Cylinder head
Maximum gasket deflection:
4-cylinder engines:
- Longitudinal - 0.15 mm
- Transverse - 0.05 mm
All engines except 4-cylinder gasoline:
- Pro longitudinal - 0.08 mm
- Transverse - 0 mm
Minimum height after sanding:
- 4 - cylinder gasoline engines - 97.8 mm
- 6-cylinder petrol engines* - 89.5 mm
- Diesel engines - 142.4 mm
Protrusion of the combustion chamber (diesel engines) - 7.6 to 8.1 mm
Maximum valve drop below the sealing surface of the cylinder head (wear limit):
4 - cylinder gasoline engines:
1.8 and 2.0 liter engines:
- Inlet - 2.3 mm
- Graduation - 0.9 mm
2.3 liter engines:
- Inlet - 1.7 mm
- Graduation - 0.9 mm
6-cylinder petrol engines:
- Inlet - 1.7 mm
- Graduation - 1.5 mm
Diesel engines (intake and exhaust valves) - 0.7 mm
*Note: The total thickness of the metal removed from the cylinder head or from the mating surface of the cylinder block must not exceed 0.5 mm.
Valve*
Valve disc diameter:
4-cylinder petrol engines:
intake:
- 2.0 liter engines - 42.90 to 43.10 mm
- 2.3 liter engines - 45.90 to 46.19 mm
Graduation - 38.90 to 39.10 mm
6-cylinder petrol engines:
- Intake - 40.0 mm
- Graduation - 35.0 mm
Diesel engines:
- Intake - 37.90 to 38.10 mm
- Graduation - 34.90 to 35.10 mm
Valve stem diameter:
Petrol engines:
- Intake - 7.955 to 7.970 mm
- Graduation - 8.938 to 8.960 mm
Diesel engines:
- Intake - 7.955 to 7.970 mm
- Graduation - 8.938 to 8.960 mm
* Note: Data for 1.8 liter engines was not available at the time of writing.
Valve springs*
Free length:
- 4-cylinder petrol engines - 49.0 mm
- 6-cylinder gasoline engines - not published by the manufacturer
Diesel engines:
- Springs with yellow / green or purple / green markings - 50.8 mm
- Springs with yellow / blue or purple / blue markings - 50.0 mm
* Note: Data for 1.8 liter engines was not available at the time of writing.
Cylinder block
Cylinder diameter:
4-cylinder petrol engine:
1.8 and 2.0 liter engines:
- Standard 0 - 88.998 to 89.008 mm
- Standard 1 - 89.009 to 89.018 mm
- Standard 2 - 89.019 to 89.028 mm
- Standard A - 89.000 to 89.006 mm
- Standard X - 89.007 to 89.012 mm
- Standard B - 89.013 to 89.018 mm
- Repair dimension +0.5 - Values higher by +0.500 mm
- Repair dimension +1.0 - Values higher by +1.000 mm
2.3 liter engines:
- Standard 0 - 95.498 to 95.508 mm
- Standard 1 - 95.509 to 95.518 mm
- Standard 2 - 95.519 to 95.528 mm
- Standard A - 95.500 to 95.506 mm
- Standard X - 95.507 to 95.512 mm
- Standard B - 95.513 to 95.518 mm
- Repair dimension +0.5 - Values higher by +0.500 mm
- Repair dimension +1.0 - Values higher by +1.000 mm
6-cylinder petrol engines:
- Standard 0 - 82.898 to 82.900 mm
- Standard 1 - 82.908 to 82.918 mm
- Standard 2 - 82.918 to 82.928 mm
- Standard A - 82.900 to 82.906 mm
- Standard X - 82.906 to 82.912 mm
- Standard B - 82.912 to 82.918 mm
- Repair dimension +0.5 - Values higher by +0.500 mm
- Repair dimension +1.0 - Values higher by +1.000 mm
Diesel engines:
- Standard A - 87.000 to 87.006 mm
- Standard X - 87.006 to 87.012 mm
- Standard B - 87.012 to 87.018 mm
- Repair dimension +0.7 mm - Values higher by +0.700 mm
Maximum ovality of cylinder bore:
- Gasoline engines - 0.05 mm
- Diesel engines - 0.07 mm
Maximum taper of cylinder bore:
- Gasoline engines - 0.05 mm
- Diesel engines - 0.07 mm
Maximum block height:
- 4-cylinder engines - 292.35 mm
- 6-cylinder engines - 281.95 mm
- Diesel engines - 299.62 mm
Maximum curvature of the gasket surface:
4-cylinder petrol engines - No information available at the time of writing
6 - cylinder gasoline engines:
- Longitudinal - 0.100 mm
- Transverse - 0.05 mm
Diesel engines - 0.03 mm
Pistons
Piston diameter:
4-cylinder petrol engines:
1.8 and 2.0 liter engines:
- Standard 0 - 88.968 to 89.982 mm
- Standard 1 - 88.978 to 88.992 mm
- Standard 2 - 86.988 to 89.002 mm
- Standard A - 88.973 to 88.979 mm
- Standard X - 88.978 to 88.986 mm
- Standard B - 88.985 to 88.991 mm
- Repair dimension +0.5 - Values higher by +0.500 mm
- Repair dimension +1.0 - Values higher by +1.000 mm
2.3 liter engines:
- Standard 0 - 95.469 to 95.481 mm
- Standard 1 - 95.479 to 95.491 mm
- Standard 2 - 95.489 to 95.501 mm
- Standard A - 95.473 to 95.479 mm
- Standard X - 95.478 to 95.486 mm
- Standard B - 95.485 to 95.491 mm
- Repair dimension +0.5 - Values higher by +0.500 mm
- Repair dimension +1.0 - Values higher by +1.000 mm
6-cylinder petrol engines:
- Standard 0 - 82.868 to 82.882 mm
- Standard 1 - 82.878 to 82.892 mm
- Standard 2 - 82.888 to 82.902 mm
- Standard A - 82.873 to 82.879 mm
- Standard X - 82.878 to 82.886 mm
- Standard B - 82.885 to 82.891 mm
- Repair dimension +0.5 - Values higher by +0.500 mm
- Repair dimension +1.0 - Values higher by +1.000 mm
Diesel engines:
- Standard A - 86.970 to 86.976 mm
- Standard X - 86.975 to 86.983 mm
- Standard B - 86.982 to 86.988
- Repair dimension +0.7 mm - Values higher by +0.700 mm
Piston protrusion (diesel engines):
- Minimum - 0.735 mm
- Maximum - 0.965 mm
Piston rings *
Lock gap:
4-cylinder petrol engines:
- Top compression ring - 0.30 to 1.00 mm
- Second compression ring - 0.25 to 0.80 mm
- Oil scraper ring - 0.25 to 0.80 mm
6-cylinder petrol engines:
- Top compression ring - 0.015 to 0.050 mm
- Second compression ring - 0.020 to 0.040 mm
- Oil scraper ring - 0.01 to 0.045 mm
Diesel engines:
- Top compression ring - 0.090 to 0.20 mm
- Second compression ring - 0.050 to 0.15 mm
- Oil scraper ring - 0.030 to 0.10 mm
* Note: At the time of writing the Manual, there was no information for 1.8 liter engines.
Crankshaft
Free axial travel:
- 4-cylinder petrol engines - 0.300 mm
- 6-cylinder petrol engines - 0.100 to 0.240 mm
- Diesel engines - 0.300 mm
Thickness of persistent half rings (for all engines) - 2.15, 2.20, 2.25, 2.35 and 2.40 mm
Diameters of main journals:
4-cylinder petrol engines:
- Standard code blue - 57.960 to 57.965 mm
- Standard code yellow - 57.955 to 57.960 mm
- Standard code red - 57.950 to 57.955 mm
- Standard 1 code blue - 57.945 to 57.950 mm
- Standard 1 code yellow - 57.940 to 57.945 mm
- Standard 1 code red - 57.935 to 57.940 mm
- Repair 1 - 57.705 to 57.715 mm
- Repair 2 - 57.455 to 57.465 mm
- Repair 3 - 57.205 to 57.215 mm
- Repair 4 - 56.955 to 56.965 mm
6-cylinder gasoline engines: - No information available at the time of writing
Diesel engines:
- Standard - 57.959 to 57.965 mm
- Repair 1 - 57.700 to 57.715 mm
- Repair 2 - 57.450 to 57.465 mm
- Repair 3 - 57.200 to 57.215 mm
- Repair 4 - 56.959 to 56.965 mm
Working clearance in main bearings - 0.025 to 0.070 mm
Connecting rod diameters:
4-cylinder engines:
- Standard - 47.955 to 47.965 mm
- Repair 1 - 47.705 to 47.715 mm
- Repair 2 - 47.455 to 47.465 mm
- Repair 3 - 47.205 to 47.215 mm
- Repair 4 - 46.955 to 46.965 mm
6-cylinder engines - No information available at the time of writing
Diesel engines:
- Standard - 47.950 to 47.965 mm
- Repair 1 - 47.700 to 47.715 mm
- Repair 2 - 47.450 to 47.465 mm
- Repair 3 - 47.200 to 47.215 mm
- Repair 4 - 46.950 to 46.965 mm
Operating clearance in connecting rod bearings - 0.030 to 0.070 mm
Radial travel of the crankshaft in bearings
- 4-cylinder petrol engines - 0.070 mm
- 6-cylinder petrol engines - 0.030 to 0.050 mm
- Diesel engines - 0.080 mm
Radial travel of connecting rod bearings on the crankshaft.
- 4-cylinder petrol engines - 0.070 mm
- 6-cylinder gasoline engines - 0.030 to 0.060 mm
- Diesel engines - 0.080 mm
Connecting rod bearing cap bolts
Minimum bore 2.0- and 2.3-litre petrol engines (see paragraph 16) - 8 mm
Maximum length - all except 2.0- and 2.3-liter petrol engines (see paragraph 16) - 52.9 mm
Connection tightening torques
- 4 Cylinder Gasoline Engines - Refer to Specifications in Chapter 2A
- 6 Cylinder Gasoline Engines - Refer to Specifications in Chapter 2B
- Diesel Engines - Refer to Specifications in Chapter 2B