Note. Separate characteristics are also given in the text of the Chapter and, if they are mandatory, are highlighted in bold.
Carburetor engines 1.6 l
Cylinder block
Maximum curvature of the block surface | 0.10 mm |
Cylinder diameter: | |
| 76.000 - 76.010 mm |
| 76.010 - 76.020 mm |
| 76.020 - 76.030 mm |
Repair dimensions | as for pistons |
Maximum ovality of cylinders | Less than 0.015mm |
maximum taper of cylinders | Less than 0.010mm |
Maximum hole wear | 0.20 mm |
Piston backlash | 0.010 - 0.030 mm |
Crankshaft
Number of main bearings | 5 |
Diameter of main journals: | |
| 49.956 - 49.964 mm |
| 49.948 - 49.956 mm |
| 49.940 - 49.948 mm |
Diameter of connecting rod journals | |
| 39.968 - 39.974 mm |
| 39.962 - 39.968 mm |
| 39.956 - 39.962 mm |
Maximum crankshaft runout | less than 0.04mm |
Axial play of the crankshaft: | |
| 0.060 - 0.180 mm |
| 0.30 mm |
Thickness of main bearing shells: | |
| 1.826 - 1.830 mm |
| 1.830 - 1.834 mm |
| 1.834 - 1.838 mm |
| 1.838 - 1.842 mm |
| 1.842 - 1.846 mm |
| 1.960 - 1.964 mm |
| 2.085 - 2.089 mm |
Cylinder head
Material | Aluminium alloy |
Max. surface deformation | 0.10 mm |
Head height | 117.8 - 118.0 mm |
Valve clearances (warm): | |
| 0.21 - 0.49 mm |
| 0.32 - 0.40 mm |
| 0.30 - 0.58 mm |
| 0.37 - 0.45 mm |
Valve clearances (cold) – temperature around 20°C: | |
| 0.25 - 0.33 mm |
| 0.32 - 0.40 mm |
Valve disc diameter: | |
| 29.9 - 30.1 mm |
| 23.9 - 24.1 mm |
Total length of valves: | |
| 92.05 - 92.45 mm |
| 92.42 - 92.82 mm |
Valve stem diameter: | |
| 5.465 - 5.480 mm |
| 5.445 - 5.460 mm |
Valve seat angle | 45°15' — 45°45' |
Maximum valve stem grinding | 0.2 mm |
Minimum plate edge thickness | 0.9 - 1.1 mm |
Maximum valve stem play | 0.10 mm |
Valve guides
Inner diameter | 5.500 — 5.515 |
External diameter: | |
| 9.523 - 9.534 mm |
| 9.723 - 9.734 mm |
Machining size for repair size guide | 9.685 - 9.696 mm |
Guide tension | 0.027 - 0.049 mm |
Backlash of valve stems in guides: | |
| 0.020 - 0.050 mm |
| 0.040 - 0.016 mm |
| 0.10 mm |
Valve springs
Uncompressed Length - All Valves | 40.0 mm |
Installation height | 23.64 mm with a load of 37.7 kg |
Minimum installation length | 23.64 mm with a load of 33.7 kg |
Maximum spring deflection on the top side | less than 1.75 mm (see illustration) |
Valve lifters
External diameter | 29.960 - 29.975 mm |
Inner diameter | 30.000 - 30.021 mm |
Pusher clearance | 0.025 - 0.061 mm |
Valve seat chamfers
Chamfer Width: | |
| 1.34 - 1.63 mm |
| 1.70 — 2.12 |
Valve face diameter: | |
| 29.5 - 29.7 mm |
| 23.5 - 23.7 mm |
Machining size for repair size saddles: | |
| 31.9 - 32.1 mm |
| 25.2 - 25.4 mm |
Seat Angle: | 45° |
| 30 and 60° |
| 10 and 60° |
Camshaft and camshaft bearings
Jaw height: | |
| 39.880 - 40.070 mm |
| 39.980 - 40.070 mm |
wear limit | less than 0.20 mm |
Camshaft end play | 0.115 - 0.118 mm |
wear limit | 0.20 mm |
Maximum camshaft runout | 0.10 mm |
camshaft bearing play | 0.045 -0. 086 mm |
wear limit | 0.15mm |
Inner diameter of camshaft bores: | |
| 28.000 - 28.021 mm |
| 24.000 - 24.021 mm |
Camshaft journal diameter: | |
| 27.935 - 27.955 mm |
| 23.935 - 23.995 mm |
Distribution mechanism
Inlet valve opens | 0° (TDC) |
Inlet valve closes | 42°after BDC |
Exhaust valve opens | 42°before BDC |
Exhaust valve closes | 0° (TDC) |
Pistons
Material and construction | aluminum alloy, hard skirt pistons |
Piston rings | two compression rings, one oil scraper ring |
piston pins | float in the connecting rods, pressed into the pistons. The fingers are secured with retaining rings. |
Piston diameter: | |
| 75.980 - 75.990 mm |
| 75.990 - 76.000 mm |
| 76.000 - 76.010 mm |
| 76.490 - 76.510 mm |
| 76.990 - 77.010 mm |
Piston backlash | 0.010 - 0.030 mm |
Piston measuring points | see illustration |
Piston pin hole | 18.987 - 18.999 mm |
Piston pin diameter | 18.989 - 19.001 mm |
Piston rings
Vertical play of rings in grooves: | |
| 0.040 - 0.085 mm |
| 0.030 - 0.065 mm |
| 0.20 mm |
Piston ring gaps: | |
| 0.20 mm - 0.40 mm |
| 0.35 - 0.55 mm |
| 0.25 - 1.0 mm |
The wear limit of the gaps in the locks of the rings: | |
| 0.49 mm |
| 0.64 mm |
| 1.09 mm |
Piston pins
External diameter | 18.989 - 18.999 mm |
Piston eye diameter | 18.987 - 18.999 mm |
Piston clearance | preload - 0.004 to 0 mm |
Gap in the sleeve of the eye of the connecting rod | 0.005 - 0.017 mm |
Connecting rods
Axial play on the crankshaft journal | 0.20 - 0.47 mm |
| 0.52 mm |
Bearing play | 0.010 - 0.035 mm |
| 0.055 mm |
Maximum deformation | 0.15mm per 100mm |
Maximum twist of the cranks | 0.3 mm per 100 mm |
Crank length, center to center | 140.45 - 140.55 mm |
Connecting rod eye hole diameter | 19.000 — 19.012 (bushing tensioned) |
Connecting rod bearing bore diameter | 43.000 — 43.013 (without inserts) |
Connecting rod bearing shells | |
| 1.505 — 1.508 (three tolerance classes) |
Connecting rod bearing shells | |
| 0.08; 0.12 and 0.25 mm |
Injection engines 2.0 l
Cylinder block
Maximum curvature of the block surface | 0.10 mm |
Cylinder diameter: | |
| 86.000 - 86.010 mm |
| 86.010 - 86.020 mm |
| 86.020 - 86.030 mm |
Repair dimensions | as for pistons |
Maximum ovality of cylinders | Less than 0.015mm |
maximum taper of cylinders | Less than 0.010mm |
Maximum hole wear | 0.20 mm |
Piston backlash | 0.010 - 0.030 mm |
Crankshaft
Number of main bearings | 5 |
Diameter of main journals: | |
| 54.974 - 54.980 mm |
| 54.968 - 54.974 mm |
| 54.962 - 54.968 mm |
Crankpin diameter: | |
| 47.968 - 47.974 mm |
| 47.962 - 47.968 mm |
| 47.956 - 47.962 mm |
Maximum crankshaft runout | less than 0.025 mm |
Axial play of the crankshaft: | |
| 0.012 - 0.026 mm |
| 0.30mm |
Thickness of main bearing shells: | |
| 1.977 - 1.980 mm |
| 1.980 - 1.983 mm |
| 1.983 - 1.986 mm |
| 1.986 - 1.989 mm |
| 1.989 - 1.992 mm |
| 1.992 - 1.995 mm |
| 1.995 - 1.998 mm |
| 2.109 - 2.117 mm |
Cylinder head
Material | Aluminium alloy |
Max, surface deformation | 0.10 mm |
Head height | 136.9 - 137.1 mm |
Valve disc diameter: | |
| 34.0 - 34.2 mm |
| 30.0 - 30.2 mm |
Total length of valves: | |
| 101.24 - 101.56 mm |
| 102.11 - 102.53 mm |
Valve stem diameter: | |
| 5.965 - 5.980 mm |
| 6.945 - 6.960 mm |
| 5.945 - 5.560 mm |
Valve seat angle | 45°15' — 45°45' |
Maximum valve stem grinding | 0.2 mm |
The minimum thickness of the edge of the valve disc: | |
| 1.3mm |
| 1.6mm |
Maximum valve stem play | 0.10 mm |
Valve guides
Bore, inlet valves | 6.000 - 6.018 mm |
Inner diameter, exhaust valves: | |
| 7.000 - 7.018 mm |
| 6.000 - 6.018 mm |
Outer Diameter - Inlet Valves: | |
| 10.023 - 10.034 mm |
Outer Diameter - Exhaust Valves: | |
| 11.023 - 11.034 mm |
| 10.023 - 10.034 mm |
| 11.223 - 11.234 mm |
| 10.223 - 10.234 mm |
Processing size for repair size guide: | |
| 10.175 - 10.196 mm |
| 11.175 - 11.196 mm |
| 10.175 - 10.196 mm |
Guide tension | 0.027 - 0.059 mm |
Backlash of valve stems in guides: | |
| 0.020 - 0.053 mm |
| 0.040 - 0.073 mm |
| 0.10 mm |
Valve springs
Uncompressed Length - All Valves | 49.36 mm |
Installation height | 30.00 mm with a load of 58 - 66.5 kg |
Minimum installation length | 30.00 mm with a load of 56 kg |
Maximum spring deflection on the top side | less than 2.20 mm (see illustration) |
Hydraulic valve lifters
External diameter | 16.980 - 16.993 mm |
Inner diameter | 17.000 - 17.020 mm |
Pusher gap | 0.007 - 0.040 mm |
Valve seat chamfers
Chamfer Width: | |
| 1.40 - 1.70 mm |
| 1.70 - 2.00 mm |
Valve face diameter: | |
| 33.6 - 33.8 mm |
| 29.4 - 29.6 mm |
Machining size for repair size saddles: | |
| 35.500 - 35.516 mm |
| 31.500 - 31.516 mm |
Seat Angle | 45°C |
Camshaft and camshaft bearings
Jaw height: | |
| 38.408 - 38.598 mm |
| 37.920 - 38.110 mm |
| 37.920 - 38.110 mm |
| 37.920 - 38.110 mm |
wear limit | less than 0.20 mm |
Camshaft end play | 0.055 - 0.139 mm |
| 0.20 mm |
Maximum camshaft runout | 0.10 mm |
| 0.045 - 0.086 mm |
| 0.12mm |
Camshaft bearing inner diameter | 28.000 - 28.021 mm |
Camshaft journal diameter | 27.935 - 27.955 mm |
Distribution mechanism
SR20DE engine | SR20Di engine | |
Inlet valve opens | 9°before TDC | 14°before TDC |
Inlet valve closes | 59°after BDC | 46°after BDC |
Exhaust valve opens | 51°before BDC | 58°before BDC |
Exhaust valve closes | 9°after TDC | 2°after TDC |
Pistons
Material and construction | aluminum alloy, hard skirt pistons |
Piston rings | two compression rings, one oil scraper ring |
piston pins | float in the connecting rods, pressed into the pistons. The fingers are secured with retaining rings. |
Piston diameter: | |
| 85.980 - 85.990 mm |
| 85.990 - 86.000 mm |
| 86.000 - 86.010 mm |
| 86.180 - 86.210 mm |
Piston backlash | 0.010 - 0.030 mm |
Piston measuring points | see illustration |
Piston pin holex | 0.010 - 0.030 mm |
Piston pin diameter | 21.989 - 22.001 mm |
Piston rings
Vertical play of rings in grooves: | |
| 0.040 - 0.080 mm |
| 0.030 - 0.070 mm |
| 0.20 mm |
Piston ring gaps: upper compression ring | 0.20 - 0.30 mm |
| 0.35 - 0.50 mm |
| 0.20 - 0.60 mm |
| 1.0 mm |
Piston pins
External diameter | 21.989 - 22.001 mm |
Piston eye diameter | 21.987 - 21.999 mm |
Piston clearance | preload - 0.004 to 0 mm |
Gap in the sleeve of the eye of the connecting rod | 0.005 - 0.017 mm |
| 0.023 mm |
Connecting rods
Axial play on the crankshaft journal | 0.20 - 0.35 mm |
| 0.50 mm |
Bearing play | 0.020 - 0.045 mm |
| 0.09 mm |
Maximum deformation | 0.15mm per 100mm |
Maximum twist of the cranks | 0.3 mm per 100 mm |
Crank length, center to center | 136.30 mm |
Connecting rod eye hole diameter | 22.000 — 22.012 (bushing tensioned) |
Connecting rod bearing bore diameter | 51.000 - 51.013 mm (without inserts) |
Connecting rod bearing shells | |
| 1.500 — 1.503 (three tolerance classes) |
Connecting rod bearing shells | |
| 0.08; 0.12 and 0.25 mm |
Miscellaneous data
Camshaft sprocket runout | max.0.25mm |
Max, runout of the friction surface of the flywheel | max.0.10mm |
Valve clearance adjusting washers: | |
| from 2.80 to 3.20 mm |
| 0.025 mm |
Designations in washers | 28 = 2.8mm |
Lubrication system
Design | gear pump, different tooth shape on 1.6 and 2.0 liter engines. Driven from the front of the crankshaft. It is located in the cover of the timing gear drive. |
Pump Clearances - 1.6L Engine | |
| 0.11 - 0.20 mm |
| 0.0385 - 0.3015 mm |
| 0.0375 - 0.3825 mm |
| 0.05 - 0.09 mm |
| 0.05 - 0.11 mm |
Pump Clearances - 2.0L Engine | |
| 0.1 - 0.20 mm |
| less than 0.18mm |
| 0.05 - 0.09 mm |
| 0.11 - 0.20 mm |
Oil pressure: | |
| see above |
| see above |
Oil quantity | see Types and volumes of lubricants and fluids used in Chapter Ongoing care and maintenance |
Oil filter | |
| cartridge |
Tightening force of threaded connections, Nm
Fastener tightening torques are given in the text of the Chapter and in some illustrations*.
* The tightening torques shown in bold type must be strictly adhered to; Efforts not in bold type are indicative only.
Carbureted engine
Cylinder head bolts: | |
| 30 |
| 59 |
| loosen all bolts |
| 30 |
| tighten by an angle of 50 - 55°or 60±5 |
Connecting rod nuts: | |
| 14 — 16 |
| 23 - 29 or 35 - 40° |
| 85 — 95 |
| 47 — 53 |
| 6.5 — 8.5 |
| 30 — 40 |
| 100 — 130 |
| 45 — 60 |
| 135 — 155 |
| 13 — 19 |
| 6 — 12 |
| 6.5 — 8.5 |
| 6.5 — 8.5 |
| 9 — 12 |
| 3.7 — 5.0 |
| 2 — 4 |
| 16 — 21 |
| 6.3 — 8.3 |
| 6.3 — 8.3 |
| 6.3 — 8.4 |
| 16 — 21 |
| 9 — 12 |
| 16 — 21 |
| 32 — 43 |
| 16 — 21 |
| 38 — 50 |
Injection engine
Cylinder head bolts: | |
| 39 |
| 78 |
| loosen all bolts |
| 35 — 45 |
| tighten by 90 - 100° |
Connecting rod nuts: | |
| 14 — 16 |
| 38 - 44 or 60 - 65° |
| 85 — 95 |
| 85 — 95 |
Main bearing cap bolts: | |
| 32 — 38 |
| 73 - 82 or 45 - 50° |
| 6.5 — 7.5 |
| 6.5 — 7.5 |
| 10 — 13 |
| 30 — 40 |
| 140 — 160 |
| 145 — 155 |
| 13 — 19 |
| 6.3 — 8.3 |
| 16 — 19 |
| see illustrations Camshaft bearing cap tightening sequence. Large cover refers to the left camshaft and The individual bolts mentioned in the text are marked with letters from A to D. |
| see illustration |
| 16 — 22 |
| 45 — 60 |
| 16 — 21 |
| 16 — 21 |
| 6.3 — 8.3 |
| 8 — 12 |
| 6.3 — 8.3 |
| 13 — 16 |