Specifications of all engines (Opel Astra G)

Contents: General parameters ⬇ Designations of engines covered in…⬇ Main performance characteristics ⬇ Cylinder head ⬇ Camshaft ⬇ Valves and guide bushings ⬇ Balancing assembly (2.0 DOHC petrol…⬇ Cylinder block ⬇ Connecting rod and piston assemblies ⬇ Crankshaft ⬇ Lubrication system ⬇

General parameters

Full list of engines used to equip Opel Astra-G/ Zafira models

Petrol engines

Astra-G

Working volume (l)	Code designation	Type	Developed power kW (hp)	Year of issue
1.2	X12XE	1.2i 16V DOHC	kW (hp)	03/1988-
1.2	Z12XE	1.2i 16V DOHC	48 (65)	sep.00
1.4	X14XE	1.4i 16V DOHC	55 (75)	03/1998-
1.4	Z14XE	1.4i 16V DOHC	66 (89)	09/2000-
1.6	X16SZR	1.6i SOHC	66 (89)	03/1998-08/2000
	X16XEL	1.6i 16V DOHC	55 (75)	03/1998-08/2000
	C16SEL	1.6i SOHC	74 (100)	09/1998-
	C16SEL	1.6i CS, CD, CDE DOHC 16V	74 (100)	10/1999-
	Z16SE	1.6i SOHC	74 (100)	09/2000-
	Z16XE	1.6i 16V DOHC	62 (85)
	Z16XE	Cabrio 1.6i 1 DOHC	74 (100)	03/2001-
1.8	X18XE1	1.8i 16V DOHC	74 (100)	03/1998-08/2000
	X18XE1	Coupe 1.8i 16V DOHC	85 (115)	09/1999-08/2000
	X18XE1	1.8i CDE, CSE 16V DOHC	85 (115)	oct.99
	Z18XE	Coupe 1.8i 16V DOHC	85 (115)	09/2000-
	Z18XE	1.8i 16V DOHC	92 (125)	09/2000-
	Z18XEL	Coupe 1.8i DOHC	92 (125)	03/2001-
	Z18XE	Cabrio 1.8i 1 DOHC	85 (115)	03/2001-
2.0	X20XEV	2.0i 16V DOHC	92 (125)	03/1988-
	C20SEL	2.0i CDX, CSX DOHC	100 (136)	10/1999-
	Z20XER	2.0i 16V DOHC	95 (129)	09/2000-
	Z20LET	Coupe 2.0i 16V DOHC	118 (160)	12/2000-
2.2	Z22SE	2.2i 16V DOHC	141 (192)	09/2000-
	Z22SE	Coupe 2.2i 16V DOHC	108 (147)	12/2000-
	Z22SE	Cabrio 2.2i 1 DOHC	108 (147)	03/2001-

Zafira

Working volume (l)	Code designation	Type	Developed power kW (hp)	Year of issue
1.6	X16XEL	1.6i 16V DOHC	74 (100)	03/1999-08/2000
	Z16XEL	1.6i 16V DOHC	74 (100)	09/2000-
	CNG (Gasmotor)	1.6i 16V	71 (96)	09/2001-
1.8	X18XE1	1.8i 16V DOHC	85 (115)	03/1999-08/2000
1.8	Z18XE	1.8i 16V DOHC	92 (125)	09/2000-
2.0	Z20	2.0 16V Turbo	141 (192)	09/2001-
2.1	Z22SE	2.2 16V DOHC	108 (147)	09/2000-

Diesel engines

Astra-G

Working volume (l)	Code designation	Type	Developed power kW (hp)	Year of issue
1.7	X17DTL	1.7DTL SOHC-Turbo	50 (75)	03/1998-08/2000
	Y17DT	1.7DT DOHC	55 (75)	09/2000-
	Y17DIT	1.7DIT DOHC-Turbo	55 (75)	08/2000-
2.0	X20DTL	2.0DTL 16V SOHC-Turbo	60 (82)	03/1998-08/2000
	Y20DTL	2.0DTL 16V SOHC-Turbo	60 (82)	09/2000-
	Y20DTH	2.0DTH 16V SOHC-Turbo	74 (100)	09/2000-
2.2	Y2.2DTR	2.2DTR	-	-

Zafira

Working volume (l)	Code designation	Type	Developed power kW (hp)	Year of issue
2.0	X20DTL	2.0DTL 16V SOHC-Turbo	60 (82)	03/1998-08/2000
2.0	Y20DTL	2.0DTL 16V SOHC-Turbo	74 (100)	09/2000-
2.2	Y2.2DTR	2.2DTR	-	-

Designations of engines covered in this Manual

Petrol engines

1.6L 8-valve SOHC engine	X16SZR
16-valve DOHC engines
1.4 l	X14XE
1.6 l	X16XEL
1.8 l	X18XE1
2.0 l	X20XEV

Diesel engines

1.7L SOHC 8-valve engine with low-pressure turbocharged	X17DTL
1.7L 16-valve DOHC non-turbo engine	Y17DT
2.0L 16-valve DOHC low-pressure turbocharged engine	X20DTL/Y20DTL
2.0L 16-valve DOHC high-pressure turbocharged engine	Y20DTH

Main performance characteristics

Working volume of cylinders, cm³

Petrol engines
1.2 l	1199
1.4 l	1389
1.6 l	1598
1.8 l	1796
2.0 l	1998
2.2 l	2198
Diesel engines
1.7 l	1686
2.0 l	1995
2.2 l	2172

Engine power, kW (at rpm)/Torque, Nm (at rpm)

X12XE	48(5600)/110(4000)
Z12XE	55(5600)/110(4000)
Z14XE/X14XE	66(6000)/125(4000)
Z16SE/X16SE	62(5400)/138(2600)
Z16XE/X16XE	74(6000)/150(3600)
Z16XEP/X16XEP	76(6000)/147(3600)
Z18XE/X18XE	92(5600)/170(3800)
Z20LET/X20LET	141(5400)/250(1950—5300)
X20XEV	100(5600)/188(3400)
X20XER	118(6800)/188(4300)
Z22SE/X22SE	108(5800)/203(4000)
Y17DT/X17DT	55(4400)/165(1800—3000)
Y17DT (ECO)	55(4400)/165(1800—3000)
X20DTL/Y20DTL	60(4300)/185(1800—2750)
Y20DTH	74(4300)/230(1950—2500)
Y22DTR	92(4000)/280(1500—2750)

Compression ratio

Z12XE/X12XE	10.1:1
Z14XE/X14XE	10.5:1
X16SZR	9.6:1
Z16SE/X16SE	9.6:1
Z16XE/X16XE	10.5:1
Z16XEP/X16XEP	10.5:1
Z18XE/X18XE	10.5:1
Z20LET/X20LET	8.8:1
X20XEV	10.8:1
X20XER	10.8:1
Z22SE/X22SE	10.0:1
Y17DT/X17DT	18.4:1
Y17DT (ECO)	18.4:1
X20DTL/Y20DTL	18.5:1
Y20DTH	18.5:1
Y22DTR	18.5:1

Compression pressure

The data is provided only for the engines discussed in this Manual.

Petrol engines
Nominal value (all considered in the Guide engines), bar	12—15
Maximum permissible difference between cylinders (all considered in the Engine Manual), bar	1
Diesel engines
Nominal value, bar
X17DT Engines	12—15
Y17DT Engines	26—30
X20DTL/Y20DTL and Y20DTH motors	25—28
Maximum permissible difference between cylinders, bar
X17DT Engines	1
Y17DT Engines	1
X20DTL/Y20DTL and Y20DTH motors	1

Maximum allowable rotation speed, rpm

Z12XE/X12XE	6250
Z14XE/X14XE	6400
Z16SE/X16SE	6000
Z16XE/X16XE	6400
Z16XEP/X16XEP	6400
Z18XE/X18XE	6400
Z20LET/X20LET	6400
X20XEV	Data not provided
X20XER	Data not provided
Z22SE/X22SE	6500
Y17DT/X17DT	5100—5300
Y17DT (ECO)	5200
X20DTL/Y20DTL	4750
Y20DTH	4950—5050
Y22DTR	4920—5080

Arrangement/number of cylinders/number of valves per cylinder

SOHC engines	in-line/4/2
DOHC engines	in-line/4/4

Cylinder firing order

1-3-4-2 (the first cylinder is located on the timing drive side)

Normal direction of rotation of the crankshaft

Clockwise

Cylinder diameter, mm

Z12XE/X12XE	72.5
Z14XE/X14XE	77.6
Z16SE/X16SE	79.0
Z16XE/X16XE	79.0
Z16XEP/X16XEP	79.0
Z18XE/X18XE	80.5
Z20LET/X20LET	86.0
X20XEV	86.0
X20XER	86.0
Z22SE/X22SE	86.0
Y17DT/X17DT	79.0
Y17DT (ECO)	79.0
X20DTL/Y20DTL	84.0
Y20DTH	84.0
Y22DTR	84.0

Piston stroke, mm

Z12XE/X12XE	72.6
Z14XE/X14XE	73.4
Z16SE/X16SE	81.5
Z16XE/X16XE	81.5
Z16XEP/X16XEP	81.5
Z18XE/X18XE	88.5
Z20LET/X20LET	86.0
X20XEV	86.0
X20XER	86.0
Z22SE/X22SE	94.5
Y17DT/X17DT	86.0
Y17DT (ECO)	86.0
X20DTL/Y20DTL	90.0
Y20DTH	90.0
Y22DTR	98.0

Operating parameters of engines

Operating parameters are given only for the engines discussed in this Manual (see above).

Dimensional characteristics of valve installation

1 — Cylinder head height

2 — Valve guide bushing installation height

3 — Valve installation height

4 — Width of the working chamfer of the valve seat in the cylinder head

5 — Valve seat chamfer angle

6 — Valve stem diameter

7 — Valve plate chamfer angle

8 — Valve length

9 — Valve plate diameter

Cylinder head

Maximum permissible non-flatness of the mating surface, mm

Petrol engines	0.05
Diesel engines
Engines 1.7 l SOHC and DOHC	0.1
2.0L Engines	Data not provided

Cylinder head height, mm

Petrol engines
Engine 1.6L SOHC	95.9—96.1
Engines 1.4, 1.6 l DOHC	134.9—135.1
Engine 1.8L DOHC	135.8—36.0
Engine 2.0L DOHC	134
Diesel engines
Engine 1.7L SOHC
Nominal value	106.10
Maximum permissible value	105.75
Engines 1.7L DOHC	94.95—95.05
2.0L Engines	140.0

Width of working chamfers of valve seats, mm

Petrol engines
Engine 1.6L SOHC
Intake valves	1.3—1.5
Exhaust valves	1.6—1.8
Engines 1.4, 1.6, 1.8 and 2.0 l DOHC
Intake valves	1.0—1.4
Exhaust valves	1.4—1.8
Diesel engines
Engine 1.7 SOHC (inlet and outlet)
Nominal value	1.3
Maximum permissible value	2.0
Engines 1.7L DOHC (inlet and outlet)	1.5—1.7
2.0L Engines (inlet and outlet)	1.4—1.8

Valve seat chamfer angle

Diesel engines 1.7L DOHC

90°

Camshaft

Axial clearance, mm

Petrol engines
Engine 1.6L SOHC	0.09—0.21
Engines 1.4, 1.6, 1.8 and 2.0 l DOHC	0.04—0.015
Diesel engines
Engine 1.7L SOHC	0.05—0.20
Engine 1.7L DOHC	Data not provided
2.0L Engines	0.04—0.14

Maximum permissible value of radial runout, mm

Petrol engines	0.040
Diesel engines
Engines 1.7 l SOHC and DOHC	0.05
2.0L Engines	0.06

Height of cam lift, mm

Petrol engines
Engine 1.6L SOHC
Intake valves	5.61
Exhaust valves	6.12
Engines 1.4, 1.6,1.8 DOHC
Intake valves	8.5
Exhaust valves	8.0
2.0L DOHC
Intake valves	10.0
Exhaust valves	10.0
Diesel engines
Engine 1.7L SOHC
Intake valves	9.40
Exhaust valves	9.40
Engine 1.7L DOHC
Intake valves	7.68
Exhaust valves	7.77
2.0L Engines
Intake valves	8.0
Exhaust valves	8.0

The size of the clearances in the support bearings

Data not provided

Valves and guide bushings

Height of protrusion of guide bushings above head surface, mm

Petrol engines
Engine 1.6L SOHC	80.85—81.25
Engines 1.4, 1.6 and 1.8 l DOHC	10.70—11.00
Engine 2.0L DOHC	13.7—14.0
Diesel engines
2.0L Engines	11.20—11.50

Valve stem diameter, mm

Petrol engines
Engine 1.6L SOHC
Standard size (identification mark K)
Intake valves	6.998—7.012
Exhaust valves	6.978—6.992
Repair size 0.075 mm (identification mark K1)
Intake valves	7.073—7.087
Exhaust valves	7.053—7.067
Repair size 0.150 mm (identification tag K2)
Intake valves	7.148—7.162
Exhaust valves	7.128—7.142
Engines 1.4 and 1.6 l DOHC
Standard size (gM identification tag)
Intake valves	5.995—5.970
Exhaust valves	5.935—5.950
Repair size 0.075 mm (identification mark K1)
Intake valves	6.030—6.045
Exhaust valves	6.010—6.025
Repair size 0.150 mm (identification tag K2)
Intake valves	6.105—6.120
Exhaust valves	6.085—6.100
Engines 1.8L DOHC
Standard size (gM identification tag)
Intake valves	4.955—4.970
Exhaust valves	4.935—4.950
Engine 2.0L DOHC
Standard size (gM identification tag)
Intake valves	5.955—5.970
Exhaust valves	5.945—5.960
Repair size 0.075 mm (identification mark K1)
Intake valves	6.030—6.045
Exhaust valves	6.020—6.035
Repair size 0.150 mm (identification tag K2)
Intake valves	6.105—6.120
Exhaust valves	6.095—6.110
Diesel engines
Engines 1.7L DOHC
Standard size
Intake valves	7.970—7.985
Exhaust valves	7.955—7.970
Repair size 0.075 mm
Intake valves	8.045—8.060
Exhaust valves	8.030—8.045
Repair size 0.150 mm
Intake valves	8.120—8.135
Exhaust valves	8.105—8.120
Engines 1.7L DOHC
Intake valves	6.00
Exhaust valves	6.00
2.0L Engines
Standard size (identification mark K)
Intake valves	5.955—5.970
Exhaust valves	5.945—5.960
Repair size 0.075 mm (identification mark K1)
Intake valves	6.030—6.045
Exhaust valves	6.020—6.035
Repair size 0.150 mm (identification tag K2)
Intake valves	6.105—6.120
Exhaust valves	6.095—6.110

Maximum permissible valve runout, mm

All engines

0.03

Inner diameter of guide bushings, mm

Petrol engines
Engine 1.6L SOHC
Standard size (identification mark K)	7.030—7.050
Repair size 0.075 mm (identification mark K1)	7.105—7.125
Repair size 0.150 mm (identification tag K2)	7.180—7.200
Engines 1.4 and 1.6 l DOHC
Standard size (gM identification tag)	6.000—6.012
Repair size 0.075 mm (identification mark K1)	6.075—6.090
Repair size 0.150 mm (identification tag K2)	6.150—6.165
Engines 1.8L DOHC
Standard size	5.000—5.012
Repair size 0.075 mm	5.075—5.087
Repair size 0.150 mm	5.150—5.162
Engine 2.0L DOHC
Standard size (gM identification tag)	6.000—6.012
Repair size 0.075 mm (identification mark K1)	6.075—6.090
Repair size 0.150 mm (identification tag K2)	6.150—6.165
Diesel engines
Engines 1.7L DOHC
Standard size	8.000—8.017
Repair size 0.075 mm	8.075—8.092
Repair size 0.150 mm	8.150—8.167
Engines 1.7L DOHC	7.000—7.015
2.0L Engines
Standard size (identification mark K)	6.000—6.012
Repair size 0.075 mm (identification mark K1)	6.075—6.090
Repair size 0.150 mm (identification tag K2)	6.150—6.165

Valve stem seat clearance in guide bushing, mm

Petrol engines
Engine 1.6L SOHC
Intake valves	0.018—0.052
Exhaust valves	0.038—0.072
Engines 1.4, 1.6 and 1.8 l DOHC	Data not provided
Engine 2.0L DOHC
Intake valves	0.030—0.057
Exhaust valves	0.040—0.067
Diesel engines
Engine 1.7L SOHC
Nominal value
Intake valves	0.015
Exhaust valves	0.030
Maximum permissible value
Intake valves	0.047
Exhaust valves	0.062
Engines 1.7L DOHC
Nominal value
Intake valves	0.019
Exhaust valves	0.0215
Maximum permissible value	Data not provided
2.0L Engines	Data not provided

Valve length, mm

Petrol engines
Engine 1.6L SOHC
Intake valves	99.35
Exhaust valves	99.65
Engines 1.4 and 1.6 l DOHC
Intake valves	101.51—101.93
Exhaust valves	100.55—100.97
Engine 1.8L DOHC
Intake valves	100.1—100.3
Exhaust valves	99.4—99.6
Engine 2.0L DOHC
Intake valves	102.0—102.2
Exhaust valves	92.15—92.35
Diesel engines
Engine 1.7L SOHC	123.22—123.27
Engines 1.7L DOHC
Intake valves	98.45
Exhaust valves	98.10
2.0L Engines
Intake valves	97.1—97.2
Exhaust valves	96.9—97.0

Height of installed valves, mm

1.6L SOHC petrol engine

13.75—14.35

Valve plate diameter, mm

Petrol engines
Engine 1.6L SOHC
Intake valves	38.0
Exhaust valves	31.0
Engines 1.4 and 1.6 l DOHC
Intake valves	31.0
Exhaust valves	27.5
Engine 1.8L DOHC
Intake valves	31.2
Exhaust valves	27.5
Engine 2.0L DOHC
Intake valves	31.9—32.1
Exhaust valves	28.9—29.1
Diesel engines
Engine 1.7L SOHC
Intake valves	36.0
Exhaust valves	32.0
Engines 1.7L DOHC
Intake valves	27.15
Exhaust valves	28.5
2.0L Engines
Intake valves	28.9—29.1
Exhaust valves	25.9—26.1

Angle of inclination of working chamfers of valve plates

Diesel engines 1.7L DOHC

89°

Valve guide bush length, mm

Diesel engines 1.7L DOHC

41.75—42.25

Valve clearances on a cold engine (only diesel engine 1.7L DOHC), mm

Intake valves	0.4 ±0.5
Exhaust valves	0.4 ±0.5

Balancing assembly (2.0 DOHC petrol engine when equipped accordingly)

Gap size, mm

0.02—0.6

The ratio of the plate code to its thickness

Code 55	0.535—0.565
Code 58	0.565—0.595
Code 61	0.595—0.625
Code 64	0.625—0.655
Code 67	0.655—0.685
Code 70	0.685—0.715
Code 73	0.715—0.745
Code 76	0.745—0.775
Code 79	0.775—0.805
Code 82	0.805—0.835
Code 85	0.835—0.865

Cylinder block

Maximum permissible non-flatness of the mating surface, mm

Petrol engines	0.05
Diesel engines
Engines 1.7 l SOHC and DOHC	0.1
2.0L Engines	Data not provided

Cylinder diameter, mm

Petrol engines
Engines 1.6L SOHC
Standard size
Group 8	78.975—78.985
Group 99	78.985—78.995
Group 00	78.995—79.005
Group 01	79.005—79.015
Group 02	79.015—79.025
Repair size 0.5 mm (Group 7)	79.465—79.475
Engines 1.4L DOHC
Standard size
Group 8	77.575—77.585
Group 99	77.585—77.595
Group 00	77.595—77.605
Group 01	77.605—77.615
Group 02	77.615—77.625
Repair size 0.5 mm (Group 7)	78.065—78.075
Engines 1.6L DOHC
Standard size
Group 8	78.975—78.985
Group 99	78.985—78.995
Group 00	78.995—79.005
Group 01	79.005—79.015
Group 02	79.015—79.025
Repair size 0.5 mm (Group 7)	79.465—79.475
Engines 1.8L DOHC
Standard size
Group 99	80.485—80.495
Group 00	80.495—80.505
Group 01	80.505—80.515
Group 02	80.515—80.525
Repair size 0.5 mm (Group 00)	80.995—81.005
Engine 2.0L DOHC
Standard size
Group 8	85.975—78.985
Group 99	85.985—85.995
Group 00	85.995—86.005
Group 01	86.005—86.015
Group 02	86.015—86.025
Repair size 0.5 mm (Group 7)	86.465—86.475
Diesel engines
Engine 1.7L SOHC
Standard size
Group 8	82.475—82.485
Group 99	82.485—82.495
Group 00	82.495—82.505
Group 01	82.505—82.515
Group 02	82.515—82.525
Repair size 0.5 mm (Group 7)	82.965—82.975
Engines 1.7L DOHC
Group A	79.000—79.009
Group B	79.010—79.019
Group C	79.020—79.029
2.0L Engines
Standard size
Group 8	83.975—83.985
Group 99	83.985—83.995
Group 00	83.995—84.005
Group 01	84.005—84.015
Group 02	84.015—84.025
Repair size 0.5 mm	84.465—84.475

Inner diameter of main bearing beds without liners (1.7L DOHC diesel engines only), mm

Group 1	55.992—56.000
Group 2	55.984—55.992
Group 3	55.976—55.984

Maximum permissible ovality of cylinders, mm

Petrol engines

0.013

Maximum permissible taper of cylinders, mm

Petrol engines	0.013
Diesel engines
Engines 1.7 l SOHC and DOHC	0.015
2.0L Engines	Data not provided

Connecting rod and piston assemblies

Pistons and piston rings

Piston diameter, mm

Petrol engines
Engines 1.6L SOHC
Standard size
Group 8	78.955—78.965
Group 99	78.965—78.975
Group 00	78.975—78.985
Group 01	78.985—78.995
Group 02	78.995—79.005
Repair size 0.5 mm (Group 7)	79.445—79.455
Engines 1.4L DOHC
Standard size
Group 8	77.555—77.565
Group 99	77.565—77.575
Group 00	77.575—77.585
Group 01	77.585—77.595
Group 02	77.595—77.605
Repair size 0.5 mm (Group 7)	78.045—78.055
Engines 1.6L DOHC
Standard size
Group 8	78.955—78.965
Group 99	78.965—78.975
Group 00	78.975—78.985
Group 01	78.985—78.995
Group 02	78.995—79.005
Repair size 0.5 mm (Group 7)	79.445—79.455
Engines 1.8L DOHC
Standard size
Group 99	80.455—80.465
Group 00	80.465—80.475
Group 01	80.475—80.485
Group 02	80.485—80.495
Repair size 0.5 mm (Group 00)	80.965—80.975
Engine 2.0L DOHC
Standard size
Group 8	85.945—78.955
Group 99	85.955—85.965
Group 00	85.965—85.975
Group 01	85.975—85.985
Group 02	85.985—85.995
Repair size 0.5 mm (Group 7)	86.435—86.445
Diesel engines
Engine 1.7L SOHC
Standard size
Group 8	82.445—82.455
Group 99	82.455—82.465
Group 00	82.465—82.475
Group 01	82.475—82.485
Group 02	82.485—82.495
Repair size 0.5 mm (Group 7)	82.935—82.945
Engines 1.7L DOHC
Group A	78.930—78.939
Group B	78.940—78.949
Group C	78.950—78.959
2.0L Engines
Engine X20DTL/Y20DTL
Standard size
Group 8	83.905—83.915
Group 99	83.915—83.925
Group 00	83.925—83.935
Group 01	83.935—83.945
Group 02	83.945—83.955
Repair size 0.5 mm	84.395—84.405
X20DTH Engine
Standard size
Group 8	83.885—83.915
Group 99	83.895—83.905
Group 00	83.905—83.915
Group 01	83.915—83.925
Group 02	83.925—83.935
Repair size 0.5 mm	84.375—84.385

Piston clearance in cylinder, mm

Petrol engines	0.02—0.04
Diesel engines
Engine 1.7L SOHC	0.02—0.04
Engine 1.7L DOHC	0.061—0.08
2.0L Engines
Engine X20DTL/Y20DTL	0.06—0.08
Y20DTH Engine	0.08—0.10

Piston protrusion value (diesel engines 1.7 l), mm

SOHC Engine	0.65—0.095
DOHC Engine	0.063—0.083

Clearances in piston ring locks, mm

Petrol engines
Compression rings	0.3—0.5
Oil scraper ring	0.4—1.4
Diesel engines
Engine 1.7L SOHC
Compression rings	0.20—0.40
Oil scraper ring	0.25—0.50
Engine 1.7L DOHC
Upper compression ring	0.25—0.35
Second compression ring	0.20—0.30
Oil scraper ring	0.20—0.40
2.0L Engines
Compression rings	0.25—0.50
Oil scraper ring	0.25—0.50

Piston ring thickness, mm

Petrol engines
Engine 1.6L SOHC
Upper compression ring	1.2
Second compression ring	1.5
Oil scraper ring	3.0
Engine 1.4L DOHC
Upper compression ring	1.2
Second compression ring	1.5
Oil scraper ring	3.0
1.6 and 2.0 L DOHC engines
Upper compression ring	1.5
Second compression ring	1.5
Oil scraper ring	3.0
Engine 1.8L DOHC
Upper compression ring	1.2
Second compression ring	1.2
Oil scraper ring	2.0
Diesel engines
Engine 1.7L SOHC
Compression rings	2.0
Oil scraper ring	3.0
Engine 1.7L DOHC
Upper compression ring	2.0
Second compression ring	1.5
Oil scraper ring	3.0
2.0L Engines
Upper compression ring
Engine X20DTL/Y20DTL	2.0
Y20DTH Engine	2.5
Second compression ring	1.75
Oil scraper ring	3.0

The value of the lateral clearance of the ring seat in the piston groove, mm

Petrol engines
Engine 1.6L SOHC and 1.4, 1.6 and 1.8L DOHC
Upper compression ring	0.02—0.04
Second compression ring	0.04—0.06
Oil scraper ring	0.01—0.03
Engine 2.0 DOHC
Compression rings	0.02—0.04
Oil scraper ring	0.01—0.03
Diesel engines
Engine 1.7L SOHC
Upper compression ring	0.12—0.18
Second compression ring	0.12—0.15
Oil scraper ring	0.025—0.15
Engine 1.7L DOHC
Upper compression ring	0.09—0.15
Second compression ring	0.04—0.15
Oil scraper ring	0.02—0.15
2.0L Engines
Engine X20DTL/Y20DTL
Upper compression ring	0.11—0.16
Second compression ring	0.05—0.09
Oil scraper ring	0.03—0.07
Y20DTH Engine
Upper compression ring	0.08—0.12
Second compression ring	0.05—0.09
Oil scraper ring	0.03—0.07

Piston pins

Diameter, mm

Petrol engines
Engines 1.6L SOHC and 1.4, 1.6 and 1.8L DOHC	17.997—18.000
Engine 2.0L DOHC	21.000
Diesel engines
Engine 1.7L SOHC	26
Engine 1.7L DOHC	27
2.0L Engines	29

Length, mm

Petrol engines
Engines 1.6L SOHC and 1.4, 1.6 and 1.8L DOHC	55
Engine 2.0L DOHC	55.7—58.0
Diesel engines
Engine 1.7L SOHC	69
Engine 1.7L DOHC	64
2.0L Engines	68

Clearance of the pin seat in the piston, mm

Petrol engines
Engines 1.6L SOHC	0.009—0.012
Engines 1.4, 1.6 and 1.8 l DOHC	0.007—0.010
Engine 2.0L DOHC	0.011—0.014
Diesel engines
Engine 1.7L SOHC	0.007—0.011
Engine 1.7L DOHC	0.002—0.012

Clearance of the pin seat in the upper head of the connecting rod, mm

Diesel engines
Engine 1.7L SOHC	0.014—0.025
Engine 1.7L DOHC	0.002—0.015

Connecting rods

Axial clearance value on crankshaft journal, mm

Petrol engines
Engine 1.6L SOHC	0.07—0.24
Engines 1.4, 1.6 and 1.8 l DOHC	0.11—0.24
Engine 2.0L DOHC	0.07—0.24
Diesel engines
Engine 1.7L SOHC	0.20—0.40
Engine 1.7L DOHC	0.25—0.58
2.0L Engines	0.07—0.28

Maximum allowable difference in connecting rod weight (only diesel engines 1.7L SOHC and DOHC), G

Crankshaft

Axial clearance of the crankshaft, mm

Petrol engines
Engines 1.6L SOHC and 1.4, 1.6 and 1.8L DOHC	0.1—0.2
Engine 2.0L DOHC	0.03—0.15
Diesel engines
Engine 1.7L SOHC	0.06—0.30
Engine 1.7L DOHC	0.03—0.15
2.0L Engines	0.05—0.15

Main journal diameter, mm

Petrol engines
Engines 1.6L SOHC and 1.4, 1.6 and 1.8L DOHC
Standard size	54.980—54.997
First repair size (0.25 mm)	54.730—54.747
Second repair size (0.50 mm)	54.482—54.495
Engine 2.0L DOHC
Standard size
First size group (white mark)	57.974—57.981
Second size group (green mark)	57.981—57.988
Third size group (brown mark)	57.988—57.995
First repair size (0.25 mm)	57.732—57.745
Second repair size (0.50 mm)	57.482—57.495
Diesel engines
Engine 1.7L SOHC
Standard size	57.974—57.995
First repair size (0.25 mm)	57.732—57.738
Second repair size (0.50 mm)	57.482—57.495
Engine 1.7L DOHC
First size group (one cutout)	51.928—51.938
Second size group (two cutouts)	51.918—51.928
Engine 2.0 l
Standard size
First size group (green mark)	67.966—67.974
Second size group (brown mark)	67.974—67.982
First repair size (0.25 mm)	67.716—67.732
Second repair size (0.50 mm)	67.466—67.482

Diameter of connecting rod journals, mm

Petrol engines
Engines 1.6L SOHC and 1.4, 1.6 and 1.8L DOHC
Standard size	42.971—42.987
First repair size (0.25 mm)	42.721—42.737
Second repair size (0.50 mm)	42.471—42.487
Engine 2.0L DOHC
Standard size	48.970—48.988
First repair size (0.25 mm)	48.720—48.738
Second repair size (0.50 mm)	48.470—48.488
Diesel engines
Engine 1.7L SOHC
Standard size	48.970—48.988
First repair size	48.720—48.738
Second repair size (0.50 mm)	48.470—48.488
Engine 1.7L DOHC	Data not provided
Engine 2.0 l
Standard size	48.971—48.990
First repair size (0.25 mm)	48.721—48.740
Second repair size (0.50 mm)	48.471—48.490

Maximum permissible value of neck ovality, mm

Petrol engines	0.04
Diesel engines
Engines 1.7 l SOHC and DOHC	Data not provided
2.0L Engines	0.03

Maximum permissible value of neck taper, mm

Petrol engines	Data not provided
Diesel engines	Data not provided

Maximum permissible value of shaft radial runout, mm

Petrol engines	0.03
Diesel engines
Engines 1.7L SOHC	0.06
Engines 1.7L DOHC	0.04—0.082
2.0L Engines	0.03

Clearance size in main bearings, mm

Petrol engines
Engines 1.6L SOHC and 1.4, 1.6 and 1.8L DOHC	0.017—0.047
Engine 2.0L DOHC	0.015—0.040
Diesel engines
Engines 1.7L SOHC	0.030—0.080
Engines 1.7L DOHC	0.030—0.058
2.0L Engines	0.016—0.069

Clearance size in connecting rod bearings, mm

Petrol engines
Engines 1.6L SOHC and 1.4, 1.6 and 1.8L DOHC	0.019—0.071
Engine 2.0L DOHC	0.006—0.031
Diesel engines
Engines 1.7L SOHC	0.025—0.100
Engines 1.7L DOHC	0.025—0.058
2.0L Engines	0.022—0.061

Lubrication system

Oil pump type

Petrol engines
Engines 1.6L SOHC	Gear, with direct drive from the crankshaft shaft
Engines 1.4, 1.6, 1.8 and 2.0 l DOHC	Rotary, timing belt driven
Diesel engines
Engine 1.7L SOHC	Rotary, direct drive from the crankshaft
Engine 1.7L DOHC	Rotary, timing belt driven
2.0L Engines	Gear, with direct drive from the crankshaft shaft

Minimum allowable pressure at idle speed with engine temperature not lower than 80°C, bar

Petrol engines	1.5
Diesel engines
Engine 1.7L SOHC	3.9
Engine 1.7L DOHC	1.27
2.0L Engines	1.5

The size of the working clearances in the oil pump, mm

Petrol engines
Engines 1.6L SOHC
Gear tooth engagement gap	0.08—0.15
Axial clearance of gears	0.10—0.20
Engines 1.4, 1.6, 1.8 and 2.0 l DOHC
Gap between gear teeth	0.10—0.20
Axial clearance of gears	0.03—0.10
Diesel engines
Engine 1.7L SOHC
Lateral clearance of outer rotor fit
Nominal value	0.24—0.36
Maximum permissible value	0.40
Gap between rotor teeth
Nominal value	0.10
Maximum permissible value	0.145
Axial play of rotors
Nominal value	0.035—0.100
Maximum permissible value	0.150
Engine 1.7L DOHC
Lateral clearance of outer rotor fit
Nominal value	0.24—0.36
Maximum permissible value	0.40
Gap between rotor teeth
Nominal value	0.13—0.15
Maximum permissible value	0.20
Axial play of rotors
Nominal value	0.035—0.100
Maximum permissible value	0.150
2.0L Engines	Data not provided

Tightening force of threaded connections, Nm

Connection type	Meaning
Wheel mounting bolts	110

Petrol engines

Engine 1.6L SOHC

Connection type	Meaning
Timing Belt Cover Fastening Bolts
External covers	4
Back cover	6
Timing Belt Tensioner Fixing Bolt	20
Timing mechanism cover mounting bolts	8
Camshaft timing gear bolt	45
Camshaft Rear Thrust Plate Bolts	8
Timing mechanism housing end cover bolts	8
Connecting rod lower head cap bolts *
Stage 1	25
Stage 2	extend to an angle of 30°
Water pump mounting bolts	8
Crankshaft Pulley Bolt *
Stage 1	95
Stage 2	extend to an angle of 30°
Stage 3	extend to an angle of 15°
Crankshaft Position Sensor (CKP) Rotor Mounting Bolts	8
Cylinder head mounting bolts *
Stage 1	25
Stage 2	pull to an angle of 60°
Stage 3	pull to an angle of 60°
Stage 4	pull to an angle of 60°
Drive Disc Mounting Bolts *
Stage 1	55
Stages 2	extend to an angle of 30°
Stage 3	extend to an angle of 15°
Drive Disc Cover Fastener	8
Powertrain suspension mounts
Left support
Bolts for fastening the carrier bracket to the adapter	55
Bolts for fastening the support to the bracket	55
Bolts for fastening the support to the body	20
Bolts for fastening the bracket to the adapter	35
Bolts for fastening the battery mounting tray to the body	15
Front support
Bolt for fastening the support to the body	55
Rear support
Bolts for fastening the support to the bracket	55
Bolts for fastening the support to the subframe	55
Bolts for fastening the bracket to the transmission housing	60
Right support
Bolts for fastening the support to the bracket	55
Bolts for fastening the support to the body	35
Engine to transmission mounting bolts
M12 bolts	60
Flywheel mounting bolts *
Stage 1	35
Stage 2	extend to an angle of 30°
Stage 3	extend to an angle of 15°
Front subframe mounting bolts *
Stage 1	90
Stage 2	pull to an angle of 45°
Stage 3	extend to an angle of 15°
Crankshaft main bearing cap fastening bolts shaft
Stage 1	50
Stage 2	pull to an angle of 45°
Stage 3	extend to an angle of 15°
Oil pressure alarm sensor	30
Oil pump
Mounting bolts	8
Cover mounting bolts	6
Pressure reducing valve plug	50
Oil intake mounting bolts	8
Engine oil pan mounting bolts
Models without K/V (stamped pallet)
Oil pan to cylinder block/oil pump mounting bolts	10
Drain plug of the pan	55
Models with K/V (cast pallet)
Oil pan to cylinder block/oil pump mounting bolts	10
M10 bolts for fastening the sump flange to the transmission housing	40
Drain plug	45

* Use new bolts.

Engines 1.4, 1.6 and 1.8 l DOHC

Connection type	Meaning
Timing Belt Cover Bolts
External covers	3
Back cover	6
Timing drive intermediate roller mounting bolt	25
Timing Belt Tensioner Fastening Bolt	20
Auxiliary drive belt tensioner mounting bolt units to the generator bracket	35
Oil pan deflector plate bolts	8
Camshaft Bearing Cap Bolts	8
Timing mechanism housing cover bolts	8
Camshaft Position Sensor Mounting Bolts shaft (CMP)	8
Camshaft timing gear mounting bolt *
Stage 1	50
Stage 2	pull to an angle of 60°
Stage 3	extend to an angle of 15°
Bolt for fastening the lower connecting rod head caps *
Stage 1	25
Stage 2	turn 30°
Crankshaft Pulley Bolt *
Stage 1	95
Stage 2	extend to an angle of 30°
Stage 3	extend to an angle of 15°
Position sensor mounting bracket mounting bolt crankshaft (CKP)	8
Cylinder head mounting bolts *
Stage 1	25
Stage 2	pull to a 90° angle
Stage 3	pull to a 90° angle
Stage 4	pull to a 90° angle
Stage 5	pull to an angle of 45°
Drive Disc Mounting Bolts	60
Powertrain suspension mounts
Left support
Bolts for fastening the support to the body	20
Bolts for fastening the bracket to the transmission housing	35
Bolts for fastening the support to the bracket	55
Front support
Bolts for fastening the support to the transmission housing	60
Bolts for fastening the support to the subframe	55
Rear support
Bolts for fastening the support to the bracket	55
Bolts for fastening the support to the subframe	55
Bolts for fastening the bracket to the transmission housing	55
Right support
Engine support mounting bolts	50
Nuts for fastening the support to the body	45
Bolt for fastening the support to the adapter	55
Adapter to cylinder block mounting bolts	55
Engine to transmission mounting bolts
M12 bolts	60
Front subframe mounting bolts *
Stage 1	90
Stage 2	pull to an angle of 45°
Stage 3	extend to an angle of 15°
Flywheel mounting bolts *
Stage 1	35
Stage 2	extend to an angle of 30°
Stage 3	extend to an angle of 15°
Main Bearing Cap Bolts *
Stage 1	50
Stage 2	pull to an angle of 45°
Stage 3	extend to an angle of 15°
Engine oil level sensor mounting bolts with tORX type head	8
Oil pump
Mounting bolts	8
Pump cover mounting screws	6
Pressure reducing valve plug	50
Oil pressure alarm sensor	30
Oil intake mounting bolts	8
Engine oil pan mounting bolts
Oil pan to cylinder block/oil pump housing mounting bolts	10
M10 bolts for fastening the sump flange to the transmission housing	40
Drain plug
Hexagon socket head (TORX) (rubber seal ring)	10
With hex head (metal sealing ring)	45

* Use new bolts.

Engine 2.0L DOHC

Connection type	Meaning
Timing Belt Cover Bolts	6
Timing drive intermediate roller mounting bolt
Roller mounting bolt	25
Support bracket mounting bolts	25
Timing Belt Tensioner Fastening Bolt	20
Auxiliary drive belt tensioner mounting bolt units to the generator bracket
Models without K/V	35
Models with K/V	25
Bolts for fastening the balancing assembly to the cylinder block
Stage 1	20
Stage 2	pull to an angle of 45°
Oil pan deflector plate mounting bolts	8
Camshaft bearing cap mounting bolts	8
Timing mechanism cover mounting bolts	8
Camshaft Position (CMP) Sensor Mounting Bolts	6
Camshaft timing gear mounting bolt *
Stage 1	50
Stage 2	pull to an angle of 60°
Stage 3	extend to an angle of 15°
Bolts for fastening the lower connecting rod head caps *
Stage 1	35
Stage 2	pull to an angle of 45°
Stage 3	extend to an angle of 15°
Central crankshaft pulley mounting bolt *
Stage 1	95
Stage 2	extend to an angle of 30°
Stage 3	extend to an angle of 15°
Crankshaft pulley mounting bolts	20
Crankshaft timing gear mounting bolt
Stage 1	130
Stage 2	extend to an angle of 50°
Cylinder head mounting bolts *
Stage 1	25
Stage 2	pull to a 90° angle
Stage 3	pull to a 90° angle
Stage 4	pull to a 90° angle
Stage 5	extend to an angle of 15°
Drive Disc Mounting Bolts *
Stage 1	55
Stage 2	extend to an angle of 30°
Stage 3	extend to an angle of 15°
Powertrain suspension mounts
Left support
Bolts for fastening the support to the body	20
Bolts for fastening the bracket to the transmission housing	35
Bolts for fastening the support to the bracket	55
Front support
Bolts for fastening the support to the transmission housing	60
Bolts for fastening the support to the subframe	55
Rear support
Bolts for fastening the support to the bracket	55
Bolts for fastening the support to the subframe	55
Bolts for fastening the bracket to the transmission housing	55
Right support
Engine support mounting bolts	50
Nuts for fastening the support to the body	45
Bolt for fastening the support to the adapter	55
Adapter to cylinder block mounting bolts	55
Engine to transmission mounting bolts
M12 bolts	60
Flywheel mounting bolts *
Stage 1	65
Stage 2	extend to an angle of 30°
Stage 3	extend to an angle of 15°
Bolts for fastening the main bearing cap bridge to the block cylinders
Stage 1	20
Stage 2	pull to an angle of 45°
Main Bearing Cap Bolts *
Stage 1	50
Stage 2	pull to an angle of 45°
Stage 3	extend to an angle of 15°
Bridge cap bolts to main bearing caps	20
Oil level sensor mounting bolts (with TORX head)	8
Oil pump
Mounting bolts	8
Pump cover mounting screws	6
Pressure reducing valve plug	50
Oil intake mounting bolts
Fastening the oil intake to the block	8
Fastening the oil intake to the main bearing cap bridge	20
Engine oil pan mounting bolts
Lower section pallet mounting bolts
Stage 1	8
Bolts for fastening the main (cast) section of the pallet
Bolts securing the main section to the cylinder block	20
Bolts securing the main section to the transmission housing	40
Drain plug	10

* Use new bolts/nuts.

Diesel engines

Engines 1.7L SOHC

Connection type	Meaning
Compressor support bracket mounting bolts K/V	40
Compressor fastener K/V	20
Generator Upper Support Bracket Fastener	18
Lower generator mounting bolt	25
Fastening the compressor bracket to the drive belt tensioner auxiliary units
Timing mechanism cover mounting bolts	8
Camshaft timing gear mounting bolt *
Stage 1	75
Stage 2	turn 60°
Fastening the cooling system hose to the cylinder block	20
Water pump
Pump mounting bolts	25
Pulley mounting bolts	10
Bolts for fastening the lower connecting rod head caps *
Stage 1	35
Stage 2	pull to an angle of 45°
Stage 3	extend to an angle of 15°
Crankshaft pulley mounting bolts	20
Crankshaft speed sensor mounting bolt	8
Crankshaft timing gear mounting bolt *
Stage 1	130
Stage 2	pull to an angle of 45°
Cylinder head mounting bolts
Stage 1	25
Stage 2	pull to a 90° angle
Stage 3	pull to a 90° angle
Stage 4	pull to an angle of 45°
Stage 5	after warming up the engine in 2 stages, tighten to angles of 30° 15°
Powertrain suspension mounts
Left support
Bolt for fastening the bracket to the adapter	55
Bolts for fastening the support to the bracket	55
Bolts for fastening the support to the body	20
Adapter to transmission housing mounting bolts	35
Bolts for fastening the battery mounting tray to the body	15
Front support
Bolts for fastening the support to the transmission housing	60
Bolts for fastening the support to the body	55
Rear support
Bolts for fastening the support to the bracket	55
Bolts for fastening the support to the subframe	55
Bolts for fastening the bracket to the transmission housing	80
Right support
Bolts for fastening the support to the bracket	55
Bolts for fastening the bracket to the spacer	55
Bolts for fastening the support to the body	35
Bolts for fastening the spacer to the cylinder block	50
Engine to transmission mounting bolts	60
Bolts for fastening the transport eyes of the power unit	25
Exhaust system inlet pipe mounting bolts	20
EGR valve to exhaust manifold mounting bolts	8
Exhaust manifold to cylinder head mounting nuts *	22
Exhaust manifold to cylinder head mounting bolts	22
Exhaust manifold support bracket fastener	25
Flywheel mounting bolts *
Stage 1	65
Stage 2	extend to an angle of 30°
Stage 3	extend to an angle of 15°
Fuel injection pump gear mounting bolts	15
Fuel injection pump connector bolts	25
Main bearing cap bridge mounting bolts
Stage 1	20
Stage 2	pull to an angle of 45°
Main Bearing Cap Bolts *
Stage 1	50
Stage 2	pull to an angle of 45°
Stage 3	extend to an angle of 15°
Oil cooler support bracket mounting bolts	5
Oil cooler pipe nipple connection	30
Bolt for fastening the support bracket of the measuring probe guide tube engine oil level to the block	25
Oil filter	15
Oil pressure reducing valve mounting bolts	50
Oil pressure sensor	40
Oil pump mounting bolts to cylinder block	8
Oil pump cover mounting bolts	10
Oil Intake Mounting Bolts *
Stage 1	8
Stage 2	extend to an angle of 30°
Mounting the oil temperature sensor in the main section of the pan	18
Engine oil pan mounting bolts
Bolts/nuts securing oil pump cover to main sump section	20
Bolts securing the main section of the oil pan to the transmission housing	40
Bolts securing the bottom section of the tray to the main section
Stage 1	8
Stage 2	extend to an angle of 30°
Drain plug	10
Wheel mounting bolts	110
Thermostat housing	15
Timing Belt Cover Fastening Bolts	8
Timing Belt Drive Idler Roller Fastening Bolt	40
Timing Belt Tensioner Roller Fastening Bolt	25
Fastening the turbocharger oil pipe to the cylinder block	20
Fastening the oil pipe to the turbocharger	30
Fastening the oil return pipe to the pan	45
Fastening the vacuum pump to the timing case	28

* Use new mounting bolts/nuts.

Engines 1.7L DOHC

Connection type	Meaning
Generator mounting bolts to support bracket
Bolt M8	19
Bolt M10	48
Fastening the auxiliary drive belt tensioner to the bracket generator	50
Fastening the guide roller of the auxiliary drive belt to the generator bracket	38
Bolts securing the oil pan deflector plate to the cylinder block	19
Nuts for fastening the camshaft support bearing caps
Nuts M8	21
Nuts M10	43
Timing mechanism cover mounting bolts	10
Fastening the timing case	22
Fastening the camshaft thrust plate	8
Water pump mounting bolts
Pump mounting bolts	24
Pulley mounting bolts	10
Fastening the cooling system hose to the cylinder block	95
Coolant Temperature (ECT) Sensor	22
Connecting rod lower head cap fastening nuts *
Stage 1	25
Stage 2	extend to an angle of 100°
Stage 3	extend to an angle of 15°
Fastening the crankshaft speed sensor	10
Crankshaft Pulley Bolts	20
Crankshaft oil seal housing bolts	10
Crankshaft timing gear bolt	196
Cylinder head mounting bolts *
Stage 1	40
Stage 2	pull to an angle of 60°
Stage 3	extend to an angle of 15°
Stage 4	pull to an angle of 60°
Stage 5	extend to an angle of 15°
Powertrain suspension mounts
Left support
Bolts for fastening the support to the body	20
Bolts for fastening the bracket to the transmission housing	35
Bolts for fastening the support to the bracket	55
Front support
Bolts for fastening the support to the transmission housing	60
Bolts for fastening the support to the subframe	55
Rear support
Bolts for fastening the support to the bracket	55
Bolts for fastening the support to the subframe	55
Bolts for fastening the bracket to the transmission housing	60
Right support
Engine support mounting bolts	50
Nuts for fastening the support to the body	45
Bolts for fastening the support to the bracket	55
Engine to transmission mounting bolts
M10 bolts	40
M12 bolts	60
Fastening the engine control unit bracket to the timing case mechanism	10
Fastening the engine control unit to the bracket	6
Fastening the engine transport eyes	25
Fastening the EGR pipe bracket to the valve timing case	8
Fastening the EGR valve to the manifold	25
Flywheel mounting bolts *
Stage 1	30
Stage 2	pull to an angle of 45°—60°
Fastening the fuel return line to the valve body mechanism	15
Glow plugs	20
Fastening the heat exchanger to the oil filter housing	12
Fastening of the fuel injection pump control unit	10
Fastening the fuel injection pump control unit bracket to the cylinder block	48
Fastening the injection pump to the bracket	19
Fastening the injection pump bracket to the cylinder block	54
Fastening the fuel injection pump to the cylinder block	20
Fuel injection pump gear fastening nut	69
Fastening the oil spray bracket to the valve body mechanism	22
Fuel line nipple connectors	23
Main bearing cap mounting bolts	88
Oil level dipstick guide tube mounting bolts	10
Fastening the oil feed pipe to the turbocharger	10
Fastening the oil filter cover	25
Fastening the oil filter to the cylinder block	25
Pressure reducing valve adjustment bolt	30
Oil pressure alarm sensor	20
Oil pump cover mounting bolts	10
Fastening the oil pump drive gear to the pump	44
Oil intake mounting bolts	19
Engine oil pan mounting bolts
Bolts securing the main section of the pan to the block	10
Bolts securing the bottom section of the tray to the main section	10
Drain plug	78
Fastening the thermostat housing to the cylinder head	24
Fastening the thermostat housing cover	24
Timing Belt Cover Fastening Bolts	10
Idler pulley bolt	76
Fastening the timing belt tensioner pulley to the cylinder block	38
Timing Belt Tensioner Spring Retainer to Rear Cover	10
Fastening the turbocharger to the support bracket	26
Fastening the turbocharger to the manifold	26
Fastening the turbocharger oil feed pipe to the cylinder block	10
Fastening the electrical wiring route channel to the cylinder head	6

* Use new bolts/nuts.

2.0L Engines

Connection type	Meaning
Belt tensioner mechanism bolts auxiliary drive units
Pulley base axle bolt	42
Rack mounting bolts	23
Bolts for fastening the covers of the support valve timing mechanism	8
Camshaft Sprocket Mounting Bolt *
Stage 1	90
Stage 2	pull to an angle of 60°
Stage 3	extend to an angle of 30°
Bolt for fastening the lower connecting rod head caps *
Stage 1	35
Stage 2	pull to an angle of 45°
Stage 3	extend to an angle of 15°
Crankshaft pulley mounting bolt
Stage 1	150
Stage 2	pull to an angle of 45°
Stage 3	extend to an angle of 15°
Cylinder head mounting bolts *
Stage 1	25
Stage 2	pull to an angle of 65°
Stage 3	pull to an angle of 65°
Stage 4	pull to an angle of 65°
Stage 5	pull to an angle of 65°
Stage 6	extend to an angle of 15°
Timing chain cover mounting bolts
X20DTL/Y20DTL	20
Y20DTH *
Stage 1	20
Stage 2	pull to an angle of 30°
Stage 3	extend to an angle of 5°
Powertrain suspension mounts
Left support
Bolts for fastening the support to the body	20
Bolts for fastening the bracket to the transmission housing	35
Bolts for fastening the support to the bracket	55
Front support
Bolts for fastening the support to the transmission housing	60
Bolts for fastening the support to the subframe	55
Rear support
Bolts for fastening the support to the bracket	55
Bolts for fastening the support to the subframe	55
Bolts for fastening the bracket to the transmission housing	60
Right support
Nuts for fastening the support to the body	45
Bolts for fastening the support to the bracket	55
Engine to transmission mounting bolts
M10 bolts	40
M12 bolts	60
Flywheel mounting bolts *
Stage 1	45
Stage 2	extend to an angle of 30°
Stage 3	extend to an angle of 15°
Fuel injection pump sprocket mounting bolts
X20DTL/Y20DTL	20
Y20DTH	28
Fuel injection pump sprocket cover mounting bolts	6
Main Bearing Cap Bolts *
Stage 1	90
Stage 2	pull to an angle of 60°
Stage 3	extend to an angle of 15°
Crankshaft main bearing cap bridge mounting bolts	20
Oil cooler to oil filter housing mounting bolts	15
Oil pump
Pressure equalization valve plug	60
Pump cover mounting screws	8
Oil intake mounting bolts	8
Pressure reducing valve plug	45
Bolts for fastening oil sprayers in the block	22
Engine oil pan mounting bolts
Bolts securing the oil pan to the cylinder block/timing drive cover	20
Bolts securing the oil pan to the transmission housing
Bolts M8	20
M10 bolts	40
Drain plug	18
Timing chain cover bolts	20
Timing chain guide mounting bolts	8
Timing chain tensioner shoe axle bolt	20
Fastening the timing chain tensioner cover	60