Engine
Four-stroke, four-cylinder, in-line, carburetor, water-cooled engine, camshaft in the cylinder head, mounted transversely in front of the car with a 6°back tilt, front-wheel drive.
Type | TU 3.2 K |
Working volume | 1360 cm3 |
Cylinder diameter | 75 mm |
piston stroke | 77 mm |
Compression ratio | 9,3 |
Compression pressure | 1.1 MPa |
Max Power | 56 kW (76 hp) |
Maximum moment | 114 Nm at 3800 rpm |
Gas distribution system
Valve timing: | |
– valve clearance for control of valve timing | 0.7 mm |
- opening the intake valve | 7°05' before TDC |
- closing the intake valve | 41°27' after BDC |
- opening the exhaust valve | 52°42' before BDC |
- closing the exhaust valve | 1°14' before TDC |
Camshaft
The camshaft is mounted in the cylinder head and mounted on five bearings, driven by a toothed belt, the belt tensioner is mechanical.
Camshaft designation | letter B (from the ignition system) |
Longitudinal play of the camshaft | 0.07 - 0.16 mm (adjustable with a washer on the ignition side) |
Toothed belt
The toothed belt drives the camshaft and the coolant pump.
Type | Pirelli Isoran 108 RPP 170 HSL |
Number of teeth | 108 |
Width | 15 mm |
Number of pulley teeth: | |
- crankshaft | 21 |
- camshaft | 42 |
Valves
The valves in the V system are set at an angle of 33°, actuated from the camshaft through double-sided levers. The number of valves per cylinder is 2.
Inlet valve: | |
- length | 110.76±0.15mm |
- contact angle | 120° |
- fit width | 1.9mm |
– rod diameter | 6.90 - 0.015 mm |
- plate diameter | 36.8mm |
- the minimum thickness of the chamfer of the plate | 1.0 mm |
Exhaust valve: | |
- length | 110.6 mm |
- contact angle | 90° |
- fit width | 2.2mm |
– rod diameter | 6.980 - 0.015 mm |
- plate diameter | 29.4mm |
- the minimum thickness of the chamfer of the plate | 1.5mm |
Valve clearance (on a cold engine): | |
- inlet valve | 0.20 mm |
- Exhaust valve | 0.40 mm |
Valve seats
Inlet valve: | |
- contact angle | 90° |
- outside diameter: | |
• nominal 1 | 38.122 - 38.147 mm |
• nominal 2 | 38.422 - 38.447 mm |
• repair 1 | 38.322 - 38.347 mm |
• repair 2 | 38.622 - 38.647 mm |
- inner diameter | 29.5 mm |
– nominal height | 6.648 + 0.1 mm |
– repair height | 7.000 + 0.1 mm |
Exhaust valve: | |
- contact angle | 90° |
- outside diameter: | |
• nominal 1 | 31.122 - 31.147 mm |
• nominal 2 | 31.422 - 31.447 mm |
• repair 1 | 31.322 - 31.347 mm |
• repair 2 | 31.622 - 31.647 mm |
- inner diameter | 24.3mm |
– nominal height | 6.648 + 0.1 mm |
– repair height | 7.000 + 0.1 mm |
Valve guides
Inner diameter | 7+ 0,022 mm |
Outside diameter: | |
– nominal 1 | 13,02+ 0,039 or 13.02+ 0,028 mm |
– nominal 2 | 13,13-0,011 mm |
– repair size 1 | 13,29-0,011 mm |
– repair size 2 | 13,59-0,011 mm |
Valve springs
One spring per valve is used. The intake and exhaust valves have the same springs.
Coil inner diameter | 21,4+0,4 mm |
Spring wire diameter | 3.6mm |
Height: | |
– at a load of 280 N | 40 mm |
– at a load of 500 N | 32 mm |
Cylinder head
The head is made of light alloy and has inserted steel valve seats.
Height: | |
– nominal | 111.2±0.08mm |
– minimum | 111 mm |
Attention! Cylinder heads that have been ground to the minimum height are marked with an R on the head below the third cylinder exhaust port.
Such cylinder heads can no longer be ground during repairs. In addition, they always require the use of a gasket during installation, also marked with the letter R (with thickness increased by 0.2 mm).
Maximum flatness tolerance of the bottom surface of the head | 0.05 mm |
Cylinder head gasket
The cylinder head gasket has a metal border around the cylinders.
Brand | Payen Curty |
Gasket thickness: | |
– nominal | 1.3mm |
– for reground head | 1.5mm |
Engine block
The engine cylinder block is made of light alloy, consists of two parts, is divided along the axis of the crankshaft and has plug-in wet cylinder liners.
Block top height | 206.98 mm |
Cylinder liners
Cylinder liners made of cast iron are divided into three groups, indicated by the corresponding number of dashes.
Cylinder liner diameter: | |
– group 1 (1 dash) | 75.00 - 75.01 mm |
– group 2 (2 dashes) | 75.01 - 75.02 mm |
– group 3 (3 dashes) | 75.02 - 75.03 mm |
Sleeve protrusion | 0.03 - 0.10 mm |
Maximum difference between four points on one sleeve | 0.02mm |
Maximum difference between cylinders | 0.05 mm |
Sleeve O-Ring Diameter | 1.15 - 1.35 mm |
Crank mechanism
Pistons
The pistons are made of light alloy and have three rings.
Piston diameter (mm): | |
– group A | 74,960 – 74,970 |
- group B | 74,970 – 74,980 |
- group C | 74,980 – 74,990 |
Mounting clearance of the piston in the cylinder | 0.03 - 0.05 mm |
Installation | the arrow on the piston crown must be directed towards the valve timing |
Ring lock gaps: | |
- first (upper) | 0.30 - 0.50 mm |
- second (average) | 0.30 - 0.50 mm |
- third (lower) | 0.25 - 0.50 mm |
Piston pins
The steel pins are divided into 3 groups corresponding to the piston groups and are marked with dashes.
Finger diameter: | |
– group 1 (on piston 1, on pin I) | 19.495 - 19.498 mm |
– group 2 (on piston 2, on pin II) | 19.492 - 19.495 mm |
– group 3 (on piston 3, on pin III) | 19.489 - 19.492 mm |
Piston pin clearance | 0.01 - 0.016 mm |
Finger length | 62±0.25mm |
Connecting rods
The connecting rods are forged from steel.
Maximum mass difference between connecting rods of the same engine | 3 g |
center distance | 126±0.07mm |
Connecting rod diameter | 19,463+0,013 mm |
Connecting rod bore diameter | 48,655+0,016 mm |
Crankshaft
The crankshaft is made of cast iron and is supported by five main bearings.
Axial play of the crankshaft | 0.1 - 0.3 mm |
Crankshaft dimensions: | |
- nominal: | |
• diameter of main journals | 49,981-0,016 mm |
• width 2 main neck | 23,6+0,052 mm |
• diameter of connecting rod journals | 45,0-0,009 or 45.0-0,025 mm |
• Diameter of the seal neck on the flywheel | 85,0-0,065 mm |
- repair: | |
• diameter of main journals | 49,681-0,016 mm |
• width 2 main neck | 23,8+0,052, 23,9+0,052, 24,0+0,052 mm |
• diameter of connecting rod journals | 47,7-0,025 mm |
• Diameter of the seal neck on the flywheel | 84,8-0,065 mm |
Main bearing shells
Thickness: | |
– nominal | 1.829±0.003mm |
- repair size | 1.979±0.003mm |
Connecting rod bearing shells
Thickness: | |
– nominal | 1.817±0.003 mm |
- repair size | 1.967±0.003mm |
Thrust rings
Thickness: | |
– nominal | 2.4 mm |
– repair size 1 | 2.50 mm |
– repair size 2 | 2.55mm |
– repair size 3 | 2.60 mm |
Flywheel
Maximum beats | 0.05 mm |
Maximum thinning after processing | 1.0 mm |
Lubrication system
Pressure lubrication is provided by an external gear oil pump attached to the bottom of the cylinder block and driven by a single row chain from the crankshaft.
Oil pressure (at 90°С)
Depending on the engine speed, the oil pressure is: | |
– at 750 rpm | 0.15 MPa |
– at 1000 rpm | 0.20 MPa |
– at 2000 rpm | 0.30 MPa |
– at 4000 rpm | 0.40 MPa |
Oil filter
The oil filter has a paper replaceable element.
Brand and type | Purflux LS 468 A or Mann 6740 258 035 |
Cooling system
The cooling system has a closed forced circulation circuit, which is carried out by a centrifugal pump (driven toothed belt). The cooling system consists of a radiator, a coolant pump, an expansion tank and a fan with an electric motor controlled by a thermal switch.
Thermostat
Type | Calorstat |
Opening start temperature | 88°C |
Full opening temperature | 102°C |
Valve travel | minimum 7.5 mm |
Fan
The fan is eight-blade, 120 W, diameter 285 mm.
Switch-on temperature | 98°С |
Shutdown temperature | 92°C |
Temperature sensor
The sensor installed in the cylinder head causes the control lamp on the instrument cluster to light up when the coolant reaches a temperature of 118°C.
Fuel system
Fuel pump
The diaphragm fuel pump is driven mechanically by the camshaft.
Electrical Type - External (early models) or internal (later models).
Pressure | 25 kPa |
Pump feed pressure: | |
– Fenix IB, MM G5 and MM G6 | 0.7 - 0.8 bar |
– Bosch MA3. 0 | 1.0±0.1 bar. |
Pump performance: | |
– Fenix IB and Bosch MA3. 0 | 370 cm3 in 15 seconds |
– MM G5 and G6 systems | 360 cm3 in 15 seconds |
Air filter
The dry air filter has a replaceable paper element.
Type | Purflux F 973 |
Carburetor
The two-chamber carburetor has a manually operated starting device.
Type | Solex Z2/528 or Weber 34 TLP |
Carburetor Solex Z2/528: | |
– diffuser diameter: | |
• 1 camera | 24 |
• 2 cameras | 25 |
- main fuel jet: | |
• 1 camera | 115 |
• 2 cameras | 120 |
- main air jet: | |
• 1 camera | 155 |
• 2 cameras | 160 |
- idle fuel jet | 40 |
- jet transition system (bypass) | 50 |
- enrichment jet | 45 |
- accelerator pump jet: | |
• 1 camera | 35 |
• 2 cameras | 35 |
- econostat fuel jet | 80 |
– needle valve seat diameter | 1,6 |
- throttle opening | 0.5 mm |
- opening the air damper | 3.0±0.5mm |
- float position (measured from the lower surface of the float to the plane of the cover with the gasket in a horizontal position using a special template) | 33.5mm |
- idle speed | 750 rpm |
– CO content | 1,5% |
– minimum CO content2 | 10% |
Weber carburetor: | |
- float installation height | 32.0 mm |
- opening the damper after the start | 5.0 mm |
Fuel injection system
System type: | |
– TU3 engine (K12X) | Solex Fenix IB single point |
– TU3 engine (K12X) | Bosch Monotronic MA3. 0 single point |
Ignition system
The transistorized ignition system has an ignition distributor with a non-contact pulse generator, with a centrifugal and vacuum ignition timing controller, mounted on the rear end of the camshaft.
Distributor
Type | Bosch 0237 009 604 or Ducellier 2 525 275 |
Ignition order | 1–3–4–2 (#1 flywheel side) |
Initial ignition timing (at 750 rpm of the engine and the pipeline of the vacuum regulator is disconnected) | 8°before TDC |
Ignition coil
Brand | Ducellier BTR 05 |
winding resistance (at 20°С): | |
– primary | 0.7 ohm |
- secondary | 6.6 kOhm |
Gain module | Bosch 0227 100 140 |
Spark plug
Type | Champion C9YCX or Eyquem FC 52 LS |
Gap between electrodes | 0.8 mm |
Clutch
Friction clutch, single disc, dry, with a central spring, mechanically controlled, with automatic adjustment.
Type | Valeo 180 SR 3300 |
Disc outer diameter | 180 mm |
Full pedal travel | 140±5mm |
Transmission
The gearbox is mechanical, five speeds plus reverse gear, forward gears are synchronized.
Type | MA 5 |
Gear ratios: | |
– 1st gear | 3,41 |
- 2nd gear | 1,80 |
– 3rd gear | 1,27 |
- 4th gear | 0,97 |
– 5th gear | 0,77 |
Reverse gear | 3,58 |
Final drive ratio | 4,08 |
Drive shafts
Drive shafts connected on both sides by parallel three-arm joints on the gearbox side and ball joints (Rzeppa) from the side of the wheels.
Steering system
Mechanical (without hydraulic booster) or mechanical with hydraulic booster (additional equipment), with adjustable tilt steering column.
Steering gear
Steering gear - rack and pinion in a mechanical system and rack and pinion with a distributing valve and a servomotor in a system with a hydraulic booster.
Steering without hydraulic booster
gear ratio | 23,8 |
Number of gear teeth | 6 |
The number of turns of the steering wheel from lock to lock | 4,1 |
Turning radius: | |
- between walls | 5.5 m |
- between sidewalks | 5.275 m |
Power Steering
gear ratio | 17,9 |
Number of gear teeth | 8 |
The number of turns of the steering wheel from lock to lock | 3,1 |
Turning radius: | |
- between walls | 5.5 m |
- between sidewalks | 5.275 m |
Power steering pump
The vane pump is driven from the crankshaft by a V-belt. The brand of the pump is Saginaw.
V-belt
Type | Kleber Venuflex 10 x 650 Le |
Tension: | |
- new belt | 500 - 550 N |
- used belt | 400 - 500 N |
Front suspension
Independent, Mac Pherson type, with lower control arms and transverse stabilizer.
The front wheel hub is on a double-row ball bearing.
Stabilizer diameter | 20 mm |
suspension spring: | |
- thread diameter | 157 mm |
– rod diameter | 12 mm |
– compression under load 1000 N | 63 mm |
- full compression | 195.2 mm |
Installing the front wheels (curb car)
Convergence (regulated) | 3.5±1mm (0° 35' ± 10') |
Tilt wheel (not regulated) | 0° 13' ± 30' |
Advance of a finger of a rotary fist (not regulated) | 1° 10' ± 30' |
Steering pin tilt (not regulated) | 10° 40' ± 30' |
Rear suspension
Independent, on separate levers connected by a torsion bar (behind the axle) and stabilizer (mounted in front of the axle), with double-acting longitudinal hydraulic telescopic shock absorbers mounted horizontally.
The rear wheel hub is on a double-row ball bearing.
Stabilizer diameter | 18 mm |
Torsion: | |
– diameter | 18.6mm |
– elasticity of the wheel at a load of 1000 N | 63 mm |
- full wheel bend | 257.6 mm |
Installing the rear wheels (car without load)
Suspension reference height (not regulated) | 205±7mm |
discrepancy (not regulated) | 0.5±1mm (0° 05' ± 10') |
Tilt wheel (not regulated) | 1° 20' ± 30' |
Brake system
Service brake system hydraulic, dual-circuit (diagonal division), with vacuum brake booster.
The handbrake acts mechanically on the rear wheel brakes.
Front wheel brakes
Disc, floating caliper, Bendix IV.
Outer disc diameter | 266 mm |
Disc Thickness: | |
– nominal | 10 mm |
– minimum (after repair) | 9 mm |
Permissible disc runout | 0.07mm |
brake pads | Abex 903 or Valeo F 599 |
Minimum allowable pad thickness | determined by the erasing of the middle groove in the block material, signaled by the corresponding control lamp lighting up (electrical wear signaling by means of a wire pressed into the inside of the brake pad) |
Caliper cylinder diameter | 48 mm |
Rear wheel brakes
Drum type, with automatic shoe clearance adjustment, with pressure limiters built into the brake cylinders.
Working cylinder diameter: | |
- nominal | 228.6 mm |
- maximum (after repair) | 229.6 mm |
brake pads | Valeo F 154 |
Nominal lining thickness | 5 mm |
Lining width | 40 mm |
Cylinder diameter | 20.6mm |
Master brake cylinder | in tandem, Bendix or ATE system |
Piston diameter | 20.6mm |
vacuum booster | type Isovac, Bendix or ATE |
Piston diameter | 203.2 mm |
Wheels and tires
Disks | 5.00 J x 14 FH 4.25 |
Tires | 165/ 70 R 14 T |
Tire pressure: | |
- front wheels | 0.21 MPa |
– rear wheels | 0.21 MPa |
Electrical equipment
Battery | 12V 175A or 12V 200A minus (-) on mass |
Generator | 55 A, Bosch or Valeo |
V-belt | Hutchinson AV 10 |
Belt deflection | 5 - 10 mm under finger pressure at half the distance between the pulleys |
Starter | Bosch 0001 112 019 or Valeo 126 RA 37 |
Power | 1256 W |
Idling: | |
- voltage | 11.4 V |
– current | maximum 60 A |
Braking: | |
- voltage | 11.4 V |
– current | maximum 500 A |
Circuit breakers | 7 x (12 V, 5 A); 3 x (12 V, 10 A); 5 x (12 V, 15 A); 2 x (12 V 20 A); 2 x (12 V, 25 A) |
Bulbs: | |
- headlights | H4 55/ 60W |
– fog lights | 55 W |
- marker lights front and rear | 5 W |
- direction indicators | 21 W |
- braking lights | 21 W |
- reversing lights | 21 W |
- fog tail lights | 21 W |
Masses
Own weight | 1030 kg |
Full mass | 1470 kg |
Maximum trailer weight without brakes | 435 kg |
Maximum trailer weight with brakes | 900 kg |
Fuel consumption
At a speed of 90 km/h | 5.5 dm3/ 100 km |
At a speed of 120 km/h | 7.5 dm3/ 100 km |
urban cycle | 8.3 dm3/ 100 km |
The maximum speed is 169 km / h.
Tightening torques
Engine
Cylinder head bolts: | |
- Stage 1 | 20 Nm |
– stage 2 | tighten by 240° |
valve cover | 16 Nm |
Camshaft pulley | 80 Nm |
Toothed belt tensioner pulley | 23 Nm |
Ignition distributor housing | 16 Nm |
Connecting rod bearing caps | 40 Nm |
Main bearing caps: | |
- Stage 1 | 20 Nm |
– stage 2 | tighten by 45° |
Bottom of block to top of block | 8 Nm |
Flywheel | 65 Nm |
Pulley to crankshaft | 110 Nm |
Oil pump to cylinder block | 8 Nm |
Drain plug to oil pan | 30 Nm |
Spark plug | 17.5 Nm |
Clutch drive to flywheel | 10 Nm |
Engine to gearbox | 45 Nm |
Transmission
Box housing to clutch housing | 18 Nm |
Back cover | 18 Nm |
Input shaft nut | 140 Nm |
Intermediate plate to clutch housing | 50 Nm |
Oil drain plug from gearbox | 25 Nm |
Steering system
Steering gear to cross member | 40 Nm |
Clamp to steering shaft | 20 Nm |
Tie rod end to shoulder | 35 Nm |
Transfer valve to steering gear | 12.5 Nm |
Wheel Disc Bolt | 85 Nm |
Front suspension
Cross member to chassis | 90 Nm |
Rear attachment of the lever to the beam | 45 Nm |
Front attachment of the lever to the beam | 45 Nm |
Steering knuckle holder | 55 Nm |
Steering knuckle to lever | 30 Nm |
Steering knuckle to steering knuckle | 260 Nm |
Rod connecting the stabilizer to the lever | 65 Nm |
Tie rod end to shoulder | 35 Nm |
Suspension column to the body | 25 Nm |
hub axle nut | 265 Nm |
Rear suspension
Shock absorber to lever | 110 Nm |
shock absorber to bracket | 110 Nm |
Shoulders of the front beam to the chassis | 60 Nm |
Front rubber bushing to chassis | 55 Nm |
Rear rubber bushing to chassis | 55 Nm |
Torsion bar and stabilizer clip | 55 Nm |
Side torsion bar bolts | 17.5 Nm |
hub axle nut | 275 Nm |
Brake system
Support for steering knuckle | 120 Nm |