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303-01D Engine - 1.9L Diesel > < Assembly|Installation|Engine

Galaxy 2000.75 (04.2000-02.2006)

Engine - 2.8L - Specifications Galaxy 2000.75 (04/2000-02/2006)

Engine Data

Description
Engine management Motronic ME 7.1
European emission standard Stage IV
Engine code AYL
Firing order 1 – 5 – 3 – 6 – 2 – 4
Bore (mm) 90.3
Stroke (mm) 81
Cubic capacity (cm 3) 2792
Compression ratio 10.5:1
Power output (EC) kw/PS, at 6200 rpm 150/204
Torque (EC) Nm, at 3400 rpm 265
Idle speed rpm 650 – 750
Number of main bearings 7
Number of camshaft bearings per camshaft 7
Cast mark – cylinder head and cylinder block 2.8
Valve timing DOHC
Valve clearance adjustment Hydraulic tappets
Spark plug AGPS44 F
Electrode gap – spark plugs (mm) 1.1

Engine Oil

Description Viscosity Specification
Recommended engine oils
XR+ High Performance SAE 10W-40 ACEA A3/B3
Formula S SAE 5W-40 ACEA A3/B3
Engine oils (for refills only)
Super Multigrade SAE 15W-40 ACEA A3/B3

Capacities

Litres
Engine oil – initial fill including filter 5.1
Engine oil – oil change including filter change (every 15.000 km) 5.5
Engine oil – oil change without filter change 5.0

Lubricants, Fluids, Sealers and Adhesives

Item Specification
Lubricant - spark plug threads, H02S sensors (Never-seeze) ESE-M1244-A
Sealer, contact faces between cylinder block and oil pan D 176 404 A2
Sealer, contact faces between cylinder block, timing chain upper and lower cover and crankshaft rear oil seal carrier AMV 188 001 02
Lock compound D 000 600 A2

Cylinder Block

Description mm
Cylinder bore diameter, class A 80.03 - 81.09
Main bearing shell inner diameter 59.998 - 60.018
Main bearing clearance 0.02 - 0.06 (max 0.1)
Main bearing parent bore diameter, standard 65.000 - 65.010
Vertical inside diameter, standard 55.003 — 55.030
Vertical inside diameter, 1st undersize 0.05 54.953 — 54.980
Vertical inside diameter, 2nd undersize 0.25 54.753 — 54.780
Vertical inside diameter, 3rd undersize 0.50 54.503 — 54.530
Vertical inside diameter, 4th undersize 0.75 54.253 — 54.280
Main bearing parent bore diameter, standard 59.287 — 59.300
Main bearing parent bore diameter, oversize 0.40 59.687 — 59.700

Crankshaft

Description mm
End float 0.07 - 0.23
Main bearing journal diameter, standard 59.958 - 59.978
Big-end bearing journal diameter, standard 53.958 - 53.978
Thrust half-washer thickness, standard 1.678 - 1.723
Connecting rod end float in relation to crank web 0.05 - 0,31
The crankshaft must not be reground

Connecting Rods

Description mm
Bore diameter, large end 56.800 - 56.891
Bore diameter, small end 20.009 - 20.015
Large end bearing shell inner diameter 53.996 - 54.025
Large end bearing clearance (radial) 0.02 - 0.07
Distance between connecting rod bores, class A 164

Pistons

Description mm
Piston clearance, class A 0.025
Piston pin length 56.800 - 57.000
Piston pin diameter 19.997 - 20.000
Piston pin clearance in piston 0.002 - 0.009
Clearance in connecting rod bore 0.009 - 0.0018
Piston pin type Floating in piston and connecting rods
Piston pin retention Circlips
Piston ring gap (fitted), upper compression ring 0.20 - 0.40
Piston ring gap (fitted), lower compression ring 0.20 - 0.40
Piston ring gap (fitted), oil control ring 0.25 - 050
Piston ring clearance in groove, upper compression ring 0.04 - 0.09
Piston ring clearance in groove, lower compression ring 0.03 - 0.06
Piston ring clearance in groove, oil control ring 0.02 - 0.06

* Piston ring positions - distribute the ring gaps at 120 degrees intervals around the circumference of the piston. This also applies to the elements of the oil control ring.

Cylinder Head

Description mm
Upper correction angle — inlet (production) 30 degrees
Upper correction angle — exhaust (production) 30 degrees
Valve seat angle 45 degrees
Valve seat width, inlet 0.90 – 1.50
Valve seat width, exhaust 1.20 – 1.70
Upper correction angle – inlet (production) 60 degrees
Upper correction angle – exhaust (production) 60 degrees
Maximum permissible distortion - measured longitudi-nally/diagonally across 0.05
Camshaft bearing diameter, Standard 26.000 - 26.021
Valve tappet bore diameter, Standard 35.00 - 35.02

Camshafts

Description mm
Drive Single roller chain
Camshaft end float 0.10
Valve timing, inlet opens after TDC 18.5 degrees
Valve timing, inlet closes after TDC 223.5 degrees
Valve timing, exhaust opens before TDC 211.5 degrees
Valve timing, exhaust closes before TDC 6.5 degrees

Valves

Description mm
Valve length, inlet (short) 102.2
Valve length, inlet (long) 136.1
Valve length, exhaust (short) 102.5
Valve length, exhaust (long) 136.4
Valve head diameter, inlet 31
Valve head diameter, exhaust 27
Valve stem diameter, standard inlet 5.96
Valve stem diameter, standard exhaust 5.94
Valve stem guide clearance, inlet 0.8
Valve stem guide clearance, exhaust 0.8

Lubrication System

Description
Oil pressure at 650 - 750 rpm (at a temperature of 80ºC) 2.0 bar
Oil pressure at 2000 rpm (at a temperature of 80ºC) 3.0 - 5.5 bar
Pressure relief valve open at 5.30 - 5.70 bar
Oil pump, max. backlash 0.20 mm
Oil pump, max. backlash 0.10 mm

Torque Specifications

Description Nm lb-ft lb-in
Valve cover retaining bolts 10 – 89
Fuel line bracket to valve retaining bolts 10 – 89
Fuel rail retaining bolts 8 – 71
Wiring loom bracket 10 – 89
Intake manifold to cylinder head retaining nuts and bolts 13 10 –
Intake manifold to retaining bracket bolts 20 15 –
Intake manifold to retaining bracket bolts 10 – 89
Throttle body retaining bolts 10 – 89
Engine undershield retaining bolts and nuts 10 – 89
Exhaust manifold bolts 13 10 –
Exhaust manifold bolts 30 22 –
Exhaust heat shield retaining bolts 10 – 89
Exhaust downpipe to exhaust manifold bolts 40 30 –
Exhaust downpipe to catalytic converter bolts 25 18 –
Generator retaining bolts 23 17 –
Generator bracket retaining bolts 23 17 –
Transaxle retaining bolts 44 32 –
Transaxle retaining bolts 80 59 –
Driveshaft center bearing carrier retaining bolts 40 30 –
Driveshaft center bearing carrier bracket retaining bolts 45 33 –
Left-hand halfshaft to transaxle output drive shaft bolts 80 59 –
Right-hand halfshaft to center bearing carrier bolts 80 59 –
Air conditioning compressor retaining bolts 45 33 –
Water pump retaining bolts 20 15 –
Thermostat housing retaining bolts 8 – 71
Power steering pump retaining bolts 23 17 –
Power steering pump pulley retaining bolts 23 17 –
Accessory drive belt tensioner retaining bolts 23 17 –
Secondary air injection pump retaining bolts 10 – 89
Secondary air injection pump to retaining bracket bolts 10 – 89
Secondary air injection valve to cylinder head bolts 9 – 80
Left-hand air conditioning line support bracket bolts 43 32 –
Left-hand air conditioning line to support bracket bolts 8 – 71
Right-hand air conditioning line to cylinder block 35 26 –
Engine support insulator retaining bolts 100 74 –
Engine front mounting bracket to hydraulic engine mounting bolts 54 40 –
Engine front mounting bracket to engine support plate bolts 61 45 –
Engine support plate to engine bolts 58 43 –
Engine rear mounting to body bolts 25 18 –
Engine rear mounting to transaxle a – –
Oil pan retaining bolts 12 9 –
Oil drain plug 30 22 –
Oil filter housing retaining bolts 23 17 –
Oil pump pickup tube retaining bolts 8 – 71
Oil pump retaining bolts 23 17 –
Oil level indicator and tuberetaining bolts 8 – 71
Main bearing caps bolts a – –
Connecting rod bearing cap bolts a – –
Crankshaft position (CKP) sensor retaining bolts 10 – 89
Timing chain lower cover retaining bolts (6 mm) 8 – 71
Timing chain lower cover retaining bolts (8 mm) 23 17 –
Timing chain upper cover retaining bolts (6 mm) 8 – 71
Timing chain upper cover retaining bolts (8 mm) 23 17 –
Timing chain upper guide retaining bolts 23 17 –
Timing chain upper tensioner retaining bolts 40 30 –
Timing chain lower tensioner retaining bolts 8 – 71
Intermediate sprocket bolt a – –
Flywheel a – –
Cylinder head bolts a – –
Camshaft bearing cap bolts a – –
Camshaft swivelling adjuster retaining bolts a – –
Camshaft control housing retaining bolts 8 – 71
Battery tray retaining bolts 20 15 –
Battery side cover retaining bolts 10 – 89
Spark plugs 25 18 –

a) Refer to procedure in this section.

303-01D Engine - 1.9L Diesel > < Assembly|Installation|Engine