Note: Individual characteristics are also given in the text of the Chapter
OHC Engines - General Data
| Engine type: - 2.0 l engine up to mid-1995 - 2.4 l engine up to mid-1995 - 2.0 l engine since mid-1995 | C 20 NE C 24 NE X 20 SE | |
| Design features: - 2.0 l engine - 2.4 l engine | Four-cylinder petrol engine with overhead camshaft and toothed belt drive Four-cylinder, chain-driven, overhead camshaft petrol engine | |
| Number of cylinders | 4 | |
| Cylinder arrangement | In-line | |
| Valve timing mechanism: - 2.0 l engine - 2.4 l engine | Hanging valves, overhead camshaft positioned in a separate housing, driven by a toothed belt. Hydraulic clearance compensators. Valve drive from rocker arms Parallel hung valves, 2 valves per cylinder, overhead camshaft, chain driven. Hydraulic clearance compensators. Valve drive from rocker arms | |
| Cylinder firing order | 1 - 3 - 4 - 2 | |
| Maximum power: - 2.0 l engine up to mid-1995 - 2.0 l engine since mid-1995 - 2.4 l engine | 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 capacity 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: - 2.0 l engine up to mid-1995 - 2.0 l engine since mid-1995 - 2.4 l engine | 170 Nm at 2600 rpm 172 Nm at 2800 rpm 195 Nm at 2600 rpm | |
| Cylinder diameter: - all engines 2.0 l - 2.4 l engines | 86.00 mm 95.00 mm | |
| Piston stroke: - all engines 2.0 l - 2.4 l engines | 86.00 mm 85.00 mm | |
| Compression ratio: - 2.0 l engine up to mid-1995 - 2.0 l engine since mid-1995 - 2.4 l engine | 9.2: 1 10.0: 1 9.2: 1 | |
Engine 2.0 l (C 20 NE since mid-1995) | ||
| Cylinder head | ||
| Cylinder head height | 95.75 - 96.25 mm (between mating planes) | |
| Max non-flatness of the mating plane with the cylinder block | 0.10 mm | |
| Max. non-flatness of planes of conjugation 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 the valve stem to guide bushing connection: - intake valves - exhaust valves | 0.018 - 0.052 mm 0.038 - 0.072 mm | |
| Valve installation height | 17.85 - 18.25 mm. Measured by KM-512 caliber. Carry out only in a car repair shop | |
| Installation height of guide bushings | New guides in accordance with the original size are pressed into the cylinder head. Specified size 83.50 - 83.80 mm | |
| Valve seats | ||
| Chamfer angle | 45° | |
| Lower correction angle | 75° | |
| Upper correction angle | 15° | |
| Valve seat chamfer width (new valve) | See above | |
| Valves | ||
| Valve stem diameter - intake valves: - specified 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: - specified 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 the valve-guide interface: - intake valves - exhaust valves | 0.018 - 0.052 mm 0.038 - 0.072 mm | |
| Valve Plate Diameter: - intake valves - exhaust valves | 41.8 mm 35.6 mm | |
| 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 coding - normal size - repair, reduced by 0.10 mm | No Violet | |
| Max. shaft runout | 0.03 mm | |
| Axial clearance of the shaft | 0.09 - 0.21 mm | |
| Cam stroke | 6.67mm, intake and exhaust valves | |
| Bearing clearance: - normal value - wear limit | 0.04 - 0.082 mm 0.11 mm | |
| Neck diameter | The necks have different diameters. Shafts with a repair journal diameter 0.1 mm smaller have a purple marking. The 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 diameters of the holes vary, as do the diameters of the camshaft journals. The 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 - 1st grade - 4th grade | - 85.96 mm (8 on the piston bottom) - 85.97 mm (99 on the piston bottom); 89.98 mm (00 on the piston bottom); 89.99 mm (01 on the piston bottom); 86.00 mm (02 on the piston bottom) | |
| Repair size increased by 0.5 mm | 86.45 mm (7 + 0.5 at the piston bottom) | |
| Clearance in the piston-cylinder interface | 0.02 - 0.04 mm | |
| Piston pins | ||
| Length | 61.1 mm | |
| Finger planting | Pressed into the connecting rod head | |
| Clearance in the mating of the pin with the piston | 0.011 - 0.014 mm | |
| O.D | 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 3.0 mm | |
| Piston ring gaps: - compression rings - oil scraper ring | 0.30 - 0.50 mm 0.40 - 1.40 mm | |
| Clearance in the mating 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 cylinder diameter | The cylinder diameters of each class are 0.02 mm larger than the corresponding piston diameters. The marking on the piston bottom corresponds to the marking on the cylinder block | |
| Max. permissible cylinder diameter | 0.5 mm more than the nominal value | |
| Max. ovality and taper | 0.013 mm | |
| Clearance in the piston connection | 0.02 - 0.04 mm | |
| Piston diameter measurement points | At the bottom of the skirt, at right angles to the piston pin hole | |
| Crankshaft | ||
| Number of bearings | 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 markings) 57.4820 - 57.4885 mm (green/blue marking) 57.4885 - 57.4950 mm (brown/blue markings) | |
| Guide Bearing Width: - nominal size - repair, reduced by 0.25 mm - repair, reduced by 0.50 mm |
| |
| Colour coding of bearing shells | ||
Lids | Block | |
| - 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 the color markings and class | |
| Crankshaft axial clearance | 0.050 - 0.152 mm | |
| Permissible clearance in the main bearing | 0.015 - 0.040 mm | |
| Permissible clearance in connecting rod bearing | 0.006 - 0.031 mm | |
| Permissible axial clearance of 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 | |
Width of connecting rod | 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 since mid-1995) | ||
| Cylinder head | ||
| Cylinder head height | 95.75 - 96.25 mm (between mating planes) | |
| Max non-flatness of the mating plane with the cylinder block | 0.10 mm | |
| Max. surface non-flatness connections to 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 the valve stem to guide bushing connection: - intake valves - exhaust valves | 0.018 - 0.052 mm 0.038 - 0.072 mm | |
| Allowable valve stem runout - intake valves - exhaust valves | 0.03 mm 0.33 mm | |
| Valve installation height | 17.85 - 18.25 mm. Measured by KM-512 caliber. Carry out only in a car repair shop | |
| Installation height of guides bushings | New guides in accordance with the original size are pressed into the cylinder head. Specified size 83.25 - 83.05 mm | |
| Valve seats | ||
| Chamfer angle | 45° | |
| Lower correction angle | 75° | |
| Upper correction angle | 15° | |
| Valve chamfer width (new valve) | See above | |
| Valves | ||
| Valve stem diameter - intake valves: - specified 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: - specified 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 the valve-guide interface: - intake valves - exhaust valves | 0.018 - 0.052 mm 0.038 - 0.072 mm | |
| Valve Plate Diameter: - intake valves - exhaust valves | 41.8 mm 36.5 mm | |
| 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 coding - normal size - repair, reduced by 0.10 mm | no violet | |
| Max. shaft runout | 0.04 mm | |
| Axial clearance of the shaft | 0.09 - 0.21 mm | |
| Cam stroke | 6.67mm intake and exhaust valves | |
| Bearing clearance: - normal value - wear limit | 0.04 - 0.082 mm 0.11 mm | |
| Neck diameter | The necks have different diameters. Shafts with repair diameter of journals 0.1 mm smaller have purple markings. The 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 diameters of the holes vary, as do 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 - 1st grade - 4th grade | - 85.955 - 85.985 mm (8 on the piston bottom) - 85.965 - 85.975 mm (99 on the piston bottom); 89.975 - 85.985 mm (00 on the piston bottom); 89.985 - 85.995 mm (01 on the piston bottom); 85.995 - 86.005 mm (02 on the piston bottom); 86.445 - 86.455 mm (7 + 0.5 on the piston bottom); 86.455 - 86.465 mm (8 + 0.5 on the piston bottom) | |
| Repair size increased by 0.5 mm 86.465 - 86.475 mm | (9 + 0.5 on the piston bottom) | |
| Repair size increased by 0.5 mm 86.475 - 86.485 mm | (0 + 0.5 at the piston bottom) | |
| Clearance in the piston-cylinder interface | 0.02 - 0.04 mm | |
| Piston pins | ||
| Length | 61.1 mm | |
| Finger planting | Pressed into the connecting rod head | |
| Clearance in the mating of the pin with the piston | 0.003 - 0.010 mm | |
| O.D | 21.0 mm | |
| Clearance in the mating with the connecting rod head | Interference fit | |
| 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 3.0 mm | |
| Piston ring gaps: - compression rings - oil scraper ring | 0.30 - 0.50 mm 0.40 - 1.40 mm | |
| Clearance in the mating 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 cylinder diameter | The cylinder diameters of each class are 0.02 mm larger than the corresponding piston diameters. The marking on the piston bottom corresponds to the marking on the cylinder block | |
| Max. permissible cylinder diameter | 0.5 mm more than the nominal value | |
| Max. ovality and taper | 0.013 mm | |
| Clearance in the piston connection | 0.02 - 0.04 mm | |
| Piston diameter measurement points | At the bottom of the skirt, at right angles to the piston pin hole | |
| Crankshaft | ||
| Number of bearings | 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 markings) 57.482 - 57.488 mm (green/blue marking) 57.488 - 57.495 mm (brown/blue markings) | |
| 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 | |
| Colour 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 the color markings and class | |
| Crankshaft axial clearance | 0.050 - 0.152 mm | |
| Permissible clearance in the main bearing | 0.015 - 0.040 mm | |
| Permissible clearance in connecting rod bearing | 0.006 - 0.031 mm | |
| Permissible axial clearance of 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 | |
| Width of connecting rod | 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 type: | X 22 XE, "Ecotec" | |
| Design features: | Four-cylinder petrol engine with two overhead camshafts, 16 valves | |
| Number of cylinders | 4 | |
| Cylinder arrangement | In-line | |
| Valve timing mechanism: | Hanging valves, overhead camshafts with toothed belt drive, tension adjustment. Hydraulic clearance compensators. Coolant pump drive by toothed belt | |
| Cylinder firing order | 1 - 3 - 4 - 2 | |
| Maximum power: | 100 kW (136 hp) at 5200 rpm | |
| Max. torque: | 202 Nm at 2600 rpm | |
| Cylinder diameter: | 86.0 mm | |
| Piston stroke: | 94.6 mm | |
| Cylinder capacity | 2198 cm³ | |
| Compression ratio: | 10.5: 1 | |
| Injection system type | Multi-position Motronic M 1.5.4 | |
DOHC Engine | ||
| Cylinder head | ||
| Cylinder head height | 95.75 - 96.25 mm (from mating plane to mating plane) | |
| Max non-flatness of the mating plane with the cylinder block | 0.025 mm | |
| Max. non-flatness of planes of conjugation 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 the valve stem to guide bushing connection: - 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 chamfer 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: - specified 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 the valve-guide interface: - intake valves - exhaust valves | 0.03 - 0.057 mm 0.04 - 0.067 mm | |
| Valve Plate 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 | |
| Axial clearance of the shaft | 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 body | 28.021 - 28.000 mm | |
| Pistons and connecting rods | ||
| Installation direction | Arrow towards the drive side Timing belt | |
| Piston diameter - 1st grade - 2 - 4 grade | - 85.955 - 85.965 mm (8 on the piston bottom) - 85.965 - 85.975mm (99 on the piston bottom); 89.975 - 85.985 mm (00 on the piston bottom); 85.985 - 85.995 mm (01 on the piston bottom); 85.995 - 86.005 mm (02 on the piston bottom) | |
| Repair size increased by 0.5 mm | 86.445 - 86.455mm (7 + 0.5 on the piston bottom) 86.455 - 86.465 mm (8 + 0.5 on the piston bottom) 86.455 - 86.475 mm (9 + 0.5 on the piston bottom) 86.475 - 86.485 mm (0 + 0.5 at the piston bottom) | |
| Clearance in the piston-cylinder interface | 0.003 - 0.01 mm | |
| Piston pins | ||
| Length | 61.1 mm | |
| Finger planting | Hot pressing in the connecting rod head | |
| Clearance in the mating of the pin with the piston | 0,003 - 0, 01 | |
| O.D | 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 3.0 mm | |
| Piston ring gaps: - compression rings - oil scraper ring | 0.30 - 0.50 mm 0.40 - 1.40 mm | |
| Clearance in the mating 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 cylinder diameter - 1st grade - 2nd grade | - 85.975 - 85.985 mm (8 on the piston bottom) - 85.985 - 85.995 mm (99 on the piston bottom); 85.995 - 86.005 mm (00 on the piston bottom); 89.005 - 86.115 mm (01 on the piston bottom); 85.115 - 86.025 mm (02 on the piston bottom) | |
| Max. permissible cylinder diameter | 0.5 mm more nominal value | |
| Max. ovality and taper | 0.013 mm | |
| Clearance in the piston connection | 0.02 - 0.04 mm | |
| Piston diameter measurement points | At the bottom of the skirt, at right angles to the opening under the piston pin | |
| Crankshaft | ||
| Number of bearings | 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 | |
| The diameter of the main journal is repair, reduced by 0.25 mm: - green/blue marking - brown/blue marking | 57.732 - 57.738 mm 57.738 - 57.745 mm | |
| The diameter of the main journal is repair, reduced by 0.50 mm: - green/white marking - brown/white markings | 57.482 - 57.488 mm 57.488 - 57.495 mm | |
| Diameter of holes in the cylinder block | Depending on color coding 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 | |
| Width of connecting rod | 26.390 - 26.338 mm for all sizes | |
| Crankshaft axial clearance | 0.050 - 0.152 mm | |
| Permissible clearance of the main bearing | 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 | Violet | |
| Stamping marking | x 24 | |
| Cylinder head height | 102.45 - 102.925 mm | |
| Max non-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 planes of conjugation with pipelines | 0.10 mm | |
| Gasket thickness | 0.80 - 0.90 mm | |
| Clearance in the valve stem-guide connection: - 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 - increased 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 the valve-guide interface: - intake valves - exhaust valves | 0.035 - 0.073 mm 0.045 - 0.085 mm | |
| Valve Plate 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 coding - normal size - repair, reduced by 0.10 mm | Blue/brown Violet | |
| Max. shaft runout | 0.025 mm | |
| Axial clearance of the shaft | 0.10 - 0.20 mm | |
| Cam stroke | 6.68 mm both valves | |
| Clearance in mating with bearings: - normal value - wear limit | 0.04 - 0.082 mm 0.11 mm | |
| Neck diameter | The necks have different diameters. Shafts with a repair journal diameter 0.1 mm smaller have a purple marking. The 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 diameters of the holes vary, as do the diameters of the camshaft journals. Repair dimensions are given in brackets - 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 bottom, 5 on the cylinder block); 94.92 mm (8 on the piston bottom, 7 on the cylinder block); 94.94 mm (6 on the piston bottom, 5 on the cylinder block) - 94.94 mm (8 on the piston bottom, 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 bottom, 0 on the cylinder block) 94.98 mm (02 on the piston bottom, 01 on the cylinder block) 94.98 mm (02 on the piston bottom, 02 on the cylinder block) 95.00 mm (04 on the piston bottom, 03 on the cylinder block) - 95.00 mm (04 on the piston bottom, 04 on the cylinder block) 95.02 mm (06 on the piston bottom, 05 on the cylinder block) 95.02 mm (06 on the piston bottom, 06 on the cylinder block) 95.04 mm (06 on the piston bottom, 07 on the cylinder block) 95.04 mm (06 on the piston bottom, 08 on the cylinder block) 95.04 mm (06 on the piston bottom, 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) | |
| Clearance in the piston-cylinder interface | 0.03 mm | |
| Piston pins | ||
| Length | 65.0 mm | |
| Finger planting | Floating in the connecting rod head | |
| Clearance in the mating of the pin with the piston | 0.006 - 0.013 mm | |
| Installation instructions | Heat the connecting rod head to 280°C | |
| O.D | 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 the mating 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 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 cylinder diameter | The cylinder diameters correspond to the piston diameters. The cylinder block marking indicates the diameter, for example, "04" means a diameter of 95.04 mm, "09" a diameter of 95.09 mm | |
| Max. permissible cylinder diameter | 0.5 mm more than the nominal value | |
| Max. ovality and taper | 0.005 mm | |
| Clearance in the piston connection | 0.02 - 0.05 mm | |
| Piston diameter measurement points | At the bottom of the skirt, at right angles to the piston pin hole | |
| Crankshaft | ||
| Number of bearings | 5 | |
| Bearing type | With inserts | |
| Main bearing diameter Bearings No. 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 | |
| Crankshaft axial clearance | 0.050 - 0.152 | |
| Permissible clearance of the main bearing | 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 | |
Valve timing mechanism
Engine 2.4 l produced before 1995 | |
| Timing belt parameters: - number of teeth - belt width - tooth pitch | 111 20 mm 9.525 mm |
| Belt tension | The data is consistent according to the KM-510-A device readings |
| - New belt: - cold - heated up - Used belt: - cold - heated up | 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 |
2.0L engine since mid-1995 | |
| Timing belt parameters: - number of teeth - width - distance between teeth | 146 20 mm 8 mm |
DOHC 2.2L Engine | |
| Timing Belt Parameters - number of teeth - width - distance between teeth | 171 24 mm 8 m |
Lubrication system
| Amount of oil to be poured | Cm. 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 - 2.4 l engines - DOHC 2.2L engines | 1.5 bar 1.0 bar 1.5 bar |
| Oil pump: - type - clearances in gears: max. clearance between the tops of the gear teeth and the housing | Gear 0.03 - 0.10 mm |
| Lateral clearance in gear engagement | 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 2.0L engine produced before 1995
- Starter, gearbox side 75
- Starter, engine side 45
- Intake manifold to cylinder block 22
- Exhaust manifold to cylinder block 22
- Release bearing guide bushing
- bearing to gearbox 22
- Generator to console 25
- Gearbox to engine 75
- Generator console to cylinder block 40
- Engine Mount Holder for Gearbox 60 (new locking plate)
- Engine Mount Holder for Gearbox 60
- Engine support to longitudinal beam 65
- Engine support to front axle beam 40
- Bearing cap camshaft 8
- Pump/compressor console to engine 40
- Oil line to cylinder block 6 (on the sealant)
- Rear timing belt cover 6
- Crankshaft pulley to timing gear 20
- Main bearing cap mounting bolts 60 + 40 to 50° (replace the bolts)
- Camshaft Bearing Cap Fastening Bolts 45
- Connecting rod bearing cap mounting bolts:
- 1 reception 35
- Step 2 turn 45° (use new bolts)
- Oil drain plug 45
- Oil pressure indicator sensor to oil pump 30
- Oil pan to cylinder block 8 (on sealant)
- Oil pan to cylinder block (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)
- Generator support 25
- Starter support to cylinder block 15
- Thermostat housing to cylinder head 15
- Muffler to the flange of the inlet pipe 25
- Front Timing Belt Cover 4
- Oil pump to cylinder block 25
- Gear to crankshaft:
- 1 reception 130
- 2nd step, turn it at an angle of 40 - 50°
- Tension roller to oil pump 25
- Spark plug 25
- Cylinder head mounting bolts:
- 1 reception 25
- Step 2 Turn 90°
- Step 3 Turn 90°
- Step 4 Turn 90°
- Fuel line to intake manifold 8
- Ground cable to cylinder head 20
- Oil filter 15
- Cable harness to camshaft bearing housing 8
- Cable harness to timing belt cover 4
OHC 2.0L engine since mid-1995
- Starter to cylinder block 60
- Intake manifold to cylinder head 22
- Exhaust manifold to cylinder block 22
- Drive flange to crankshaft (automatic transmission) 60
- Torsional vibration damper to crankshaft 20
- Crankcase ventilation flange to cylinder block 25
- Sprocket of angular velocity sensor to crankshaft 13
- Additional unit console to cylinder block 35
- Starter support to cylinder block 25
- Generator mounting bracket to cylinder block 35
- Oil receiver pipe to cylinder block 6
- Power steering pump to powertrain beam 25
- Compressor Console, Rear Bolts 18
- Rear cover of the toothed belt to the oil pump and the camshaft bearing housing 6
- Cable holder to camshaft bearing housing 8
- Cable channel to front timing belt cover 4
- V-belt tension roller to auxiliary unit beam 35
- Knock sensor to cylinder block 25
- Compressor mounting console to 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 angular speed sensor in cylinder block 6
- Main bearing cap fastening bolts 50 NChm + 45° + 15°
- Bearing bridge and oil baffle plate to cylinder block 20
- Oxygen sensor in muffler 30
- Power steering pump support to cylinder block 20
- Ground cable to cylinder block 20
- Rear engine mount to gearbox 80
- Rear engine mount to crossmember 50
- Front engine mount to engine beam 85
- Front engine mount to chassis 50
- Beam to cylinder block 60
- Engine bracket to gearbox and cylinder block 40
- Lifting eye to camshaft bearing housing 15
- Cover for camshaft bearing housing 8
- Camshaft gear to shaft 45
- Oil Drain Plug in Oil Pan 55
- Oil receiver pipe to oil pump 8
- Oil pressure indicator sensor to oil pump 40
- Oil filter for oil pump 15
- Oil cooler holders for radiator 25
- Oil pump to cylinder block 6
- Oil pump cover to pump 6
- Oil pan to oil pump and cylinder block:
- up to 1997 release 15
- since 1997 release 20
- Connecting rod bearing cap to connecting rod:
- 1 reception 35
- Step 2 Turn 45°
- Step 3 Turn 15°
- Oil sump protective sheet mounting bolts 57
- Flywheel to crankshaft:
- 1 reception 65
- Step 2 Turn 30°
- Step 3 Turn 15°
- Brace for exhaust manifold and generator 18
- Support for intake manifold and generator 18
- Thermostat housing to cylinder block 15
- Pressure reducing valve for oil pump 30
- Brake booster vacuum line to intake manifold 20
- Lower generator mounting bolt to console 35
- Front to rear timing belt cover 4
- Front compressor mounting bolts to unit beam 35
- Inlet pipe with catalytic converter to exhaust manifold and muffler 25
- Heat shield sheet for cylinder head 30
- Gear to crankshaft:
- 1 reception 130
- Step 2 Turn 40 - 50°
- Timing Belt Tensioner Roller to Oil Pump 25
- Spark plugs 25
- Flywheel to crankshaft:
- 1 reception 65
- 2nd turn Turn 45°
- Step 3 Turn 15°
- Head to cylinder block:
- 1 reception 25
- Step 2 Turn 90°
- Step 3 Turn 90°
- Step 4 Turn 90°
DOHC 2.2L Engine
- Starter to cylinder block 60
- Intake manifold to cylinder head 22
- Exhaust manifold to cylinder block 22
- Drive flange to crankshaft (automatic transmission) 60
- Ignition module to adapter 8
- Torsional vibration damper to crankshaft 20
- Crankcase ventilation flange to cylinder block 25
- Sprocket of angular velocity sensor to crankshaft 13
- Additional unit console to cylinder block 35
- Starter support to cylinder block 25
- Generator mounting bracket to cylinder block 35
- Oil receiver pipe to cylinder block 6
- Power steering pump to powertrain beam 25
- Compressor Console, Rear Bolts 18
- Compressor Console Front Bolts 35
- Rear cover of the toothed belt to the oil pump and the camshaft bearing housing 6
- Cable holder to camshaft bearing housing 8
- Cable channel to front timing belt cover 4
- V-belt tension roller to auxiliary unit beam 35
- Knock sensor to cylinder block 20
- Compressor mounting console to 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 angular speed sensor in cylinder block 6
- Main bearing cap fastening bolts 50 Nm + 45° + 15°
- Bearing bridge and oil baffle plate to cylinder block 20
- Oxygen sensor in muffler 30
- Power steering pump support to cylinder block 20
- Ground cable to cylinder block 20
- Rear engine mount to gearbox 80
- Rear engine mount to crossmember 50
- Front engine mount to engine beam 85
- Front engine mount to chassis 50
- Beam to cylinder block 60
- Engine bracket to gearbox and cylinder block 40
- Lifting eye to camshaft bearing housing 15
- Camshaft Bearing Housing 8
- Cover for camshaft bearing housing 8
- Camshaft gear to shaft 45
- Oil Drain Plug in Oil Pan 45
- Oil receiver pipe to oil pump 8
- Oil pressure indicator sensor to oil pump 40
- Oil filter for oil pump 15
- Oil cooler holders for radiator 25
- Oil pump to cylinder block 6
- Oil pump cover to pump 6
- Oil pan to oil pump and cylinder block:
- up to 1997 release 15
- since 1997 release 20
- Connecting rod bearing cap to connecting rod:
- 1 reception 35
- Step 2 Turn 45°
- Step 3 Turn 15°
- Oil sump protective sheet mounting bolts 57
- Flywheel to crankshaft:
- 1 reception 65
- Step 2 Turn 30°
- Step 3 Turn 15°
- Brace for exhaust manifold and generator 18
- Support for intake manifold and generator 18
- Thermostat housing to cylinder block 15
- Pressure reducing valve for oil pump 30
- Brake booster vacuum line to intake manifold 20
- Lower generator mounting bolt to console 35
- Front to rear timing belt cover 4
- Inlet pipe with catalytic converter to exhaust manifold and muffler 25
- Heat shield sheet for cylinder head 30
- Gear to crankshaft:
- 1 reception 130
- Step 2 Turn 40 - 50°
- Timing Belt Tensioner Roller to Oil Pump 25
- Spark plugs 25
- Flywheel to crankshaft:
- 1 reception 65
- 2nd turn Turn 45°
- Step 3 Turn 15°
- Head to cylinder block:
- 1 reception 25
- Step 2 Turn 90°
- Step 3 Turn 90°
- Step 4 Turn 90°
Engine 2.4 l
- Power steering pump mounting bolts 25
- Compressor mounting bolts (air conditioner) 50
- Generator Holders 25
- Compressor Adjusting Bolt Clamp 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 nut 40
- Oxygen sensor 30
- Eye bolt, V-belt adjusting bolt 25
- Camshaft chain tensioner mounting bolts 50
- Exhaust manifold mounting bolts 35
- Crankshaft Wheel Fastening Bolt 120
- Clutch basket mounting bolts 22
- Main bearing mounting bolts 120
- Engine support to longitudinal beam 52
- Engine support to beam 85
- Camshaft gear mounting bolts 25
- Oil pan 8
- Connecting rod bearing cap mounting bolts 43
- Flywheel mounting bolts 60
- Bolts for fastening the distribution mechanism housing 15
- Bolts for fastening the timing gear drive gear 25
- Coolant pump mounting bolts 15
- Bolts securing the cylinder head to the distribution mechanism housing 25
- Coolant pump V-belt tensioner nut 25
- Valve Drive Rocker Arm Pin 40
- Temperature sensor 10
- Spark plugs 40
- cylinder head mounting bolts:
- 1 reception 60
- 2nd reception 90 + 35°
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