Contents: Valves and related components ⇓ Rocker arm and shaft ⇓ Crankshaft and connecting rods ⇓ Engine block ⇓ Pistons and rings ⇓ Cylinder head ⇓ Camshaft ⇓ General ⇓
Valves and related components
Valve bevel angle - 45°
Valve seat angle - 45°
Valve head thickness:
- Inlet - 0.5 mm
- Outlet - 1.0 mm
Valve stem diameter:
- 1.6L and 2.0L engines:
- Inlet - 8.030-8.045 mm
- Permissible wear gap - 7.980 mm
- Exhaust - 8.025-8.040 mm
- 2.2L Engine:
- Intake - 6.970-6.985 mm
- Exhaust - 6.965-6.980 mm
Valve guide inner diameter:
- Engines 1.6 l and 2.0 l - 8.07-8.09 mm
- 2.2L engines — 7.01-7.03 mm
Clearance between valve stem and guide:
- Inlet and outlet - 0.025-0.060 mm
- Permissible wear limit is 0.20 mm
- Valve seat width: 1.2-1.6 mm
Valve stem exit from the guide:
- Engines 1.6 l and 2.0 l - 46.5 mm
- Permissible wear limit: 48.0 mm
- 2.2L Engines - 50.2mm
- Permissible wear limit: 51.0 mm
Valve spring angle limit is 1.81 mm
Free length of valve spring:
- Internal - 45.7 mm
- Permissible wear limit: 44.3 mm
- External - 52.4 mm
- Permissible wear limit: 50.4 mm
Rocker arm and shaft
Rocker arm bore: 16.000-16.027 mm
Shaft diameter: 15.966-15.984 mm
Rocker arm clearance: 0.016-0.061 mm
Permissible wear limit is 0.10 mm
Crankshaft and connecting rods
Crankshaft axial clearance: 0.03-0.13 mm
Permissible wear limit: 0.30 mm
Connecting rod head clearance (side clearance) — 0.110-0.262 mm
Permissible wear limit: 0.30 mm
Main bearing journal diameter: 59.937-59.955 mm
Permissible wear limit: 0.05 mm
The permissible grinding limit is 0.75 mm
Main bearing working clearance: 0.031-0.049 mm
Permissible wear limit: 0.08 mm
Connecting rod bearing journal diameter: 50.940-50.955 mm
Permissible wear limit: 0.05 mm
The permissible grinding limit is 0.75 mm
The diameter of the crank pin bore is 21.943-21.961 mm
Connecting rod bearing working clearance: 0.027-0.067 mm
Permissible wear limit is 0.10 mm
The taper limit of the crankshaft journal is 0.0020-0.05 mm
Crankshaft wear limit: 0.03 mm
Engine block
Cylinder liner diameter:
- 2.0 l and 2.2 l - 86.000-86.019 mm
- 1.6 l — 81.000-81.019 mm
- Permissible wear limit is 0.15 mm
Cylinder bore dimensions for engine repair:
- 2.0 l and 2.2 l — +0.25 and 0.50 mm
- 1.6 l - +0.25, 0.50, 0.75 and 1.0 mm
- The limit of block surface distortion is 0.15 mm
Pistons and rings
Piston diameter:
- 2.0 l and 2.2 l - 85.944-85.964 mm
- 1.6 l — 80.944-80.964 mm
Piston-to-cylinder clearance: 0.036-0.075 mm
Permissible wear limit is 0.15 mm
Ring groove width:
- Upper and second - 1.52-1.54 mm
- Oil - 4.02-4.04 mm
Piston ring-groove gap (side):
- Upper and second - 0.03-0.07 mm
- Permissible wear limit is 0.15 mm
Piston ring gap:
- Upper - 0.2-0.3 mm
- Second - 0.15-0.3 mm
- Oil - 0.3 0.9 mm
Permissible wear margin is 1.0 mm
Piston pin diameter: 21.974-21.980 mm
Piston-pin clearance Free - 0-0.024 mm
Connecting rod-pin clearance - Pressed in
(The article is based on website data: «MazBook»)
Cylinder head
Height (standard) - 91.95-92.05 mm
Processing limit: 0.20 mm
Distortion limit: 0.15 mm
Camshaft
Wear - 0.03 mm
Lateral play: 0.08-6.16 mm
Permissible wear limit is 0.20 mm
Bearing journal diameter:
- Front (No. 1) - 31.940-31.965 mm
- Central (Nos. 2, 3, 4) — 31.910-31.935 mm
- Rear (No. 5) - 31.940- 31.965 mm
- Permissible wear limit: 0.05 mm
Bearing working clearance:
- Front (No. 1) - 0.035-0.085 mm
- Central (Nos. 2, 3, 4) — 0.065-0.115 mm
- Rear (No. 5) - 0.035-0.085 mm
- Permissible wear limit is 0.15 mm
Cam protrusion:
- Intake - 38.157 mm
- Permissible wear limit: 37.957 mm
- Exhaust - 38.160 mm
- Permissible wear limit: 37.960 mm
General
Compression
Standard - 11.3 bar at 270 rpm
Minimum - 7.9 bar at 270 rpm
Cylinder numbering is 1-2-3-4 (from front to back)
The firing order of the cylinders is 1-3-4-2
Oil pressure at 3000 rpm - 3.4-4.5 kg/cm²
Tightening torques
Generator/engine bracket bolt - 37-63
Generator adjusting bolt - 19-35
Cylinder head mounting bolts:
- The engine is warm - 95-110
- Cold engine - 82-88
Main bearing cap bolts - 83-89
Connecting rod nuts - 51-56
Camshaft Sprocket Bolt - 48-66
Camshaft Cover Bolts - 18-28
Crankshaft Pulley Bolts:
- 1.6 l — 8-12
- 2.0 l and 2.2 l - 11-16
Exhaust Manifold Bolts/Nuts - 22-29
Engine mount bolts:
- Engine-transmission mount cushion No. 1 - 37-52
- Engine-to-body mount cushion No. 1 — 44-55
- Engine-transmission mount cushion No. 2 - 37-52
- Engine-to-body mount cushion No. 2 — 44-55
- Engine-to-body mount cushion No. 3 — 44-55
- Engine mount cushion no. 3 - 57-81
Flywheel/Drive Disc Bolts - 98-105
Intake Manifold Bolts/Nuts - 19-26
Pan bolts - 7-12
Timing Belt Sprocket Bolt - 110-120
Drive Belt Tensioner Lock Bolt - 39-52
Anti-rotation stop bolt to engine - 68-77
Anti-rotation stop bolt to body - 55-69
Oil pressure sensor - 12-18
Cooling bypass hose clamp. liquids - 19-35
Oil cooler center nut - 30-40
Oil pump/block bolts — 19-26
Oil pump inlet pipe flange bolts - 8-12
Rear crankshaft oil seal retaining bolts (back cover) — 8-12