SINGLE-CYLINDER ENGINES
ing it out with an appropriate size drift or
pin punch. When removing a large core
plug, the use
of
a universal impact slide
hammer
is recommended.
3. Clean the plug bore thoroughly to remove all traces
of
the old sealer. Inspect the bore for any damage that might
interfere with proper sealing
of
the new plug.
97
4. Coat the inside diameter
of
the plug bore and the outer
diameter
of
the new plug with sealer. Use an oil-resistant
sealer if the plug is to be installed in an oil gallery or a wa-
ter-resistant sealer for plugs installed in the water jacket.
5. Install the new core plug with an appropriate size core
plug installation tool
(Figure 92), driver or socket. The
outside edge
ofthe
plug should be 2-3 mm (0.08-0.12 in.)
inside the block.
6. Repeat Steps 1-5to replace each remaining core plug.
Bore
Stroke
Displacement
Number of cylinders
Cylinder bore diameter
Bore
out-of-round-max.
Cylinder block
warpage-max.
Piston diameter
Standard
Wear limit
Piston top clearance
Piston ring side clearance
Top ring
Second ring
Oil ring
Ring end gap (all rings)
Piston pin diameter
Piston pin hole diameter
In piston
In rod
Piston pin clearance
In rod
In piston
Piston ring width
Top
& second ring
Oil control ring .
Crankshaft main journal diameter
Timing gear end
Flywheel end
Journal
out-of-round-max.
Crankshaft end play
Crankshaft
runout-max.
Main bearing clearance
Timing gear end
Flywheel end
Crankshaft thrust
bearlng-min.
Front
Inner
Crankpin diameter
Journal
out-of-round-max.
Crankpin bearing clearance
Connecting rod side clearance
Cylinder head
warpage-max.
Table
1
ENGINE
SPECIFICATIONS
(1GM,
1GM10)
75 mm (2.95 in.)
72 mm (2.83 in.)
318 cc (19.4 cu.
ln.)
1
75.000-75.030 mm (2.9528-2.9540 in.)
0.02 mm (0.0008 in.)
0.07 mm (0.0028
ln.)
74.910-74.940 mm (2.9492-2.9504 ln.)
74.850 mm max. (2.9468 ln.)
0.68-0.88 mm (0.027-0.035 in.)
0.065-0.100 mm (0.0026-0.0039 in.)
0.035-0.070 mm (0.0014-0.0028 in.)
0.020-0.055 mm (0.0008-0.0022
ln.)
0.20-0.40 mm (0.008-0.016 in.)
19.991-20.000 mm (0.7870-0.7874
ln.)
19.995-20.008 mm (0.7872-0.7877 ln.)
20.000 mm (0.7874 in.)
0.025-0.047 mm (0.0010-0.0019 in.)
0.005 mm tight-O.017 mm loose
(0.0002 in. tight-0.0007 in. loose)
1.97-1.99 mm (0.0776-0.0783 in.)
3.97-3.99 mm (0.1563-0.1571
ln.)
43.950-43.964 mm (1.7303-1.7309 in.)
59.950-59.964 mm (2.3602-2.3608
ln.)
0.01 mm (0.0004 In.)
0.06-0.19 mm (0.0024-0.0075 in.)
0.15 mm (0.006 in.)
0.036-0.092 mm (0.0014-0.0036 in.)
0.036-0.095 mm (0.0014-0.0037 in.)
2.75 mm (0.108 in.)
2.25 mm (0.089 in.)
39.950-39.964 mm (1.5728-1.5734 in.)
0.01 mm (0.0004 in.)
0.028-0.086 mm (0.0011-0.0034 in.)
0.2-0.4 mm (0.008-0.016 in.)
0.07 mm (0.003 in.)
(continued)
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