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4.4. Diesel engines 16D and 16DA

Engine type
The four-cylinder, four-cycle engine, with one camshaft of the top arrangement, not direct injection and compression ignition
Marking:
  – till 1985
16D
  – since 1986
16DA
Diameter of the cylinder
80,00 mm
Piston stroke
79,50 mm
Volume
1598 cm3
Sequence of operation of cylinders
1–3–4–2 (the cylinder No. 1 is located from a pulley)
Extent of compression
23: 1
Maximum torque:
  – 16D
96 Nanometer at 2400 rpm
  – 16DA
95 Nanometer at 2400 rpm

Gear belt

Belt tension (it is measured by means of the KM-510-A tool):
  – the new belt, the engine is warmed
9,0
  – new belt, engine cold
6,5
  – the used belt, the engine is warmed
8,0
  – the used belt, the engine cold
4,0

Head of the block of cylinders

Determination of thickness of laying:
  – a piston ledge to 0,75 mm:
     • thickness
1,3 mm
     • marking
No
  – ledge of the piston of 0,75 - 0,85 mm:
     • thickness
1,4 mm
     • marking
One cut
  – piston ledge over 0,85 mm:
     • thickness
1,5 mm
     • marking
Two cuts
Adjustment of gaps of valves
It is carried out by automatically hydraulic pushers
Valve saddle width in a head of cylinders:
  – inlet
1,3 – 2,0 mm
  – final
1,3 – 2,6 mm
Valve core side play in the directing plug:
  – inlet valve
0,015 – 0,047 mm
  – final valve
0,030 – 0,062 mm
Deepening of a head of the valve
0,25 – 0,75 mm
Ledge of the vortex camera
0,00 – 0,04 mm
Grinding of the interfaced surface
At most 0,025 mm
Height of a head of the block of cylinders:
  – maximum
106,10 mm
  – minimum
105,75 mm
Not planeness of the interfaced surfaces
At most 0,15 mm

Valves

Valve length
123,25 mm
Diameter of a plate of the valve:
  – inlet
36 mm
  – final
32 mm
Diameter of a core of the valve (nominal):
  – inlet
7,970 – 7,985 mm
  – final
7,955 – 7,970 mm
Internal diameter of the directing valve plug (nominal)
8,000 – 8,017 mm
Diameter of a core of the valve after boring of the plug:
  – marking 1
+0,075 mm
  – marking 2
+0,150 mm
  – marking And (the inlet valve) or To (the final valve)
+0,250 mm
Valve facet corner in a head of cylinders
44 °

Camshaft and bearings

Diameter of a neck of the bearing (nominal):
  – No. 1
42,455 – 42,470 mm
  – No. 2
42,705 – 42,720 mm
  – No. 3
42,955 – 42,970 mm
  – No. 4
43,205 – 43,220 mm
  – No. 5
43,455 – 43,470 mm
Diameter of the bearing (nominal):
  – No. 1
42,500 – 42,525 mm
  – No. 2
42,750 – 42,775 mm
  – No. 3
43,000 – 43,025 mm
  – No. 4
43,250 – 43,275 mm
  – No. 5
43,500 – 43,525 mm
Diameters of necks and bearings after processing
- 0,1 mm
Marking of the camshaft:
  – alphabetic
In
  – color – a standard shaft
no
  – color – after processing
violet
Radial beating
At most 0,03 mm
Axial side play
0,04 – 0,14 mm
Height of raising of cams (inlet and final valves)
6,12 mm
Ovality and conicity of the cylinder
0,013 mm at most

Cylinders

Cylinder
Diameter (± 0,005 mm)
Marking
Category 1
79,95 mm
5
79,96 mm
6
79,97 mm
7
Category 2
79,98 mm
8
79,99 mm
99
80,00 mm
00
80,01 mm
01
80,02 mm
02
80,03 mm
03
Category 3
80,04 mm
04
80,05 mm
05
80,06 mm
06
80,07 mm
07
80,08 mm
08
80,09 mm
09
80,10 mm
1
The increased size (on 0,5 mm)
80,47 mm
7+0,5
80,48 mm
8+0,5
80,49 mm
9+0,5
80,50 mm
0+0,5
The increased size (on 1,0 mm)
80,97 mm
7+1,0
80,98 mm
8+1,0
80,99 mm
9+1,0
81,00 mm
0+1,0

Pistons

Producer
Mahle or Alcan
Marking of the producer:
  – Mahle
m
  – Alcan
D
Diameter:
  – Mahle
is 0,030 mm less, than diameter of the cylinder
  – Alcan
is 0,020 mm less, than diameter of the cylinder
Marking on categories corresponds to marking of cylinders. A piston ledge in the top dead point (it is used for determination of thickness of laying of a head of the block of cylinders)
0,65 – 0,95 mm
Assembly gap:
  – Mahle
0,020 – 0,040 mm
  – Alcan
0,015 – 0,035 mm

Piston rings

Thickness:
  – compression rings
1,978 – 1,990 mm
  – oil scraper ring
2,975 – 3,010 mm
Gap in the lock of rings
0,2 – 0,4 mm
Gap between a piston ring and a side surface of a flute of a ring
It is not defined
Shift of locks of piston rings relatively each other
180 °

Piston fingers

Length
64,7 – 65,0 mm
Diameter
25,995 – 26,000 mm
Gap:
  – between a piston finger and the piston
0,007 – 0,011 mm
  – between a piston finger and a rod
0,014 – 0,025 mm

Rods

Difference between the next rods in weight
4 g
Marking on weight:
  – 785 g
Black / 1
  – 789 g
Blue / 2
  – 793 g
Green / 3
  – 797 g
Yellow / 4
  – 807 g
White / 5
  – 805 g
Gray / 6
Side play on cranked to a shaft
0,07 – 0,24 mm

Bent shaft and bearings

Diameter of a neck of the radical bearing:
  – nominal
57,982 – 57,995 mm
  – the reduced size (on 0,25)
57,732 – 57,745 mm
  – the reduced size (on 0,50)
57,482 – 57,495 mm
Diameter of a neck of the conrod bearing:
  – nominal
48,971 – 48,987 mm
  – the reduced size (on 0,25)
48,721 – 48,737 mm
  – the reduced size (on 0,50)
48,471 – 48,487 mm
Ovality and conicity of bearings of a bent shaft
At most 0,004 mm
Shaft beating
At most 0,03 mm
Side play
0,07 – 0,30 mm
Working gap of the radical bearing
0,015 – 0,040 mm
Working gap of the conrod bearing
0,019 – 0,063 mm

Marking of inserts of bearings

Inserts
Color
Marking
Standard size:
  – the top inserts of radical bearings, except an average
Brown
413N or 403N
  – top average insert of the radical bearing
Brown
400N or 410N
  – the lower inserts of radical bearings, except an average
Green
414N or 404N
  – lower average insert of the radical bearing
Green
401N or 411N
  – inserts of the conrod bearing
No
419N
The reduced size (0,25):
  – the top inserts of radical bearings, except an average
Brown-blue
415A or 405A
  – top average insert of the radical bearing
Brown-blue
402A or 412A
  – the lower inserts of radical bearings, except an average
Green-blue
416A or 406A
  – lower average insert of the radical bearing
Green-blue
403A or 413A
  – inserts of the conrod bearing
Blue
420A
The reduced size (0,50):
  – the top inserts of radical bearings, except an average
Brown-white
236B or 407
  – top average insert of the radical bearing
Brown-white
238B or 414B
  – the lower inserts of radical bearings, except an average
Green-white
237B or 408
  – lower average insert of the radical bearing
Green-white
239B or 415B
  – vladysh of the conrod bearing
White
421B

Flywheel

Beating
At most 0,5 mm
Maximum wear of a frictional surface
At most 0,3 mm

Lubrication system

System type
The oil pallet, giving under pressure, the full-line filter
Filter
Champion G105
Oil pressure (the engine is warmed and idles)
1,5 bars
Gaps of the oil pump:
  – a gap between teeths of gear wheels
0,1 – 0,2 mm
  – a gap between an external gear wheel and a casing of the pump
0,03 – 0,10 mm
  – a gap between the plane of gear wheels and the plane of the pump
0,03 – 0,10 mm

Water pump

Type
Centrifugal pump
Drive
From a bent shaft wedge-shaped belt

Thermostat

Temperature began opening
91 °C
Temperature of full opening
106 °C
Marking
91

Tightening moments

Engine 16D
Bolts of fastening of a pulley of a bent shaft
20
Central bolt of a pulley of a bent shaft
155
The bolts fixing a starter to the block of cylinders of the engine
45
The bolts fixing a starter to the block of cylinders of the engine
45
Camshaft pulley bolt:
  – step 1
75
  – step 2
To tighten on a corner 30 °
Bolts of covers of radical bearings
80
Bolts of covers of conrod bearings
50
Cap of the reducing valve of the oil pump
30
Bolts of the oil pallet
5
Bolts of a head of the block of cylinders: *
  – step 1
25
  – step 2
To tighten on a corner 90 °
  – step 3
To tighten on a corner 90 °
  – step 4
To tighten on a corner 45 °
  – step 5
To tighten on a corner 30 °
  – step 6
To tighten on a corner 45 °
The bolts fixing the vacuum pump to a cover of a head of the block of cylinders
28
Switch of a control lamp of pressure of oil
30
The bolts fixing an oil separator of system of ventilation of a case of the engine
15
Bolts of an arm of the right support of the engine
50
Bolts of other support of the engine
40
Masloslivny stopper
45
Bolts of the water pump
25
The bolts fixing a thermostat casing to a head of the block of cylinders
15
The bolts fixing the sensor of temperature of cooling liquid to a thermostat casing
8
Engines 16DA
Central bolt of a pulley of a bent shaft: *
  – step 1
130
  – step 2
To tighten on a corner 45 °
Bolts of fastening of a flywheel: *
  – step 1
50
  – step 2
To tighten on a corner 30 °
Bolts of covers of radical bearings: *
  – step 1
50
  – step 2
To tighten on a corner 45 °
Bolts of covers of conrod bearings: *
  – step 1
35
  – step 2
To tighten on a corner 30 °
Bolts of a head of the block of cylinders: *
  – step 1
25 Nanometer
  – step 2
To tighten on a corner 90 °
  – step 3
To tighten on a corner 90 °
  – step 4
To tighten on a corner 45 °
  – step 5
To tighten on a corner 30 °
  – step 6
To tighten on a corner 45 °
Glow plugs
20

* At installation it is necessary to use new bolts.