished in the course of overhauling the cylinder block. This
work reduces the distance from
the sealing surface to the crankshaft. The piston height must
consequently be reduced by the
same amount that was removed
by the remachining work on the
cylinder block.
If a piston with a standard compression height is still used
despite this work on the surface
of the cylinder block, the clearance between the piston and the
cylinder head is frequently no
longer warranted in the top dead
centre. As long as the engine is
still cold, the clearance is often
sufficient, so that when the engine
is turned by hand the piston does
not necessarily hit against the

Fig. 2
MSI Motor Service International GmbH
Untere Neckarstrae
D-74172 Neckarsulm

Phone +49-71 32-33-33 33


Fax
+49-71 32-33-28 64
info@msi-motor-service.com

www.msi-motor-service.com

Service
information
SI 0010
 2/4
cylinder head. At operating
temperature, however, the piston
becomes longer due to the natural
thermal expansion of the material,
thus reducing the clearance and
causing the piston to strike

against the cylinder head when


the engine is running. The vibrations also affect the injection nozzles. The result is that the nozzles
cannot withstand the pressure
and the fuel injection is no longer

controlled. Consequence of this is


an abnormal combustion with
severe damage to the piston and/
or fuel overflow, increased piston
ring and cylinder wear, and high oil
consumption.

Machining the Piston Head


to Size
is a method that is still widely
used to adapt the compression
height of a standard piston to the
special requirements of engine
reconditioning. At the same time,
however, machining the piston
head to size alters the geometry
and the volume of the combustion
bowl and of the valve pockets.
This frequently causes problems
affecting the free running of
components and the compression.
New engines that are subjected to
stringent exhaust gas ratings for
the purpose of observing national
and international emission regulations react very sensitively to
even minor alterations in the
shape of the combustion space.
Increased pollutant emissions,
higher fuel consumption and
unsatisfactory engine performance are the results. The reason
for this is that the shape and
injection angle of the injection
nozzles are structurally coordinated with utmost precision to the
geometry of the combustion bowl.
The injection nozzle, the piston
prechamber and the compression
together constitute a combustion
system, as it were. By altering
this system, the correct
function - that has been harmonised in the course of endless
tests and series of processes - is
questionable. Piston damage
frequently occurs in such a case
because, once the piston has

Fig. 4

been machined to size, the jet of


injected fuel hits against the edge
of the combustion bowl that is
subjected to higher heat stress.
Pistons with Anodised Piston
Heads
are utilised to enhance thermal
resistance (Fig. 4). In the course
of machining the piston head to
size, the anodic layer is partly or
completely machined off and the
piston no longer has the necessary strength and heat resistance
to rule out cracking. Pistons with
anodised piston heads can be
identified in the KS Piston Catalogue by Lox in Column 4.

Attention:
For the above reasons,
we urgently advise
against conducting resurfacing
work on the piston. MSI reject all
liability, in particular where the
liability for defects is concerned,
for damage arising as a result of
piston modifications.

Service
information
SI 0010
 3/4

KH

77,30 -0,2 mm D 0226 MC, -MCE, -MCFO, -MK, -MKE, -MKF, -MKFA, MKFO, -MKH, -ML, -MLE, -MT, -MTE, -MTE 51, -MTXE
77,10 -0,4 mm 51,

MAN

102

93 721 600

MAN

102

93 722 600

MAN

108

91 075 600

72,70 -0,2 mm D 0824 GF, -GF 01, -GF 02, D 0826 F, -F 01, -F 02, -FO, FO 01, -FO 02, -FR, -FR 01, -FR 02, -GF, -GF 01, -GF 02, GF 03, -GF 04, -GFA, -GFA 03, -GFA 04, -OH 01, -OH 02,
-OH 03,

MAN

108

93 138 600

72,80 -0,2 mm D 0826 LE 51, -LE 52, -LFL 10, -LUE, -LUE 130, -LUE 160,
-LUE 51, -LUE 52, -TUE 51,

MAN

108

94 413 600

MAN

108

94 414 600

MAN

108

94 415 600

MAN
MAN
MAN

108
108
121

90 049 600
90 050 600
92 988 600

72,80 -0,2 mm D 0824 LF 01, -LFL 01, -LFL 05,


D 0826 LE 10, -LF 01, -LF 02, -LF 04, -LF 05, -LF 06, -LF
72,60 -0,4 mm 07, -LF 08, -LFL, -LFL 01, -LFL 02, -LFL 05, -LFL 06, -LOH
72,40 -0,6 mm 06, -LUH 01, -LUH 02, -LUH 03, -LUH 04, -LUH 05, -LUH
06, -LUH 10,
75,20 -0,2 mm D 0826 K, -LF217, -LOH 01, -T, -TF, -TOH 01,
75,00 -0,4 mm
93,60 -0,4 mm D 2156 6 U, -HM 2, -HM 3, -HM 6, -HM 9, -HMN 3, -HMN
6, -HMN 8, -HMN 9, -HNY, -MGN, -MNY, -MY, -MYN,

MAN

125

92 994 600

MAN

125

92 995 600

MAN

125

93 275 600

MAN

125

93 329 600

MAN

125

93 405 600

MAN

125

93 553 600

MAN

125

93 554 600

MAN
MAN
MAN
MAN
MAN

128
128
128
128
128

90 336 600
90 337 600
90 482 600
90 342 600
90 584 600

89,60
89,40
89,20
89,67
89,55

-0,2 mm
-0,4 mm
-0,6 mm
-0,2 mm
-0,2 mm

D 2866 FZ, -KF, -KFZ, -KOH, -KU, -KUH, -KUL, -LF, -LFZ, LU, -LUH, -LUL, -LULK, -LXF, -T, -TOH, -TU, -TUH, -TUH
01,

Mercedes-Benz
Mercedes-Benz
Mercedes-Benz
Mercedes-Benz
Mercedes-Benz
Mercedes-Benz

87
87
87
89
89
89

94 674 600
94 674 610
94 674 620
94 675 600
94 675 610
94 675 620

44,65
44,65
44,65
44,45
44,45
44,45

-0,2 mm
-0,2 mm
-0,2 mm
-0,2 mm
-0,2 mm
-0,2 mm

OM 601.911, -912, -913, OM 602.911, -912, -930, -931, 938, -939, -990, OM 603.912, -913, -931,

89,67 -0,2 mm D 2565 HM, -M, -MF, -MFR, -MH, -MR, -MUE, -MUH, MUL,
89,47 -0,4 mm D 2566 HM, -M, -ME, -MF, -MFO, -MFR, -MH, -MHO, MUE, -MUH, -MUL, -MUM, -MXF,
89,60 -0,2 mm D 2565 MK, -MKUL, -MT,
D 2566 KUL, -MFT, -MK, -MKE, -MKF, -MKUH, -MKUL, 89,40 -0,4 mm
MLE, -MLUH, -MLUM, -MT, -MTE, -MTF, -MTH, -MTHO, 89,20 -0,6 mm MTU, -MTUE, -MTUH, -MTUM,
89,67 -0,2 mm D 2565 HM, -M, -ME, -MF, -MFR, -MH, -MR, -MUE, -MUH,
-MUL,
89,47 -0,4 mm D 2566 M, -ME, -MF, -MFO, -MFR, -MH, -MHO, -MUE, MUH, -MUM, -MXF,

D 2866 E 20, -F, -FOH, -OH, -U, -UE, -UH, -UM,


D 2865 LF, -LF 02, -LF 03, -LF 04, -LF 05, -LF 06, -LF 10, LF 14, -LF 15, -LOH, -LU 01, -LU 02, -LU 03, -LU 04, -LU
06, -LUH 02,
D 2866 KF 09, -LF 02, -LF 03, -LF 04, -LF 05, -LF 06, -LF
07, -LF 09, -LF 10, -LF 15, -LFG, -LOH 02, -LOH 20, -LOH
21, -LOH 22, -LOH 23, -LOH 24, -LOH 25, -LOH 26, -LOH
30, -LOH 31, -LU 01, -LU 03, -LU 04, -LU 05, -LU 09, -LX, LXE 30, -LXFG, -LXOH, -LXU, -LXUH,

OM 601.900-000, -940, -941, -942, -943, OM 602.900-000, 940, -941, -942, -946, -947, -948, -991, -994, -995, OM
661.911, OM 662.911,

*Non-binding extract from our catalogue; for details of the correct use and allocation of components, please refer to the latest KS Catalogue Pistons / Cylinders / Kit Sets

Service
information
SI 0010
 4/4

KH

62,50 -0,3 mm OM 304.900-001, -010, -401, -410, -016, -017, -018, -413, 414, -415, -416, -417, -510, OM 356.940, -984, -985, OM
62,50 -0,3 mm 364.901/-400, -500, -950, -951, -952, -954, -980, -981, 62,20 -0,6 mm 984, -901/-400, OM 366.901/-500, -540, -541, OM 366.944,
-945, -946, -947, -948, -949, -951, -952, -953, -954, -955, 9 8 960
962
963
96-905,
966
96-907,
968
969
OM 356.901,
-902,
-903,
-904,
-906,
-908,
-909,
62,50 -0,3 mm 9

Mercedes-Benz

97,5

90 532 600

Mercedes-Benz

97,5

90 532 610

Mercedes-Benz

97,5

90 533 600

Mercedes-Benz

97,5

91 551 610

Mercedes-Benz

97,5

93 964 600

Mercedes-Benz

97,5

93 964 610

Mercedes-Benz

125

94 656 600

87,15 -0,3 mm OM 401.901-504, -970, -972, -973, -974, -975, -976, -977, 978, -979, -980, -981, -984, -985, -986, -987, -988, -989, 990, -991, -993, -994,
OM 402.901/-504, -970, -971, -972, -973, -974, -975, -976, 977, -978, -980, -981, -982, -983, -984, -985, -986, -987, 988, -989, -990, -991, -992, -995, -996,

Mercedes-Benz

128

91 597 600

89,70 -0,3 mm OM 447.900/-000, -901/-200, -905, -906, -907, -908, -910, 911, -912, OM 475.907-505, -907-506, -950, -951, -952, 953, -954, -982, OM 485.980,

Mercedes-Benz

128

91 622 600

89,55 -0,3 mm OM 427.902/-400, -500, -903/-600, -905, -950, -951, -952,


OM 429.951, -952, -953, -955,
OM 447.902, -902-400, -902-500, -902-520, -902-521, 903/-600, -903-705, -950, -951, -952, -953,

Mercedes-Benz

128

91 630 600

81,05 -0,3 mm OM 441.901, -901/-400, -901-500, -901-505, -901-520, 901-530, -950, -951, -953, -955, -960, -961, -962, -981, 982, -983, -985,
OM 442.901/-400, -901-500, -901-501, -901-502, -941, 942, -943, -944, -945, -946, -950, -951, -952, -953, -954, 955, -957, -958, -959, -960, -961, -962, -963, -964, -965, 966, -967, -968, -969-502, -969-503, -971, -972, -974, -975,
-976, -980, -982, -983, -985, -989, -991, -992, -993, -994,
OM 443.901/-400, -901-500, -940, -980,
OM 444.901/-400, -901-500,

Mercedes-Benz

128

94 516 600

81,05 -0,3 mm OM 441.901/-400, -901-500, -901-505, -901-520, -950, 951, -953, -955, -960, -961, -962, -981, -982, -983, -985,
OM 442.901/-400, -901-404, -901-500, -901-501, -901-502,
-901-505, -901-506, -901-520, -941, -942, -943, -944, -945,
-946, -950, -951, -952, -953, -954, -955, -957, -959, -960, 961, -962, -963, -964, -965, -966, -968, -971, -972, -974, 975, -976, -980, -982, -983, -985, -989, -991, -992, -993, 994, OM 443.901/-400, -901-500, -940, -980, OM 444.901/400, -500,

Mercedes-Benz

128

94 655 600

81,15 -0,3 mm OM 440.940, -941, -942, -945, -978, -979, OM 441.990,

Mercedes-Benz

130

91 621 600

81,05 -0,3 mm OM 440.909, -910, -911, OM 441.900/-000, -905, -906, 907, -908, -909, -911, -912, -913, -914, -915, -916, -917, 918, -919, -920, -921, -923, -924, -925, -926, -927,
OM 442.900/-000, -905, -906, -907, -908, -909, -910, -911, 914, -915, -916, -917, -918, -919, -920, -921, -922, -923, 924, -925, -926, -927, -928, -929, -930, -932, -933, -934, 935, -939, OM 443.900/-000, -905,

-910, -911, -912, -914, -915, -916, OM 364.900-004, -918, 919, -920, -921, OM 366.900-004, -911, -915,

62,50 -0,3 mm OM 356.913, OM 364.900/-000, -900-040, -906, -907, -908,


-909, -911, -912, -913, OM 366.900/-000, -905, -906, -907, 908, -909, -910, -912, -913, -914, -917, -918, -919, -930, 62,50 -0,3 mm 931, -932, -933, -935, -936, -939, OM 370.905, -952, OM
372.906, -907, -930,

*Non-binding extract from our catalogue; for details of the correct use and allocation of components, please refer to the latest KS Catalogue Pistons / Cylinders / Kit Sets