General Data

• Engine Type

4-Cylinder Inline

• Number of Valves

16

• Displacement

1.796 l

63 cu ft

• Bore

80.5 mm

3.2 in

• Bore distance

86 mm

3.4 in

• Stroke

88.2 mm

3.5 in

• Compression Ratio

10.5

• Maximum Power @ engine speed kW/RPM

103 KW / 6300

• Maximum Torque @ engine speed Nm/RPM / lbf ft/RPM

175 Nm / 3800

129 lbf ft /3800

• Idle Speed

780-1000

Overspeed RPM

6500

• Firing Order

1-3-4-2

Block

• Cylinder block height

198.5 mm

8 in

• Cylinder Bore Diameter -- Standard Size Guiding Value 00

80.492-80.508 mm

3.169-3.1694 in

• Cylinder Bore Diameter -- Standard Size Guiding Value 05

80.542-80.558 mm

3.171-3.1716 in

• Cylinder Bore Diameter -- Oversize Guiding Value 00+05

80.992-81.008 mm

3.188-3.1893

• Compression height

25,4 mm

1 in

• Connecting Rod length

129.75 mm

5.1 in

Crankshaft

• Crankshaft Main Bearing Journal 1-5 Diameter -- Standard Size (brown/green)

54.800-54.997 mm

2.158-2.166 in

• Crankshaft Main Bearing Journal 1-5 Diameter -- Undersize 0.25 (brown/green)

54.730-54.747 mm

2.155-2.156 in

• Crankshaft Main Bearing Journal 1-5 Diameter -- Undersize 0.50 (brown/green)

54.482-54.495 mm

2.145-2.146 in

• Crankshaft Main Bearing Journal 3 Width -- Standard Size

26.000-26.052 mm

1.024-1.026 in

• Crankshaft Main Bearing Journal 3 Width -- Undersize 0.25

26.200-26.252 mm

1.032-1.034 in

• Crankshaft Main Bearing Journal 3 Width -- Undersize 0.50

26.400-26.452 mm

1.040-1.042 in

• Con-Rod Bearing Journal -- Standard Size

42.971-42.987 mm

1.692-1.693 in

• Con-Rod Bearing Journal -- Undersize 0.25 (blue)

42.721-42.737 mm

1.682-1.683 in

• Con-Rod Bearing Journal -- Undersize 0.50 (white)

42.471-42.487 mm

1.672-1.673 in

• Crankshaft Main Bearing 1-5 -- Bearing Shell Thickness -- Standard Size (brown)

1.987-1.993 mm

0.0783-0.0785 in

• Crankshaft Main Bearing 1-5 -- Bearing Shell Thickness -- Standard Size (green)

1.993-1.999 mm

0.0785-0.0787 in

• Crankshaft Main Bearing 1-5 -- Bearing Shell Thickness -- Undersize 0.25 (brown/blue)

2.112-2.118 mm

0.0832-0.0834 in

• Crankshaft Main Bearing 1-5 -- Bearing Shell Thickness -- Undersize 0.25 (green/blue)

2.118-2.124 mm

0.0834-0.0836 in

• Crankshaft Main Bearing 1-5 -- Bearing Shell Thickness -- Undersize 0.50 (brown/blue)

2.237-2.243 mm

0.0842-0.0844 in

• Crankshaft Main Bearing 1-5 -- Bearing Shell Thickness -- Undersize 0.50 (green/blue)

2.243-2.249 mm

0.0884-0.0886 in

• Crankshaft Bearing Allowable Clearance

0.005-0.059 mm

0.0002-0.0024 in

• Crankshaft Bearing Allowable End Clearance

0.100-0.202 mm

0.004-0.008 in

• Crankshaft Main Bearing 3 Width -- Standard Size

25.85-25.90 mm

1.018-1.020

• Crankshaft Main Bearing 3 Width -- Undersize 0.25

26.05-26.10 mm

1.026-1.028 in

• Crankshaft Main Bearing 3 Width -- Undersize 0.50

26.25-26.30 mm

1.034-1.036 in

• Con-Rod Bearing Shell Thickness -- Standard Size

1.485-1.497 mm

0.0585-0.0590 in

• Con-Rod Bearing Shell Thickness -- Undersize 0.25

1.610-1.622 mm

0.0634-0.0639

• Con-Rod Bearing Shell Thickness -- Undersize 0.50

1.735-1.747 mm

0.0684-0.0688

• Con-Rod Bearing Allowable Clearance

0.019-0.071 mm

0.0007-0.0028 in

Camshaft

• Cam Stroke Intake

9.3 mm

0.367 in

• Cam Stroke Exhaust

8.3 mm

0.327 in

Cylinder Head

• Surface Flatness -- Block Deck -- Longitude

If the deck surface is out of specification, replace the cylinder head. Do not machine the cylinder head.

• Surface Flatness -- Block Deck -- Overall

If the deck surface is out of specification, replace the cylinder head. Do not machine the cylinder head.

• Surface Flatness -- Block Deck -- Transverse

If the deck surface is out of specification, replace the cylinder head. Do not machine the cylinder head.

• Valve Seat Width -- Intake

1.0-1.4 mm

0.040-0.056 in

• Valve Seat Width -- Exhaust

1.4-1.8 mm

0.056-0.071 in

• Valve Seat Angle

90°-30'

• Valve Seat Angle Adjustment -- Upper

60°+/-1°

• Valve Seat Angle Adjustment -- Lower

120°+/-1°

• Valve Guide Bore Norm Size

5.000-5.016 mm

0.1969-0.1975 in

• Valve Guide Bore Oversize 0.075

5.075-5.091 mm

0.1999-0.2005 in

• Valve Guide Bore Oversize 0.150

5.150-5.166 mm

0.2028-0.2034 in

• Valve Guide Assembly Height

10.70-11.00 mm

0.422-0.434 in

• Valve Guide Longitude

36.70-37.00 mm

1.445-1.457 in

• Valve Assembly Height -- Intake

47.75 mm

1.880 in

• Valve Assembly Height -- Exhaust

47.73 mm

1.880 in

Engine Oil

Viscosity

SAE 0-W30, 0-W40, 5-W30 and 5-W40

Quality

ACEA A3 / B3, GM-LL-A-025

Oil Pump Design

Eaton Pump

Quantity

• Oil change incl. Filter

4.5 l

4.76 quarts

Pistons and Pins

• Piston Diameter -- Standard Size Guiding Value 00

80.455-80.465 mm

3.1676-3.1680 in

• Piston Diameter -- Standard Size Guiding Value 00

80-505-80.51 mm

3.1695-3.1697 in

• Piston Diameter -- Oversize Guiding Value 00+05

80.955-80.965 mm

3.1872-3.1876 in

• Piston Clearance

0.027-0.053 mm

0.0011-0.0021 in

• Pin Diameter

19 mm

0.785 in

• Pin Longitude

49.84 mm

1.97 in

• Pin to Piston Clearance

0.020-0.060 mm

0.0008-0.0024 in

• Pin to Con-Rod Clearance

0.015-0.021 mm

0.0006-0.0009 in

Piston Rings

• Piston Ring Thickness -- First Compression Ring

1.170-1.190 mm

0.0461-0.0469 in

• Piston Ring Thickness -- Second Compression Ring

1.170-1.190 mm

0.0461-0.0469 in

• Piston Ring Thickness -- Oil Control Ring

1.900-1.980 mm

0.0749-0.0780 in

• Piston Ring End Gap -- First Compression Ring

0.20-0.40 mm

0.0079-0.158 in

• Piston Ring End Gap -- Second Compression Ring

0.40-0.60 mm

0.0158-0.0237 in

• Piston Ring End Gap -- Oil Control Ring

0.25-0.75 mm

0.010-0.030 in

• Piston Ring to Groove Clearance -- First Compression Ring

0.040-0.080 mm

0.0016-0.032 in

• Piston Ring to groove Clearance -- Second Compression Ring

0.030-0.070 mm

0.0012-0.0028 in

• Piston Ring to Groove Clearance -- Oil Control Ring

0.030-0.130 mm

0.0012-0.006

Valve System

• Valves Norm Longitude -- Intake

113.60-114.00 mm

4.473-4.489 in

• Valves Norm Longitude -- Exhaust

112.96-113,36 mm

4.448-4.449 in

• Valves Oversize Longitude 0.075 -- Intake

113.60-114.00 mm

4.473-4.489 in

• Valves Oversize Longitude 0.075 -- Exhaust

112.96-113,36 mm

4.448-4.449 in

• Valves Oversize Longitude 0.150 -- Intake

113.60-114.00 mm

4.473-4.489 in

• Valves Oversize Longitude 0.150 -- Exhaust

112.96-113,36 mm

4.448-4.463 in

• Valves -- Valve Stem Norm Diameter -- Intake

4.965-4.980 mm

0.1955-0.1961 in

• Valves -- Valve Stem Norm Diameter -- Exhaust

4.950-4.965 mm

0.1949-0.1955 in

• Valves -- Valve Stem Oversize Diameter 0.075 -- Intake

5.040-5.055 mm

0.1985-0.1991

• Valves -- Valve Stem Oversize Diameter 0.075 -- Exhaust

5.025-5.050 mm

0.1979-0.1989

• Valves -- Valve Stem Oversize Diameter 0.150 -- Intake

5.115-5.130 mm

0.2014-0.2020 in

• Valves -- Valve Stem Oversize Diameter 0.150 -- Exhaust

5.100-5.115 mm

0.2008-0.2014

• Valves -- Valve Stem to Guide Clearance -- Intake

0.020-0.051 mm

0.0008-0.0021 in

• Valves -- Valve Stem to Guide Clearance -- Exhaust

0.035-0.066 mm

0.0014-0.0026 in

• Valves -- Valve Stem allowable Run-Out

0.03 mm

0.0012 in

• Valves -- Valve Disk Diameter -- Intake

31.1-31.3 mm

1.225-1.233 in

• Valves -- Valve Disk Diameter -- Exhaust

27.4-27.6 mm

1.079-1.087 in

• Valves -- Valve Seat Angle on Valve Disk

90°40'+/-15'

• Valves -- Valve Clearance Cold -- Intake

0.20-0.30 mm

0.0079-0.0120 in

• Valves -- Valve Clearance Cold -- Exhaust

0.24-0.36 mm

0.0095-0.0142

• Valve Springs Longitude

41.6 mm

1.64 in

• Valve Springs Longitude under Load -- open

35.0 mm

1.38 in

• Valve Springs Longitude under Load -- close

25.5 mm

1.01 in

Cooling System

Coolant Specification

GM Long-Life Coolant -- Specification B040 1065

Water Pump Design

Rotary Pump

Cooling System Capacity

6,1 l without A/C

6,3 l with A/C

6.45 quarts without A/C

6.66 quarts with A/C

Flow (engine outlet 6000 min ^-1 , Thermostat fully open)

160 l/min

42.27 US gal/min

Thermostat

Thermostat Opening -- electrical

90°C

194°F

Thermostat Opening -- thermic

105°C

221°F

General Data

• Engine Type

4-Cylinder Inline

• Displacement

1.598 l

57 cu ft

• Bore

79 mm

3.1 in

• Bore distance

86 mm

33.859 in

• Stroke

81.5 mm

3.2 in

• Compression Ratio

10.8

• Maximum Power @ engine speed kW/RPM

85 KW / 6000

• Maximum Torque @ engine speed Nm/RPM / lbf ft/RPM

155 Nm / 4000

114 lbf ft / 4000

• Firing Order

1-3-4-2

Block

• Cylinder block height

198.5 mm

8 in

• Cylinder Bore Diameter

79 mm

3.1 in

• Compression height

27,2 mm

1 in

• Connecting Rod length

129.75 mm

5,1 in

Crankshaft

Cylinder Head

• Surface Flatness -- Block Deck -- Longitude

If the deck surface is out of specification, replace the cylinder head. Do not machine the cylinder head.

• Surface Flatness -- Block Deck -- Overall

If the deck surface is out of specification, replace the cylinder head. Do not machine the cylinder head.

• Surface Flatness -- Block Deck -- Transverse

If the deck surface is out of specification, replace the cylinder head. Do not machine the cylinder head.

• Valve Seat Width -- Intake

1.000-1.400 mm

0.394-0.552 in

• Valve Seat Width -- Exhaust

1.400-1.800 mm

0.552-0.709 in

• Valve Seat Angle

90°-30'

• Valve Seat Angle Adjustment -- Upper

60°+/- 1°

• Valve Seat Angle Adjustment -- Lower

120°+/-1°

• Valve Guide Bore Standard Size

5.000-5.016 mm

1.969-1.975 in

• Valve Guide Bore Oversize 0.075

5.075-5.091 mm

1.999-2.005 in

• Valve Guide Bore Oversize 0.150

5.150-5.166 mm

2.028-2.034 in

• Valve Guide Assembly Height

36.700-37.000 mm

1.445-1.457 in

• Valve Guide Longitude

10.700-11.000 mm

4.213-4.331 in

Engine Oil

Viscosity

SAE 0-W30, 0-W40, 5-W30 and 5-W40

Quality

GM-LL-A-025

Quantity

• Oil change incl. Filter

4.5 l

4.75 quarts

Oil consumption Liter/1 000 km (US gallon/621.371 miles)

(5 000 km up to 100 000 km 3106.856 miles up to 62137.12 miles)

max. 0.6 l

max. 0.634 quarts

Pistons and Pins

• Pin Outside Diameter

51.00 mm

20.079 in

Valve System

• Valves Standard Longitude -- Intake

117.000-117.400 mm

46.063-46.221 in

• Valves Standard Longitude -- Exhaust

116.160-116.360 mm

45.733-45.812 in

• Valves Oversize Longitude 0.075 -- Intake

117.000-117.400 mm

46.063-46.221 in

• Valves Oversize Longitude 0.075 -- Exhaust

116.160-116.360 mm

45.733-45.812 in

• Valves Oversize Longitude 0.150 -- Intake

117.000-117.400 mm

46.063-46.221 in

• Valves Oversize Longitude 0.150 -- Exhaust

116.106-116.360 mm

45.733-45.812 in

• Valves -- Valve Stem Standard Diameter -- Intake

4.965-4.980 mm

1.956-1.962 in

• Valves -- Valve Stem Standard Diameter -- Exhaust

4.950-4.965 mm

1.950-1.956 in

• Valves -- Valve Stem Oversize Diameter 0.075 -- Intake

5.030-5.045 mm

1.982-1.988 in

• Valves -- Valve Stem Oversize Diameter 0.075 -- Exhaust

5.025-5.040 mm

1.980-1.986 in

• Valves -- Valve Stem Oversize Diameter 0.150 -- Intake

5.105-5.120 mm

2.011-2.017 in

• Valves -- Valve Stem Oversize Diameter 0.150 -- Exhaust

5.100-5.115 mm

2.009-2.018 in

• Valves -- Valve Stem to Guide Clearance -- Intake

0.020-0.051 mm

0.009-0.022 in

• Valves -- Valve Stem to Guide Clearance -- Exhaust

0.035-0.066 mm

0.015-0.027 in

• Valves -- Valve Disk Diameter -- Intake

31.100-31.300 mm

12.246-12.324 in

• Valves -- Valve Disk Diameter -- Exhaust

27.400-27.600 mm

10.789-10.868 in

• Valves -- Valve Clearance Cold -- Intake

0.210-0.290 mm

0.084-.0116 in

• Valves -- Valve Clearance Cold -- Exhaust

0.260-0.340 mm

0.104-0.135 in

• Valve Springs Longitude

41.000 mm

1.616 in

• Valve Springs Longitude under Load -- open

35.000 mm

1.379 in

• Valve Springs Longitude under Load -- close

25.500 mm

1.005 in

Cooling System

Coolant Specification

GM Long-Life Coolant -- Specification B040 1065

Water Pump Design

Rotary Pump   

Flow (engine outlet 6000 min ^-1 , Thermostat fully open)

165 l/min

43.588 US gal

Thermostat

Thermostat Opening -- electrical

90°C

194°F

Thermostat Opening -- thermic

105°C

221°F

General Data

• Engine Type

4-Cylinder Inline

• Displacement

1.598 l

57 cu ft

• Bore

79 mm

3.1 in

• Bore distance

86 mm

3.3859 in

• Stroke

81.5 mm

3.2 in

• Compression Ratio

8.8

• Maximum Power @ engine speed kW/RPM

132 kW / 5500

• Maximum Torque @ engine speed Nm/RPM / lbf ft/RPM

230 Nm / 2200

167 lbf ft / 2200

• Firing Order

1-3-4-2

Block

• Cylinder block height

198.5 mm

8 in

• Cylinder Bore Diameter

79 mm

3.1 in

• Compression height

27.2 mm

1 in

• Conrod length

129.75 mm

5.1 in

• Surface Flatness -- Block Deck -- Longitude

If the deck surface is out of specification, replace the cylinder head. Do not machine the cylinder head.

• Surface Flatness -- Block Deck -- Overall

Do not machine the cylinder head.

• Surface Flatness -- Block Deck -- Transverse

If the deck surface is out of specification, replace the cylinder head. Do not machine the cylinder head.

• Valve Seat Width -- Intake

1.000-1.400 mm

0.039-0.055 in

• Valve Seat Width -- Exhaust

1.400-1.800 mm

0.055-0.070 in

• Valve Seat Angle

90°-30'

• Valve Seat Angle Adjustment -- Upper

60°+/- 1°

• Valve Seat Angle Adjustment -- Lower

120°+/-1°

• Valve Guide Bore Standard Size

5.000-5.016 mm

1.969-1.975 in

• Valve Guide Bore Oversize 0.075

5.075-5.091 mm

1.999-2.005 in

• Valve Guide Bore Oversize 0.150

5.150-5.166 mm

2.028-2.034 in

• Valve Guide Assembly Height

36.700-37.000 mm

1.445-1.457 in

• Valve Guide Longitude

10.700-11.000 mm

4.213-4.331 in

Engine Oil

Viscosity

SAE 0-W30, 0-W40, 5-W30 and 5-W40

Quality

GM-LL-A-025

Quantity

• Oil change incl. Filter

4.5 l

4.75 quarts

Oil consumption Liter/1 000 km (US gallon/621.371 miles)

(5 000 km up to 100 000 km 3106.856 miles up to 62137.12 miles)

max. 0.6 l

max. 0.634 quarts

Pistons and Pins

• Pin Outside Diameter

51.00 mm

20.079 in

Valve System

• Valves Standard Longitude -- Intake

117.000-117.400 mm

46.063-46.221 in

• Valves Standard Longitude -- Exhaust

116.160-116.360 mm

45.733-45.812 in

• Valves Oversize Longitude 0.075 -- Intake

117.000-117.400 mm

46.063-46.221 in

• Valves Oversize Longitude 0.075 -- Exhaust

116.160-116.360 mm

45.733-45.812 in

• Valves Oversize Longitude 0.150 -- Intake

117.000-117.400 mm

46.063-46.221 in

• Valves Oversize Longitude 0.150 -- Exhaust

116.106-116.360 mm

45.733-45.812 in

• Valves -- Valve Stem Standard Diameter -- Intake

4.965-4.980 mm

1.956-1.962 in

• Valves -- Valve Stem Standard Diameter -- Exhaust

4.950-4.965 mm

1.950-1.956 in

• Valves -- Valve Stem Oversize Diameter 0.075 -- Intake

5.030-5.045 mm

1.982-1.988 in

• Valves -- Valve Stem Oversize Diameter 0.075 -- Exhaust

5.025-5.040 mm

1.980-1.986 in

• Valves -- Valve Stem Oversize Diameter 0.150 -- Intake

5.105-5.120 mm

2.011-2.017 in

• Valves -- Valve Stem Oversize Diameter 0.150 -- Exhaust

5.100-5.115 mm

2.009-2.018 in

• Valves -- Valve Stem to Guide Clearance -- Intake

0.25-0.040 mm

0.009-0.0015 in

• Valves -- Valve Stem to Guide Clearance -- Exhaust

0.3-0.04 mm

0.012-0.0015 in

• Valves -- Valve Disk Diameter -- Intake

31.100-31.300 mm

12.246-12.324 in

• Valves -- Valve Disk Diameter -- Exhaust

27.400-27.600 mm

10.789-10.868 in

• Valves -- Valve Clearance Cold -- Intake

0.210-0.290 mm

0.084-.0116 in

• Valves -- Valve Clearance Cold -- Exhaust

0.260-0.340 mm

0.104-0.135 in

• Valve Springs Longitude

41.000 mm

1.616 in

• Valve Springs Longitude under Load 175 - 195N (40-44 lbf) -- open

35.000 mm

1.379 in

• Valve Springs Longitude under Load 427-473N (96-107) -- close

25.500 mm

1.005 in

Cooling System

Water Pump Design

Rotary Pump

Flow (engine outlet 6000 min ^-1 , Thermostat fully open)

165 l/min

43.588 US gal

Thermostat

Thermostat Opening - electrical

90°C

194°F

Thermostat Opening - thermic

105°C

221°F