Type - In-line, 4-cylinder with overhead camshafts
Displacement, cm³
- 2.0 (G4KD) - 1998
- 2.4 (G4KE) - 2359
Cylinder diameter, mm
- 2.0 (G4KD) - 86
- 2.4 (G4KE) - 88
Piston stroke, mm
- 2.0 (G4KD) - 86
- 2.4 (G4KE) - 97
Compression ratio – 10.5
Cylinder firing order – 1–3–4–2
Idle speed, min¹ – 800±100
Ignition advance angle at idle, ° BTDC – 5±2
Technical data
Name - Nominal values
Valve timing
Intake valve:
- Opening (after TDC), ° 7 ~ 38
- Closing (after BDC), ° 67 ~ 22
Exhaust valve:
- Opening (before BDC), ° 44 ~ 4
- Closing (after TDC), ° 0 ~ 40
Valve length, mm
- – Intake valve 113.18 Maximum allowable 112.93
- – Exhaust valve 105.84 Maximum allowable 105.59
Valve stem diameter, mm
- – intake valve 5.465 ~ 5.480
- – exhaust valve 5.458 ~ 5.470
Working chamfer angle 45.25° ~ 45.75°
Valve head working chamfer thickness, mm:
- Intake 1.02
- Exhaust 1.09
Valve to guide clearance, mm:
- Intake 0.020 ~ 0.047 tolerance 0.07
- Exhaust 0.030 ~ 0.054 tolerance 0.09
Valve guide:
Length, mm
- Intake 43.8 ~ 44.2
- Outlet 52.8 ~ 53.2
Valve seat
Contact surface thickness, mm:
- Intake 1.16 ~ 1.46
- Outlet 1.35 ~ 1.65
Valve seat working surface angle 44.75° ~ 45.10°
Valve springs
Length in free state, mm 47.44
Length under load, mm:
- 19.0±0.6 kg/35.0
- 39.8±1.2 kg/26.0
Deviation from vertical axis 1.5° or less
Valve clearance with cold engine (20°C), mm:
- Intake 0.17 ~ 0.23 with tolerance 0.10 ~ 0.30
- Exhaust 0.27 ~ 0.33 with tolerance 0.20 ~ 0.40
Cylinder head
- – deviation from flatness of mating surface, mm max. 0.05
- – deviation from flatness of the manifold mating surface, mm max. 0.10
Cylinder diameter, mm:
- 2.0 (G4KD) – 86.00 ~ 86.03
- 2.4 (G4KE) – 88.00 ~ 88.03
Deviation from the shape of a circle and taper of the cylinder, mm less than 0.05
Deviation from the flatness of the mating surface of the cylinder block, mm 0.05
Piston diameter, mm:
- 2.0 (G4KD) – 85.975 ~ 86.0050
- 2.4 (G4KE) – 87.975 ~ 88.005
Piston to cylinder clearance, mm 0.015 ~ 0.035
Piston rings
Ring groove width, mm:
- Compression No. 1 1.235 ~ 1.250 tolerance 1.26
- Compression No. 2 1.230 ~ 1.250 tolerance 1.26
Oil scraper ring groove width, mm 2.01 ~ 2.03 tolerance 2.05
Side clearance, mm:
- Compression No. 1 0.05 ~ 0.08 tolerance 0.1
- Compression No. 2 0.04 ~ 0.08 tolerance 0.1
Side clearance of oil scraper ring, mm 0.06 ~ 0.13 tolerance 0.2
Gap in the lock, mm:
- Compression No. 1 0.15 ~ 0.30 tolerance 0.6
- Compression No. 2 0.30 ~ 0.52 tolerance 0.7
Gap of oil scraper ring, mm 0.20 ~ 0.70 tolerance 0.8
Piston pin
Permissible bending, mm: 0.05 or less
Permissible twist, mm: 0.1 or less
Clearance between connecting rod and crankshaft side surface, mm: 0.100 ~ 0.250 tolerance 0.35
Connecting rod bearing shells
Bearing clearance, mm: 0.025 ~ 0.043 tolerance 0.05
Camshaft
Cam lobe height, mm:
- Intake 44.20 tolerance 44.518
- Exhaust 45.00 tolerance 44.418
Outer diameter of shaft journal, mm:
Intake No. 1: 30/24
Outlet #2, 3, 4, 5: 36/24
Bearing oil clearance:
- Inlet #1: 0.022 ~ 0.057 tolerance 0.09
- Outlet #2, 3, 4, 5: 0 ~ 0.032/0.045 ~ 0.082 tolerance 0.12
Axial clearance, mm: 0.04 ~ 0.16 tolerance 0.20
Crankshaft
Connecting rod journal diameter, mm: 47.954 ~ 47.972
Main journal diameter, mm: 51.942 ~ 51.960
Axial clearance, mm: 0.07 ~ 0.25
Crankshaft bearing shells
Bearing oil clearance, mm 0.020 ~ 0.038
Cooling system
Forced water cooling
Thermostat with dry filler of the thermoelement:
- Opening start temperature 82° C
- Full opening temperature 95° C
Centrifugal water pump
Coolant temperature sensor
Type – heated resistor
Resistance, kOhm 2.31 ~ 2.59 at 20° C
Air filter
- – dry type
- – non-woven fabric element
Resonant expansion muffler type
Rubber muffler suspension system
Threaded connection tightening torques, Nm
- Engine mount mounting bolts (12x15 mm) 90–110
- Engine mount bracket fastening nuts 60–80
- Engine mount bracket fastening bolts (12x60 mm) 60–80
- Front bracket stopper fastening bolts to engine subframe 60–80
- Front stopper support fastening bolts and nuts (10x85 mm) 50–65
- Front stopper support fastening bolts to gearbox 60–80
- Rear stopper support fastening bolts to engine subframe 50–65
- Rear stopper support fastening bolts and nuts 50–65
- Rear stopper support bracket fastening bolts to gearbox 60–80
- Gearbox fastening nuts to additional bracket 60–80
- Gearbox to bracket mounting bolts 60–80
- Gearbox to support mounting bolts (12x115 mm) 90–110
- Air conditioning compressor mounting bolts to bracket 23–27
- Power steering oil pump to bracket 35–45
- Front exhaust pipe to exhaust manifold 30–40
- Cylinder head cover mounting bolts 8–10
- Center cover mounting bolt 4–5
- Camshaft pulley mounting bolt 80–100
- Camshaft bearing cap mounting bolts 19–21
- Rotation angle sensor 10–13
- Throttle body support 15–22
- Air filter housing mounting bolt 8–10
- Crankshaft pulley mounting bolt 110–130
- Drive belt pulley to crankshaft pulley mounting bolt 20–30
Cylinder head mounting bolts (cold engine)
With bolt replacement 64+20+ (90°–94°) + (90°–94°);
Without bolt replacement 20+ (90°–94°) + (90°–94°)
Intake manifold support 18–25
Bracket mounting bolt 23–37
Automatic tensioner mounting bolt 20–27
Tensioner mounting bolt 45–55
Idle pulley mounting bolt 45–55
Front exhaust pipe mounting clamp bolt 20–30
Oil pan 10–12
Oil pan drain plug 35–45
Oil filter 15–22
Oil pump pulley mounting nuts 50–60
Oil pressure sensor 8–12
Oil filter bracket mounting bolt 20–27
Oil pump cover mounting bolt 15–18
Oil Seal Housing Fastening Bolt 10–12
Spark Plugs 20–27
Front Housing Fastening Bolt (M6) 20–27
Driven Gear Fastening Bolt 34–40
Water Pump Pulley Fastening Bolt 8–10
Upper Timing Belt Cover 8–10
Lower Timing Belt Cover 8–10
Flywheel 130–140
Drive Plate 130–140
Right Rear Timing Belt Cover 10–12
Bolts Fastening Left Rear Timing Belt Cover to Bracket 30–42
Upper left rear timing belt cover 10–12
Connecting rod cap mounting bolts 18–22+(90°–94°)
Main bearing cap mounting bolts 20+(90°–94°)
Engine lifting hooks
- М8 25–30
- М10 35–55
Generator base mounting bolt 20–25
Generator support mounting bolt 12–15
Water pump to cylinder block (bolt marked "7") 15–22
Coolant temperature sensor 10–12
Coolant temperature sensor 20–40
Coolant outlet fitting mounting bolts 10–15
Air filter mounting bolts 8–10
Resonator mounting bolt 8–10
Resonator mounting nut 8–10
Line mounting bolt to engine 10–13
Accelerator cable mounting bolts to intake manifold 4–6
Throttle assembly mounting bolts to intake manifold 15–22
Intake manifold support mounting bolts 18–22
M8 intake manifold mounting bolt 15–20
Nuts and Intake Manifold Mounting Bolts 30–42
Rod Mounting Bolts to Bracket 35–55
Ignition Coil Mounting Bolts 8–12
Power Switch Mounting Bolts 10–12
EGR Valve Mounting Bolts 17–26
EGR Temperature Sensor (California) 10–12
Front Exhaust Pipe Mounting Nuts to Exhaust Manifold 30–40
Front Exhaust Pipe Mounting Bolts to Engine 20–30
Center Exhaust Pipe Mounting Nuts to Catalytic Converter 20–30
Center Exhaust Pipe Mounting Bolts to Main Muffler 30–40
Center Exhaust Pipe Mounting Bolts to bracket 10–15
Rear mounting bolts rubber suspension to the body
- M8 25–30
- M10 35–55
Bolt for fastening rubber suspension to the main muffler 10–15
Nuts for fastening exhaust manifold to engine 25–30
Oxygen sensor 40–50
Bolt for fastening protective screen to exhaust manifold 12–15