Note. Individual characteristics are also given in the text of the Chapter
OHC engines - general data
| Engine's type: - engine 2.0 l until the middle of 1995 release - engine 2.4 l until the middle of 1995 release - engine 2.0 l from the middle of 1995 release | C 20 NE C 24 NE X 20 SE | |
| Design features: - engine 2.0 l - engine 2.4 l | Four-cylinder gasoline engine with an overhead camshaft and toothed belt drive Four-cylinder, chain-driven, overhead-camshaft gasoline engine | |
| Number of cylinders | 4 | |
| Cylinder arrangement | inline | |
| Gas distribution mechanism: - engine 2.0 l - engine 2.4 l | Hanging valves, overhead camshaft located in a separate housing, driven by a toothed belt. Gap lifters. Valve drive from rocker arms Hanging parallel valves, 2 valves per cylinder, overhead camshaft, chain driven. Gap lifters. Valve drive from rocker arms | |
| The order of operation of the cylinders | 1 - 3 - 4 - 2 | |
| Max Power: - engine 2.0 l until the middle of 1995 release - engine 2.0 l from the middle of 1995 release - engine 2.4 l | 85 kW (115 hp) at 5200 rpm 85 kW (115 hp) at 5200 rpm 92 kW (125 hp) at 4800 rpm | |
| The number "20" in the engine designation indicates a cylinder displacement of 2.0 liters; "22" for a volume of 2.2 l; "24" for a volume of 2.4 liters. The letter "C" or "X" in front of the engine designation indicates the presence of a catalytic converter. | ||
| Max. torque: - engine 2.0 l until the middle of 1995 release - engine 2.0 l from the middle of 1995 release - engine 2.4 l | 170 nm at 2600 rpm 172 nm at 2800 rpm 195 nm at 2600 rpm | |
| Cylinder diameter: - all engines 2.0 l - engines 2.4 l | 86.00 mm 95.00 mm | |
| Stroke: - all engines 2.0 l - engines 2.4 l | 86.00 mm 85.00 mm | |
| Compression ratio: - engine 2.0 l until the middle of 1995 release - engine 2.0 l from the middle of 1995 release - engine 2.4 l | 9.2: 1 10.0: 1 9.2: 1 | |
Engine 2.0 l (C 20 NE from mid 1995) | ||
| cylinder head | ||
| Cylinder head height | 95.75 - 96.25 mm (between mating planes) | |
| Max flatness of the mating plane with the cylinder block | 0.10 mm | |
| Max. non-flatness of interface planes with pipelines | 0.10 mm | |
| Gasket thickness | 1.15 - 1.30 mm | |
| Cylinder head seat chamfer width: - intake valves - exhaust valves | 1.0 - 1.5 mm 1.7 - 2.2 mm | |
| Clearance in mating the valve stem with the guide sleeve: - intake valves - exhaust valves | 0.018 - 0.052 mm 0.038 - 0.072 mm | |
| Valve installation height | 17.85 - 18.25 mm. Measured by caliber KM-512. Carry out only in the workshop | |
| Installation height of guide sleeves | New guides in accordance with the original size are pressed into the cylinder head. Target size 83.50 - 83.80 mm | |
| valve seats | ||
| Chamfer angle | 45° | |
| Lower correction angle | 75° | |
| Upper correction angle | 15° | |
| Valve seat bevel width (new valve) | See above | |
| valves | ||
| Valve stem diameter - inlet valves: - given size, designation K - repair, increased by 0.075 mm, designation K1 - repair, increased by 0.150 mm, designation K2 - repair, increased by 0.250 mm, designation A | 7.012 - 6.998 mm 7.087 - 7.073 mm 7.162 - 7.148 mm 7.262 - 7.248 mm | |
| Valve Stem Diameter - Exhaust Valves: - given size, designation K - repair, increased by 0.075 mm, designation K1 - repair, increased by 0.150 mm, designation K2 - repair, increased by 0.250 mm, designation A | 6.992 - 6.978 mm 7.067 - 7.053 mm 7.142 - 7.128 mm 7.242 - 7.228 mm | |
| Clearance in mating the valve with the guide: - intake valves - exhaust valves | 0.018 - 0.052 mm 0.038 - 0.072 mm | |
| Valve disc diameter: - intake valves - exhaust valves | 41.8 mm 35.6mm | |
| Valve length: - intake valves - exhaust valves | 104.20 mm (spare valves 103.8 mm) 104.00 mm (spare valves 103.6 mm) | |
| Camshaft | ||
| Shaft designation | J | |
| Shaft color code - normal size - repair, reduced by 0.10 mm | No Violet | |
| Max. shaft runout | 0.03mm | |
| Shaft axial clearance | 0.09 - 0.21 mm | |
| Cam stroke | 6.67 mm, intake and exhaust valves | |
| Bearing clearance: - normal value - wear limit | 0.04 - 0.082 mm 0.11mm | |
| Neck diameter | Necks have different diameters. Shafts with a 0.1 mm smaller journal diameter are marked purple. Repair diameters are given in brackets: - bearing no. 1 42.470 - 42.455 mm (42.370 - 42.355 mm) - bearing no. 2 42.720 - 42.705 mm (42.620 - 42.505 mm) - bearing no. 3 42.970 - 42.955 mm (42.870 - 42.855 mm) - bearing no. 4 43.220 - 43.205 mm (43.120 - 43.105 mm) - bearing no. 5 43.470 - 43.455 mm (43.370 - 43.355 mm) | |
| Holes in the camshaft bearing housing | The hole diameters are different, as are the diameters of the camshaft journals. Repair dimensions are given in brackets: - bearing no. 1 42.525 - 42.500 mm (42.425 - 42.400 mm) - bearing no. 2 42.775 - 42.750 mm (42.675 - 42.650 mm) - bearing no. 3 42.025 - 43.000 mm (42.925 - 42.900 mm) - bearing no. 4 43.275 - 43.250 mm (43.175 - 43.150 mm) - bearing no. 5 43.525 - 43.500 mm (43.425 - 43.400 mm) | |
| Pistons and connecting rods | ||
| Installation direction | Arrow to the distribution side | |
| Piston diameter - 1 class - 4th grade | - 85.96 mm (8 on the piston crown) - 85.97 mm (99 on the piston crown); 89.98 mm (00 on the piston crown); 89.99 mm (01 on the piston crown); 86.00 mm (02 on the piston crown) | |
| Repair size increased by 0.5 mm | 86.45 mm (7 + 0.5 on the piston crown) | |
| Piston-cylinder clearance | 0.02 - 0.04 mm | |
| piston pins | ||
| Length | 61.1 mm | |
| Finger landing | Pressed into the connecting rod head | |
| Piston clearance | 0.011 - 0.014 mm | |
| Outside diameter | 21.0 mm | |
| Piston rings | ||
| Number of rings | 2 compression and 1 oil scraper | |
| Ring thickness: - top ring - middle ring - oil scraper ring | 1.50 mm 1.50 mm 3.0mm | |
| Piston ring gaps: - compression rings - oil scraper ring | 0.30 - 0.50 mm 0.40 - 1.40 mm | |
| Clearance in pairing of the ring with the groove in the piston: - top ring - middle ring - oil scraper ring | 0.12 - 0.18 mm 0.05 - 0.15 mm 0.025 - 0.15 mm | |
| Connecting rod bearings | ||
| Neck diameters | see Section Crankshaft and crankshaft bearings | |
| Type | With inserts | |
| Axial clearance | 0.07 - 0.24 mm | |
| Cylinder block | ||
| Nominal diameter of cylinders | The cylinder diameters of each class are 0.02 mm larger than the corresponding piston diameters. The marking on the piston crown corresponds to the marking on the cylinder block | |
| Max. permissible cylinder diameter | 0.5 mm over nominal value | |
| Max. ovality and taper | 0.013 mm | |
| Piston clearance | 0.02 - 0.04 mm | |
| Piston measurement points | At the bottom of the skirt, at right angles to the piston pin bore | |
| Crankshaft | ||
| Number of bearing | 5 | |
| Bearing type | With inserts | |
| Main bearing diameter - nominal diameter - nominal diameter - repair, reduced by 0.25 mm - repair, reduced by 0.25 mm - repair, reduced by 0.50 mm - repair, reduced by 0.50 mm | 57.8200 - 57.9885 mm (green marking) 57.9885 - 57.9950 mm (brown marking) 57.7320 - 57.7385 mm (green/blue marking) 57.7385 - 57.7450 mm (brown/blue marking) 57.4820 - 57.4885 mm (green/blue marking) 57.4885 - 57.4950 mm (brown/blue marking) | |
| Guide Bearing Width: - nominal size - repair, reduced by 0.25 mm - repair, reduced by 0.50 mm |
| |
| Color coding of bearing shells | ||
Lids | Blok | |
| - nominal size - repair, reduced by 0.25 mm - repair, reduced by 0.50 mm | brown green brown/blue brown/white | green brown green/blue (selective assembly) green/white (selective assembly) |
| Holes in the cylinder block | Depending on color markings and class | |
| Axial clearance of the crankshaft | 0.050 - 0.152 mm | |
| Permissible clearance in the main bearing | 0.015 - 0.040 mm | |
| Permissible clearance in the connecting rod bearing | 0.006 - 0.031 mm | |
| Permissible axial clearance of the connecting rod bearing | 0.07 - 0.24 mm | |
| Diameter of connecting rod journals | ||
| - nominal size - repair, reduced by 0.25 mm - repair, reduced by 0.50 mm | 48.988 - 48.970 mm 48.738 - 48.720 mm 48.488 - 48.470 mm | |
Connecting rod width | 26.580 - 26.460 mm | |
| Oil pump | See Section Lubrication system | |
| injection system | see chapterPower and exhaust systems | |
| Ignition system | See chapters Power and exhaust systems and Engine electrical equipment | |
Engine 2.0 l (X 20 SE from mid-1995 release) | ||
| cylinder head | ||
| Cylinder head height | 95.75 - 96.25 mm (between mating planes) | |
| Max flatness of the mating plane with the cylinder block | 0.10 mm | |
| Max. non-flatness of surfaces interface with pipelines | 0.10 mm | |
| Gasket thickness | 1.15 - 1.30 mm | |
| Cylinder head seat chamfer width: - intake valves - exhaust valves | 1.0 - 1.5 mm 1.7 - 2.2 mm | |
| Clearance in mating the valve stem with the guide sleeve: - intake valves - exhaust valves | 0.018 - 0.052 mm 0.038 - 0.072 mm | |
| Allowable valve stem runout - intake valves - exhaust valves | 0.03mm 0.33 mm | |
| Valve installation height | 17.85 - 18.25 mm. Measured by caliber KM-512. Carry out only in the workshop | |
| Mounting height of guide rails bushings | New guides in accordance with the original size are pressed into the cylinder head. Target size 83.25 - 83.05 mm | |
| valve seats | ||
| Chamfer angle | 45° | |
| Lower correction angle | 75° | |
| Upper correction angle | 15° | |
| Valve face width (new valve) | See above | |
| valves | ||
| Valve stem diameter - inlet valves: - given size, designation K - repair, increased by 0.075 mm, designation K1 - repair, increased by 0.150 mm, designation K2 - repair, increased by 0.250 mm, designation A | 7.012 - 6.998 mm 7.087 - 7.073 mm 7.162 - 7.148 mm 7.262 - 7.248 mm | |
| Valve Stem Diameter - Exhaust Valves: - given size, designation K - repair, increased by 0.075 mm, designation K1 - repair, increased by 0.150 mm, designation K2 - repair, increased by 0.250 mm, designation A | 6.992 - 6.978 mm 7.067 - 7.053 mm 7.142 - 7.128 mm 7.242 - 7.228 mm | |
| Clearance in mating the valve with the guide: - intake valves - exhaust valves | 0.018 - 0.052 mm 0.038 - 0.072 mm | |
| Valve disc diameter: - intake valves - exhaust valves | 41.8 mm 36.5mm | |
| Valve length: - intake valves - exhaust valves | 104.20 mm (spare valves 103.8 mm) 104.00 mm (spare valves 103.6 mm) | |
| Camshaft | ||
| Shaft designation | J | |
| Shaft color code - normal size - repair, reduced by 0.10 mm | No violet | |
| Max. shaft runout | 0.04 mm | |
| Shaft axial clearance | 0.09 - 0.21 mm | |
| Cam stroke | 6.67mm intake and exhaust valves | |
| Bearing clearance: - normal value - wear limit | 0.04 - 0.082 mm 0.11mm | |
| Neck diameter | Necks have different diameters. Shafts with repair neck diameter 0.1 mm less have a purple marking. Repair diameters are given in brackets: - bearing no. 1 42.470 - 42.455 mm (42.370 - 42.355 mm) - bearing no. 2 42.720 - 42.705 mm (42.620 - 42.505 mm) - bearing no. 3 42.970 - 42.955 mm (42.870 - 42.855 mm) - bearing no. 4 43.220 - 43.205 mm (43.120 - 43.105 mm) - bearing no. 5 43.470 - 43.455 mm (43.370 - 43.355 mm) | |
| Holes in the camshaft bearing housing | The hole diameters are different, as are the diameters of the camshaft journals. Repair dimensions are given in parentheses - bearing no. 1 42.525 - 42.500 mm (42.425 - 42.400 mm) - bearing no. 2 42.775 - 42.750 mm (42.675 - 42.650 mm) - bearing no. 3 42.025 - 43.000 mm (42.925 - 42.900 mm) - bearing no. 4 43.275 - 43.250 mm (43.175 - 43.150 mm) - bearing no. 5 43.525 - 43.500 mm (43.425 - 43.400 mm) | |
| Pistons and connecting rods | ||
| Installation direction | Arrow to the distribution side | |
| Piston diameter - 1 class - 4th grade | - 85.955 - 85.985 mm (8 on the piston crown) - 85.965 - 85.975 mm (99 on the piston crown); 89.975 - 85.985 mm (00 on the piston crown); 89.985 - 85.995 mm (01 on the piston crown); 85.995 - 86.005 mm (02 on the piston crown); 86.445 - 86.455 mm (7 + 0.5 on the piston crown); 86.455 - 86.465 mm (8 + 0.5 on the piston crown) | |
| Repair dimension increased by 0.5 mm 86.465 - 86.475 mm | (9 + 0.5 on the piston crown) | |
| Repair dimension increased by 0.5 mm 86.475 - 86.485 mm | (0 + 0.5 on the piston crown) | |
| Piston-cylinder clearance | 0.02 - 0.04 mm | |
| piston pins | ||
| Length | 61.1 mm | |
| Finger landing | Pressed into the connecting rod head | |
| Piston clearance | 0.003 - 0.010 mm | |
| Outside diameter | 21.0 mm | |
| Clearance in conjunction with the connecting rod head | Interference landing | |
| Piston rings | ||
| Number of rings | 2 compression and 1 oil scraper | |
| Ring thickness: - top ring - middle ring - oil scraper ring | 1.50 mm 1.50 mm 3.0mm | |
| Piston ring gaps: - compression rings - oil scraper ring | 0.30 - 0.50 mm 0.40 - 1.40 mm | |
| Clearance in pairing of the ring with the groove in the piston: - top ring - middle ring - oil scraper ring | 0.12 - 0.18 mm 0.05 - 0.15 mm 0.025 - 0.15 mm | |
| Connecting rod bearings | ||
| Neck diameters | see Section Crankshaft | |
| Type | With inserts | |
| Axial clearance | 0.07 - 0.24 mm | |
| Cylinder block | ||
| Nominal diameter of cylinders | The cylinder diameters of each class are 0.02 mm larger than the corresponding piston diameters. The marking on the piston crown corresponds to the marking on the cylinder block | |
| Max. permissible cylinder diameter | 0.5 mm over nominal value | |
| Max. ovality and taper | 0.013 mm | |
| Piston clearance | 0.02 - 0.04 mm | |
| Piston measurement points | At the bottom of the skirt, at right angles to the piston pin hole | |
| Crankshaft | ||
| Number of bearing | 5 | |
| Bearing type | With inserts | |
| Main bearing diameter | ||
| - nominal diameter - nominal diameter - nominal size - repair, reduced by 0.25 mm - repair, reduced by 0.25 mm - repair, reduced by 0.50 mm - repair, reduced by 0.50 mm | 57.974 - 57.931 mm (white marking) 57.982 - 57.988 mm (green marking) 57.988 - 57.995 mm (brown marking) 57.732 - 57.738 mm (green/blue marking) 57.738 - 57.745 mm (brown/blue marking) 57.482 - 57.488 mm (green/blue marking) 57.488 - 57.495 mm (brown/blue marking) | |
| Guide Bearing Width: - nominal size - repair, reduced by 0.25 mm - repair, reduced by 0.50 mm | 26.002 - 25.950 mm 26.202 - 25.150 mm 26.402 - 26.350 mm | |
| Color coding of bearing shells | ||
| - nominal size - repair, reduced by 0.25 mm - repair, reduced by 0.50 mm | brown/green/white (selective selection) brown/blue and green/blue (selective selection) brown/blue and green/blue (selective selection) | |
| Holes in the cylinder block | Depending on color markings and class | |
| Axial clearance of the crankshaft | 0.050 - 0.152 mm | |
| Permissible clearance in the main bearing | 0.015 - 0.040 mm | |
| Permissible clearance in the connecting rod bearing | 0.006 - 0.031 mm | |
| Permissible axial clearance of the connecting rod bearing | 0.07 - 0.24 mm | |
| Diameter of connecting rod journals | ||
| - nominal size - repair, reduced by 0.25 mm - repair, reduced by 0.50 mm | 48.988 - 48.970 mm 48.738 - 48.720 mm 48.488 - 48.470 mm | |
| Connecting rod width | 26.580 - 26.460 mm | |
| Oil pump | See Section Lubrication system | |
| injection system | see chapterPower and exhaust systems | |
| Ignition system | See chapters Power and exhaust systems and Engine electrical equipment | |
DOHC engine - general data
| Engine's type: | X 22 XE, "Ecotec" | |
| Design features: | Four-cylinder gasoline engine with two overhead camshafts 16 valves | |
| Number of cylinders | 4 | |
| Cylinder arrangement | inline | |
| Gas distribution mechanism: | Hanging valves, overhead camshafts driven by a toothed belt, tension adjustment. Gap lifters. Coolant pump drive from toothed belt | |
| The order of operation of the cylinders | 1 - 3 - 4 - 2 | |
| Max Power: | 100 kW (136 hp) at 5200 rpm | |
| Max. torque: | 202 nm at 2600 rpm | |
| Cylinder diameter: | 86.0 mm | |
| Stroke: | 94.6 mm | |
| Cylinder volume | 2198 cm3 | |
| Compression ratio: | 10.5: 1 | |
| Type of injection system | Multiposition Motronic M 1.5.4 | |
DOHC engine | ||
| cylinder head | ||
| Cylinder head height | 95.75 - 96.25 mm (from mating to mating plane) | |
| Max flatness of the mating plane with the cylinder block | 0.025 mm | |
| Max. non-flatness of interface planes with pipelines | 0.10 mm | |
| Gasket thickness | 1.15 - 1.25 mm | |
| Cylinder head seat chamfer width: - intake valves - exhaust valves | 1.0 - 1.5 mm 1.7 - 2.2 mm | |
| Clearance in mating the valve stem with the guide sleeve: - intake valves - exhaust valves | 0.03 - 0.057 mm 0.04 - 0.067 mm | |
| Valve installation height | 13.70 - 14.00 mm | |
| valve seats | ||
| Chamfer angle | 45° | |
| Lower correction angle | 75° | |
| Upper correction angle | 15° | |
| Valve seat bevel width (new valve) - intake valves - exhaust valves | 1.0 - 1.5 mm 1.7 - 2.2 mm | |
| valves | ||
| Valve stem diameter - inlet valve: - given size, designation K - repair, increased by 0.075 mm, designation K1 - repair, increased by 0.150 mm, designation K2 | 5.970 - 5.955 mm 6.045 - 6.030 mm 6.120 - 6.105 mm | |
| Valve Stem Diameter - Exhaust Valves: - given size, designation K - repair, enlarged by 0.075 mm, designation K1 - repair, enlarged by 0.150 mm, designation K2 | 5.960 - 5.945 mm 6.035 - 6.020 mm 6.110 - 6.095 mm | |
| Valve stem bore - all valves: - designation K 6. - designation K1 - designation K2 | 012 - 6.000 mm 6.090 - 6.075 mm 6.165 - 6.150 mm | |
| Clearance in mating the valve with the guide: - intake valves - exhaust valves | 0.03 - 0.057 mm 0.04 - 0.067 mm | |
| Valve disc diameter: - intake valves - exhaust valves | 32.0 mm + 0.1 mm 29.0 mm + 0.1 mm | |
| Valve length: - intake valves - exhaust valves | 102.0 mm (spare valves 101.7 mm) 92.0 mm (spare valves 91.8 mm) | |
| Camshaft | ||
| Max. shaft runout | 0.06 mm | |
| Shaft axial clearance | 0.04 - 0.144 mm | |
| Cam stroke | 10.0 mm both valves | |
| Bearing clearance: | Equal to the difference in diameters necks and holes | |
| Neck diameter | 27.960 - 27.939 mm | |
| Holes in the housing | 28.021 - 28.000 mm | |
| Pistons and connecting rods | ||
| Installation direction | Arrow to drive side timing | |
| Piston diameter - 1 class - 2 - 4 class | - 85.955 - 85.965 mm (8 on the piston crown) - 85.965 - 85.975mm (99 on the piston crown); 89.975 - 85.985 mm (00 on the piston crown); 85.985 - 85.995 mm (01 on the piston crown); 85.995 - 86.005 mm (02 on the piston crown) | |
| Repair size increased by 0.5 mm | 86.445 - 86.455mm (7 + 0.5 on the piston crown) 86.455 - 86.465 mm (8 + 0.5 on the piston crown) 86.455 - 86.475 mm (9 + 0.5 on the piston crown) 86.475 - 86.485 mm (0 + 0.5 on the piston crown) | |
| Piston-cylinder clearance | 0.003 - 0.01 mm | |
| piston pins | ||
| Length | 61.1 mm | |
| Finger landing | Hot fitting in the connecting rod head | |
| Piston clearance | 0,003 - 0, 01 | |
| Outside diameter | 21.0 mm | |
| Piston rings | ||
| Number of rings | 2 compression and 1 oil scraper | |
| Ring thickness: - top ring - middle ring - oil scraper ring | 1.50 mm 1.50 mm 3.0mm | |
| Piston ring gaps: - compression rings - oil scraper ring | 0.30 - 0.50 mm 0.40 - 1.40 mm | |
| Clearance in pairing of the ring with the groove in the piston: - top ring - middle ring - oil scraper ring | 0.12 - 0.18 mm 0.05 - 0.15 mm 0.025 - 0.15 mm | |
| Connecting rod bearings | ||
| Type | With inserts | |
| Axial clearance | 0.07 - 0.24 mm | |
| Cylinder block | ||
| Nominal diameter of cylinders - 1 class - Grade 2 | - 85.975 - 85.985 mm (8 on the piston crown) - 85.985 - 85.995 mm (99 on the piston crown); 85.995 - 86.005 mm (00 on the piston crown); 89.005 - 86.115 mm (01 on the piston crown); 85.115 - 86.025 mm (02 on the piston crown) | |
| Max. permissible cylinder diameter | 0.5 mm more nominal value | |
| Max. ovality and taper | 0.013 mm | |
| Piston clearance | 0.02 - 0.04 mm | |
| Piston measurement points | At the bottom of the skirt, at right angles to the opening under the piston pin | |
| Crankshaft | ||
| Number of bearing | 5 | |
| Bearing type | With inserts | |
| Main journal diameter - nominal diameter: - white marking - green marking - brown marking | 57.974 - 57.981 mm 57.981 - 57.988 mm 57.988 - 57.995 mm | |
| Diameter of the main neck - repair, reduced by 0.25 mm: - green/blue marking - brown/blue marking | 57.732 - 57.738 mm 57.738 - 57.745 mm | |
| Diameter of the main neck - repair, reduced by 0.50 mm: - green/white marking - brown/white marking | 57.482 - 57.488 mm 57.488 - 57.495 mm | |
| Bore diameter in cylinder block | Depending on the color marking and class | |
| Diameter of connecting rod journals | ||
| - nominal size - repair, reduced by 0.25 mm - repair, reduced by 0.50 mm | 48.988 - 48.970 mm 48.738 - 48.720 mm 48.488 - 48.470 mm | |
Crankpin Width: | 26.580 mm 26.580 - 26.460 mm 26.580 - 26.460 mm | |
| Connecting rod width | 26.390 - 26.338 mm for all sizes | |
| Axial clearance of the crankshaft | 0.050 - 0.152 mm | |
| Permissible main bearing clearance | 0.015 - 0.040 mm | |
| Permissible clearance of connecting rod bearing | 0.006 - 0.031 mm | |
| Permissible axial clearance of the connecting rod | 0.07 - 0.24 mm | |
Engine 2.4 l | ||
| cylinder head | ||
| Color coding | purple | |
| stamping marking | x 24 | |
| Cylinder head height | 102.45 - 102.925 mm | |
| Max flatness of the mating plane with the cylinder block | 150 mm 0.015 mm | |
| Max. flatness over the entire length | 0.050 mm | |
| Max. non-flatness of interface planes with pipelines | 0.10 mm | |
| Gasket thickness | 0.80 - 0.90 mm | |
| Clearance in mating the valve stem with the guide: - intake valves - exhaust valves | 0.04 mm, max. 0.03 mm, max. | |
| valve seats | ||
| Chamfer angle | 45° | |
| Lower correction angle | 75° | |
| Upper correction angle | 15° | |
| Valve markings: - given size - repair enlarged 1 - repair enlarged 2 - repair enlarged 3 | No white green No | |
| valves | ||
| Valve Stem Diameter - Inlet Valve: - given size - enlarged by 0.075 mm, repair - increased by 0.150 mm, repair 2 - increased by 0.300 mm, repair 3 | 8.990 - 8.977 mm 1 9.065 - 9.052 mm 9.140 - 9.127 mm 9.290 - 9.277 mm | |
| Valve Stem Diameter - Exhaust Valves: - given size - increased by 0.075 mm, repair 1 - increased by 0.150 mm, repair 2 - increased by 0.300 mm, repair 3 | 8.980 - 8.965 mm 9.055 - 9.040 mm 9.055 - 9.040 mm 9.280 - 9.265 mm | |
| Clearance in mating the valve with the guide: - intake valves - exhaust valves | 0.035 - 0.073 mm 0.045 - 0.085 mm | |
| Valve disc diameter: - intake valves - exhaust valves | 45.0 mm 40.0 mm | |
| Valve length: - intake valves - exhaust valves | 123.0 mm 123.7 mm | |
| Camshaft | ||
| Shaft designation | U | |
| Shaft color code - normal size - repair, reduced by 0.10 mm | Blue/brown Violet | |
| Max. shaft runout | 0.025 mm | |
| Shaft axial clearance | 0.10 - 0.20 mm | |
| Cam stroke | 6.68mm both valves | |
| Clearance in conjunction with bearings: - normal value - wear limit | 0.04 - 0.082 mm 0.11mm | |
| Neck diameter | Necks have different diameters. Shafts with a 0.1 mm smaller journal diameter are marked purple. Repair diameters are given in brackets: - bearing No. 1 48.970 - 48.955 mm (48.870 - 48.855 mm); - bearing no. 2 48.720 - 48.705 mm (48.620 - 48.605 mm); - bearing no. 3 48.595 - 48.580 mm (48.495 - 48.480 mm); - bearing no. 4 48.470 - 48.485 mm (43.370 - 48.355 mm) | |
| Holes in the camshaft bearing housing | The hole diameters are different, as are the diameters of the camshaft journals. Repair dimensions are given in parentheses - bearing no. 1 53.350 - 53.500 mm - bearing no. 2 53.280 - 53.250 mm - bearing no. 3 53.030 - 53.000 mm - bearing no. 4 52.780 - 52.750 mm | |
| Pistons and connecting rods | ||
| Installation direction | Arrow to the distribution side | |
Piston diameter | - 94.92 mm (6 on the piston crown, 5 on the cylinder block); 94.92 mm (8 on the piston crown, 7 on the cylinder block); 94.94 mm (6 on the piston crown, 5 on the cylinder block) - 94.94 mm (8 on the piston crown, 8 on the cylinder block) 94.96 mm (00 on the piston crown, 99 on the cylinder block) 94.96 mm (00 on the piston crown, 0 on the cylinder block) 94.98 mm (02 on the piston crown, 01 on the cylinder block) 94.98 mm (02 on the piston crown, 02 on the cylinder block) 95.00 mm (04 on the piston crown, 03 on the cylinder block) - 95.00 mm (04 on the piston crown, 04 on the cylinder block) 95.02 mm (06 on the piston crown, 05 on the cylinder block) 95.02 mm (06 on the piston crown, 06 on the cylinder block) 95.04 mm (06 on the piston crown, 07 on the cylinder block) 95.04 mm (06 on the piston crown, 08 on the cylinder block) 95.04 mm (06 on the piston crown, 09 on the cylinder block) | |
| Repair size increased by 0.5 mm | 95.43 mm (7 + 0.5 on the piston crown, 95.47 on the cylinder block) 95.44 mm (8 + 0.5 on the piston crown, 95.48 on the cylinder block) 95.45 mm (9 + 0.5 on the piston crown, 95.49 on the cylinder block) 95.46 mm (0 + 0.5 on the piston crown, 95.50 on the cylinder block) | |
| Piston-cylinder clearance | 0.03mm | |
| piston pins | ||
| Length | 65.0 mm | |
| Finger landing | Floating in the connecting rod head | |
| Piston clearance | 0.006 - 0.013 mm | |
| Installation instructions | Heat the connecting rod head to 280°C | |
| Outside diameter | 22.0 mm | |
| Piston rings | ||
| Number of rings | 2 compression and 1 oil scraper | |
| Ring thickness: - top ring - middle ring - oil scraper ring | 1.478 - 1.490 mm 1.478 - 1.490 mm 2.975 - 2.990 mm | |
| Piston ring gaps: - compression rings - oil scraper ring | 0.40 - 0.65 mm 0.30 - 0.60 mm | |
| Clearance in pairing of the ring with the groove in the piston: - top ring - middle ring - oil scraper ring | 0.12 - 0.18 mm 0.05 - 0.15 mm 0.025 - 0.15 mm | |
| Connecting rod bearings | ||
| Type | With inserts | |
| Sorting of connecting rods by weight: - black marking - blue marking - green marking - white marking - gray marking | 648 - 656 g 652 - 660 g 656 - 664 g 654 - 672 g 668 - 676 g | |
| Axial clearance | all engines 0.11 - 0.24 mm | |
| Cylinder block | ||
| Nominal diameter of cylinders | The cylinder diameters correspond to the piston diameters. The marking of the cylinder block indicates the diameter, for example, "04" means the diameter is 95.04 mm, "09" is the diameter 95.09 mm | |
| Max. permissible cylinder diameter | 0.5 mm over nominal value | |
| Max. ovality and taper | 0.005mm | |
| Piston clearance | 0.02 - 0.05 mm | |
| Piston measurement points | At the bottom of the skirt, at right angles to the piston pin bore | |
| Crankshaft | ||
| Number of bearing | 5 | |
| Bearing type | With inserts | |
| Main bearing diameter Bearings #1-4: - nominal diameter - repair, reduced by 0.25 mm - repair, reduced by 0.50 mm Bearing No. 5 (guide) | 58.003 - 57.987 mm 57.753 - 57.737 mm 57.503 - 57.487 Like other bearings | |
| Guide Bearing Width: - nominal size - repair, reduced by 0.25 mm - repair, reduced by 0.50 mm | 27.512 - 27.450 mm 27.712 - 27.650 mm 27.912 - 27.650 mm | |
| Axial clearance of the crankshaft | 0.050 - 0.152 | |
| Permissible main bearing clearance | 0.02 - 0.060 mm | |
| Permissible clearance of connecting rod bearing | 0.034 - 0.079 mm | |
| Permissible axial clearance of the connecting rod | 0.11 - 0.24 mm | |
Gas distribution mechanism
Engine 2.4 l until 1995 release | |
| Toothed belt parameters: - number of teeth - belt width - tooth pitch | 111 20 mm 9.525 mm |
| Belt tension | Data match readings of the KM-510-A device |
| - New belt: - cold - heated - Used belt: - cold - heated | 0.5 7.5 2.5 7.0 |
| Toothed belt with tension roller - number of teeth - belt width - distance between teeth | 145 20 mm 8 mm |
Engine 2.0 l since the middle of 1995 of release | |
| Toothed belt parameters: - number of teeth - width - distance between teeth | 146 20 mm 8 mm |
Engine DOHC 2.2 l | |
| Timing belt parameters - number of teeth - width - distance between teeth | 171 24 mm 8 m |
Lubrication system
| The amount of oil to be filled | See Types and volumes of lubricants and fluids used |
| Difference between "Min" "Max" marks: | 1.0 l |
| Oil pressure at idle - all engines 2.0 l - engines 2.4 l - DOHC 2.2L engines | 1.5 bar 1.0 bar 1.5 bar |
| Oil pump: - type - gaps in gears: max. clearance between gear teeth and housing | gear 0.03 - 0.10 mm |
| Lateral clearance in the meshing of gears | 0.10 - 0.20 mm |
| Oil drain plug tightening torque | 55 Nm |
| Oil filter type | Main stream filter |
Tightening force of threaded connections, Nm
Note. Fastener tightening torques are also given in the text of the Chapter.
OHC 2.0 l engine until 1995 release
- Starter, gearbox side 75
- Starter, engine side 45
- The inlet pipeline to the block of cylinders 22
- Exhaust manifold to cylinder block 22
- Guide sleeve for release
- bearing to gearbox 22
- Generator to console 25
- Gearbox to engine 75
- Generator console to cylinder block 40
- Engine support holder to gearbox 60 (new stop plate)
- Engine support holder to gearbox 60
- Engine support to longitudinal beam 65
- Engine support to front axle beam 40
- Camshaft bearing cap 8
- Pump/compressor console to engine 40
- Oil line to cylinder block 6 (for sealant)
- Rear timing belt cover 6
- Crankshaft pulley to timing gear 20
- Main bearing cap bolts 60 + 40 to 50° (replace bolts)
- Bolts of fastening of covers of bearings of a camshaft 45
- Connecting rod bearing cap bolts:
- 1 reception 35
- 2 reception tighten 45° (use new bolts)
- Oil drain plug 45
- Oil pressure gauge sensor to oil pump 30
- Oil pan to cylinder block 8 (on sealant)
- The pallet of a crankcase to the block of cylinders (curing) 15 (on sealant)
- Oil line to oil pump 8
- Power steering pump to cylinder block 30
- Flywheel to crankshaft 65 (bolts are always replaced)
- Support to generator 25
- Starter support to cylinder block 15
- Thermostat housing to cylinder head 15
- Silencer to exhaust pipe flange 25
- Front timing belt cover 4
- Oil pump to cylinder block 25
- Gear to crankshaft:
- 1 reception 130
- 2nd reception tighten by an angle of 40 - 50°
- Tension roller to oil pump 25
- Spark plug 25
- Cylinder head bolts:
- 1 reception 25
- Step 2 Tighten 90°
- Step 3 Tighten 90°
- Step 4 Tighten 90°
- Fuel line to intake manifold 8
- Earth cable to cylinder head 20
- Oil filter 15
- Cable harness to camshaft bearing housing 8
- Cable harness to toothed belt cover 4
OHC 2.0 L engine from mid-1995 release
- Starter to cylinder block 60
- The inlet pipeline to a head of cylinders 22
- Exhaust manifold to cylinder block 22
- Drive flange to crankshaft (automatic transmission) 60
- Vibration damper to crankshaft 20
- Crankcase ventilation flange to cylinder block 25
- An asterisk of the sensor of angular speed to a cranked shaft 13
- The console of the additional unit to the block of cylinders 35
- Starter support to cylinder block 25
- Arm of fastening of the generator to the block of cylinders 35
- Oil receiver pipe to cylinder block 6
- The hydraulic booster pump to a beam of the power unit 25
- Compressor console, rear bolts 18
- Rear toothed belt cover to oil pump and camshaft bearing housing 6
- Cable holder to camshaft bearing housing 8
- Cable channel to toothed belt front cover 4
- V-belt tensioner to auxiliary unit beam 35
- Knock sensor to cylinder block 25
- Console for attaching the compressor to the unit beam 35
- Fuel distribution line to exhaust manifold 8
- Coolant pump to cylinder block 25
- Coolant temperature sensor to hose 11
- Coolant temperature sensor in thermostat housing 10
- Crankshaft speed sensor in cylinder block 6
- Main bearing cap bolts 50 NCm + 45°+ 15°
- Bearing bridge and oil damping sheet to cylinder block 20
- Silencer oxygen sensor 30
- Power steering pump support to cylinder block 20
- Ground cable to cylinder block 20
- Engine mount rear to gearbox 80
- Engine mount rear to cross member 50
- Front engine support to the engine beam 85
- Front engine support to chassis 50
- Beam to cylinder block 60
- Engine bracket to gearbox and cylinder block 40
- Lifting eye to the camshaft bearing housing 15
- Cover to camshaft bearing housing 8
- Camshaft gear to shaft 45
- Oil drain plug in the oil pan 55
- Oil receiver pipe to oil pump 8
- Oil pressure gauge sensor to oil pump 40
- Oil filter to oil pump 15
- Oil cooler holders to radiator 25
- Oil pump to cylinder block 6
- Oil pump cover to pump 6
- Oil pan to oil pump and cylinder block:
- until 1997 release 15
- since 1997 release 20
- Connecting rod bearing cap to connecting rod:
- 1 reception 35
- Step 2 Tighten 45°
- Step 3 Tighten 15°
- Bolts of fastening of a protective sheet of the pallet sump 57
- Flywheel to crankshaft:
- 1 reception 65
- Step 2 Tighten 30°
- Step 3 Tighten 15°
- Strut to the exhaust manifold and generator 18
- Support to intake manifold and generator 18
- Thermostat housing to cylinder block 15
- Pressure reducing valve to oil pump 30
- Vacuum line of brake booster to inlet line 20
- The lower bolt of fastening of the generator to the console 35
- Front toothed belt cover to rear 4
- Front bolts of fastening of the compressor to a beam of the unit 35
- Downpipe with catalytic converter to exhaust manifold and muffler 25
- Heat shield to cylinder head 30
- Gear to crankshaft:
- 1 reception 130
- Step 2 Tighten 40 - 50°
- Timing belt tensioner to oil pump 25
- Spark plugs 25
- Flywheel to crankshaft:
- 1 reception 65
- 2 prem Tighten by 45°
- Step 3 Tighten 15°
- Head to cylinder block:
- 1 reception 25
- Step 2 Tighten 90°
- Step 3 Tighten 90°
- Step 4 Tighten 90°
Engine DOHC 2.2 l
- Starter to cylinder block 60
- The inlet pipeline to a head of cylinders 22
- Exhaust manifold to cylinder block 22
- Drive flange to crankshaft (automatic transmission) 60
- Ignition module to adapter 8
- Vibration damper to crankshaft 20
- Crankcase ventilation flange to cylinder block 25
- An asterisk of the sensor of angular speed to a cranked shaft 13
- The console of the additional unit to the block of cylinders 35
- Starter support to cylinder block 25
- Arm of fastening of the generator to the block of cylinders 35
- Oil receiver pipe to cylinder block 6
- The hydraulic booster pump to a beam of the power unit 25
- Compressor console, rear bolts 18
- Compressor console, front bolts 35
- Rear toothed belt cover to oil pump and camshaft bearing housing 6
- Cable holder to camshaft bearing housing 8
- Cable channel to toothed belt front cover 4
- V-belt tensioner to auxiliary unit beam 35
- Knock sensor to cylinder block 20
- Console for attaching the compressor to the unit beam 35
- Fuel distribution line to exhaust manifold 8
- Coolant pump to cylinder block 25
- Coolant temperature sensor to hose 11
- Coolant temperature sensor in thermostat housing 10
- Crankshaft speed sensor in cylinder block 6
- Main bearing cap bolts 50 Nm + 45°+ 15°
- Bearing bridge and oil damping sheet to cylinder block 20
- Silencer oxygen sensor 30
- Power steering pump support to cylinder block 20
- Ground cable to cylinder block 20
- Engine mount rear to gearbox 80
- Engine mount rear to cross member 50
- Front engine support to the engine beam 85
- Front engine support to chassis 50
- Beam to cylinder block 60
- Engine bracket to gearbox and cylinder block 40
- Lifting eye to the camshaft bearing housing 15
- Camshaft bearing housing 8
- Cover to camshaft bearing housing 8
- Camshaft gear to shaft 45
- Oil drain plug in the oil pan 45
- Oil receiver pipe to oil pump 8
- Oil pressure gauge sensor to oil pump 40
- Oil filter to oil pump 15
- Oil cooler holders to radiator 25
- Oil pump to cylinder block 6
- Oil pump cover to pump 6
- Oil pan to oil pump and cylinder block:
- until 1997 release 15
- since 1997 release 20
- Connecting rod bearing cap to connecting rod:
- 1 reception 35
- Step 2 Tighten 45°
- Step 3 Tighten 15°
- Bolts of fastening of a protective sheet of the pallet sump 57
- Flywheel to crankshaft:
- 1 reception 65
- Step 2 Tighten 30°
- Step 3 Tighten 15°
- Strut to the exhaust manifold and generator 18
- Support to intake manifold and generator 18
- Thermostat housing to cylinder block 15
- Pressure reducing valve to oil pump 30
- Vacuum line of brake booster to inlet line 20
- The lower bolt of fastening of the generator to the console 35
- Front toothed belt cover to rear 4
- Downpipe with catalytic converter to exhaust manifold and muffler 25
- Heat shield to cylinder head 30
- Gear to crankshaft:
- 1 reception 130
- Step 2 Tighten 40 - 50°
- Timing belt tensioner to oil pump 25
- Spark plugs 25
- Flywheel to crankshaft:
- 1 reception 65
- 2 prem Tighten by 45°
- Step 3 Tighten 15°
- Head to cylinder block:
- 1 reception 25
- Step 2 Tighten 90°
- Step 3 Tighten 90°
- Step 4 Tighten 90°
Engine 2.4 l
- Bolts of fastening of the pump of the hydraulic booster 25
- Compressor mounting bolts (air conditioner) 50
- Generator holders 25
- Clamp bolt for compressor adjusting bolt 45
- Clamp bolt, power steering pump to adjusting bolt (with air conditioning) 40
- Clamp bolt, power steering pump to adjusting bolt (without air conditioning) 25
- V-belt adjusting bolt lock 40
- Oxygen sensor 30
- Eyebolt, V-belt adjusting bolt 25
- Camshaft chain tensioner bolts 50
- Bolts of fastening of a final collector 35
- Bolt of fastening of a wheel of a cranked shaft 120
- Clutch basket mounting bolts 22
- Main bearing bolts 120
- Engine support to longitudinal beam 52
- Engine support to beam 85
- Bolts of fastening of a cogwheel of a camshaft 25
- Oil pan 8
- Connecting rod bearing cap bolts 43
- Flywheel mounting bolts 60
- Bolts of fastening of the case of the mechanism of distribution 15
- Bolts of fastening of a cogwheel of a drive of the mechanism of distribution 25
- Bolts of fastening of the pump of a cooling liquid 15
- Bolts of fastening of a head of cylinders to the case of the mechanism of distribution 25
- Nut of the tension mechanism of the V-belt of the coolant pump 25
- Valve rocker pin 40
- Thermal sensor 10
- Spark plugs 40
- cylinder head bolts:
- 1 reception 60
- 2 reception 90 + 35°
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