Specifications of gasoline engines

Engines - gasoline, four-stroke, four-cylinder, in-line, water-cooled, have a camshaft in the cylinder head, mounted transversely in front of the car.

Main settings

Engine	1,3 HC OHC	1.6 NS ONS	1.6 NS ONS economical	2.0 NS ONS
engine's type	JCT	LCT	LCS	NET
Cylinder diameter (mm)	79,02	87,67	87,67	90,82
piston stroke (mm)	66,00	66,00	66,00	76,95
Volume (see3)	1294	1593	1593	1993
Compression ratio	9,0	9,2	9,2	9,2
Compression pressure (MPa)	1,1 – 1,3	1,1 – 1,3	1,1 – 1,3	1,1 – 1,3
Rated power:
– kW at rpm	44 at 5700	55 at 5300	55 at 5700	77 at 5200
– HP at rpm	60 at 5700	75 at 5600	75 at 5700	105 at 5200
Max Torque (Nm at rpm)	98 at 3100	120 at 2900	120 at 2900	157 at 4000

Cylinder head

The head is made of a special alloy and has valve seats molded directly into the material of the cylinder head.

Designation:
– 1.3 dm engine3	3
– 1.6 dm engine3	6
– 2.0 dm engine3	0
Valve contact angle	44°30' – 45°
Valve seat width:
- inlet	1.5mm
- graduation	2.0 mm
Maximum grinding depth of the lower plane of the cylinder head	0.154 mm
Camshaft bearing bore diameters:
- front bearing	45.072 - 45.102 mm
– middle bearing	47.692 - 47.772 mm
- rear bearing	48.072 - 48.102 mm

Cylinder head gasket

Brand: Reinz.

Valve guides

The guide holes are made directly in the cylinder head.

Nominal diameter	8.063 - 8.088 mm
Repair size:
– exceeding 0.2	8.263 - 8.288 mm
– exceeding 0.4	8.463 - 8.488 mm

Valves

The valves are installed in the cylinder head and inclined at an angle of 7°30' to the cylinder axis.

Valve sizes (mm)

Engine	1.3 dm3	1.6 dm3	2.0 dm3
Inlet valve:
- length	112,65 – 113,65	112,65 – 113,65	110,65 – 111,65
- plate diameter	38,30 – 38,70	41,80 – 42,20	41,80 – 42,20
Exhaust valve:
- length	112,05 – 113,75	112,05 – 113,75	110,10 – 112,05
- plate diameter	29,80 – 30,20	34,00 – 34,40	35,80 – 36,20

Inlet valve sizes are common to all engines.

Rod diameter

Nominal	8.025 - 8.043 mm
Repair size +0.2	8.225 - 8.243 mm
Repair size +0.4	8.425 - 8.443 mm
Repair size +0.6	8.625 - 8.643 mm
Repair size +0.8	8.825 - 8.843 mm

Exhaust valve sizes are common to all engines.

Rod diameter

Nominal	7.999 - 8.017 mm
Repair size +0.2	8.199 - 8.217 mm
Repair size +0.4	8.399 - 8.417 mm
Repair size +0.6	8.599 - 8.617 mm
Repair size +0.8	8.799 - 8.817 mm

The gap of the rod in the guide is 0.046–0.089 mm.

Valve clearance (with a cold engine):
- inlet valve	0.20 mm
- Exhaust valve	0.25 mm

Valve springs

The same springs are used for intake and exhaust valves.

Spring diameter	23.445 - 23.95 mm
Spring wire diameter	3.87 - 3.93 mm
Number of turns	4,7
free length	47.00 mm

Engine block

The engine block is cast iron. The cylinders are made directly in the cylinder block.

Support bearing width	27.17 - 27.22 mm
Internal diameters of main bearings (measured vertically):
- nominal	57.000 - 57.034 mm
- repair size -0.25	56.750 - 56.784 mm
– repair size -0.50	56.500 - 56.534 mm
– repair size -0.75	56.250 - 56.284 mm
– repair size -1.00	56.000 - 56.034 mm
Bore diameters of the main bearing seats in the cylinder block:
- nominal size	60.620 – 60.640 mm
– repair size +0.4	61.020 – 61.040 mm

Cylinder diameters (mm)

Engine	1.3 dm3	1.6 dm3	2.0 dm3
Designation	13	16	20
Nominal standard diameters:
– group 1	79,000 – 79,010	87,650 – 87,660	90,800 – 90,810
– group 2	79,010 – 79,020	87,660 – 87,670	90,810 – 90,820
– group 3	79,020 – 79,030	87,670 – 87,680	90,820 – 90,830
– group 4	79,030 – 79,040	87,680 – 87,690	90,830 – 90,840
Nominal diameters with tolerance:
– group A	79,510 – 79,520	88,160 – 88,170	91,310 – 91,320
- group B	79,520 – 79,530	88,170 – 88,180	91,320 – 91,330
- group C	79,530 – 79,540	88,180 – 88,190	91,330 – 91,340
Repair dimensions:
– standard	79,030 – 79,040	87,680 – 87,690	90,830 – 90,840
- with a tolerance of 0.5	79,530 – 79,540	88,180 – 88,190	91,330 – 91,340
– with a tolerance of 1.0	80,030 – 80,040	88,680 – 88,690	91,830 – 91,840

Crank mechanism

Crankshaft

The steel crankshaft is supported by five bearings.

Axial play	0.08 - 0.28 mm
Diameters of main journals:
- nominal size	56.970 - 56.990 mm
- repair size -0.25	56.720 - 56.740 mm
– repair size -0.50	56.470 - 56.490 mm
– repair size -0.75	56.220 - 56.240 mm
– repair size -1.00	55.970 - 55.990 mm
Clearance in main bearings	0.010 - 0.064 mm
The measurement is carried out using Plastigage measuring rods.
Connecting rod diameters:
- nominal size	51.980 – 52.000 mm
- repair size -0.25	51.730 – 51.750 mm
– repair size -0.50	51.480 – 51.500 mm
– repair size -0.75	51.230 – 51.250 mm
Thickness of thrust half rings:
- nominal size	2.30 - 2.35 mm
- repair size	2.50 - 2.55 mm

Flywheel

The flywheel is fixed to the crankshaft flange with six bolts.

Intermediate shaft

The intermediate shaft is located in front of the cylinder block, on the left side. Provides a drive for the ignition distributor, as well as oil and fuel pumps.

Axial clearance - 0.050–0.204 mm.

Connecting rods

The connecting rods are forged from steel and have an I-beam profile in their cross section. The piston pin is pressed into the connecting rod head.

Connecting rod head bore diameter	23.964 - 23.976 mm
Pin tension in the connecting rod head:	0.018 - 0.039 mm
Heating temperature of the connecting rod head during pin installation	250 - 300°С
Connecting rod bore diameter	55.000 – 55.020 mm
The inner diameters of the holes of the connecting rod bearings:
- nominal size	52.006 - 52.044 mm
- repair size -0.25	51.756 - 51.794 mm
– repair size -0.50	51.706 - 51.744 mm
– repair size -0.75	51.256 - 56.294 mm
– repair size -1.00	51.006 - 51.044 mm
Clearance in main bearings	0.006 - 0.064 mm
The measurement is carried out using Plastigage measuring rods.
Permissible non-perpendicularity of the axis of the holes relative to the axis of the connecting rod:
- head hole	0.10 mm
- base hole	0.15mm

Pistons

The pistons are made of light alloy, without grooves on the conductive part, with a cast invar ring to limit thermal dimensional errors. In the upper part there are three grooves for piston rings. The axis of the piston pin hole is offset relative to the piston axis. Pistons are supplied in kits with pins and connecting rods.

Installation Method: The arrow on the bottom of the piston must point towards the front of the engine (towards the drive of the gas distribution system).

Piston pins

Pins made of alloy steel and heat treated are pressed into the connecting rod heads (hot mounting at head temperature 250°–300°С) and rotate in the piston hubs.

Length:
– engine 1.3 dm3	60.0 - 60.8 mm
– engine 1.6 dm3	68.0 - 68.8 mm
– engine 2.0 in.3	72.0 - 72.8 mm
Diameter:
- marking in red	23,994 – 23,997
- marked in blue	23,997 – 24,000
- marking in red	22,000 – 24,003
Clearance in piston hubs	0.008 - 0.014 mm
Tension in the connecting rod head	0.018 - 0.039 mm

Piston dimensions (mm)

Engine	1.3 dm3	1.6 dm3	2.0 dm3
Nominal standard diameters:
– group 1	78,965 – 78,975	87,615 – 87,625	90,765 – 90,775
– group 2	78,975 – 78,985	87,625 – 87635	90,775 – 90,785
– group 3	78,985 – 78,995	87,635 – 87,645	90,785 – 90,795
– group 4	78,995 – 79,005	87,645 – 87,655	90,795 – 90,805
Repair dimensions:
– standard	78,900 – 79,015	87,640 – 87,665	90,780 – 90,805
- with a tolerance of 0.5	79,490 – 79,515	88,140 – 88,165	91,280 – 91,305
– with a tolerance of 1.0	79,990 – 80,015	88,640 – 88,665	91,780 – 91,805
Clearance of new pistons in cylinders	0,015 – 0,050	0,015 – 0,050	0,025 – 0,060

Piston rings

Each piston has three rings: two sealing and one oil scraper.

O-ring lock clearance (located in the cylinder):
– engine 1.3 in.3 and engine 1.6 in.3	0.30 - 0.50 mm
– engine 2.0 in.3	0.038 - 0.048 mm
Clearance of the lock of an oil scraper ring	0.40 - 1.40 mm

Location of ring locks:

• sealing – 150°each (in opposite directions) regarding the lock of the oil scraper ring;
• oil scraper - the lock of the expanding spring is installed in accordance with the direction of the arrow on the bottom of the piston; the locks of the upper and lower plates are set 25 mm to the right and left of the direction of the arrow.

Gas distribution system

Four-cylinder in-line engine ONS (general form)

The camshaft is located in the cylinder head, drives the valves through the valve lever and is driven by a toothed belt.

Valve clearance (cold):

• intake: 0.20 mm;
• graduation: 0.25 mm.

Distribution phases

Engine	1.3 dm3 and 1.6 dm3	2.0 dm3
OZD	22°before TDC	24°before TDC
ZZD	54°after BDC	64°after BDC
OZW	64°before BDC	70°before BDC
ZZW	12°after TDC	18°after TDC

OZD and ZZD - opening and closing of the intake valve, respectively;
OZW and ZZW - opening and closing of the exhaust valve, respectively;
TDC and BDC are top and bottom dead center respectively.

Toothed belt

Brand: Ford Powergrip
Type:
– engine 1.3 dm3	70NM 6288 AA
– engine 1.6 dm3	70NM 6288 AA
– engine 2.0 dm3	70NM 6268 AA
Number of teeth
– engine 1.3 dm3	119
– engine 1.6 in.3	119
– engine 2.0 dm3	122

Camshaft

The camshaft rotates in three bearings.

Camshaft bearing diameters:
- front	41.987 - 42.013 mm
– medium	44.607 - 44.633 mm
- rear	44.987 - 45.013 mm
Inner diameters of bearing bushes:
- front	42.035 - 42.055 mm
– medium	44.655 - 44.675 mm
- rear	45.035 - 45.055 mm
Camshaft end play	0.104 - 0.204 mm
Thickness of camshaft thrust pads	3.96 - 4.01 mm
Cam lift:
– engine 1.3 dm3	5.9639 mm
– engine 1.6 dm3	5.9639 mm
– engine 2.0 dm3	6.3323 mm
Jaw height:
– engine 1.3 dm3	35.894 - 36.234 mm
– engine 1.6 in.3	35.894 - 36.234 mm
– engine 2.0 dm3	36.260 – 36.600 mm