Engine overhaul specifications

Total information

engine's type

-

4 cylinders (in-line)

Working volume

cm³

2,405

Bore and stroke

mm (in.)

87.5 x 100 (3.44 x 3.94)

Compression ratio

-

9.6: 1

Ignition sequence

-

1-3-4-2

Max. power

kW

100 kW (5000 rpm)

Max. torque

N·m

220 Nm (2200 rpm)

cylinder bore

Diameter

mm (in.)

87.485~87.505 (3.444~3.445)

Out-of-roundness (Max.)

mm (in.)

0.013 (0.0005)

Taper (Max.)

mm (in.)

0.013 (0.0005)

Piston protrusion

mm (in.)

0

Allowance (measure to replace the piston before a new bore)

mm (in.)

Available in size 0.50 mm (0.019 inch) according to hole

Block Surface Deformation

mm (in.)

0.01 max. (0.00039)

Piston

Diameter

mm (in.)

87.465~87.485 (3.443~3.445)

clearance to cylinder

mm (in.)

0.010~0.030 (0.00039~0.0020)

Ring groove width

Top part

mm (in.)

1,230...1,250 (0,04842... 0,04921)

2nd

mm (in.)

1,510...1,530 (0,05945...0,0602)

Oil

mm (in.)

2,530...2,550 (0,09961...0,10040)

Ring groove inner diameter

Top part

mm (in.)

79,96...80,66 (3,1480...3,1756)

2nd

mm (in.)

78,40...79,10 (3,0866...3,1142)

Oil

mm (in.)

80,06...80,76 (3,15197...3,17953)

Piston rings

End clearance of the upper compression ring

mm (in.)

0,21...0,36 (0,00827...0,01417)

End clearance of the second compression ring

mm (in.)

0,36...0,61 (0,01417...0,02402)

End clearance of the oil scraper ring

mm (in.)

0,16...0,76 (0,0063...0,02992)

Piston ring width

Top part

mm (in.)

1,170...1,190 (0,04606...0,04685)

2nd

mm (in.)

1,466...1,490 (0,05772...0,05866)

Oil

mm (in.)

2.5 (0.09842)

End ring thickness

Top part

mm (in.)

2,86...3,15 (0,11260...0,12402)

2nd

mm (in.)

3,50...3,70 (0,13780...0,14567)

Oil

mm (in.)

2,159...2,337 (0,085...0,092)

Ring groove clearance

Top part

mm (in.)

0,040...0,080 (0,00157...0,00315)

2nd

mm (in.)

0,020...0,064 (0,00079...0,00252)

Oil

mm (in.)

0,3...0,5 (0,01181...0,01969)

piston pin

Diameter

mm (in.)

20.9910~20.9970 (0.82641~0.82665)

Finger displacement

mm (in.)

0.7~0.9 (0.0275~0.0354) towards the stop

Clearance: In the piston

mm (in.)

0.011~0.014 (0.00043~0.00055)

Clearance: In the connecting rod

mm (in.)

Interference fit in the connecting rod

Length

mm (in.)

61.5 (2.42)

Camshaft

Valve lift

Inlet

mm (in.)

9.2 (0.36)

Release

mm (in.)

9.2 (0.36)

Gap between camshaft head and bearing journal

mm (in.)

0.04~0.144 (0.0015~0.0056)

Bearing journal outside diameter

mm (in.)

42.455~43.470 (1.6714~1.7114)

Crankshaft

Main neck: Diameter (All)

mm (in.)

57.974 - 57.995 (2.2824~2.2833)

Main bearing journal - radial runout (shaft bracket on bearings No. 1 and No. 5, measured at journal No. 3)

mm (in.)

0.03 (0.00118)

Main bearing clearance (All)

mm (in.)

0.015~0.040 (0.00059~0.00157)

Axial play

mm (in.)

0.070~0.302 (0.0027~0.0118)

Allowance for repairs (there are 2 sizes)

mm (in.)

0.25 and 0.5 (0.00098 and 0.019)

Connecting rod neck

Diameter (All)

mm (in.)

48.970~48.988 (1.9279~1.9287)

Out-of-roundness (Max.)

mm (in.)

0.004 (0.00015)

Rod bearing play.

mm (in.)

0.006~0.031 (0.00023~0.00122)

Stem bearing clearance

mm (in.)

0.013~0.041 (0.0005~0.0016)

cylinder head

Valve stem protrusion

mm (in.)

39.2 max. (1.544)

Valve Guide Height

mm (in.)

13.7~14.0 (0.53~0.55)

Overall Height

mm (in.)

133.975~134.025 (5.2741~5.2759)

Minimum overall height after processing

mm (in.)

133.9 (5.271)

Valve system

Valve clearance compensators

-

hydraulic

Saddle runout (max., all)

mm (in.)

0.03 (0.0018)

Chamfer runout (max., all)

mm (in.)

0.03 (0.0018)

Valve diameter

Inlet

mm (in.)

32 ± 0.1 (1.2598 ± 0.0039)

Release

mm (in.)

29 ± 0.1 (1.1417 ± 0.00039)

Valve stem diameter

Inlet

mm (in.)

5.955~5.970 (0.234~0.235)

Release

mm (in.)

5.945~5.960 (0.2346~0.2360)

Valve seat width

Inlet

mm (in.)

1.0~1.5 (0.039~0.059)

Release

mm (in.)

1.7~2.2 (0.066~0.086)

Valve face angle

mm (in.)

44°

Valve seat angle

mm (in.)

45°

Valve guide inner diameter

mm (in.)

6.000~6.012 (0.2362~0.2367)

Oil pump

Type

-

Rotary (trochoid)

Bearing clearance

-

0.10~0.20 (0.0040~0.008)

External gear to body

mm (in.)

0.11~0.19 (0.0043~0.0074)

External gear to crescent

mm (in.)

0.11~0.24 (0.0043~0.009)

Internal gear to crescent

mm (in.)

0.18~0.26 (0.007~0.010)

end clearance

mm (in.)

0.03~0.10 (0.001~0.004)

Seals and adhesives

Rear main bearing housing cover

-

Three-Bond 1217F

Camshaft support to cylinder head

-

HN 1581 (Loctite® 515)

Oil pan screws

-

HN 1256 (Loctite® 542)

Oil pump screws

-

HN 1256 (Loctite® 542)

Oil pan feed pipe screws

-

HN 1256 (Loctite® 542)

Grease channel plug

-

HN 1256 (Loctite® 542)

Cooling jacket caps and plugs (cooling plugs)

-

HN 1756 (Loctite® 176)

Exhaust manifold pins/nuts

-

Anti-Seize Compound

Lubrication system

Type

-

Forced submission

Oil pump type

-

Rotary (trochoid)

Oil filter type

-

Cartridge

oil pan capacity (along with oil filter)

l

4.5 l

Oil pan capacity without oil filter)

l

4.3 l

Engine oil type

-

API SL (ILSAC GF-III) SAE class 5W-30

* Hot zone: SAE 10W-30

Air filter element cover screws

2

-

18

Air filter housing screws

6

-

53

Battery Clamp Locking Screws

10

-

89

Battery tray locking screws

10

-

89

Camshaft bearing cap screws

8

-

71

Connecting rod bearing screws

35 + 45° + 15°

26 + 45° + 15°

-

Coolant bypass housing screws

15

11

-

Bolts of the balancer assembly with the crankshaft, assy

20 + 45°

15 + 45°

-

Main bearing cap screws

50 + 45° + 15°

37 + 45° + 15°

-

crankshaft pulley screws

20

15

-

Crankshaft timing belt drive gear bolt

135 + 30° + 10°

100 + 30° + 10°

-

Cylinder head screws

25 + 90° + 90° + 90°

18 + 90° + 90° + 90°

-

Cylinder head cover screws

8

-

71

Bolts of a fastening arm of system of direct ignition and recirculation of the fulfilled gases (EGR)

25

18

-

Engine cover bolts and nuts

8

-

71

Engine Cover Bracket Retaining Bolt

20

15

-

Engine Fuse Box Bottom Cover Screws

10

-

89

Engine Fuse Block Locking Screws

3

-

27

Engine mount adapter bolts

50

37

-

Engine Mount Adapter Support Bracket Bolts

45

33

-

Engine Mount Frame Side Bracket Bolt

100

74

-

Engine mount frame side bracket nuts

90

66

-

Bolt of an arm of the electromagnetic valve of a purge of an adsorber SUBP

5

-

44

Exhaust camshaft gear screws

50 + 60° + 15°

37 + 60° + 15°

-

Bolt and nut of a fastening arm of a reception pipe of the muffler

40

30

-

Exhaust manifold heat shield screws

15

11

-

Exhaust manifold lock nuts

22

16

-

Flexible plate screws

65

48

-

Flywheel screws

65 + 30° + 15°

48 + 30° + 15°

-

Timing Belt Front Cover Screws

6

-

53

Fuel rail assembly retaining screws

25

18

-

Coupling bolt and nut securing the alternator to the alternator lower support bracket

40

30

-

Alternator to intake manifold bracket bolt on intake manifold

25

18

-

Bolt of a bracket of fastening of the generator to an inlet manifold on the generator

35

26

-

Alternator lower support bracket screws

25

18

-

Alternator upper bracket bolts to intake manifold and coolant bypass housing

25

18

-

Alternator upper bracket bolt on alternator

35

26

-

Intake camshaft gear screw

50 + 60° + 15°

37 + 60° + 15°

-

Intake manifold retaining bolt and nuts

18

13

-

Intake manifold support bracket bolt

25

18

-

Intermediate Shaft Support Bracket Bolts

70

52

-

Bolts of fastening of an adapter of the oil filter to the oil pump

8

-

71

Oil pan drain plug

18

13

-

Stop bolts of fastening of a flange of the oil pallet to a support

50

37

-

Oil pan retaining screws

20

15

-

Oil pressure sensor

40

30

-

Oil Pump Rear Cover Screws

20

15

-

Oil pump retaining screws

10

-

89

Oil suction pipe retaining bolts

8

-

71

Lock nuts of fastening of catalytic converter to a reception pipe of the muffler

40

30

-

Timing Belt Rear Cover Screws

7

-

62

Relief valve screw

30

22

-

Spark plug

25

18

-

Screw of fastening of a starter to the block of cylinders

75

55

-

Screw of fastening of a starter to a transmission

75

55

-

Timing belt automatic tensioner bolt

25

18

-

Bolt and nut of the timing belt idler pulley

25

18

-

Stop bolts of a forward suspension bracket of a transmission with the final drive assy

50

37

-

Coupling bolt of fastening of a forward suspension bracket of a transmission to a transmission with the final drive assy

90

66

-

Stop bolts of a suspension bracket of a transmission with the final drive assy

37

27

-

Retaining bolts of an arm of a suspension bracket of a transmission with the final drive assy

50

37

-

Retaining bolts of a back suspension bracket of a transmission with the final drive assy

90

66

-

Retaining bolts of a back bracket of a suspension bracket of a transmission with final drive assy

90

66

-

Coupling bolt of fastening of a back suspension bracket of a transmission with the final drive assy to an arm

90

66

-

Bolt of fastening of a transmission with the main transfer assy to an oil pan flange

50

37

-

Torque converter bolts with final drive assy

45

33

-