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4. Enlarge the oil gallery at the rear of the cylinder
head to be diameter 9mm, depth 8mm.
5. Tap in the steel ball (3) from the side to the oil gallery
using the punch (13).
6. Pull out the steel ball (3) using the round bar (12).
7. Enlarge the oil gallery to be diameter 9mm, depth
8mm.
8. Make a screw hole at the oil gallery using M10 x 1
thread.
9. All the oil gallery should be cleaned with the com-
pressed air.
10. Apply the Loctite 270 to new plug and press in using
a suitable drift (arrow).
11. Tighten the screw plug with the seal (arrow).
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1B1 -- 104 M162 ENGINE MECHANICAL
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CORE PLUGS IN CRANKCASE
Preceding Work: Draining of the coolant
1 Core Plug Replace.........................
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Replacement Procedure
1. Remove the intake and exhaust manifolds.
2. Pull back the core plug until the end of one side
comes out using the screw driver.
3. Pull out the plug carefully using a pliers.
4. Clean the sealing surface and apply Loctite 241.
5. Press in new plug using a drift.
Notice:Wait for about 45minutes before filling the cool-
ant so that the Loctite 240 hardens.
6. Warm up the engine and check the coolant for leaks.
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1B1 -- 106 M162 ENGINE MECHANICAL
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CYLINDER BORE
Group Code Letter and Cylinder Bore Size
Group Code Letter of CylinderPiston Type to be UsedCylinder Bore Size (mm)
AAorXφ89.900 --φ89.906
XA, X or Bφ89.906 --φ89.912
BXorBφ89.912 --φ89.918
X+5X+5φ89.950 --φ89.968
X+10X+10φ90.000 --φ90.018
Repair Size
Ty peGroup Code Letter 1)Cylinder Bore Size (mm)
Standard Sizeφ89.9Aφ89.900 --φ89.906φ
Xφ89.906 --φ89.912
Bφ89.912 --φ89.918
1st Repair Size
(StddSi025)
Aφ90.150 --φ90.156p
(Standard Size + 0.25)Xφ89.156 --φ90.162
Bφ90.162 --φ90.168
2nd Repair Size
(StddSi05)
Aφ90.400 --φ90.406p
(Standard Size + 0.5)Xφ90.406 --φ90.412
Bφ90.412 --φ90.418
1) The group code letters are carved on the surface of the piston crown and in the mating surface of the crankcase.
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ServiceDataStandard
Wear Limit in Longitudinal and Transverse Direction0.1 mm
Permissible Deviation of Cylinder Out -- of -- roundWhen new0.007 mmy
Wear limit0.05 mm
Permissible Deviation of Rectangular Cylinder Height (Except Chamfered Area)0.05 mm
Basic Peak -- to-- valley Height After Final Honing and Brushing0.003 -- 0.006 mm
Chamfer Angle60°
Honing Angle50°±10°
Measurement of Cylinder Bore
1. Clean the cylinder wall.
2. Using a internal diameter gauge, measure the bore
size in axial and transverse direction at three points
(1,2,3).
1,2,3. Measuring Points
A. Axial Direction
B. Transverse Direction
a. Location of the No.1 Piston Ring at TDC
b. Location of the Piston BDC
c. Location of the Oil Ring at BDC
Chamfer Angle
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1B1 -- 108 M162 ENGINE MECHANICAL
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CRANKCASE MATING SURFACE
ServiceDataStandard
Height of The Crankcase ‘H’ (When new)282.25 -- 282.35mm
Minimum Height After Milling281.95mm
FlatnessCrankcase Upper Mating Surface0.03mm
Crankcase Lower Mating Surface0.04mm
Permissible Deviation of Parallelism of The
UtLMtiSf
Axial Direction0.1mm
Upper to Lower Mating SurfaceTransverse Direction0.05mm
Peak -- to-- valley HeightCrankcase Upper Mating Surface0.005 -- 0.020mmyg
Crankcase Lower Mating Surface0.025mm
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Chamfering Procedure
1. Chamfer angle : 60°
2. Polish the lower chamfered area evenly with a grinder
after finishing the chamfering with a suitable tool
(e.g., hand milling cutter).
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1B1 -- 110 M162 ENGINE MECHANICAL
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CYLINDER HEAD MATING SURFACE
Preceding Work: Removal of valves
ServiceDataStandard
Overall Height of Cylinder Head135.9 -- 136.0 mm
Minimum Height After Machining135.5 mm
FlatnessAxial Direction0.08 mm
Transverse Direction0.0 mm
Distance ‘T’
(BtChftBi
Standard SizeIntake24.21 -- 24.75 mm
(Between Camshaft Bearing
andValveStem)Exhaust22.21 -- 22.75 mmandValveStem)
Repair SizeIntake23.96 -- 24.51 mmp
Exhaust21.96 -- 22.51 mm
Notice:Do not exceed 0.4mm for the milling of the mating surface of crankcase and cylinder head.