3.1.1. A technical characteristics

THE GENERAL DATA

THE ENGINE

Head of the block of cylinders

The head is executed from an easy alloy and has the inserted saddles and directing valves. Camshaft bearings are executed in a material of a head of the block of cylinders.

Nominal height:
– Engines of 1580 sm3, 1761 sm3 and 1905 sm3 (with 8 valves) and 1998 sm3 (with 8 and 16 valves)	158,93 ± 0,05 mm
– The engine of 1905 sm3 (16 valves)	132,00 ± 0,05 mm
The minimum height after repolishing:
– Engines of 1580 sm3, 1761 sm3 and 1905 sm3 (with 8 valves) and 1998 sm3 (with 8 and 16 valves)	158,73 mm
– The engine of 1905 sm3 (16 valves)	131,80 ± 0,05 mm
The maximum admission неплоскостности the bottom surface of a head	0,05 mm
Internal diameter of bearings of a camshaft in a head of the block of cylinders:
Engines of 1580 and 1905 sm3:
– 1	27,000 – 27,033 mm
– 2	27,500 – 27,533 mm
– 3	28,000 – 28,033 mm
– 4	28,500 – 28,533 mm
– 5	36,000 – 36,039 mm

Valves

The head of the block of cylinders has 8 (or 16) the valves established in parallel among themselves and at right angle to the bottom surface of a head.

The sizes of valves

Diameter of a plate of the valve:
– Inlet valves:
• the engine of 1580 sm3	41,6 mm
• the engine of 1761 sm3	There is no data
• the engine of 1905 sm3 (with 8 valves)	41,8 mm
• the engine of 1998 sm3 (with 8 valves)	42,6 mm
• engines of 1905 sm3 and 1998 sm3 (with 16 valves)	34,7 mm
– Final valves:
• engines of 1580 sm3 and 1905 sm3	34,7 mm
• the engine of 1761 sm3	There is no data
• the engine of 1998 sm3 (with 8 valves)	34,5 mm
• engines of 1905 sm3 and 1998 sm3 (with 16 valves)	29,7 mm
Diameter of a core of the valve:
– Inlet valves:
• engines of 1580 sm3 and 1905 sm3 (with 8 valves)	7,83 – 8,13 mm
• the engine of 1761 sm3	There is no data
• the engine of 1998 sm3 (with 8 valves)	7,83 – 7,98 mm
• engines of 1905 sm3 and 1998 sm3 (with 16 valves)	6,83 – 6,98 mm
– Final valves:
• engines of 1580 sm3 and 1905 sm3	7,83 – 8,13 mm
• the engine of 1761 sm3	There is no data
• the engine of 1998 sm3 (with 8 valves)	7,82 – 8,12 mm
• engines of 1905 sm3 and 1998 sm3 (with 16 valves)	6,83 – 6,98 mm
Length of the valve:
– Inlet valves:
• engines of 1580 sm3, 1905 sm3 and 1998 sm3 (with 8 valves)	108,79 ± 0,1 mm
• the engine of 1761 sm3	There is no data
• engines of 1905 sm3 and 1998 sm3 (with 16 valves)	104,48 ± 0,1мм
– Final valves:
• engines of 1580 sm3, 1905 sm3 and 1998 sm3 (with 8 valves)	108,37 ± 0,1 mm
• the engine of 1761 sm3	There is no data
• engines of 1905 sm3 and 1998 sm3 (with 16 valves)	103,00 ± 0,1мм
Corner прилегания valves	90 °
Width of a working edge	1,1 mm
Working backlash of valves, except engines with 16 valves (on the cold engine):
– The inlet valve	0,20 mm
– The final valve	0,40 mm

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The prevention

Final valves do not grind.

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Saddles of valves

Saddles of valves are inserted into a head of the block of cylinders and are not subject to replacement.

Directing valves

Directing valves plug-in, are made of pig-iron or from a brass.

External diameter:
– The nominal	13 0,08 or 13 0,05 mm
– The repair size	13,13 ± 0,011 mm; 13,29 ± 0,011 mm; 13,59 ± 0,011 mm

Springs of valves

It is used on one spring on the valve. Inlet and final valves have identical springs.

The characteristic of springs

Engine XU5:
– A designation	The green
– Height:
• at loading 400 Н	42,5 mm
• at loading 800 Н	31,0 mm
Engine XU9:
– A designation	The black
– Height:
• at loading 410 Н	40,5 mm
• at loading 860 Н	30,0 mm
– A designation	The grey
– Height:
• at loading 395 Н	41,5 mm
• at loading 780 Н	31,0 mm

Pushers

Pushers move directly in a material of a head of the block of cylinders. Adjustment of a working backlash of valves is based on installation of adjusting plates of a corresponding thickness between cores of valves and pushers.

Engines with 16 valves have the hydraulic pushers providing automatic adjustment of backlashes of valves.

Diameter of plates	13,5 mm
Thickness of plates:
– Through each 0,025 mm	From 1,650 to 3,000 mm
– Through each 0,075 mm	From 3,025 to 3,550 mm
– Through each 0,025 mm	From 3,575 to 4,000 mm

Lining of a head of the block of cylinders

Mark	Reinz or Curty
Thickness of a lining:
– The nominal	1,2 mm
– For перешлифованной heads	1,4 mm (a designation by means of cut and an aperture in diameter of 4 mm on a ledge on one of the lining ends)
Installation	Ledge from outside a flywheel

The block of cylinders of the engine

The block of cylinders of the engine on models with working volume 1580 sm³, 1761 sm³ and 1905 sm³ (with 8 and 16 valves) is made of an easy alloy and has plug-in wet sleeves of cylinders. On models with working volume 1998 sm³ (with 8 and with 16 valves), cylinders are executed directly in a body of the block of cylinders.

Diameter of a bearing surface of radical bearings of a cranked shaft: 63,708–63,727 mm.

Sleeves of cylinders

Plug-in sleeves of cylinders of clamping type, and tightness it is provided with a round sealing ring.

Selection by steams of sleeves and pistons is obligatory: the letter designation is put on the bottoms of pistons and on the top edges of sleeves.

Diameter расточки the engine cylinder:
– Engines of 1580 sm3, 1761 sm3 and 1905 sm3 (with 8 valves):
• group A	From 83,000 to 83,010 mm
• group B	From 83,010 to 83,020 mm
• group C	From 83,020 to 83,030 mm
– Engines of 1998 sm3 (with 8 valves):
• group A	From 86,000 to 83,010 mm
• group B	From 86,250 to 86,268 mm
• group C	From 86,600 to 86,618 mm
– The engine of 1905 sm3 (with 16 valves):
• group A	From 83,000 to 83,010 mm
• group B	From 83,010 to 83,020 mm
• group C	From 83,020 to 83,030 mm
Ledge of a sleeve concerning the block of cylinders, except 1998 sm3 (measured without a round sealing ring)	0,03 – 0,10 mm
The maximum distinction between any two sleeves:
– Engines with 8 valves	0,05 mm
– Engines with 16 valves	0,02 mm

KRIVOSHIPNO-SHATUNNYJ THE MECHANISM

Cranked shaft

The cranked shaft is made of pig-iron and leans against five radical bearings.

Longitudinal backlash a cranked shaft:
– Engines with 8 valves	From 0,07 to 0,32 mm
– Engines with 16 valves	From 0,07 to 0,27 mm
Diameter of radical necks:
– Engines of 1580 sm3, 1905 sm3 and 1998 sm3:
• the standard	From 59,981 to 60,000 mm
• the repair	From 59,681 to 59,700 mm
– The engine of 1761 sm3	There is no data
Diameter шатунных necks:
– Engines of 1580 sm3, 1905 sm3 and 1998 sm3:
• the standard	From 49,984 to 50,000 mm
• the repair	From 49,684 to 49,700 mm
– The engine of 1761 sm3	There is no data
Working backlash in radical bearings:
– Engines of 1580 sm3, 1761 sm3 and 1905 sm3	From 0,025 to 0,050 mm
– Engines of 1998 sm3	From 0,038 to 0,069 mm
Working backlash in шатунных bearings (all models)	From 0,025 to 0,050 mm

Loose leaves of radical bearings

Thickness:
– The nominal	1,842 ± 0,003 mm
– The repair size	1,992 ± 0,003 mm

Loose leaves шатунных bearings

The engine of 1580 sm3:
– A nominal thickness	1,812 ± 0,01 mm
– The repair size	1,962 ± 0,01 mm
The engine of 1905 sm3:
– A nominal thickness	1,833 ± 0,003 mm
– The repair size	1,983 ± 0,003 mm

Persistent half rings (axial bearings of sliding)

Thickness:
– The nominal	2,30 or 2,35 mm
– The repair sizes	2,40, 2,45 and 2,50 mm

Flywheel

The flywheel is screwed on a cranked shaft восемью by bolts.

Number of teeths of a gear wreath: 136.

Rods

Rods are shaped from a steel. Have the thin-walled loose leaves made of an aljuminievo-tin alloy.

Distance between axes:
– The engine of 1580 sm3	150,5 mm
– The engine of 1905 sm3	143,0 mm
Diameter of an aperture of the top head of a rod	22 ± 0,029 mm
Diameter of an aperture of the bottom head of a rod:
– The engine of 1580 sm3	48,655 ± 0,016 mm
– The engine of 1905 sm3	53,695 ± 0,013 mm
The maximum difference in weight between rods of the same engine:
– Engines of 1580 sm3, 1761 sm3 and 1905 sm3	13 г
– The engine of 1998 sm3	7,0 г

Pistons

Pistons are made of an easy alloy. The finger is fixed in a rod with a tightness, and in the piston – is free.

Installation: the arrow on the piston bottom should be directed towards a camshaft drive.

Selection by steams of sleeves and pistons: 3 groups of pistons: And, In and With correspond to 3 groups of sleeves of the cylinders designated by the same letters (on the top edges).

Diameter of pistons

Engines of 1580 sm3, 1761 sm3 and 1905 sm3 (with 8 valves):
– Group And	82,960 ± 0,007 mm
– Group B	82,970 ± 0,007 mm
– Group C	82,980 ± 0,007 mm
The engine of 1905 sm3 with 16 valves:
– Group And	From 82,963 to 82,977 mm
– Group B	From 82,973 to 82,987 mm
– Group C	From 82,983 to 82,997 mm

Piston rings

Backlashes in the lock:
– The top sealing ring:
• the engine of 1580 sm3	From 0,4 to 0,6 mm
• the engine of 1905 sm3	From 0,2 to 0,4 mm
• engines of 1761 sm3 and 1998 sm3	From 0,3 to 0,5 mm
– The second sealing ring:
• engines of 1580 sm3 and 1905 sm3	From 0,15 to 0,35 mm
• engines of 1761 sm3 and 1998 sm3	From 0,3 to 0,5 mm
The maslosemnoe ring, all models	From 0,3 to 0,5 mm

As spare parts rings UFLEX which have replaced earlier applied rings are now delivered only. Are established without a backlash on the lock. Their installation demands strong compression, and also большего attention and accuracy not to break a ring.

Piston fingers

Steel fingers are ground. Fasten freely in pistons and with a tightness in rods. There are 3 groups of the fingers corresponding to piston groups, designated by a colour paint.

On models with 16 valves piston fingers have sliding landing in a rod and are fixed by lock rings.

Conformity of a designation on the piston to colour of a sign on a finger

1	The blue
2	The white
3	The red

SYSTEM GAZORASPREDELENIJA

The system timing consists of the block of cylinders of the camshaft fixed in five bearings and put in action by a gear belt established in a head. The camshaft operates work of valves by means of the pushers supplied with plates of adjustment of a backlash.

Phases timing are defined with a theoretical backlash in 1 mm.

Engine XU5:
– Opening of the inlet valve	6 ° 30 ' an advancing
– Closing of the inlet valve	31 ° 18'
– Opening of the final valve	41 ° 18'
– Closing of the final valve	3 ° 30'
Engine XU9:
– Opening of the inlet valve	3 ° delay
– Closing of the inlet valve	46 °
– Opening of the final valve	40 ° 8'
– Closing of the final valve	2 ° 2'

Camshaft

The camshaft is established in a head of the block of cylinders and fixed in five bearings executed directly in a material of a head of the block of cylinders, and put in action by a gear belt.

Diameter of bearings of a camshaft (engines of 1580 sm3 and 1905 sm3):
– 1	26,980 – 26,959 mm
– 2	27,480 – 27,459 mm
– 3	27,980 – 27,959 mm
– 4	28,480 – 28,459 mm
– 5	35,975 – 35,950 mm

Gear belt

Mark: Uniroyal Powergrip 58113 x 17.

The belt tension provides the roller tension device.

GREASING SYSTEM

Greasing under pressure is provided with the oil pump put in action by a chain from a cranked shaft.

The gauge of pressure of oil is adjusted on 0,08 МПа.

Since April, 1987 the oil pump above on 5 mm. The remote element which was between the pump and the block of cylinders, and also the intermediate plug fastening on the block of cylinders is cleaned.

The new pump can be established instead of old provided that the intermediate element will be cleaned, and under bolts of fastening of the pump washers will be enclosed.

The length of a chain of a drive remained invariable.

The oil pump

The case шестеренчатого the oil pump is made of an easy alloy.

Pressure of oil at temperature 90 ° With:
– Engine XU5	0,35 МПа at 4000 rpm
– Engine XU7	0,53 МПа at 4000 rpm
– Engine XU9	0,41 МПа at 4000 rpm
– Engine XU10	0,52 МПа at 4000 rpm

The oil filter

The oil filter with a replaced element has connected bypass the valve.

Mark and type: Purflux LS 468 A.

Engine oil

Quantity:
– Engine XU (8 valves) without the filter	4,5 дм3
– Engine XU (8 valves) with the filter	5,0 дм3
– Engine XU (16 valves) without the filter	5,0 дм3
– Engine XU (16 valves) with the filter	5,3 дм3
Recommended type	SAE 10W/40 or 15W/50, API SF, CCMC G3, Esso Super Oil 10W/40 or Shell Puissance 5 SAE 10W/40

COOLING SYSTEM

The engine is cooled under pressure (0,1 МПа) a mix of water and a special nonfreezing liquid. Into structure of system of cooling enter: a radiator, the pump of a cooling liquid, a broad tank and the fan with the electric motor.

The pump of a cooling liquid

The centrifugal pump of a cooling liquid is established in the block of cylinders of the engine and put in action by a gear belt.

Radiator

The radiator has an aluminium core of a horizontal current.

Mark: Chausson or Valeo.

The thermostat

Temperature of the beginning of opening:
– Engines of 1580 sm3:
• all engines except B2A (XU52C) and BDY (XU5M)	88 ° C
• engines B2A (XU52C) and BDY (XU5M)	82 ° C
– Engines of 1761 sm3	88 ° C
– Engines of 1905 sm3:
• all engines, except D2H (XU92C), D5A (XU92C) and D6D (XU9J2)	88 ° C
• engines D2H (XU92C), D5A (XU92C) and D6D (XU9J2)	82 ° C
– Engines of 1998 sm3:
• engines RFX (XU10J2C) and RFY (XU10J4)	89 ° C
• engine RGZ (XU10J4)	88 ° C
Temperature of full opening:
– Engines of 1580 sm3:
• all engines, except B2A (XU52C), B3B (XU51C) and BDY (XU5M)	100 ° C
• engine B2A (XU52C)	93 ° C
• engine B3B (XU51C)	102 ° C
• engine BDY (XU5M)	94 ° C
– Engines of 1761 sm3	100 ° C
– Engines of 1905 sm3:
• all engines, except D2H (XU92C), D5A (XU92C) and D6D (XU9J2)	100 ° C
• engines D2H (XU92C) and D5A (XU92C)	93 ° C
• engine D6D (XU9J2)	94 ° C
– Engines of 1998 sm3:
• engines RFX (XU10J2C) and RFY (XU10J4)	101 ° C
• engine RGZ (XU10J4)	100 ° C

The fan

The fan is put in action by the electric motor and has two speeds.

Temperature	1 speed	2 speed
Inclusions	90 ° C	94 ° C
Deenergizings	86 ° C	90 ° C

The temperature gauge

Temperature of inclusion of a control bulb: 110 ° C.

Cooling liquid

Quantity	6,6 дм3
Recommended type	Mix of water and nonfreezing liquid in a proportion 1:1 (to-17 °)
Periodicity of replacement of a cooling liquid and washing of a contour of cooling	Each 2 years

THE POWER SUPPLY SYSTEM

Fuel tank

The fuel tank is made of an artificial material and established under a floor before a back axis.

Volume: 70 дм³ (gasoline 98 or неэтилированный gasoline Eurosuper 95).

The fuel pump

Mechanical, диафрагменный the fuel pump is put in action by the clown of a camshaft.

The air filter

Kind	The dry filter
Mark and type	Mann Microtop C 33 156

The carburettor

The two-chamber carburettor has the automatic starting arrangement, pneumatic enrichment at the maximum capacity and blocking of the second chamber at the cold engine.

Mark and type:

 – Engine XU5: Solex 34/34 Z1 a designation 446/460;
 – Engine XU9: Solex 34/34 Z1 a designation 447/462.

Carburettor type	Solex 34/34 Z1 446/460		Solex 34/34 Z1 447/462
	1 chamber	2 chamber	1 chamber	2 chamber
Diameter диффузора (mm)	25	27	26	27
The main fuel jet	1,150	1,275	1,200	1,225
The main air jet	1,450	1,600	1,500	1,600
The main air jet	18	ZC	BZ	ZC
Fuel jet of idling	0,46	0,90	0,45	0,90
Air jet of idling	1,45	1,45	1,45	1,45
The calibrated jet of the enriching device	0,5		0,5
Diameter of a saddle of the needle valve	1,8		1,8
Spray of the accelerating pump	0,35	0,35	0,40	0,40
Opening of 2 chambers	–	9 °	–	9 °
Fuel level in поплавковой to the chamber (mm)	33,5		33,5
Turns of "fast" idling (rpm)	2450 – 2600		2450 – 2600
Turns of idling (rpm)	750 ± 100		750 ± 100
The maintenance FROM (%)	0,8 – 1,5		0,8 – 1,5
The minimum maintenance СО2 (%)	10		10

ONE-DOT SYSTEM OF INJECTION OF FUEL

System type:
– Engine XU5 (BDZ and BDY)	Magneti Marelli G5 the one-dot
– Engine XU5 (BDY)	MagnetiMarelli G6 the one-dot
– Engine XU9 (DDZ)	Solex Fenix IB the one-dot

The fuel pump

Electric type, external (early models) or internal (later models).

Pressure of giving of the pump:
– System of injection Fenix IB, MM G5 and MM G6	0,7 – 0,8 bar
– System of injection Bosch MA3. 0	1,0 ± 0,1 bar
Productivity of the pump:
– System of injection Fenix IB and Bosch MA3	0 – 370 sm3 for 15 seconds
– System of injection MM G5 and G6	360 sm3 for 15 seconds

MULTIDOT SYSTEMS OF INJECTION OF FUEL

System type:
– Engine XU5 (BFZ), XU7 (LFZ), XU10 (RFX), XU10 (R6D)	Magnett Marelli 8P the multidot
– Engine XU5 (BFZ)	Sagern-Lucas 4GJ the multidot
– Engine XU7 (LFZ)	Bosch Motronic MP5. l the multidot
– Engine XU9 (D6A and D6D)	Bosch L3. l-Jetronic the multidot
– Engine XU9 (D6D)	Bosch Motronic MP3. l the multidot
– Engine XU9 (DKZ and DFZ)	Bosch LU2-JETRONIC the multidot
– Engine XU9 (DKZ and DFV), XU9 (DFW with 16 valves)	Bosch Motronic MI. 3 multidot
– Engine XU9 (D6C with 16 valves)	Bosch Motronic ML4. l the multidot
– Engine XU10 (RFY with 16 valves), XUIO (RFT)	Bosch Motronic MP3. 2 multidot

The fuel pump

Electric type, external (early models) or internal (later models).

The pressure created by the fuel pump at specified speed of idling:
– System Bosch L3. l	2,5 bar
– Others Bosch systems	3,0 ± 0,2 bar
– System Magneti Marlli	2,5 ± 0,2 bar
Speed of idling:
– System Boscn L3	925 ± 25 rpm
– Other systems	850 ± 50 rpm

Recommended fuel

Minimum октановое number:
– Engines TU3 (KIA), TU3A (KIG), XU92C (D2D), XU9J2 (DGA), XU9J4 (D6C), XU52C (B2A)	97
– Other models	95

IGNITION SYSTEM

Models with carburettor L3. l-Jetronlc and LU2-JETRONIC	Contactless system of ignition
Other models except XU10J4 with 16 valves	The compound system of ignition operated block ECU
Models XU10J4 (with 16 valves)	The direct system of ignition operated block ECU

The transistor contactless system of ignition has the distributor with the built in gauge of effect of the Hall, and also regulators – centrifugal and vacuum.

The distributor

Mark	Bosch or Ducellier
Designation of characteristics:
– Engine XU5	With 005 and D 020
– Engine XU9	With 053 and D 040
Initial corner of an advancing of ignition:
– Engines XU5 (B2A) and XU9 (D2H) with the carburettor	10 ° before ВМТ at 750 rpm
– Models with system of injection of fuel:
• L3. l-Jetronic	5 ° before ВМТ at 900 rpm
• LU2 - Jetronic	10 ° before ВМТ at 850 rpm
– All other models	Cope block ECU it (is not regulated)
Ignition order	1–3–4–2 (№1 from outside a camshaft drive)

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The prevention

If fuel with low octane number is used, installation of a corner of an advancing of ignition should be reduced on 3 ° on following engines: XU92C (D2D), XU9J2 (D6A), XU9J4 (D6C) and XU52C (B2A).

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Characteristics of an advancing ignitions (engine XU9)

And – a centrifugal regulator, In – a vacuum regulator

During check at the stand (the ignition distributor is removed) values are necessary for reducing by half. During check of the distributor established in the car, it is necessary to add size of an initial corner of an advancing of ignition.

Characteristics of an advancing ignitions (engine XU5)

And – a centrifugal regulator, In – a vacuum regulator

During check at the stand (the ignition distributor is removed) values are necessary for reducing by half. During check of the distributor established in the car, it is necessary to add size of an initial corner of an advancing of ignition.

The ignition coil

Mark	Bosch or Ducellier
Resistance of a winding:
– The primary	0,7 Ohm
– The secondary	6,6 clod

Spark plugs

Spark plugs have конусное consolidation (have no lining).

Mark and type: Champion C7YCX or Eyquem FC 62 LS.

THE TIGHTENING MOMENTS

Engines XU5, XU7 and XU9

Head of the block of cylinders:
– 1 stage	Tightening the moment of 60 Nanometers
– 2 stage	Unscrewing, and then tightening the moment of 20 Nanometers
– 3 stage:
• bolts Torx	Tightening on a corner 300 °
• шестигранные bolts	Tightening on a corner 120 °
Casing of a gear belt	8 Nanometers
Bolt of a pulley of the mechanism of a tension of a gear belt	20 Nanometers
The oil pump	13 Nanometers
Cover of the bearing of the bottom head of a rod:
– 1 stage	Tightening the moment of 40 Nanometers
– 2 stage	Unscrewing, and then tightening the moment of 20 Nanometers
– 3 stage	Tightening on a corner 70 °
Forward consolidation	16 Nanometers
Covers of radical bearings	52,5 Nanometers
Lateral bolts of covers of radical bearings	22 Nanometers
Pulley of a cranked shaft:	120 Nanometers
Flywheel	50 Nanometers
Camshaft pulley	80 Nanometers
Camshaft bearings	15 Nanometers
The oil pallet	20 Nanometers
Cover of a head of the block of cylinders	10 Nanometers
Spark plugs	17,5 Nanometers

Engines XU10

Cover of a head of the block of cylinders	10 Nanometers
Casing of a gear belt	8 Nanometers
Pulley of a cranked shaft	110 Nanometers
The mechanism of a tension of a gear belt	20 Nanometers
Bolts of fastening of a head of the cylinder:
– 1 stage	Tightening the moment of 35 Nanometers
– 2 stage	Tightening the moment of 70 Nanometers
– 3 stage	Tightening on a corner 160 °
The oil pallet	16 Nanometers
The oil pump	13 Nanometers
Cover of the bearing of the bottom head of a rod:
– 1 stage	Tightening the moment of 40 Nanometers
– 2 stage	Unscrewing, and then tightening the moment of 20 Nanometers
– 3 stage	Tightening on a corner 70 °