Cylinder Taper and Cylinder Out of Round

Aditya Patel

Equipment Utilized

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An assortment of hand tools, pullers and specialty measuring tools were used during this assignment

Health and Safety Precautions

Safety boots and glasses were mandatory in the shop

Proper lifting techniques, and getting help lifting was very important

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Unit Identification

GM 3100 Engine

References

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GM 3100 service manual, and our classroom text book were used. Lab notes and internet were used for some of the notes.

Method

1. List all the steps needed to measure cylinder taper and out of round.

• a bore gauge calibration unit was set up by using fixture and calibration unit

• the bore gauge was placed in this unit and calibrated using the micrometre scale on the unit. To calibrate for specific bore, use the standards. For example, for 4.406 bore, install 4.000+ standard and set the scale to 0.406. Bore gauge is calibrated until the dial shows 0 on it. Or more adjustment should be done.

• the bore gauge was then placed inside the cylinder at Top thrust surface and rock the bore gauge front and back until dial goes up and comes back. Note the highest reading, the dial reaches. Do same for bottom thrust surface.

• To measure the cylinder out of round, measure top thrust surface of the cylinder but perpendicular to the first measured.

• Now compare both reading for top thrust surfaces readings. If the difference between the measured reading is more than 0.0005 then the cylinder is out of round or else, it is good.

• To measure the taper, subtract the reading of bottom thrust surface from top thrust surface. If the reading is more than 0.0008 then cylinder is not good.

Cylinder Taper is the difference of the diameter between top of the cylinder bore under the ridge and bottom of the cylinder

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Cylinder out of Round is the difference of diameter when measured parallel to crankshaft and then perpendicular to the same at top of the cylinder using bore gauge.

Method – Continued   

2. Document 2 methods of measuring piston to cylinder bore clearance.

Feeler Strip Method

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• Remove all compression and oil control rings from pistons

• Invert the piston and place it back in the cylinder in upside down position with feeler strip. The feeler strip should not be on the piston pin hole. After piston is placed in the cylinder slowly take the filler gauge out. While taking the filler gauge out, if it feels too hard or loose the try different size of the gauge until you get the perfect size. The perfect size of filler gauge should not feel too tight or smooth while taking it out.

(Measuring clearance using feeler strip)

Calculated Method

• Measure the diameter of the piston across the skirt with well calibrated micrometre. Note the reading.

• Now using the bore gauge measure the cylinder diameter under the ridge. Record the reading.

• Now subtract the piston diameter from cylinder diameter. The measurement achieved is the piston to cylinder clearance.

• Note that before taking any reading the micrometre should be well calibrated and the surfaces should be cleaned.

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(Bore gauge measuring the cylinder diameter)

(Measuring piston diameter using Micrometre)

3. Construct a chart listing cylinder, piston ring and crankshaft clearances.

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• Located under observations heading

4. Record how to check ring clearances. (side and end)

Side Clearance

• Remove all compression and oil control rings from pistons

• Clean the piston ring groove before measuring.

• For measuring the ring clearance, the ring doesn’t need to be installed in the piston. Gently place the ring in the groove. After placing the ring measure the clearance with the help of feeler gauge between the ring and upper edge of the groove.

• Compare the measured ring clearance with the manufacturers specification. If the measured clearance is more then the manufacturers specification the change the ring.

(Measuring Ring Clearance using Feeler Strip)

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End Gap

• Remove all compression and oil control rings from pistons

• Place the ring in the same cylinder from which piston come out.

• Using the piston slowly push the ring in the cylinder. Then measure the gap between the two ends of the rings with filler strip.

• The filler strip should not too hard or too smooth to pass between the two ends of the rings.

• Then do same for the second ring and note the measurement. Compare this measurement with the manufacturers specification.

• If the measured end gap is more then the actual specification the change the ring.

(Measuring piston ring end gap using feeler strip)

5. Describe 2 methods of measuring crankshaft bearing clearance.

Plastigauge Method

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• remove the main bearing caps from the block and clean the surface of the crankshaft journals with a clean rag.

• Now place a piece of plastigauge according to the width of the journal.

• Install back main bearing caps on their same position as before.

• Check that the bearings are in the correct direction.

• Install the bolts and tighten them with torque wrench at the manufacturers specification.

• Now remove the main bearing caps and check the spread of plastigauge.

• Compare with the marking given on the cover of the plastigauge and note the reading.

• Now compare this reading with the actual specification.

• Before installing main bearings back, carefully wipe the plastigauge marks.

(Measuring the Crankshaft bearing clearance using plasti gauge)

Calculated Method

• Measure the crankshaft journal diameter using a well calibrated micrometre. Measure every journal two times both perpendicular at each other. Note every reading.

• Now put the bearing journals back on. Use torque wrench to tight the bearings with specified torque. Using inside micrometre or bore dial gauge measure the diameter of the bearing. Note the reading.

• To measure bearing clearance, subtract the crankshaft journal diameter measurement from bearing journal diameter.

• The allowable clearance for crankshaft is between 0.0008-0.0025.

6. Explain what causes cylinder taper and cylinder out of round

Cylinder Taper is caused by wear caused by friction and combustion cause the bore to be cone shaped.

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Cylinder Out of Round is caused by pressure created by piston rings to the cylinder walls.

Observations

Cylinder

Measurements	Cyl #1	Cyl #2	Cyl #3	Cyl #4	Cyl #5	Cyl #6
(Thrust Surface – Under Ridge) A How Do I Order a Paper? It’s a breeze—submit your order online with a few clicks, then track progress with drafts as your writer brings it to life. Once it’s ready, download it from your account, review it, and release payment only when you’re totally satisfied—easy, affordable help whenever you need it. Plus, you can reach out to support 24/7 if you’ve got questions along the way!	0.0016	0.0018	0.0018	0.0015 How Quick Can You Write? Need it fast? We can whip up a top-quality paper in 24 hours—fully researched and polished, no corners cut. Just pick your deadline when you order, and we’ll hustle to make it happen, even for those nail-biting, last-minute turnarounds you didn’t see coming.	0.0015	0.0014
(Thrust Surface – Bottom) B	0.0013	0.0014 Can You Handle Tough Topics? Absolutely—bring it on! Our writers, many with advanced degrees like Master’s or PhDs, thrive on challenges and dive deep into any subject, from obscure history to cutting-edge science. They’ll craft a standout paper with thorough research and clear writing, tailored to wow your professor.	0.0012	0.0014	0.0011	0.0013
(90 ° – Under Ridge) C How Do You Match Professor Expectations? We follow your rubric to a T—structure, evidence, tone. Editors refine it, ensuring it’s polished and ready to impress your prof.	0.0012	0.0015	0.0012	0.0013 How Do You Edit My Work? Send us your draft and goals—our editors enhance clarity, fix errors, and keep your style. You’ll get a pro-level paper fast.	0.001	0.0011

Taper (Subtract “B” from “A”)

Measurements	Cyl #1	Cyl #2	Cyl #3	Cyl #4	Cyl #5	Cyl #6
(Thrust Surface – Under Ridge) A	0.0016 Can You Brainstorm Topics? Yep! We’ll suggest ideas tailored to your field—engaging and manageable. Pick one, and we’ll build it into a killer paper.	0.0018	0.0018	0.0015	0.0015	0.0014
(Thrust Surface – Bottom) B	0.0013 Do You Offer Fast Edits? Yes! Need a quick fix? Our editors can polish your paper in hours—perfect for tight deadlines and top grades.	0.0014	0.0012	0.0014	0.0011	0.0013
Taper Can You Start With an Outline? Sure! We’ll sketch an outline for your approval first, ensuring the paper’s direction is spot-on before we write.	0.0003	0.0004	0.0006	0.0001	0.0004	0.0001
Specification	0.0008 Can You Add Charts or Stats? Definitely! Our writers can include data analysis or visuals—charts, graphs—making your paper sharp and evidence-rich.	———	———	———	———	———

Out of Round ( Subtract “C” from “A” )

Measurements	Cyl #1	Cyl #2	Cyl #3	Cyl #4	Cyl #5	Cyl #6
( Thrust Surface – Under Ridge ) A	0.0016	0.0018	0.0018 What About Multi-Part Projects? We’ve got it—each section delivered on time, cohesive and high-quality. We’ll manage the whole journey for you.	0.0015	0.0015	0.0014
( 90 ° – Under Ridge ) C	0.0012 Do You Adapt to International Rules? Yes! UK, US, or Aussie standards—we’ll tailor your paper to fit your school’s norms perfectly.	0.0015	0.0012	0.0013	0.0010	0.0011 What does a complex assignment mean? If your assignment needs a writer with some niche know-how, we call it complex. For these, we tap into our pool of narrow-field specialists, who charge a bit more than our standard writers. That means we might add up to 20% to your original order price. Subjects like finance, architecture, engineering, IT, chemistry, physics, and a few others fall into this bucket—you’ll see a little note about it under the discipline field when you’re filling out the form. If you pick “Other” as your discipline, our support team will take a look too. If they think it’s tricky, that same 20% bump might apply. We’ll keep you in the loop either way!
Out of Round	0.0004	0.0003	0.0006 Who is my writer? How can I communicate with him/her? Our writers come from all corners of the globe, and we’re picky about who we bring on board. They’ve passed tough tests in English and their subject areas, and we’ve checked their IDs to confirm they’ve got a master’s or PhD. Plus, we run training sessions on formatting and academic writing to keep their skills sharp. You’ll get to chat with your writer through a handy messenger on your personal order page. We’ll shoot you an email when new messages pop up, but it’s a good idea to swing by your page now and then so you don’t miss anything important from them.	0.0002	0.0005	0.0003
Specification	0.0005	———	———	———	———	———

Observations – Continued

Piston Ring Clearance

Measurements	Specs	#1	#2	#3	#4	#5	#6
Ring End Gap:
Top Ring	0.006-0.014	0.24	0.24	0.24	0.27	0.17	0.19
Second Ring	0.0197-0.0280	0.30	0.16	0.20	0.18	0.16	0.19
Ring Groove Clearance:
Top Ring	0.002-0.0033	0.002	0.0025	0.002	0.002	0.002	0.002
Second Ring	0.002-0.0035	0.002	0.002	0.0025	0.002	0.002	0.002

Bearing Clearance

Checks	Specs	#1	#2	#3	#4
Bearing Bore Dia. (A)	2.6472 – 2.6502	2.649	2.652	2.648	2.650
Journal Diameter (B)	2.6473 – 2.6483	2.647	2.646	2.647	2.645
Clearance (A – B)	0.0008 – 0.0025	0.002	0.006	0.001	0.005
Plastigauge Clearance	0.0008-0.0025	0.0015	0.0020	0.0010	0.0020

Conclusions

Upon completing the measurements and visual inspections, I would recommend that due to the excessive wear and out of round cylinder, the cylinder should be bored. While measuring the piston ring clearance we noticed that the piton rings were replaced and were both of same size on one piston.    

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