Section 04
ENGINE (DI)
Subsection 05
(TOP END)
SMR2002-062_04_05A.FM
04-05-7
INSPECTION
Visually inspect all parts for corrosion damage.
Inspect piston for damage. Light scratches can be
sanded with a fine sand paper.
NOTE:
When repairing a seized engine, connecting
rods should be checked for straightness and crank-
shaft for deflection/misalignment. Refer to BOTTOM
END for procedures.
Inspect plane surfaces for warpage. Small deforma-
tion can be corrected by grinding surface with a fine
sand paper. Install sand paper on a surface plate and
rub part against oiled sand paper.
The inspection of engine top end should include
the following measurements.
N.A.: Not Applicable
NOTE:
Replacement cylinder sleeves are available if
necessary. Also, oversize pistons of 0.25 mm (.010 in)
are available for all engines and oversize pistons of
0.5 mm (.020 in) are available for the 717 engine.
Cylinder Taper
Using a cylinder bore gauge, measure cylinder diam-
eter at 16 mm (5/8 in) from top of cylinder just below
auxiliary transfer port, facing exhaust port and just be-
low the auxiliary transfer port facing the exhaust port.
Compare readings. If the difference between read-
ings exceed specification, cylinder should be rebored
and honed or replaced.
1. Measuring perpendicularly (90
°
) to piston pin axis
2. Auxiliary transfer port
A. 16 mm (5/8 in)
Cylinder Out of Round
Using a cylinder bore gauge, measure cylinder di-
ameter at 16 mm (5/8 in) from top of cylinder. Mea-
sure diameter in piston pin axis direction then per-
pendicularly (90
°
) to it. If the difference between
readings exceed specification, cylinder should be
rebored and honed or replaced.
1. Measuring in piston pin axis
2. Measuring perpendicularly (90
°
) to piston pin axis
A. 16 mm (5/8 in)
ENGINE
MEASUREMENT
TOLERANCES
NEW PARTS
WEAR
LIMIT
(min.)
(max.)
Cylinder taper
N.A.
0.05 mm
(.002 in)
0.1 mm
(.004 in)
Cylinder out of round
N.A.
0.08 mm
(.003 in)
0.08 mm
(.003 in)
Piston/cylinder wall
clearance for the
0.12 mm
(.0047 in)
N.A.
0.20 mm
(.008 in)
Ring/piston groove
clearance for the
0.044 mm
(.002 in)
0.089 mm
(.003 in)
0.20 mm
(.008 in)
Ring end gap for the
0.55 mm
(.022 in)
0.70 mm
(.028 in)
1.1 mm
(.043 in)
A
F01D8AA
1
2
A
F01D8BA
A
1
2
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Summary of Contents for GTX 4-TEC 5573 2002
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