Contents: Cylinder head ↳ Intake valves ↳ Exhaust valves ↳ Rods and rocker arm ↳ Cylinder block ↳ Pistons and piston rings ↳ Connecting rods ↳ Crankshaft and bearings ↳ Camshaft ↳ Tightening torques for connections -… ↳
Cylinder head
Valve seat angle:
- Inlet valves - 30°-30° 30'
- Exhaust valves - 45°-45° 30'
Inner diameter of valve guide bushing (all valves) — 8.982-9.013 mm
Intake valves
- Plate diameter: 41.90-42.10 mm
- Rod diameter: 8.491-8.966 mm
- Valve seat angle: 29°30'-30
- The length of the valve spring in a free state is 51 mm
Exhaust valves
- Plate diameter: 36.20-36.40 mm
- Rod diameter: 8.923-8.948 mm
- Valve seat angle: 44°30'-45
- The length of the valve spring in a free state is 51 mm
Rods and rocker arm
- Valve rocker shaft diameter: 18.87-18.90 mm
- The gap between the rocker arm and the axle is 0.02-0.08 mm
- Push rod diameter: 17.745-17.488 mm
- Bar length: 153.87-154.87 mm
Cylinder block
Engine cylinder diameter:
- Class 1 - 93.648-93.660 mm
- Class 2 - 93.660-93.696 mm
- Class 3 - 93.672-93.684 mm
- Class 4 - 93.684-93.696 mm
Pistons and piston rings
Diameter (mahle pistons):
- Class 1 - 93.508-93.520 mm
- Class 2 - 93,520-93,532 mm
- Class 3 - 93,532-93,544 mm
- Class 4 - 93.544-93.556 mm
Diameter (H&G pistons):
- Class 1 - 93.621-93.633 mm
- Class 2 - 93.633-93.645 mm
- Class 3 - 93.645-93.657 mm
- Class 4 - 93.657-93.669 mm
Permissible increase in piston diameter for various repair sizes is 0.65 mm, 1.00 mm
Clearance between piston and cylinder bore:
- For Mahle pistons - 0.021-0.059 mm
- For H&G pistons - 0.015-0.039 mm
Piston pin bore diameter:
- For Mahle pistons - 43.5 mm
- For H&G pistons - 81.5 mm
The gap between the top of the piston and the cylinder block surface at TDC (piston protrusion):
- Nominal - 0.301-0.503 mm
- Repair - 0.211-0.503 mm
- Piston pin clearance in the piston: 0.002-0.010 mm
Piston ring gaps(nominal):
- Compression rings - 0.40-0.65 mm
- Oil scraper ring - 0.38-1.14 mm
Clearance between piston ring and groove (nominal):
- Upper compression ring - 0.14-0.17 mm
- Second compression ring - 0.06-0.095 mm
- Oil scraper ring - 0.02-0.055 mm
Connecting rods
Piston pin bushing diameter: 29.010-29.032 mm
The gap between the piston pin and the bushing is 0.006-0.026 mm
Crankshaft and bearings
Nominal diameter of main bearing journal:
Back:
- Size 1 - 76.980-77.000 mm
- Size 2 - 76.730-76.750 mm
Rest:
- Size 1 - 69.980-70.000 mm
- Size 2 - 69.730-69.750 mm
Repair diameter of main bearing journal:
Back:
- Size 3 - 76.490-76.500 mm
- Size 4 - 76.240-76.250 mm
Rest:
- Size 3 - 69.490-69.500 mm
- Size 4 - 69.240-69.250 mm
Working clearance of the main journal in the bearings:
- Necks 1-4 - 0.052-0.090 mm
- Neck 5 - 0.056-0.094 mm
Nominal diameter of crank pins:
- Size 1 - 60.000-59.980 mm
- Size 2 - 59.750-59.730 mm
Permissible diameter reduction for various repair sizes is 0.25, 0.50, 0.75 mm
The working clearance of the connecting rod journals is 0.030-0.095 mm
The working clearance between the bearing shell and the journal of the lower connecting rod head is 0.075-0.325 mm
Camshaft
Cam stroke:
- Inlet valve - 7.3 mm
- Exhaust valve - 7.6 mm
Bearing journal diameter: 55.966-55.941 mm
Bearing journal working clearance: 0.072-0.116 mm
Axial runout of the camshaft: 0.10-0.25 mm
Flywheel Flywheel runout (maximum) - 0.130 mm at a distance of 120 mm from the center
Tightening torques for connections - Nm
- Camshaft Rear Plate - 20-25
- Camshaft thrust plate - 20-25
Connecting rod lower head bolts:
- Stage 1 - 47-65
- Stage 2 - 65-72
Engine Intermediate Plate:
- Bolts 1-8 - 32-40
- Bolt 9-20-25
Main Bearing Cap Bolts:
Models before 1992:
- Stage 1 - all bolts - 110-126
- Stage 2 - central cap - 140-155
- Stage 2 - remaining caps - 126-140
Models since 1992:
- Stage 1 - all bolts - 72-90
- Stage 2 - all bolts - 160-180
Lubrication system pressure reducing valve - 52-58
Oil intake pipe - 16-20