Cylinder diameter, mm - 93
Piston stroke, mm - 72.7
Compression ratio - 9.6 + 04
Maximum power:
- CEE (kW at min-1) — 123 at 5000
- DIN (hp at min-1) — 170 at 5000
Maximum torque:
- CEE (kg m at min-1) — 23.5 at 4500
- DIN (kg m at min-1) — 24.5 at 4500
Cylinder head
The engine has two cylinder heads made of aluminum alloy with hemispherical combustion chambers. The valve seats and guides are pressed into the cylinder head. The camshaft bearings are bored directly into the cylinder head. Nominal height of the cylinder head between mating surfaces, mm - 110.9±0.1
Deviation from the flatness of the mating surface of the cylinder head, mm - 0.05
Cylinder head regrinding - not provided
Diameter of holes for valve guides, mm:
- intake valve - 12.070-12.097
- exhaust valve - 12.965-12.997
Cylinder head gaskets
Cylinder head gaskets are located between the cylinder block and the cylinder heads.
Thickness, mm - 1.45
Assembly - without using sealant
Valves
The valves are located in a V-shape at an angle of 33°and symmetrically with respect to the axis of the engine cylinders. The valves are actuated by the camshaft via rocker arms
Characteristics | Inlet valve | Exhaust valve |
Diameter of plate, mm | 46,02 | 39,02 |
Working edge angle | 90° | 90° |
Rod diameter, mm | 8 | 8 |
Total length, mm | 112,65 | 111,65 |
Valve clearance
Due to the use of hydraulic valve clearance compensators, checking and adjusting valve clearances is not required
Valve seats
Steel valve seats are pressed into the cylinder head
Working edge angle - 89°45"
Working edge width, mm - 2-2.4
Top angle - 16°
Valve guides
The valve guides, identical for the intake and exhaust valves, are made of cast iron and pressed into the cylinder head. Oil reflective caps are installed on the guide bushings.
Inner diameter, mm - 8-8.022
External diameter, mm:
- nominal - 13.048-13.059
- repair - 13,050-13,068
Height, mm:
- intake valve - 44.95±0.25
- exhaust valve - 49±0.25
Protrusion relative to the underside of the valve seat, mm
- intake valve - 14±0.5
- exhaust valve - 11±0.5
Valve springs
The intake and exhaust valve springs are identical.
Color marking - black
Outer diameter of turns, mm - 28.78
Free height, mm
Height under load 30 N, mm - 35
Height under load 66 N, mm -26
Rocker arms
The steel rocker arms for the intake and exhaust valves are identical. The rocker arms are mounted on an axle and supported by springs. The rocker arms transmit the force from the camshaft lobes to the hydraulic tappets (valve clearance compensators).
Rocker arm width, mm - 5.35
distance between rocker arms and supports, mm - 8.22
Rocker axles
The rocker arm axles have a through channel for supplying lubricant to the rocker arms and hydraulic pushers.
The rocker arm axles are identical for the two types of cylinder heads and are secured with a ring on one side and a screw on the other.
Cylinder block
The engines use aluminum alloy cylinder blocks with wet cylinder liners.
The block type aluminum alloy oil pan accommodates 4 main bearing caps.
Cylinder liners
The removable cylinder liners are made of cast iron and have cardboard gaskets in the lower part. They are not interchangeable and are supplied complete with pistons and connecting rods. Cylinder liners are grouped into 3 classes according to cylinder diameters and are marked with 1, 2 or 3 notches on the upper face.
Protrusion, mm - 0.05-0.12
The maximum permissible difference in the protrusion of liners from the cylinder block, mm - 0.04
Gasket thickness, mm:
- yellow color - 0.116 (deviation:±0.018)
- colorless - 0.136 (deviation:±0.018)
- blue color - 0.166 (deviation:±0.038)
Overall height, mm:
- J7R engine - 143.5
- J7T engine - 148.5
The height of the sleeve, measured from the base to the upper front side, mm - 93.065-93.095
Inner diameter, mm - 88
Sleeve diameter, mm:
- class A - 93 - 93.01
- class B - 93.01 - 93.02
- class C - 93.02 - 93.03
Moving parts of the engine
Crankshaft
The forged steel crankshaft is supported by 4 main bearings. Each crankpin is rotated 60°to ensure good engine balance.
Diameter of main journals, mm:
- nominal - 70.062
- tolerance - -0.019/ - 0
Width of the crankshaft axial play adjustment cover, mm:
- nominal - 29.2
- first increased size - 29.4
- second larger size - 29.5
- third increased size - 29.6
Diameter of connecting rod journals, mm:
- nominal - 60
- tolerance - 0.025 - 0.090
Crankshaft axial play - 0.07-0.27
Thickness of adjusting shims, mm
- nominal 2.30 - 2.35
- first increased size 2.40-2.45
- second increased size 2.45-2.50
- third increased size 2.50-2.55
Pistons
The pistons are made of aluminum alloy and are divided into 3 classes with markings on the piston bottom and are supplied complete with liners.
Piston diameter, mm:
- class A - 92.95-92.96
- class B - 92.96—92.97
- class C - 92.97—92.98
The piston diameter is measured in a plane perpendicular to the piston pin axis at a distance of 45 mm from the piston bottom.
Gap between piston and cylinder, mm - 0.4-0.6
Piston pin diameter, mm - 25.007-25.012
Installation position The arrow stamped on the bottom should be directed towards the gas distribution mechanism drive.
Connecting rods
I-section steel connecting rods with a lower split head.
Thickness of connecting rod bearing shells, mm - 1.83
Piston pins
The piston pins are made of steel with a case-hardened surface, of a floating type, secured in the piston by two retaining rings.
Length, mm - 58.7-59
Outer diameter, mm - 24.095-25
Gap between piston pin and piston, mm - 0.007-0.017
Piston rings
Each piston has three piston rings. When installing piston rings, the TOP mark should be on the side of the piston bottom.
Flywheel
The flywheel is attached to the crankshaft with 7 bolts.
Balance shaft
The balancing shaft is located in the upper part of the cylinder head, rests on 2 bearings and rotates at the crankshaft speed. The balancing shaft is driven by a chain from the camshaft sprocket.
Balance shaft drive chain
The single-row balancing shaft drive chain is tensioned by an automatic tensioning mechanism.
Gas distribution mechanism
The gas distribution mechanism consists of 2 camshafts installed above each row of cylinders and driven by single-row chains. The chain is tensioned by a hydraulic tensioning device.
Camshafts
Camshafts installed in cylinder heads. rest on 4 support bearings.
Valve timing
Intake valve opening angle to TDC - 1°
Intake valve closing angle after BDC - 43°
Exhaust valve opening angle to BDC - 46°
Exhaust valve closing angle after TDC - 4°
The drive chain of the gas distribution mechanism
One chain drives one camshaft
Tensioner stroke, mm - maximum 9.5
Lubrication
The engine is lubricated under pressure by a pump driven by the crankshaft. A replaceable oil filter is used to clean engine oil.
Oil pump
The oil pump consists of two parallel gears and is driven by a chain from the crankshaft sprocket. The pump socket is made of cylinder block material.
Minimum pressure created by the pump at an engine oil temperature of 80°C, bar:
- at idle - 0.8
- at 3000 min-1 - 3
Oil pump drive chain
Oil pump drive chain - single row
Tension check, mm - deflection no more than 7
Oil pressure sensor
The oil pressure sensor is screwed into the cylinder block near the oil filter.
Resistance, Ohm:
- 0 bar - 270-285
- 4 bar - 100-116
- 6 bar - 0-30
Oil filter
A replacement oil filter cleans the engine oil in the main line.
Brand and type - Purflux LS 592
Replacement frequency is after 10,000 km of vehicle mileage, then every 20,000 km of vehicle mileage or once every two years.
Fuel system
Injection system type - SIEMENS with reduced emissions and 55-pin control unit connector
Minimum octane number of fuel - 95
Characteristics tested at idle*
Idle speed, min-1
- in the automatic transmission selector position P/N - 700±50
- in automatic transmission selector position D - 850±50
Content of toxic substances in exhaust gases**
CO1 % (1) - no more than 0.5
CO2 % 14.5
CH, ppm - no more than 100
Lambda, l - 0.97 < l < 1.03
(1) At 2500 min-1 the CO content should be no more than 0.3%
* If the coolant temperature is above 80°C, check at 2500 min-1, then at idle
** Permissible levels of toxic substances in exhaust gases are regulated by local legislation
Fuel pump
The fuel pump is located in the fuel tank
Type - NARVAL
Supply voltage, V - 12
Created pressure, bar - 3
Productivity, l/hour - not less than 80
Fuel filter
The fuel filter is fixed in front of the fuel tank under the bottom of the car
Throttle assembly
Type - Solex
Catalog number - 77 00 874 766
Pressure regulator
Adjustable pressure range, bar - 4.5-7
Without vacuum, bar - 3.0±0.2
At a vacuum of up to 500 mbar, bar - 2.5±0.2
Electromagnetic fuel injectors
Type - Siemens Deka 1 863 409
Supply voltage, V - 12
Resistance, Ohm - 14.5±0.5
Idle air control valve
Brand: Hitachi, single winding
Catalog number - 77 00 744 614
Winding resistance, Ohm — 9.5±0.5
Throttle Position Potentiometer
Tested using the XR25
Idle speed control range - 0-47
With the accelerator pedal fully pressed - 138-255
Pulsation damper
Type - Bosch
Air temperature sensor
Type - CTN
Resistance, Ohm:
- at a temperature of 0°C - 8385-10610
- at a temperature of 20°C - 3279-3769
- at a temperature of 40°C - 1373-1555
Coolant temperature sensor
Type - CTN
Resistance, Ohm:
- at a temperature of 20°C - 3279-3769
- at a temperature of 40°C - 1373-1555
- at a temperature of 80°C - 315-348
- at a temperature of 90°C - 225-255
Heated oxygen sensor
An electrically heated lambda sensor is installed in the exhaust system in front of the catalytic converter.
Brand – NTK 77 00 856 629
Voltage generated at a temperature of 850°C, mV:
- rich mixture - >625
- lean mixture - 0-80
Catalytic converter
The catalytic converter is located under the vehicle's underbody
Air filter
Air filter with paper filter element
Evaporative emission system
Cleaning solenoid valve
Type - Delco Remy 199
Resistance, Ohm — 35±3
Ignition system
Static ignition system
The ignition timing adjustment function and the ignition power module are integrated into the injection system control unit
Spark plug
Brand and type - EYQUEM RFC 58LS 3 or RFC 57LS 3
Interelectrode gap of spark plugs, mm - 1.2 (not adjustable)
Attention. Install spark plugs of the specified brands and types, since the heat rating is not the only selection criterion.
Cooling system
Cooling system
The cooling system is a closed type - liquid, using a mixture of antifreeze and water as the working fluid and includes a water pump, radiator fan, radiator, expansion tank, thermostat and heater radiator.
Coolant
Coolant quantity, l — 10
Composition of coolant GLACEOL type - D
Coolant freezing temperature,°C:
- for countries with warm and temperate climates -25
- for countries with cold climates -37
Thermostat
Beginning of opening,°C — 84
Full opening,°C - 96
Stroke, mm - 9
Expansion tank plug
Opening values of the safety valves of the expansion tank plug, bar:
- brown plastic cover - 1.2
- blue plastic cover - 1.6
Water pump
The vane type centrifugal water pump is driven by a V-belt from the crankshaft pulley.
Consumables
Name | Quantity | Place of application |
Rhodorseal 5661 | Sufficient for lubrication | Holes for installing drive shaft pins |
Loctite FRENBLOC Sealant | Sufficient for lubrication | Brake caliper mounting bolts |
Loctite FRENETANCH Sealant | Sufficient for lubrication | Crankshaft pulley bolt |
MOLYKOTE BR 2 Paste for sealing pipe joints in exhaust gas systems | Sufficient for lubrication | Mounting protrusion on the hub under the central hole of the wheel rim |
Tightening torques, Nm
- Bolt securing the throttle assembly to the manifold - 23
- Camshaft sprocket mounting bolt - 70-90
- Bolt securing the front right support of the engine pendulum mount to the engine - 50-65
- Bolt for fastening the pendulum suspension bracket - 50-65
- Bolt for fastening the travel limiter of the front right pendulum suspension - 50 - 65
- Camshaft pulley mounting bolt - 60-70
- Bolts for fastening the corrugated protective cover of the drive shaft - 25
- Bolts for fastening the rear link of the pendulum suspension - 120-180
- Wheel bolts - 100
- Bolts securing the manifolds to the cylinder head - 15-20
- Mounting bolts for the fuel distribution line - damper-pressure regulator assembly - 7-11
- Bolts of the lower fastening of shock-absorbing struts— 200
- Nut for fastening the front pendulum suspension bracket - 30-45
- Nut securing the bracket cushion of the front right support of the pendulum engine mount - 30-45
- Nut securing the wheel hub to the drive shaft shank - 250
- Manifold mounting nuts on the cylinder head - 20
- Nuts securing the exhaust pipe to the manifold - 35
- Lower nut for fastening the pendulum suspension of the gearbox - 55-80
- Spark plugs - 25
- Swivel Nut (Metex) exhaust system elements - 20
- Catalytic converter inlet flange mounting nut - 22
- Nut securing the clamp connecting the catalytic converter and the resonator - 25