Opel Frontera

since 1992 of release

Repair and car operation



Fronter's Opel
+ Opel Frontera brand Cars
+ Current leaving and service
- Engine
   Removal and OHC engine installation
   Removal and DOHC engine installation
   Engine dismantling
   Engine assembly
   Head of cylinders and valves
   Pistons and rods
   Block of cylinders
   Cranked shaft and bearings of a cranked shaft
   Camshaft drive
   Engine mounts
   Compression check
   Greasing system
   Works with system of greasing of the OHC/DOHC engine of 2.0 l
   Works with greasing system on the engine of 2.4 l
   Oil filter
   Oil radiator (if it is established)
   Pressure and oil temperature
+ cooling and heating Systems
+ Power supply system and release
+ engine Electric equipment
+ Coupling
+ Manual box of gear shifting
+ Driveshafts, main transfer
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment
+ Governing bodies and operation
+ electric equipment Schemes



Engine

GENERAL INFORMATION

General information

The Dvukhdverny option of the car under the name Frontera Sport has the truncated base and the engine of 2.0 l in capacity of 115 h.p. (85 kW). The four-door option of the Frontera car has the petrol engine in capacity of 125 h.p. (92 kW). These engines were established on the car in 1992, 1993 and 1994. In 1995 (from the middle of year) on the car with the increased base the 16-klapanny engine (16V), "ECOTEC" having designation which were already applied by then on other cars of Opel firm is established. The X22 XE engine has working volume of 2.2 l and capacity of 136 h.p. (100 kW). Distinctive feature of this engine is the big torque already at number of turns of 2600 rpm. The engine has 4 valves on the cylinder and direct ignition, a control system of Motronic M1.5.4 injection, engine management and a detonation, system of a podmeshivaniye of air in an exhaust. In the engine the radiator of oil and the resonator of soaked-up air is established also.
From the middle of 1995 on cars the engine of 2.0 l is established. The engine has "X20 SE" designation. It is further development of the C20 NE engine with the top arrangement of a camshaft. In this engine the control system of Bosch-Motronic M1.5.4 injection is established. The ignition system a so-called straight line, i.e. has no distributor and copes the ignition module. In the engine regulation on a detonation is applied and there is a system of a retsirkulyatsiya of the fulfilled gases (EGR system). The system has electronic control and sends to 15 % of the fulfilled gases for an admission to combustion chambers. This engine has an oil radiator. The Campo and Brava models were at the same time let out.
Since 1997 of release in both specified models constructive changes for the purpose of decrease in noise level of the engine were made. For this purpose in the block of cylinders the bearing bridge was established and the so-called bearing pallet of a case is applied. At the engine of 2.2 l the design of chambers of combustion in a head of cylinders was changed. At this engine the system of a podmeshivaniye of air was liquidated. The characteristic of regulation of the control unit was kept by injection. The manual five-speed transmission with a two-level transfer case for fall of number of turns of back wheels at movement on a cross-country terrain is established. Peredny Bridge joins a short control lever if it is demanded by traffic conditions.
Features of a design of separate models are explained in the course of the description.

Attention

In the car there is a device of the security alarm system which works at shutdown of the storage battery. It is necessary to disconnect the security alarm system at performance of any works connected with shutdown of the storage battery.


Owing to existence of various executions of the engine, namely, the engine with one camshaft (OHC) located above and the engine with two camshafts (DOHC) located above, works on removal and installation of the engine are described separately depending on executions that facilitates understanding process.
At engines of both executions it is necessary to pay attention to laying of cables, pipelines, etc. Therefore it is recommended to mark as appropriate disunited tips and cables if their subsequent joining can appear ambiguous. The sticky tape is convenient for this purpose. The tape is pasted for the end of a cable and on it digital or alphabetic marking is inscribed by a ball pen. At the subsequent joining it is necessary to connect only a cable according to the marking.
Radio receiver with the coding. At the works, described in the present section, connected with a detachment of the storage battery, it is necessary to know a radio receiver code that later with its help again to bring a radio receiver into a working condition.

Specifications
Remark

Separate characteristics are provided also in the text of Head


OHC ENGINES - THE GENERAL DATA

Engine type:
- the engine of 2.0 l to the middle of 1995 of release
- the engine of 2.4 l to the middle of 1995 of release
- the engine of 2.0 l from the middle of 1995 of release

C 20 NE
C 24 NE
X-th 20 SE
Design features:
- engine of 2.0 l
- engine of 2.4 l

The four-cylinder petrol engine with the top arrangement of a camshaft and a drive from a gear belt
The four-cylinder petrol engine with the top arrangement of a camshaft and a drive from a chain
Number of cylinders 4
Arrangement of cylinders Ryadnoye
Gazoraspredeleniye mechanism:
- engine of 2.0 l
- engine of 2.4 l

Hanging valves, the top arrangement of a camshaft with placement in the separate case, with a drive from a gear belt. Hydrojacks of gaps. A drive of valves from yokes
The located valves hanging in parallel, 2 valves on the cylinder, the top arrangement of a camshaft, with a drive from a chain. Hydrojacks of gaps. A drive of valves from yokes
Operating procedure of cylinders 1-3-4-2
Maximum capacity:
- the engine of 2.0 l to the middle of 1995 of release
- the engine of 2.0 l from the middle of 1995 of release
- engine of 2.4 l

85 kW (115 h.p.) at 5200 rpm
85 kW (115 h.p.) at 5200 rpm
92 kW (125 h.p.) at 4800 rpm
Figure "20" in designation of the engine indicates working volume of cylinders of 2.0 l; "22" on volume of 2.2 l; "24" on volume of 2.4 l. Standing ahead of engine designation the letter "With" or "X" indicates availability of catalytic converter.
Max. torque:
- the engine of 2.0 l to the middle of 1995 of release
- the engine of 2.0 l from the middle of 1995 of release
- engine of 2.4 l

170 nanometers at 2600 rpm
172 nanometers at 2800 rpm
195 nanometers at 2600 rpm
Diameter of cylinders:
- all engines of 2.0 l
- engines of 2.4 l

86.00 mm
95.00 mm
Piston stroke:
- all engines of 2.0 l
- engines of 2.4 l

86.00 mm
85.00 mm
Extent of compression:
- the engine of 2.0 l to the middle of 1995 of release
- the engine of 2.0 l from the middle of 1995 of release
- engine of 2.4 l

9.2: 1
10.0: 1
9.2: 1
The engine of 2.0 l (C 20 NE from the middle of 1995 of release)
Head of cylinders
  Height of a head of cylinders 95.75-96.25 mm (between the interfaced planes)
  Max not planeness of the plane of interface to the block of cylinders 0.10 mm
  Max. not planeness of the planes of interface to pipelines 0.10 mm
  Thickness of laying 1.15-1.30 mm
  Width of a facet of a saddle in a head of cylinders:
  - inlet valves
  - final valves

1.0-1.5 mm
1.7-2.2 mm
  Gap in interface of a core of the valve to the directing plug:
  - inlet valves
  - final valves

0.018-0.052 mm
0.038-0.072 mm
  Adjusting valve heights 17.85-18.25 mm. It is measured by calibre KM-512. To carry out only in a repair truck
  Adjusting height of directing plugs New directing according to the original size are pressed in a head of cylinders. A given size 83.50 - 83.80 mm
Saddles of valves
  Facet corner 45 °
  Bottom adjustment corner 75 °
  Top adjustment corner 15 °
  Width of a facet of a saddle of the valve (the new valve) See above
Valves
  Diameter of a core of the valve - inlet valves:
  - a given size, designation To
  - repair, increased by 0.075 mm, designation К1
  - repair, increased by 0.150 mm, designation К2
  - repair, increased by 0.250 mm, designation And

7.012-6.998 mm
7.087-7.073 mm
7.162-7.148 mm
7.262-7.248 mm
  Diameter of a core of the valve - final valves:
  - a given size, designation To
  - repair, increased by 0.075 mm, designation К1
  - repair, increased by 0.150 mm, designation К2
  - repair, increased by 0.250 mm, designation And

6.992-6.978 mm
7.067-7.053 mm
7.142-7.128 mm
7.242-7.228 mm
  Gap in interface of the valve to the directing:
  - inlet valves
  - final valves

0.018-0.052 mm
0.038-0.072 mm
  Diameter of a plate of the valve:
  - inlet valves
  - final valves

41.8 mm
35.6 mm
  Length of the valve:
  - inlet valves
  - final valves

104.20 mm (spare valves of 103.8 mm)
104.00 mm (spare valves of 103.6 mm)
Camshaft
  Shaft designation J
  Color marking of a shaft
  - normal size
  - repair, reduced by 0.10 mm

No
The violet
  Max. shaft palpation 0.03 mm
  Axial gap of a shaft 0.09-0.21 mm
  Cam course 6.67 mm, inlet and final valves
  Gap in the bearing:
  - normal value
  - wear limit

0.04-0.082 mm
0.11 mm
  Diameter of necks Necks have different diameter. Shaft with repair diameter of necks on 0.1 mm have violet marking less.
Repair diameters are specified in brackets:
- the bearing No. 1 42.470 - 42.455 mm (42.370 - 42.355 mm)
- the bearing No. 2 42.720 - 42.705 mm (42.620 - 42.505 mm)
- the bearing No. 3 42.970 - 42.955 mm (42.870 - 42.855 mm)
- the bearing No. 4 43.220 - 43.205 mm (43.120 - 43.105 mm)
- the bearing No. 5 43.470 - 43.455 mm (43.370 - 43.355 mm)
  Openings in the case of bearings of a camshaft Diameters of openings are various, as well as diameters of necks of a camshaft. The repair sizes are specified in brackets:
- the bearing No. 1 42.525 - 42.500 mm (42.425 - 42.400 mm)
- the bearing No. 2 42.775 - 42.750 mm (42.675 - 42.650 mm)
- the bearing No. 3 42.025 - 43.000 mm (42.925 - 42.900 mm)
- the bearing No. 4 43.275 - 43.250 mm (43.175 - 43.150 mm)
- the bearing No. 5 43.525 - 43.500 mm (43.425 - 43.400 mm)
Pistons and rods
  Installation direction Arrow to the distribution party
  Diameter of pistons
  - 1 class
 - 4th class

- 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)
  The repair size increased by 0.5 mm 86.45 mm (7 + 0.5 on the piston bottom)
  Gap in interface of the piston to the cylinder 0.02-0.04 mm
Piston fingers
  Length 61.1 mm
  Finger landing It is pressed in a rod head
  Gap in interface of a finger to the piston 0.011-0.014 mm
  External diameter 21.0 mm
Piston rings
  Quantity of rings 2 kompressionny and 1 maslosjemny
  Thickness of a ring:
  - top ring
  - average ring
  - maslosjemny ring

1.50 mm
1.50 mm
3.0 mm
  Gaps in locks of piston rings:
  - kompressionny rings
  - maslosjemny ring

0.30-0.50 mm
0.40-1.40 mm
  Gap in interface of a ring to a flute in the piston:
  - top ring
  - average ring
  - maslosjemny ring

0.12-0.18 mm
0.05-0.15 mm
0.025-0.15 mm
Shatunnye bearings
  Diameters of necks see. Undressed the Cranked shaft and bearings of a cranked shaft
  Type With loose leaves
  Axial gap 0.07-0.24 mm
Block of cylinders
  Nominal diameter of cylinders Diameters of cylinders of each class on 0.02 mm more corresponding diameters of the piston.
Marking on the bottom of the piston corresponds to marking on the block of cylinders
  Max. admissible diameter of cylinders On 0.5 mm more nominal rate
  Max. ovality and konusnost 0.013 mm
  Gap in interface to the piston 0.02-0.04 mm
  Points of measurement of diameter of the piston In the lower part of a skirt, at right angle to an opening under a piston finger
Cranked shaft
  Quantity bearing 5
  Type of bearings With loose leaves
  Diameter of radical bearings
  - 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 (it is green / dark blue marking)
57.7385-57.7450 mm (it is brown / dark blue marking)
57.4820-57.4885 mm (it is green / dark blue marking)
57.4885-57.4950 mm (it is brown / dark blue marking)
  Width of the directing bearing:
  - nominal size
  - repair, reduced by 0.25 mm
  - repair, reduced by 0.50 mm


25.900-25.850 mm
26.100-26.050 mm
26.300-26.250 mm

Color marking of loose leaves of bearings
 
Covers
Block
  - nominal size
  - repair, reduced by 0.25 mm
  - repair, reduced by 0.50 mm
the brown green
it is brown / the dark blue
it is brown / the white
the green brown
it is green / dark blue (selective assembly)
it is green / white (selective assembly)
  Openings in the block of cylinders Depending on the color
marking and class
  Axial gap of a cranked shaft 0.050-0.152 mm
  Admissible gap in the radical bearing 0.015-0.040 mm
  Admissible gap in a rod the bearing 0.006-0.031 mm
  Admissible axial gap of the shatunny bearing 0.07-0.24 mm
Diameter of shatunny necks
  - 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 a rod

 

26.580-26.460 mm
Oil pump See. Section greasing System
Injection system See. Head of the Power supply system and release
Ignition system See. Heads of the Power supply system and release and engine Electric equipment
The engine of 2.0 l (X 20 SE from the middle of 1995 of release)
Head of cylinders
  Height of a head of cylinders 95.75-96.25 mm (between the interfaced planes)
  Max not planeness of the plane of interface to the block of cylinders 0.10 mm
  Max. not planeness of surfaces
interfaces to pipelines
0.10 mm
  Thickness of laying 1.15-1.30 mm
  Width of a facet of a saddle in a head of cylinders:
  - inlet valves
  - final valves

1.0-1.5 mm
1.7-2.2 mm
  Gap in interface of a core of the valve to the directing plug:
  - inlet valves
  - final valves

0.018-0.052 mm
0.038-0.072 mm
  Admissible palpation of a core of the valve
  - inlet valves
  - final valves

0.03 mm
0.33 mm
  Adjusting valve heights 17.85-18.25 mm. It is measured by calibre KM-512. To carry out only in a repair truck
  Adjusting height of the directing
plugs
New directing according to the original size are pressed in a head of cylinders. A given size 83.25 - 83.05 mm
Saddles of valves
  Facet corner 45 °
  Bottom adjustment corner 75 °
  Top adjustment corner 15 °
  Width of a facet of the valve (the new valve) See above
Valves
    Diameter of a core of the valve - inlet valves:
  - a given size, designation To
  - repair, increased by 0.075 mm, designation К1
  - repair, increased by 0.150 mm, designation К2
  - repair, increased by 0.250 mm, designation And

7.012-6.998 mm
7.087-7.073 mm
7.162-7.148 mm
7.262-7.248 mm
  Diameter of a core of the valve - final valves:
  - a given size, designation To
  - repair, increased by 0.075 mm, designation К1
  - repair, increased by 0.150 mm, designation К2
  - repair, increased by 0.250 mm, designation And

6.992-6.978 mm
7.067-7.053 mm
7.142-7.128 mm
7.242-7.228 mm
  Gap in interface of the valve to the directing:
  - inlet valves
  - final valves

0.018-0.052 mm
0.038-0.072 mm
  Diameter of a plate of the valve:
  - inlet valves
  - final valves

41.8 mm
36.5 mm
  Length of the valve:
  - inlet valves
  - final valves

104.20 mm (spare valves of 103.8 mm)
104.00 mm (spare valves of 103.6 mm)
Camshaft
  Shaft designation J
  Color marking of a shaft
  - normal size
  - repair, reduced by 0.10 mm

no
the violet
  Max. shaft palpation 0.04 mm
  Axial gap of a shaft 0.09-0.21 mm
  Cam course 6.67 mm inlet and final valves
  Gap in the bearing:
  - normal value
  - wear limit

0.04-0.082 mm
0.11 mm
  Diameter of necks Necks have different diameter. Shaft with repair diameter of necks
on 0.1 mm have violet marking less. Repair diameters are specified in brackets:
- the bearing No. 1 42.470 - 42.455 mm (42.370 - 42.355 mm)
- the bearing No. 2 42.720 - 42.705 mm (42.620 - 42.505 mm)
- the bearing No. 3 42.970 - 42.955 mm (42.870 - 42.855 mm)
- the bearing No. 4 43.220 - 43.205 mm (43.120 - 43.105 mm)
- the bearing No. 5 43.470 - 43.455 mm (43.370 - 43.355 mm)
  Openings in the case of bearings of a camshaft Diameters of openings are various, as well as diameters of necks of a camshaft. The repair sizes are specified in brackets
- the bearing No. 1 42.525 - 42.500 mm (42.425 - 42.400 mm)
- the bearing No. 2 42.775 - 42.750 mm (42.675 - 42.650 mm)
- the bearing No. 3 42.025 - 43.000 mm (42.925 - 42.900 mm)
- the bearing No. 4 43.275 - 43.250 mm (43.175 - 43.150 mm)
- the bearing No. 5 43.525 - 43.500 mm (43.425 - 43.400 mm)
Pistons and rods
  Installation direction Arrow to the distribution party
  Diameter of pistons
  - 1 class
  - 4th class

- 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)
  The repair size increased by 0.5 mm 86.465 - 86.475 mm
(9 + 0.5 on the piston bottom)
  The repair size increased by 0.5 mm 86.475 - 86.485 mm
(0 + 0.5 on the piston bottom)
  Gap in interface of the piston to the cylinder 0.02-0.04 mm
Piston fingers
  Length 61.1 mm
  Finger landing It is pressed in a rod head
  Gap in interface of a finger to the piston 0.003-0.010 mm
  External diameter 21.0 mm
  Gap in interface to a rod head Landing with a tightness
Piston rings
  Quantity of rings 2 kompressionny and 1 maslosjemny
  Thickness of a ring:
  - top ring
  - average ring
  - maslosjemny ring

1.50 mm
1.50 mm
3.0 mm
  Gaps in locks of piston rings:
  - kompressionny rings
  - maslosjemny ring

0.30-0.50 mm
0.40-1.40 mm
  Gap in interface of a ring to a flute in the piston:
  - top ring
  - average ring
  - maslosjemny ring

0.12-0.18 mm
0.05-0.15 mm
0.025-0.15 mm
Shatunnye bearings
  Diameters of necks see. Undressed the Cranked shaft
  Type With loose leaves
  Axial gap 0.07-0.24 mm
Block of cylinders
  Nominal diameter of cylinders Diameters of cylinders of each class on 0.02 mm more corresponding diameters of the piston. Marking on the bottom of the piston corresponds to marking on the block of cylinders
  Max. admissible diameter of cylinders On 0.5 mm more nominal rate
  Max. ovality and konusnost 0.013 mm
  Gap in interface to the piston 0.02-0.04 mm
  Points of measurement of diameter of the piston In the lower part of a skirt, at right angle to an opening under a piston finger
Cranked shaft
  Quantity bearing 5
  Type of bearings With loose leaves
Diameter of radical bearings
  - 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 (it is green / dark blue marking)
57.738-57.745 mm (it is brown / dark blue marking)
57.482-57.488 mm (it is green / dark blue marking)
57.488-57.495 mm (it is brown / dark blue marking)
  Width of the directing bearing:
  - 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
Color marking of loose leaves of bearings
  - nominal size
  - repair, reduced by 0.25 mm
  - repair, reduced by 0.50 mm
it is brown/is green / white (selective selection)
it is brown / dark blue and it is green / dark blue (selective selection)
it is brown / dark blue and it is green / dark blue (selective selection)
  Openings in the block of cylinders Depending on the color
marking and class
  Axial gap of a cranked shaft 0.050-0.152 mm
  Admissible gap in the radical bearing 0.015-0.040 mm
  Admissible gap in a rod the bearing 0.006-0.031 mm
  Admissible axial gap of the shatunny bearing 0.07-0.24 mm
Diameter of shatunny necks
  - 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 a rod 26.580-26.460 mm
Oil pump See. Section greasing System
Injection system See. Head of the Power supply system and release
Ignition system See. Heads of the Power supply system and release and engine Electric equipment

THE DOHC ENGINE - THE GENERAL DATA

Engine type:
X-th 22 XE, "Ecotec"
Design features:
The four-cylinder petrol engine with two camshafts located above 16 valves
Number of cylinders 4
Arrangement of cylinders Ryadnoye
Gazoraspredeleniye mechanism:
Hanging valves, the top arrangement of camshafts with a drive from a gear belt, tension adjustment. Hydrojacks of gaps. A drive of the pump of cooling liquid from a gear belt
Operating procedure of cylinders 1-3-4-2
Maximum capacity:
100 kW (136 h.p.) at 5200 rpm
Max. torque:
202 nanometers at 2600 rpm
Diameter of cylinders:
86.0 mm
Piston stroke:
94.6 mm
Volume of cylinders 2198 cm3
Extent of compression: 10.5: 1
Type of system of injection
Multiitem Motronic M 1.5.4
DOHC engine
Head of cylinders
  Height of a head of cylinders 95.75-96.25 mm (from interfaced to the interfaced plane)
  Max not planeness of the plane of interface to the block of cylinders 0.025 mm
  Max. not planeness of the planes of interface to pipelines 0.10 mm
  Thickness of laying 1.15-1.25 mm
  Width of a facet of a saddle in a head of cylinders:
  - inlet valves
  - final valves

1.0-1.5 mm
1.7-2.2 mm
  Gap in interface of a core of the valve to the directing plug:
  - inlet valves
  - final valves

0.03-0.057 mm
0.04-0.067 mm
  Adjusting valve heights 13.70-14.00 mm
Saddles of valves
  Facet corner 45 °
  Bottom adjustment corner 75 °
  Top adjustment corner 15 °
  Width of a facet of a saddle of the valve (the new valve)
  - inlet valves
  - final valves

1.0-1.5 mm
1.7-2.2 mm
Valves
  Diameter of a core of the valve - the inlet valve:
  - a given size, a boznacheniye To
  - repair, increased by 0.075 mm, designation К1
  - repair, increased by 0.150 mm, designation К2

5.970-5.955 mm
6.045-6.030 mm
6.120-6.105 mm
  Diameter of a core of the valve - final valves:
  - a given size, designation To
  - repair, increased
on 0.075 mm, designation К1
  - repair, increased
on 0.150 mm, designation К2

5.960-5.945 mm
6.035-6.020 mm
6.110-6.095 mm
  Opening under a valve core - all valves:
  - designation To 6.
  - designation К1
  - designation К2

012-6.000 mm
6.090-6.075 mm
6.165-6.150 mm
  Gap in interface of the valve to the directing:
  - inlet valves
  - final valves

0.03-0.057 mm
0.04-0.067 mm
  Diameter of a plate of the valve:
  - inlet valves
  - final valves

32.0 mm + 0.1 mm
29.0 mm + 0.1 mm
  Length of the valve:
  - inlet valves
  - final valves

102.0 mm (spare valves of 101.7 mm)
92.0 mm (spare valves of 91.8 mm)
Camshaft
  Max. shaft palpation 0.06 mm
  Axial gap of a shaft 0.04-0.144 mm
  Cam course 10.0 mm both valves
  Gap in the bearing:
  
It is equal to a difference of diameters
necks and openings
  Diameter of necks 27.960-27.939 mm
  Openings in the case 28.021-28.000 mm
Pistons and rods
  Installation direction Arrow to the drive party
ГРМ
  Diameter of pistons
  - 1 class
 - 2-4th class
- 85.955-85.965 mm (8 on the piston bottom)
- 85.965-85.975мм (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)
  The repair size increased by 0.5 mm 86.445-86.455мм
(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 on the piston bottom)
  Gap in interface of the piston to the cylinder 0.003-0.01 mm
Piston fingers
  Length 61.1 mm
  Finger landing Hot press fitting in a rod head
  Gap in interface of a finger to the piston 0,003-0, 01
  External diameter 21.0 mm
Piston rings
  Quantity of rings 2 kompressionny and 1 maslosjemny
  Thickness of a ring:
  - top ring
  - average ring
  - maslosjemny ring

1.50 mm
1.50 mm
3.0 mm
  Gaps in locks of piston rings:
  - kompressionny rings
  - maslosjemny ring
0.30-0.50 mm
0.40-1.40 mm
  Gap in interface of a ring to a flute in the piston:
  - top ring
  - average ring
  - maslosjemny ring

0.12-0.18 mm
0.05-0.15 mm
0.025-0.15 mm
Shatunnye bearings
  Type With loose leaves
  Axial gap 0.07-0.24 mm
Block of cylinders
  Nominal diameter of cylinders
  - 1 class
  - 2nd class
- 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. admissible diameter of cylinders On 0.5 mm it is more
nominal rate
  Max. ovality and konusnost 0.013 mm
  Gap in interface to the piston 0.02-0.04 mm
  Points of measurement of diameter of the piston In the lower part of a skirt, at right angle to a tverstiya
under a piston finger
Cranked shaft
  Quantity bearing 5
  Type of bearings With loose leaves
  Diameter of a radical neck - nominal diameter:
  - white marking
  - green marking
  - brown marking

57.974-57.981 mm
57.981-57.988 mm
57.988-57.995 mm
  Diameter of a radical neck - repair, reduced by 0.25 mm:
  - green/dark blue marking
  - it is brown / dark blue marking

57.732-57.738 mm
57.738-57.745 mm
  Diameter of a radical neck - repair, reduced by 0.50 mm:
  - it is green / white marking
  - it is brown / white marking

57.482-57.488 mm
57.488-57.495 mm
  Diameter of openings in the block of cylinders
Depending on
color marking and class
  Diameter of shatunny necks
  - 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 a shatunny neck:
  - nominal size
  - repair, reduced by 0.25 mm
  - repair, reduced by 0.50 mm


26.580 mm
26.580-26.460 mm
26.580-26.460 mm
  Width of a rod 26.390-26.338 mm for all sizes
  Axial gap of a cranked shaft


0.050-0.152 mm
  Admissible gap of the radical bearing 0.015-0.040 mm
  Admissible gap of the shatunny bearing 0.006-0.031 mm
  Admissible axial gap of a rod 0.07-0.24 mm
Engine of 2.4 l
Head of cylinders
  Color marking The violet
  Marking by punching x 24
  Height of a head of cylinders 102.45-102.925 mm
  Max not planeness of the plane of interface to the block of cylinders 150 mm of 0.015 mm
  Max. not planeness on all length 0.050 mm
  Max. not planeness of the planes of interface to pipelines 0.10 mm
  Thickness of laying 0.80-0.90 mm
  Gap in interface of a core of the valve to the directing:
  - inlet valves
  - final valves

0.04 mm, Max.
0.03 mm, Max.
Saddles of valves
  Facet corner 45 °
  Bottom adjustment corner 75 °
  Top adjustment corner 15 °
  Marking of valves:
  - given size
  - repair increased 1
  - repair increased 2
  - repair increased 3

no
the white
the green
no
Valves
  Diameter of a core of the valve - the 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
  Diameter of a core of the valve - final 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
  Gap in interface of the valve to the directing:
  - inlet valves
  - final valves

0.035-0.073 mm
0.045-0.085 mm
  Diameter of a plate of the valve:
  - inlet valves
  - final valves

45.0 mm
40.0 mm
  Length of the valve:
  - inlet valves
  - final valves

123.0 mm
123.7 mm
Camshaft
  Shaft designation U
  Color marking of a shaft
  - normal size
  - repair, reduced by 0.10 mm

The dark blue/brown
The violet
  Max. shaft palpation 0.025 mm
  Axial gap of a shaft 0.10-0.20 mm
  Cam course 6.68 mm both valves
  Gap in interface to bearings:
  - normal value
  - wear limit
  

0.04-0.082 mm
0.11 mm
  Diameter of necks Necks have different diameter. Shaft with repair diameter of necks on 0.1 mm have violet marking less. Repair diameters are specified in brackets:
- the bearing No. 1 48.970 - 48.955 mm (48.870 - 48.855 mm);
- the bearing No. 2 48.720 - 48.705 mm (48.620 - 48.605 mm);
- the bearing No. 3 48.595 - 48.580 mm (48.495 - 48.480 mm);
- the bearing No. 4 48.470 - 48.485 mm (43.370 - 48.355 mm)
  Openings in the case of bearings of a camshaft Diameters of openings are various, as well as diameters of necks of a camshaft. The repair sizes are specified in brackets
- the bearing No. 1 53.350 - 53.500 mm
- the bearing No. 2 53.280 - 53.250 mm
- the bearing No. 3 53.030 - 53.000 mm
- the bearing No. 4 52.780 - 52.750 mm
Pistons and rods
  Installation direction Arrow to the distribution party

  Diameter of pistons
  - 1 class
  - 2nd class
  - 3rd class

- 94.92 mm (6 on the piston bottom, 5 on the block of cylinders); 94.92 mm (8 on the piston bottom, 7 on the block of cylinders);
94.94 mm (6 on the piston bottom, 5 on the block of cylinders)
- 94.94 mm (8 on the piston bottom, 8 on the block of cylinders)
94.96 mm (00 on the piston bottom, 99 on the block of cylinders)
94.96 mm (00 on the piston bottom, 0 on the block of cylinders)
94.98 mm (02 on the piston bottom, 01 on the block of cylinders)
94.98 mm (02 on the piston bottom, 02 on the block of cylinders)
95.00 mm (04 on the piston bottom, 03 on the block of cylinders)
- 95.00 mm (04 on the piston bottom, 04 on the block of cylinders)
95.02 mm (06 on the piston bottom, 05 on the block of cylinders)
95.02 mm (06 on the piston bottom, 06 on the block of cylinders)
95.04 mm (06 on the piston bottom, 07 on the block of cylinders)
95.04 mm (06 on the piston bottom, 08 on the block of cylinders)
95.04 mm (06 on the piston bottom, 09 on the block of cylinders)
  The repair size increased by 0.5 mm 95.43 mm (7 + 0.5 on the piston bottom, 95.47 on the block of cylinders)
95.44 mm (8 + 0.5 on the piston bottom, 95.48 on the block of cylinders)
95.45 mm (9 + 0.5 on the piston bottom, 95.49 on the block of cylinders)
95.46 mm (0 + 0.5 on the piston bottom, 95.50 on the block of cylinders)
  Gap in interface of the piston to the cylinder 0.03 mm
Piston fingers
  Length 65.0 mm
  Finger landing Floating in a rod head
  Gap in interface of a finger to the piston 0.006-0.013 mm
  Instructions on installation Heat up a rod head to 280 ° With
  External diameter 22.0 mm
Piston rings
  Quantity of rings 2 kompressionny and 1 maslosjemny
  Thickness of a ring:
  - top ring
  - average ring
  - maslosjemny ring
1.478-1.490 mm
1.478-1.490 mm
2.975-2.990 mm
  Gaps in locks of piston rings:
  - kompressionny rings
  - maslosjemny ring

0.40-0.65 mm
0.30-0.60 mm
  Gap in interface of a ring to a flute in the piston:
  - top ring
  - average ring
  - maslosjemny ring

0.12-0.18 mm
0.05-0.15 mm
0.025-0.15 mm
Shatunnye bearings
  Type With loose leaves
  Sorting of rods according weight:
  - black marking
  - dark blue marking
  - green marking
  - white marking
  - gray marking

648-656 g
652-660 g
656-664 g
654-672 g
668-676 g
  Axial gap all engines 0.11 - 0.24 mm
Block of cylinders
  Nominal diameter of cylinders Diameters of cylinders correspond to diameters of pistons.
Marking of the block of cylinders specifies diameter, for example, "04" means diameter of 95.04 mm, "09" diameter of 95.09 mm
  Max. admissible diameter of cylinders On 0.5 mm more nominal rate
  Max. ovality and konusnost 0.005 mm
  Gap in interface to the piston 0.02-0.05 mm
  Points of measurement of diameter of the piston In the lower part of a skirt, at right angle to an opening under a piston finger
Cranked shaft
  Quantity bearing 5
  Type of bearings With loose leaves
  Diameter of radical bearings
  Bearings No. 1-4:
  - nominal diameter
  - repair, reduced by 0.25 mm
  - repair, reduced by 0.50 mm
  The bearing No. 5 (directing)

58.003-57.987 mm
57.753-57.737 mm
57.503-57.487
As other bearings
  Width of the directing bearing:
  - 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
  Axial gap of a cranked shaft


0.050-0.152
  Admissible gap of the radical bearing 0.02-0.060 mm
  Admissible gap of the shatunny bearing 0.034-0.079 mm
  Admissible axial gap of a rod 0.11-0.24 mm

GAZORASPREDELENY'S MECHANISM

The engine of 2.4 l till 1995 of release
Parameters of a gear belt:
- quantity of teeths
- width of a belt
- step of teeths

111
20 mm
9.525 mm
Belt tension Data correspond
to instrument readings KM-510-A
- New belt:
  - the cold
  - the warmed up
- The belt which was in the use:
  - the cold
  - the warmed up

0.5
7.5

2.5
7.0
Gear belt with a tension roller
- quantity of teeths
- width of a belt
- distance between teeths

145
20 mm
8 mm
The engine of 2.0 l from the middle of 1995 of release
Parameters of a gear belt:
- quantity of teeths
- width
- distance between teeths

146
20 mm
8 mm
DOHC engine of 2.2 l
Parameters of a gear belt
- quantity of teeths
- width
- distance between teeths

171
24 mm
8 m

GREASING SYSTEM

Amount of filled-in oil See. "Types and volumes of applied greasings
and liquids"
Hl. 2
Difference between "Min" "Max" marks: 1.0 l
Pressure of oil idling
- all engines of 2.0 l
- engines of 2.4 l
- DOHC engines of 2.2 l

1.5 bar
1.0 bar
1.5 bar
Oil pump:
- type
- gaps in gear wheels: Max. a gap between tops of teeths of gear wheels and the case

Shesterenny
0.03-0.10 mm
Lateral gap in gearing of gear wheels 0.10-0.20 mm
The moment of an inhaling of a stopper for oil plum 55 Nanometers
Type of the oil filter Filter of the main stream

Efforts of a tightening of carving connections, Nanometer

The moments of an inhaling of fixture are given also in the text of Head

The OHC engine of 2.0 l till 1995 of release
Starter, from a transmission 75
  
  


Starter, from the engine 45
The inlet pipeline to the block of cylinders 22
Final collector to the block of cylinders 22
The directing plug of the vyzhimny
the bearing to a transmission 22
The generator to the console 25
Transmission to the engine 75
The generator console to the block of cylinders 40
The holder of a support of the engine to a transmission 60
(new lock plate)
The holder of a support of the engine to a transmission 60
Engine support to a longitudinal beam 65
Engine support to a beam of the forward bridge 40
Cover of the bearing of a camshaft 8
The pump/compressor console to the engine 40
Oil pipeline to the block of cylinders 6 (on hermetic)
Back cover of a.zubchaty belt 6
Pulley of a cranked shaft to the gear
to wheel of the mechanism of distribution 20
Bolts of fastening of covers radical
bearings 60 + 40 to 50 ° (bolts replace)
Bolts of fastening of covers of bearings
camshaft 45
Bolts of fastening of covers of shatunny bearings
1 reception 35
2 reception tighten 45 ° (apply new bolts)
Opening stopper for oil 45 plum
The sensor of the index of pressure of oil to the oil pump 30
The case pallet to the block of cylinders 8 (on hermetic)
The case pallet to the block of cylinders
(curing) 15 (on hermetic)
Oil pipeline to the oil pump 8
The pump of the hydraulic booster to the block of cylinders 30
Flywheel to a cranked shaft 65 (bolts are always replaced)
Support to the generator 25
Starter support to the block of cylinders 15
The thermostat case to a head of cylinders 15
The exhaust silencer to a flange of a reception pipe 25
Forward cover of a gear belt 4
The oil pump to the block of cylinders 25
Cogwheel to a cranked shaft:
- 1 reception 130
- The 2nd reception tighten on a corner 40-50 °
Tension roller to the oil pump 25
Spark plug 25
Bolts of fastening of a head of cylinders:
- 1 reception 25
- The 2nd reception Tighten on 90 °
- The 3rd reception Tighten on 90 °
- The 4th reception Tighten on 90 °
The fuel pipeline to the inlet pipeline 8
Weight cable to a head of cylinders 20
Oil filter 15
Plait of cables to the case of bearings
camshaft 8
Plait of cables to a cover of a gear belt 4

The OHC engine of 2.0 l from the middle of 1995 of release
Starter to the block of cylinders 60
The inlet pipeline to a head of cylinders 22
Final collector to the block of cylinders 22
Driving flange to a cranked shaft
(automatic transmission) 60
Damper of krutilny fluctuations to a cranked shaft 20
Flange of ventilation of a case to the block of cylinders 25
Asterisk of the sensor of angular speed to a cranked shaft 13
The console of the additional unit to the block of cylinders 35
Starter support to the block of cylinders 25
Arm of fastening of the generator to the block of cylinders 35
Pipe of a maslopriyemnik to the block of cylinders 6
The pump of the hydraulic booster to a beam of the power unit 25
Compressor console, back bolts 18
Back cover of a gear belt to the oil pump and the case of bearings of a camshaft 6
The holder of a cable to the case of bearings
camshaft 8
The channel of cables to a forward cover of a gear belt 4
Tension roller of a maple belt
to a beam of the additional unit 35
The detonation sensor to the block of cylinders 25
The console of fastening of the compressor to a unit 35 beam
Fuel distributive highway
to a final collector 8
The pump of cooling liquid to the block of cylinders 25
The sensor of temperature of cooling liquid to a hose 11
The sensor of temperature of cooling liquid
in the thermostat 10 case
Sensor of angular speed of a cranked shaft
in the block of cylinders 6
Bolts of fastening of covers radical
bearings of 50 NChM + 45 ° + 15 °
Bridge of bearings and maslouspokoitelny
leaf to the block of cylinders 20
The oxygen sensor in the exhaust silencer 30
Support of the pump of the hydraulic booster to the block of cylinders 20
Weight cable to the block of cylinders 20
Engine support back to a transmission 80
Engine support back to a cross-piece 50
Engine support a lobby to an engine 85 beam
Engine support a lobby to the chassis 50
Beam to the block of cylinders 60
Engine arm to a transmission
and to the block of cylinders 40
Load-lifting eye to the case
bearings of a camshaft 15
Cover to the case of bearings of a camshaft 8
Camshaft cogwheel to a shaft 45
Opening stopper for oil plum in the pallet of a case 55
Pipe of a maslopriyemnik to the oil pump 8
The sensor of the index of pressure of oil to the oil pump 40
The oil filter to the oil pump 15
Holders of an oil radiator to a radiator 25
The oil pump to the block of cylinders 6
Cover of the oil pump to the pump 6
The case pallet to the oil pump and the block of cylinders:
- till 1997 of release 15
- since 1997 of release 20
Cover of the shatunny bearing to a rod:
- 1 reception 35
- The 2nd reception Tighten on 45 °
- The 3rd reception Tighten on 15 °
Bolts of fastening of a protective leaf of the pallet of a case 57
Flywheel to a cranked shaft:
- 1 reception 65
- The 2nd reception Tighten on 30 °
- The 3rd reception Tighten on 15 °
Подкос to a final collector and the generator 18
Support to the inlet pipeline and the generator 18
The thermostat case to the block of cylinders 15
The Reduktsionny valve to the oil pump 30
Vacuum pipeline of the amplifier of a brake
to the inlet pipeline 20
The bottom bolt of fastening of the generator to the console 35
Forward cover of a gear belt to back 4
Forward bolts of fastening of the compressor to a unit 35 beam
Reception pipe with catalytic converter to a final collector and the exhaust silencer 25
Heat-shielding leaf to a final collector
Heat-shielding leaf to a head of cylinders 30
Cogwheel to a cranked shaft:
1 reception 130
2 reception Tighten on 40-50 °
Tension roller of a gear belt to the oil pump 25
Spark plugs 25
Flywheel to a cranked shaft:
- 1 reception 65
- 2 pry Tighten on 45 °
- The 3rd reception Tighten on 15 °
Head to the block of cylinders:
- 1 reception 25
- The 2nd reception Tighten on 90 °
- The 3rd reception Tighten on 90 °
- The 4th reception Tighten on 90 °

DOHC engine of 2.2 l
Starter to the block of cylinders 60
The inlet pipeline to a head of cylinders 22
Final collector to the block of cylinders 22
Driving flange to a cranked shaft
(automatic transmission) 60
The ignition module to the adapter 8
Damper of krutilny fluctuations to a cranked shaft 20
Flange of ventilation of a case to the block of cylinders 25
Asterisk of the sensor of angular speed to a cranked shaft 13
The console of the additional unit to the block of cylinders 35
Starter support to the block of cylinders 25
Arm of fastening of the generator to the block of cylinders 35
Pipe of a maslopriyemnik to the block of cylinders 6
The pump of the hydraulic booster to a beam of the power unit 25
Compressor console, back bolts 18
Compressor console, forward bolts 35
Back cover of a gear belt to the oil pump and the case of bearings of a camshaft 6
The holder of a cable to the case of bearings
camshaft 8
The channel of cables to a forward cover of a gear belt 4
Tension roller of a maple belt
to a beam of the additional unit 35
The detonation sensor to the block of cylinders 20
The console of fastening of the compressor to a unit 35 beam
Fuel distributive highway
to a final collector 8
The pump of cooling liquid to the block of cylinders 25
The sensor of temperature of cooling liquid to a hose 11
The sensor of temperature of cooling liquid
in the thermostat 10 case
Sensor of angular speed of a cranked shaft
in the block of cylinders 6
Bolts of fastening of covers radical
bearings of 50 Nanometers + 45 ° + 15 °
Bridge of bearings and maslouspokoitelny
leaf to the block of cylinders 20
The oxygen sensor in the exhaust silencer 30
Support of the pump of the hydraulic booster to the block of cylinders 20
Weight cable to the block of cylinders 20
Engine support back to a transmission 80
Engine support back to a cross-piece 50
Engine support a lobby to an engine 85 beam
Engine support a lobby to the chassis 50
Beam to the block of cylinders 60
Engine arm to a transmission
and to the block of cylinders 40
Load-lifting eye to the case of bearings
camshaft 15
Case of bearings of a camshaft 8
Cover to the case of bearings of a camshaft 8
Camshaft cogwheel to a shaft 45
Opening stopper for oil plum in the pallet of a case 45
Pipe of a maslopriyemnik to the oil pump 8
The sensor of the index of pressure of oil to the oil pump 40
The oil filter to the oil pump 15
Holders of an oil radiator to a radiator 25
The oil pump to the block of cylinders 6
Cover of the oil pump to the pump 6
The case pallet to the oil pump and the block of cylinders:
- till 1997 of release 15
- since 1997 of release 20
Cover of the shatunny bearing to a rod:
- 1 reception 35
- The 2nd reception Tighten on 45 °
- The 3rd reception Tighten on 15 °
Bolts of fastening of a protective leaf of the pallet of a case 57
Flywheel to a cranked shaft:
- 1 reception 65
- The 2nd reception Tighten on 30 °
- The 3rd reception Tighten on 15 °
Подкос to a final collector and the generator 18
Support to the inlet pipeline and the generator 18
The thermostat case to the block of cylinders 15
The Reduktsionny valve to the oil pump 30
Vacuum pipeline of the amplifier of a brake
to the inlet pipeline 20
The bottom bolt of fastening of the generator to the console 35
Forward cover of a gear belt to back 4
Reception pipe with catalytic converter to a final collector and the exhaust silencer 25
Heat-shielding leaf to a final collector
Heat-shielding leaf to a head of cylinders 30
Cogwheel to a cranked shaft:
- 1 reception 130
- The 2nd reception Tighten on 40-50 °
Tension roller of a gear belt to the oil pump 25
Spark plugs 25
Flywheel to a cranked shaft:
- 1 reception 65
- 2 pry Tighten on 45 °
- The 3rd reception Tighten on 15 °
Head to the block of cylinders:
- 1 reception 25
- The 2nd reception Tighten on 90 °
- The 3rd reception Tighten on 90 °
- The 4th reception Tighten on 90 °

Engine of 2.4 l
Bolts of fastening of the pump of the hydraulic booster 25
Bolts of fastening of the compressor (conditioner) 50
Holders of the generator 25
Tightening bolt of an adjusting bolt of the compressor 45
Tightening bolt, pump of the hydraulic booster
to an adjusting bolt (at the conditioner) 40
Tightening bolt, pump of the hydraulic booster
to an adjusting bolt (without the conditioner) 25
Lock-nut of an adjusting bolt of a maple belt 40
Oxygen 30 sensor
Eye bolt, adjusting bolt of a maple belt 25
Bolts of fastening of a natyazhitel of a chain
camshaft 50
Bolts of fastening of a final collector 35
Bolt of fastening of a wheel of a cranked shaft 120
Bolts of fastening of a basket of coupling 22
Bolts of fastening of radical bearings 120
Engine support to a longitudinal beam 52
Engine support to a beam 85
Bolts of fastening of a cogwheel
camshaft 25
Pallet of a case 8
Bolts of fastening of a cover of the shatunny bearing 43
Bolts of fastening of a flywheel 60
Bolts of fastening of the case of the mechanism of distribution 15
Bolts of fastening of a cogwheel of a drive of the mechanism of distribution 25
Bolts of fastening of the pump of cooling liquid 15
Bolts of fastening of a head of cylinders to the case
mechanism of distribution 25
Nut of the mechanism of a tension of a maple belt of the pump of cooling liquid 25
Pin of a yoke of a drive of the valve 40
Temperature-sensitive element 10
Spark plugs 40
bolts of fastening of a head of cylinders:
- 1 reception 60
- 2nd reception 90 + 35 °