2.0 liter engine | |
Maximum deformation of the gasket surface |
0.05 mm
|
Cylinder head height: | |
– SOHC |
95.75 - 96.25 mm
|
– DOHC |
134 mm
|
Valve seat width: | |
– SOHC: | |
inlet |
1.0 - 1.5 mm
|
graduation |
1.7 - 2.2 mm
|
– DOHC: | |
inlet |
1.0 - 1.4 mm
|
graduation |
1.4 - 1.8 mm
|
Valve guide height in cylinder head: | |
– SOHC |
83.25 - 84.05 mm
|
– DOHC |
13.70 - 14.00 mm
|
2.5 and 3.0 liter engines | |
Maximum deformation of the gasket surface |
0.05 mm
|
Cylinder head height |
134 mm
|
Valve seat width: | |
- inlet |
1.0 - 1.4 mm
|
- graduation |
1.4 - 1.8 mm
|
Valve guide height in cylinder head |
13.7 - 14.0 mm
|
Valves and guides
2.0 liter engine | |
Valve stem diameter (SOHC) *: | |
- inlet: | |
nominal (GM) |
6.998 - 7.012 mm
|
after first boring bushings (0.075 mm - GM-K1) |
7.073 - 7.087 mm
|
after second boring bushings (0.150 mm - GM K2) |
7.148 - 7.162 mm
|
after the third boring bushings (0.250 mm - A) |
7.248 - 7.262 mm
|
- graduation: | |
nominal (GM) |
6.978 - 7.992 mm
|
after first boring bushings (0.075 mm - GM-K1) |
7.053 - 7.067 mm
|
after second boring bushings (0.150 mm - GM K2) |
7.128 - 7.142 mm
|
after the third boring bushings (0.250 mm - A) |
7.228 - 7.262 mm
|
Valve stem diameter (DOHC) *: | |
- inlet: | |
nominal (GM) |
5.955 - 5.970 mm
|
after first boring bushings (0.075 mm - GM-K1) |
6.030 - 6.045 mm
|
after second boring bushings (0.150 mm - GM K2) |
6.105 - 7.120 mm
|
- graduation: | |
nominal (GM) |
5.945 - 5.960 mm
|
after first boring bushings (0.075 mm - GM-K1) |
6.020 - 6.035 mm
|
after second boring bushings (0.150 mm - GM K2) |
6.095 - 6.110 mm
|
Valve stem runout |
less than 0.03mm
|
Valve stem guide bore diameter: | |
– SOHC: | |
nominal |
7.030 – 7.050 mm
|
after first boring bushings (0.075 mm) |
7.105 - 7.125 mm
|
after second boring bushings (0.150 mm) |
7.180 – 7.200 mm
|
after the third boring bushings (0.250 mm) |
7.280 – 7.300 mm
|
– DOHC: | |
nominal |
6.000 – 6.012 mm
|
after first boring bushings (0.065 mm) |
6.075 - 6.090 mm
|
after second boring bushings (0.150 mm) |
6.150 - 6.165 mm
|
Clearance between valve stem and guide sleeve: | |
– SOHC: | |
inlet |
0.018 - 0.052 mm
|
high school graduation |
0.038 - 0.072 mm
|
– DOHC: | |
inlet |
0.030 - 0.057 mm
|
high school graduation |
0.040 - 0.067 mm
|
Valve length (SOHC): | |
- inlet: | |
standard valve |
104.0 - 104.4 mm
|
drain valve |
103.6 - 104.0 mm
|
- graduation: | |
standard valve |
103.75 - 104.25 mm
|
drain valve |
103.35 - 103.85 mm
|
Valve length (DOHC): | |
- inlet: | |
standard valve |
101.9 - 102.3 mm
|
drain valve |
101.5 - 101.9 mm
|
- graduation: | |
standard valve |
92.05 - 92.45 mm
|
drain valve |
91.65 - 92.05 mm
|
Installed valve stem height: | |
– SOHC |
17.85 - 18.25 mm
|
– DOHC: | |
standard valve |
39.6 - 40.2 mm
|
drain valve |
39.239.8 mm
|
Valve head diameter: | |
– SOHC: | |
inlet |
41.8 mm
|
graduation |
36.5mm
|
DOHC: | |
inlet |
31.9 - 32.1 mm
|
graduation |
28.9 - 29.1 mm
|
2.5 and 3.0 liter engines | |
Valve stem diameter*: | |
- inlet: | |
nominal (GM) |
5.955 - 5.970 mm
|
after first boring bushings (0.075 mm - GM-K1) |
6.030 - 6.045 mm
|
after second boring bushings (0.150 mm - GM K2) |
6.105 - 6.120 mm
|
- graduation: | |
nominal (GM) |
5.945 - 5.960 mm
|
after first boring bushings (0.075 mm - GM-K1) |
6.020 - 6.035 mm
|
after second boring bushings (0.150 mm - GM K2) |
6.095 - 6.110 mm
|
Valve stem runout |
less than 0.03 mm
|
Valve stem guide bore diameter: | |
- nominal |
6.000 – 6.012 mm
|
– after the first boring of the bushing (0.075 mm) |
6.075 - 6.090 mm
|
– after the second boring of the bushing (0.150 mm) |
6.150 - 6.165 mm
|
Clearance between valve stem and guide sleeve: | |
- inlet |
0.030 - 0.057 mm
|
- high school graduation |
0.040 - 0.067 mm
|
Valve length: | |
- inlet: | |
standard valve |
101.9 - 102.3 mm
|
drain valve |
101.5 - 101.9 mm
|
- graduation: | |
standard valve |
92.05 - 92.45 mm
|
drain valve |
91.65 - 92.05 mm
|
Valve head diameter: | |
- inlet |
31.9 - 32.1 mm
|
- graduation |
28.9 - 29.1 mm
|
* Identification number is given in parentheses.
Cylinder block
2.0 liter engines | |
Maximum deformation of the gasket surface |
0.05 mm
|
Cylinder diameter: | |
– nominal: | |
class 8 |
85.975 - 85.985 mm
|
class 99 |
85.985 - 85.995 mm
|
class 00 |
85.995 - 86.005 mm
|
class 01 |
86.005 - 86.015 mm
|
class 02 |
86.015 - 86.025 mm
|
- after boring (0.5 mm) |
86.465 - 86.475 mm
|
Maximum cylinder out-of-roundness |
0.013 mm
|
Maximum taper of the cylinder |
0.013 mm
|
2.5 and 3.0 liter engines | |
Maximum deformation of the gasket surface |
0.05 mm
|
Cylinder diameter (2.5 liter engine): | |
– nominal: | |
class 8 |
81.575 - 81.585 mm
|
class 99 |
81.585 - 81.595 mm
|
class 00 |
81.595 - 81.605 mm
|
class 01 |
81.605 - 81.615 mm
|
class 02 |
81.615 - 81.625 mm
|
- after boring (0.5 mm) |
82.065 - 82.075 mm
|
Cylinder diameter (3.0 liter engine): | |
– nominal: | |
class 8 |
85.975 - 85.985 mm
|
class 99 |
85.985 - 85.995 mm
|
class 00 |
85.995 - 86.005 mm
|
class 01 |
86.005 - 86.015 mm
|
class 02 |
86.015 - 86.025 mm
|
- after boring (0.5 mm) |
86.465 - 86.475 mm
|
Maximum cylinder out-of-roundness |
0.013 mm
|
Maximum taper of the cylinder |
0.013 mm
|
Pistons and piston rings
2.0 liter engines | |
Piston diameter: | |
– nominal: | |
class 8 |
85.945 - 85.955 mm
|
class 99 |
85.955 - 85.965 mm
|
class 00 |
85.965 - 85.975 mm
|
class 01 |
85.975 - 85.985 mm
|
class 02 |
86.985 - 86.995 mm
|
- after boring (0.5 mm) |
86.435 - 86.445 mm
|
Clearance between piston and cylinder |
0.02 - 0.04 mm
|
End gaps of piston rings installed in cylinders: | |
- compression rings |
0.3 - 0.5 mm
|
- oil scraper ring |
0.4 - 1.4 mm
|
Piston ring thickness: | |
- compression rings |
1.5mm
|
- oil scraper ring |
3.0mm
|
Gap between piston ring and ring groove: | |
- compression rings |
0.02 - 0.04 mm
|
- oil scraper ring |
0.01 - 0.03 mm
|
2.5 and 3.0 liter engines | |
Piston diameter (2.5 liter engine): | |
– nominal: | |
class 8 |
81.540 – 81.550 mm
|
class 99 |
81.550 – 81.560 mm
|
class 00 |
81.560 - 81.570 mm
|
class 01 |
81.570 - 81.580 mm
|
class 02 |
81.580 – 81.040 mm
|
- after boring (0.1 mm) |
82.030 – 82.040 mm
|
Piston diameter (3.0 liter engine): | |
– nominal: | |
class 8 |
85.940 – 85.950 mm
|
class 99 |
85.950 – 85.960 mm
|
class 00 |
85.960 – 85.970 mm
|
class 01 |
85.970 – 85.980 mm
|
class 02 |
86.980 – 86.990 mm
|
- after boring (0.5 mm) |
86.430 – 86.440 mm
|
Clearance between piston and cylinder |
0.025 - 0.045 mm
|
End gaps of piston rings installed in cylinders: | |
- compression rings |
0.3 - 0.5 mm
|
- oil scraper ring |
0.4 - 1.4 mm
|
Piston ring thickness: | |
- compression rings |
1.5mm
|
- oil scraper ring |
3.0mm
|
Gap between piston ring and ring groove: | |
- compression rings |
0.02 - 0.04 mm
|
- oil scraper ring |
0.01 - 0.03 mm
|
Piston pins
2.0 liter engine | |
Diameter |
20.990 – 21.000 mm
|
Length |
61.2 - 61.8 mm
|
Gap between piston and piston pin |
0.011 - 0.014 mm
|
2.5 and 3.0 liter engines | |
Diameter |
20.990 – 21.000 mm
|
Length: | |
– 2.5 liters |
55.7 - 56.0 mm
|
– 3.0 liters |
57.7 - 58.0 mm
|
Clearance between piston and piston pin: | |
– 2.5 liters |
0.011 - 0.014 mm
|
– 3.0 liters |
0.001 - 0.015 mm
|
Gap between piston pin and connecting rod: | |
– 2.5 liters |
Fixed landing
|
– 3.0 liters |
0.014 - 0.030 mm
|
Crankshaft
2.0 liter engines | |
free running |
0.05 - 0.15 mm
|
Main bearing journal diameter: | |
– nominal: | |
1st group |
57.974 - 57.981 mm
|
2nd group |
57.981 - 57.988 mm
|
3rd group |
57.988 - 57.995 mm
|
- after the first turning (0.25 mm) |
57.732 - 57.745 mm
|
- after the second turning (0.50 mm) |
57.482 - 57.495 mm
|
Connecting rod journal diameter: | |
- nominal |
48.970 - 48.988 mm
|
- after the first turning (0.25 mm) |
48.720 - 48.738 mm
|
- after the second turning (0.50 mm) |
48.470 - 48.488 mm
|
Ovality of crankshaft journals |
0.04mm
|
Neck taper |
0.04mm
|
Permissible shaft runout |
less than 0.03mm
|
Operating clearance of the main bearing |
0.015 - 0.043 mm
|
Connecting rod bearing working clearance |
0.006 - 0.031 mm
|
2.5 and 3.0 liter engines | |
free running |
0.01 - 0.76 mm
|
Main bearing journal diameter: | |
- nominal |
67.980 - 67.996 mm
|
- after the first turning (0.25 mm) |
67.730 - 67.746mm
|
- after the second turning (0.50 mm) |
67.480 - 67.496 mm
|
Connecting rod journal diameter: | |
– 2.5 liters: | |
nominal |
48.971 - 48.990 mm
|
after first turning (0.25 mm) |
48.721 - 48.740 mm
|
after the second turning (0.50 mm) |
48.721 - 48.740 mm
|
- 3.0 liters: | |
nominal |
53.971 - 53.990 mm
|
after first turning (0.25 mm) |
53.721 - 53.740 mm
|
after the second turning (0.50 mm) |
53.471 - 53.490 mm
|
Ovality of crankshaft journals |
0.04mm
|
Neck taper |
0.04mm
|
Permissible shaft runout |
less than 0.03mm
|
Operating clearance of the main bearing |
0.014 - 0.043 mm
|
Connecting rod bearing working clearance |
0.010 - 0.061 mm
|
Tightening torques, Nm
SOHC 2.0 liter engine | |
Camshaft cover bolts |
8
|
Camshaft sprocket bolt |
45
|
Camshaft Thrust Plate Bolts |
8
|
Bolts of a back cover of a casing of a camshaft |
8
|
Connecting rod cap bolt: | |
– stage 1 |
35
|
– stage 2 |
Tighten another 45°
|
– stage 3 |
Tighten another 15°
|
Coolant pump bolts |
25
|
Crankcase breather tube bolts |
25
|
crankshaft pulley bolts |
20
|
Crankshaft Sensor Rotor Bolts |
13
|
Crankshaft sprocket bolt: | |
– stage 1 |
130
|
– stage 2 |
Tighten another 40 - 50°
|
Cylinder head bolts: | |
– stage 1 |
25
|
– stage 2 |
Tighten another 90°
|
– stage 3 |
Tighten another 90°
|
– stage 4 |
Tighten another 90°
|
Drive Bolts: | |
– stage 1 |
55
|
– stage 2 |
Tighten another 30°
|
– stage 3 |
Tighten another 15°
|
Engine and gearbox mounts: | |
- left and right supports: | |
nut that secures the support to the body |
55
|
nut that secures the support to her bracket |
40
|
bracket mounting bolts bearings to the cylinder block |
60
|
- back support: | |
bolts holding the support to gearbox |
40
|
nuts securing the support to the crossbar |
20
|
cross member bolts to the body |
45
|
Engine and gearbox support bracket bolts: | |
- the bolt that secures the bracket to the engine |
40
|
- bolts securing the bracket to the gearbox |
22
|
- bolts securing the gearbox to the engine |
60
|
Flywheel bolts: | |
– stage 1 |
65
|
– stage 2 |
Tighten another 30°
|
– stage 3 |
Tighten another 15°
|
Main bearing cap bolts: | |
– stage 1 |
50
|
– stage 2 |
Tighten another 45°
|
– stage 3 |
Tighten another 15°
|
Oil filter |
15
|
Oil pump: | |
- mounting bolts |
8
|
– pump cover screws |
6
|
- pressure relief valve bolt |
50
|
– oil intake pipe bolts |
8
|
– heat shields for spark plugs |
25
|
Oil pan bolts: | |
- mounting bolts |
8
|
- oil pan drain plug |
55
|
Timing belt cover bolts: | |
– outer cover |
4
|
- back cover |
6
|
Timing belt tensioner bolt |
20
|
DOHC 2.0 liter engine | |
Camshaft bearing cap bolts |
8
|
Camshaft cover bolts |
8
|
Camshaft sprocket bolt: | |
– stage 1 |
50
|
– stage 2 |
Tighten another 60°
|
– stage 3 |
Tighten another 15°
|
Coolant pump bolts |
25
|
Connecting rod cap bolt: | |
– stage 1 |
35
|
– stage 2 |
Tighten another 45°
|
– stage 3 |
Tighten another 15°
|
Crankcase breather tube bolts |
25
|
Crankshaft Balance Bolts - Engines issued since 1998: | |
– stage 1 |
20
|
– stage 2 |
Tighten another 45°
|
crankshaft pulley bolts |
20
|
Crankshaft Sensor Rotor Bolts |
13
|
Crankshaft sprocket bolt: | |
– stage 1 |
130
|
– stage 2 |
Tighten another 40 - 50°
|
Cylinder head bolts: | |
– stage 1 |
25
|
– stage 2 |
Tighten another 90°
|
– stage 3 |
Tighten another 90°
|
– stage 4 |
Tighten another 90°
|
– stage 5 |
Tighten another 15°
|
Drive Bolts: | |
– stage 1 |
55
|
– stage 2 |
Tighten another 30°
|
– stage 3 |
Tighten another 15°
|
Engine and gearbox mounts: | |
Left and right supports: | |
- the nut that secures the support to the body |
55
|
- a nut that secures the support to its bracket |
40
|
- bolts securing the support bracket to the cylinder block |
60
|
Rear support: | |
- bolts securing the support to the gearbox |
40
|
- nuts securing the support to the cross member |
20
|
- bolts securing the cross member to the body |
45
|
- bolts securing the gearbox to the engine: | |
- bolts securing the gearbox to the cylinder block |
60
|
- bolts securing the gearbox to the oil flange pallet (engines with compound oil sump) |
40
|
Engine and gearbox mounting bracket bolts (engines with solid oil pan): | |
- the bolt that secures the bracket to the engine |
40
|
- bolts securing the bracket to the gearbox |
22
|
Flywheel bolts: | |
– stage 1 |
65
|
– stage 2 |
Tighten another 30°
|
– stage 3 |
Tighten another 15°
|
Main bearing cap bolts: | |
– stage 1 |
50
|
– stage 2 |
Tighten another 45°
|
– stage 3 |
Tighten another 15°
|
Oil pan casting bolts (engines with compound oil pan): | |
– stage 1 |
20
|
– stage 2 |
Tighten another 45°
|
Oil filter |
15
|
Oil pump: | |
- mounting bolts |
8
|
– pump cover screws |
6
|
- pressure relief valve bolt |
50
|
Oil pickup bolts: | |
– Engines with solid oil sump |
8
|
– Engines with a composite oil pan: | |
bolts securing the oil pickup pipe to oil pump housing |
8
|
M6 bolts securing the oil intake pipe to the cast part of the oil pan |
10
|
M8 bolts securing the oil intake pipe to the cast part of the oil pan |
20
|
Oil pan bolts (oil pan consisting of two parts): | |
- pallet bolts: | |
stage 1 |
8
|
stage 2 |
Tighten another 30°
|
– bolts of a cast part of the oil pallet: | |
block fixing bolts to cylinder block and oil pump |
20
|
block fixing bolts gearbox |
40
|
Oil pan drain plug: | |
– plug with hexagonal head |
45
|
– plug with square head |
10
|
Timing belt cover bolts: | |
– outer cover |
6
|
- back cover |
8
|
Timing belt intermediate pulley: | |
- pulley bolt |
25
|
- bracket bolts |
25
|
- Timing belt tensioner bolt |
20
|
2.5 and 3.0 liter engines | |
Additional belt tensioner bolts |
35
|
Baffle Bolts |
8
|
Camshaft bearing cap bolts |
8
|
Camshaft cover bolts |
8
|
Camshaft sensor bolt |
8
|
Camshaft sprocket bolt: | |
– stage 1 |
50
|
– stage 2 |
Tighten another 60°
|
– stage 3 |
Tighten another 15°
|
Connecting rod cap bolt: | |
– stage 1 |
35
|
– stage 2 |
Tighten another 45°
|
– stage 3 |
Tighten another 15°
|
Bolts of a ventilating tube of the right block of cylinders |
25
|
Engine Bracket Bolt Designed for Mounting lift |
25
|
Coolant pump bolts |
25
|
Coolant pump pulley bolts: | |
– stage 1 |
8
|
– stage 2 |
Tighten another 30°
|
– stage 3 |
Tighten another 30°
|
Crankcase breather tube bolts |
8
|
crankshaft pulley bolts |
20
|
Crankshaft Sensor Rotor Bolts |
15
|
Crankshaft sprocket bolt: | |
– stage 1 |
250
|
– stage 2 |
Tighten another 45°
|
– stage 3 |
Tighten another 15°
|
Cylinder head bolts: | |
– stage 1 |
25
|
– stage 2 |
Tighten another 90°
|
– stage 3 |
Tighten another 90°
|
– stage 4 |
Tighten another 90°
|
– stage 5 |
Tighten another 15°
|
Bolts of a branch pipe of a cooling liquid of a head of cylinders |
30
|
Drive Bolts: | |
– stage 1 |
65
|
– stage 2 |
Tighten another 30°
|
– stage 3 |
Tighten another 15°
|
Engine and gearbox mounts: | |
Left and right supports: | |
- the nut that secures the support to the body |
55
|
- a nut that secures the support to its bracket |
40
|
- bolts securing the support bracket to the cylinder block |
60
|
- shock absorber bolts |
40
|
Rear support: | |
- bolts securing the support to the gearbox |
40
|
- nuts securing the support to the cross member |
20
|
- bolts securing the cross member to the body |
45
|
Bolts securing the gearbox to the engine: | |
- bolts securing the gearbox to the cylinder block |
60
|
- bolts securing the gearbox to the oil flange pallet |
40
|
Flywheel bolts: | |
– stage 1 |
65
|
– stage 2 |
Tighten another 30°
|
– stage 3 |
Tighten another 15°
|
Main bearing cap bolts: | |
– cover bolts: | |
stage 1 |
50
|
stage 2 |
Tighten another 60°
|
stage 3 |
Tighten another 15°
|
– cap block fittings |
8
|
- bolts (M8), fastening the block of covers to the block of cylinders |
20
|
Oil radiator: | |
- cover bolts |
20
|
- cover nuts |
30
|
– bolts and nuts of connections of tubes of an oil radiator |
30
|
Oil filter |
15
|
Oil pump cover screws |
8
|
Oil pump mounting bolts: | |
- M6 bolts with the original rear cover of the gas distribution belt: | |
starting torque |
8
|
final tightening torque |
10
|
- M6 bolts with a modified rear cover of the gas distribution belt |
10
|
– M8 bolts: | |
stage 1 |
12
|
stage 2 |
20
|
Oil pickup bolts |
8
|
Power steering pump pulley bolts: | |
– stage 1 |
20
|
– stage 2 |
Tighten another 30°
|
– stage 3 |
Tighten another 15°
|
Oil pan bolts: | |
- pallet bolts: | |
stage 1 |
8
|
stage 2 |
Tighten another 30°
|
Oil pan casting bolts: | |
Bolts securing the cast part to the cylinder block and oil pump |
20
|
Bolts securing the cast part of the gearbox |
40
|
Oil pan drain plug: | |
– plug with hexagonal head |
55
|
– plug with square head |
10
|
Timing belt cover bolts: | |
– outer cover |
8
|
- back cover: | |
bolts M6 |
8
|
M8 bolts |
10
|
Timing belt lower idler bolt |
40
|
Tensioner pulley and upper timing pulley belt: | |
- bolts securing the pulley bracket to the cylinder block |
40
|
- tensioner pulley nut |
20
|
- guide pulley bolt |
40
|
Visitor comments