Engine 2.0L
Nominal cylinder diameter - 82.51 mm
Piston dimensions:
Pic. 131. Piston sectional view: a = 21.3 mm; b = 5.0 mm; c = 62.9 mm; d = 21.0 mm
- «a» (pic. 131) - 21.3 mm
- «b» (pic. 131) - 5.0 mm
- «c» - diameter of the trough in the piston (pic. 131) - 62.9 mm
- «d» - piston pin diameter (pic. 131) - 21.0 mm
Compression
Normal value is 10-13 bar [1000-1300 kPa]
Limit value 7.5 bar [750 kPa]
Valve guides
The inner diameter of the bushings is 7.013-7.035 mm
Valve stem clearance:
Pic. 113. Checking the runout of the valve stem inside the guide sleeve using a measuring device VW387
- intake valves (pic. 113) - 1.0 mm
- exhaust valves (pic. 113) - 1.3 mm
Valve seats
Valve seat diameter:
- intake valves - 39.20 mm
- exhaust valves - 32.40 mm
Valve seat angle - 45°
Valve seat width:
- intake valves - 2.0 mm
- exhaust valves - 2.4 mm
External Correction Angle:
- inlet valves - 30°
- exhaust valves - 30°
Valves
Valve disc diameter:
- intake valves - 39.5 mm
- exhaust valves - 32.9 mm
Valve length:
- intake valves - 91.85 mm
- exhaust valves - 91.15 mm
Valve stem diameter:
- intake valves - 6.92 mm
- exhaust valves - 6.92 mm
Valve edge thickness Not less than - 0.5 mm
Pic. 45. Dimensions when grinding chamfers of valves: a = 45°; a = maximum 3.5 mm; b = minimum 0.5 mm
Size «b» (pic. 45):
- intake valves - 33.90 mm
- intake valves - 34.10 mm
Pistons
Piston diameter measuring point - 10.0 mm from the bottom of the piston skirt at an angle of 90°to the axis of the piston pin
Nominal diameter - 84.475 mm
Max. permissible piston wear - 0.04 mm from the specified diameter
Piston clearance:
- normal - 0.03 mm
- maximum allowable - 0.07 mm
Gap between piston rings and grooves:
- normal - 0.02-0.05 mm
- maximum allowable - 0.15 mm
Thermal gap:
- normal - compression piston rings - 0.20-0.40 mm
- normal - oil scraper ring - 0.25-0.50 mm
- maximum allowable - 1.0 mm
Connecting rods
Axial clearance of the bearing - 0.05-0.31 mm
Maximum allowable - 0.37 mm
Piston pin clearance - 0.01-0.02 mm
Crankshaft
Number of main bearings - 5
Designation of main bearings - From 1 to 5, starting from the front of the engine
Axial clearance adjustment - Thrust washers
Main and connecting rod bearings - Thin-walled bearing shells
Axial clearance of the crankshaft:
- normal - 0.07-0.17 mm
- maximum allowable - 0.25 mm
Main bearing clearance:
- normal - 0.03-0.08 mm
- maximum allowable - 0.17 mm
Connecting rod bearing clearance:
- normal - 0.02-0.076 mm
- maximum allowable - 0.12 mm
Main bearing journal diameter:
- nominal diameter - 54.00 mm
- 1st repair - 53.75 mm
- 2nd repair - 53.50 mm
- 3rd repair - 53.25 mm
Engine lubrication system
Lubrication pressure - 1.0 bar [100 kPa]
Maximum in lubrication system - 7.0 bar [700 kPa]
The amount of oil in the engine that must be filled when changing the oil:
- with filter change - 4.7 l
- without filter change - 4.2 l
Engine cooling system
The amount of coolant in the cooling system - 9.0 l
Thermal switch
1st stage start temperature - 92-97°C
1st stage cutout temperature - 84-91°C
1st stage start temperature - 99-105°C
2nd stage cutout temperature - 91-98°C
Thermostat
Opening temperature - 87°C
Closing temperature - 102°C
VR6 engine
Nominal cylinder diameter - 81.01 mm
Piston dimensions:
- 1st repair size - 81.51 mm
- 2nd repair size - 82.01 mm
Valve guides
The inner diameter of the bushings is 7.013-7.035 mm
Valve stem clearance:
Pic. 38. Checking the runout of the valve stem inside the guide sleeve using the measuring device VW387
- intake valves (pic. 38) - 1.0 mm
- exhaust valves (pic. 38) - 1.3 mm
Valve seats
Valve seat diameter:
- intake valves - 38.30 mm
- exhaust valves - 33.50 mm
Valve seat angle - 45°
Valve seat width:
- intake valves Max - 1.7 mm
- exhaust valves No more than - 2.0 mm
External Correction Angle:
- inlet valves - 30°
- exhaust valves - 75°
Max. permissible amount of additional processing (pic. 42):
Pic. 42. Measuring the height of the protrusion of the end of the valve stem above the upper edge of the cylinder head
- intake valves - 33.90 mm
- exhaust valves - 34.10 mm
Valves
Valve disc diameter:
- intake valves - 39.00 mm
- exhaust valves - 34.20 mm
Valve length:
- intake valves - 106.25 mm
- exhaust valves - 106.95 mm
Valve stem diameter:
- intake valves - 6.97 mm
- exhaust valves - 6.95 mm
Valve edge thickness — Not less than 0.5 mm
Pistons
Piston diameter measuring point - 6.0 mm from the bottom of the piston skirt at an angle of 90°to the axis of the piston pin
Piston diameter:
- nominal - 80.985 mm
- 1st repair - 81.485 mm
- 2nd repair - 81.985 mm
Max. permissible piston wear - 0.04 mm
Piston clearance:
- normal - 0.03 mm
- maximum allowable - 0.07 mm
Gap between piston rings and grooves:
- normal (compression rings) - 0.02-0.07 mm
- normal (oil scraper ring) - 0.02-0.08 mm
- maximum allowable - 0.15 mm
Thermal gap:
- normal - compression piston rings - 0.20-0.40 mm
- normal - oil scraper ring - 0.25-0.50 mm
- maximum allowable - 1.0 mm
Connecting rods
Axial clearance of the bearing - 0.05-0.31 mm
Maximum allowable - 0.37 mm
Piston pin clearance - 0.01-0.02 mm
The length of the connecting rods between the centers of the bearings - 164.0 mm
Crankshaft
Number of main bearings - 7
Designation of main bearings - From 1 to 7, starting from the front of the engine (vibration damper side)
Axial clearance adjustment - Thrust washers
Main and connecting rod bearings
Axial clearance of the crankshaft:
- normal - 0.07-0.17 mm
- maximum allowable - 0.25 mm
Main bearing clearance:
- normal - 0.02-0.06 mm
- maximum allowable - 0.1 mm
Connecting rod bearing clearance:
- normal - 0.01-0.06 mm
- maximum allowable - 0.1 mm
Main bearing journal diameter:
- nominal diameter - 60.00 mm
- 1st repair - 59.75 mm
- 2nd repair - 59.50 mm
- 3rd repair - 59.25 mm
Engine lubrication system
Lubrication pressure - 1 bar [100 kPa]
Maximum pressure in the lubrication system - 7 bar [700 kPa]
The amount of oil in the engine that must be filled when changing the oil:
- with filter change — 5.5 l
- without filter change - 5.0 l
Engine cooling system
The amount of coolant in the cooling system:
- with manual transmission - 9 l
- with automatic transmission - 9.1 l
Thermostat
Opening temperature - 85°C
Closing temperature - 105°C
Diesel engine
Cylinder diameter:
- nominal - 79.51 mm
- 1st repair size - 79.76 mm
- 2nd repair size - 80.01 mm
Valve guides
The inner diameter of the bushings is 8.013-8.035 mm
Valve stem clearance - 1.3 mm (see text)
Valve seats:
Pic. 397. Checking the valve stem clearance indicator in the valve guide
Valve seat diameter (pic. 397):
- intake valves - 35.70 mm
- exhaust valves - 31.40 mm
Valve seat angle - 45°
Valve seat width (size «With», see fig. 397):
- intake valves - 2.7 mm
- exhaust valves - 1.6 mm
External Correction Angle - 15°
Valves
Valve disc diameter:
- intake valves - 35.95 mm
- exhaust valves - 31.45 mm
Valve length - 96.85
Valve stem diameter:
- intake valves - 7.97 mm
- exhaust valves - 7.95 mm
Valve edge thickness — Not less than 0.5 mm
Pic. 399. Depth measurement a during reworking of valve seats (shown by arrows)
Size «A» (pic. 399):
- intake valves - 35.7 mm
- exhaust valves - 31.4 mm
Pistons
Piston diameter measuring point - 10.0 mm from the bottom of the piston skirt at an angle of 90°to the axis of the piston pin
Piston diameter:
- nominal diameter - 79.48 mm
- 1st repair size - 79.73 mm
- 2nd repair size - 79.98 mm
Max. permissible piston wear - 0.04 mm
Piston clearance:
- normal - 0.03 mm
- maximum allowable - 0.07 mm
Gap between piston rings and grooves:
- compression (upper) - 0.06-0.09 mm
- compression (average) - 0.05-0.08 mm
- oil scraper - 0.03-0.06 mm
- maximum allowable (compression) - 0.25 mm
- maximum allowable (oil scraper) - 0.15 mm
Thermal gap:
normal - compression piston rings - 0.20-0.40 mm
normal - oil scraper ring - 0.25-0.50 mm
maximum allowable - 1.0 mm
Piston ring lock location - Every 120°
Piston pin diameter - 26.0 mm
Connecting rods
Axial clearance of the bearing - 0.05-0.31 mm
Maximum allowable - 0.37 mm
Crankshaft
Number of main bearings - 5
Designation of main bearings - From 1 to 5, starting from the front of the engine
Axial clearance adjustment - Thrust washers
Main and connecting rod bearings - Thin-walled bearing shells
Axial clearance of the crankshaft:
- normal - 0.07-0.17 mm
- maximum allowable - 0.37 mm
Main bearing clearance:
- normal - 0.03-0.08 mm
- maximum allowable - 0.17 mm
Connecting rod bearing clearance:
- normal - 0.03-0.076 mm
- maximum allowable - 0.08 mm
Max. violation of the roundness of the journals of the bearings - 0.03 mm
Main bearing journal diameter (tolerance, mm):
- nominal diameter - 54.00 mm
- 1st repair - 53.75 mm
- 2nd repair - 53.50 mm
- 3rd repair - 53.25 mm
Connecting rod journal diameter:
- nominal diameter - 47.80 mm
- 1st repair - 47.55 mm
- 2nd repair - 47.30 mm
- 3rd repair - 47.05 mm
Width of bearing shells - 20 mm
Engine lubrication system
Lubrication system pressure - 2.0 bar [200 kPa] minimum
Minimum pressure in the lubrication system (operation of a control lamp) - 0.15-0.75 bar [15-75 kPa]
The amount of oil in the engine that must be filled when changing the oil:
- with filter change — 4.5 l
- without filter change - 4.0 l
Engine cooling system
Reducing valve opening pressure - 1.4-1.6 bar [140-160 kPa]
Vacuum valve opening pressure - 0.06-0.1 bar [6-10 kPa]
Thermal switch
1st stage start temperature - 92-97°C
1st stage cutout temperature - 84-91°C
1st stage start temperature - 99-105°C
2nd stage cutout temperature - 91-98°C
Thermostat
Opening temperature - 85°C
Fully open - 105°C
Travel - 7.0 mm
Steering
Wheel bearing adjustment:
Wheel track adjustment — +10'±25'
Camber adjustment - -201±30'
Max. difference between sides maximum - 1°
Coil Springs - Colored Dot Marking (install springs with the same markings)
Front wheel brake
Brake disc diameter - 288.0 mm
Wheel cylinder piston diameter - 57.0 mm
Brake Disc Thickness - Ventilated, 25.0mm
Minimum brake disc thickness - 23.0 mm
Brake pad thickness - 14.0 mm
The minimum thickness of the brake pad lining is 1.0 mm
The thickness of the brake pads together with the metal base is 7.0 mm
Rear wheel brakes
Brake disc diameter - 268.0 mm
Wheel cylinder piston diameter - 38.0 mm
Thickness of brake discs - 10.0 mm
Minimum brake disc thickness - 8.00 mm
Brake pad thickness - 14.0 mm
The minimum thickness of the brake pad lining is 1.0 mm
The thickness of the brake pads together with the metal base is 7.0 mm
Brake master cylinder diameter - 23.81 mm
Visitor comments