Cylinder Clearance

Joker757

Petty Officer 2nd Class
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May 13, 2009
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This is my first engine rebuild so forgive me if I seem to be asking rookie questions. Can someone please confirm that I'm measuring my piston clearance correctly?

  1. Measure skirt of cylinder with micrometer
  2. zero bore gauge to the mirometer
  3. use bore gauge to determine difference between piston and bore
  4. divide this number by 2

Engine is 99 Merc 7.4L MPI. Using this method my clearance is about .0021

Thanks
 

LAC_STS

Master Chief Petty Officer
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Jul 1, 2010
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Re: Cylinder Clearance

I just went through this my first time too.

For purposes of piston-to-wall clearance you measure the piston where the pin is. Then you mic the cyl bore at 90* angles. (like top to bottom then side to side) Then measure at the top and the bottom of the cyl bore.


Has a machine shop already bored or honed it?
 

Joker757

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Re: Cylinder Clearance

not yet but it's obviously been bored by the PO. Factory spec for the cylinders is 4.25" My pistons are 4.3" I followed the procedure like you outlined above. I get about a .0042 difference. From the markings on the piston they are .040 oversized. Do I divide the .0042 by 2? My reason is that this will be the clearance on oposite sides of the piston once it's centered in the cylinder. If not then I'm way out of spec as the manual calls for .0030 p/w max.
 

LAC_STS

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Re: Cylinder Clearance

not yet but it's obviously been bored by the PO.

Yea but when was that? Last time it was rebuilt? Unless its been freshly mic'd and bored or honed since its been taken apart, then it needs to go to the machine shop. It will need at least honed. You could do the honing but you'd be better off your first time using the machine shops services.

Did you mic the bores like I said except to check for taper? Thats how you determine if the bores need bored. I forget the exact spec but I think its if the taper is more than 3 thou it needs bored over.

Also what pistons are you using? Speed Pro pistons with the coated skirt like I have adds a thou to the pistons size. They come with instructions on how to take that into account when measuring.


But we need more info on this.


Where did you get this block? Was it in service and now your rebuilding it? If the engine was not running what happened to it? Knocking?


I dont know what all you know about all this but usually a rebuild entails having the block bored or honed, crank polished or cut, mains checked/aligned, heads refurbished (valve job etc), block checked for cracks and cleaned.


Theres alot of things that NEED done if you want even a chance of being successful.

Maybe you should start off by telling us what you have/haven't done.
 

E4ODnut

Seaman
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Aug 11, 2010
Messages
69
Re: Cylinder Clearance

not yet but it's obviously been bored by the PO. Factory spec for the cylinders is 4.25" My pistons are 4.3" I followed the procedure like you outlined above. I get about a .0042 difference. From the markings on the piston they are .040 oversized. Do I divide the .0042 by 2? My reason is that this will be the clearance on oposite sides of the piston once it's centered in the cylinder. If not then I'm way out of spec as the manual calls for .0030 p/w max.

I did some research on this. The consensus seems to be that the piston to wall clearance is simply the difference between the piston diameter and the bore diameter. It does not assume that the piston is in the centre of the bore, so you do not take the difference and divide by 2. Not a lot of clearance, but it makes sense to me. I stand to be corrected.

Hope this helps.
 

Joker757

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Re: Cylinder Clearance

The engine was a rebuild with less than 100hrs on it. Was running however the the head needed some work (stuck valve). The head has been bebuilt by a machine shop. Given that I had the engine out and heads off I decided to tear it down to make sure all was in order before it goes back in. I'm taking the the block, cam and crank to the shop next week to be cleaned and have the journals polished. There wasn't even a ridge on the cylinders. Bearings were in okay shape however given that I've got it broken down this far I ordered new main, cam and rod bearings. The machine shop is going to install the new cam bearings. Rod and main bearings are .010 oversized. Pistons are Sealed Power H727CP040. I was thinking to get the cylinders honed however I'm not sure if that would require new pistons and rings.
 

Joker757

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Re: Cylinder Clearance

So I recalibrated the bore gauge and took the measurements again. Results are:

Piston - 4.290
Cylinder - 4.292

Given this the p/w is .0020

From what I've been reading p/w clearance also dependent on piston make/model and application. I can find the specs on the piston but it doesn't list the recommended p/w clearance. Piston is Sealed Power H727CB040.
 

LAC_STS

Master Chief Petty Officer
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Re: Cylinder Clearance

Id say your good to go at 2 thou ( .002)
 

Joker757

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Re: Cylinder Clearance

if I get the cylinders honed will I need new pistons/rings?
 

Bondo

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Re: Cylinder Clearance

if I get the cylinders honed will I need new pistons/rings?

Ayuh,... Rings are Wear points,... Throw-away items,...
Like gaskets....

Pistons have to fit the bore,...
If honing causes Out of Spec,...
Then you'd need new pistons to match the overbore to the next size pistons...
 

Joker757

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Re: Cylinder Clearance

Ayuh,... Rings are Wear points,... Throw-away items,...
Like gaskets....

Pistons have to fit the bore,...
If honing causes Out of Spec,...
Then you'd need new pistons to match the overbore to the next size pistons...

how do you determine the spec for a particular piston? Does the engine manufacturer spec always apply or does it change based on piston type and application?
 

Bondo

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Re: Cylinder Clearance

how do you determine the spec for a particular piston?

Ayuh,... Mic up the piston, add the required clearance, 'n you've got the Spec....

Yes,... Pistons, 'n applications Do matter...
 

Joker757

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Re: Cylinder Clearance

Ayuh,... Mic up the piston, add the required clearance, 'n you've got the Spec....

Yes,... Pistons, 'n applications Do matter...

sorry for the back and forth on this however where do I get the required clearance? I looked up the specs for the piston however clearance isn't listed. Pistons are Sealed Power H727CB40
 

Bt Doctur

Supreme Mariner
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Aug 29, 2004
Messages
19,346
Re: Cylinder Clearance

pistons forged: .002-.005
cast aluminum: .001-.0027
standard bore 4.3602- 4.3609
 

Joker757

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Re: Cylinder Clearance

Thanks Doc! Where did you find this info? What does the standard bore represent? Standard bore on my engine is 4.25 according to the Merc service manual. My pistons are .04 oversized.
 

Joker757

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Re: Cylinder Clearance

what engine is that for? My engine is 99 7.4L MPI. I have service manual #23
 

Bt Doctur

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19,346
Re: Cylinder Clearance

Talk about brain dead, could have sworn I saw something else.
4.2500- 4.2507
cast piston clearance .0018-.0030
hi side 4.2507 + .040 is 4.2907 , so .040 oversize is possable measuring 4.3000
 

Joker757

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Re: Cylinder Clearance

Happens to all of us Doc. This is very helpful info. Thanks a bunch!
 
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