Contents Wiring diagrams Section: Diesel Engine All sections

Technical Specifications Opel Campo I

Diesel Engine 2 illustrations ~268 words

Sealants Lubricants and Locking Compounds

DescriptionPurposeCatalogue numberPart number
SealantSealer between metal surfaces cork and hard fibre seals15 03 16690 094 714
Sealing compoundSealant for screw and hose connections in conjunction with fluids15 03 29590 485 251
GreaseMulti-purpose grease for (e.g.) wheel bearings alternator starter19 48 60690 510 336
Locking compoundLocking agent as adhesive for screw connections15 10 17790 167 347
Silicone greaseGrease for all temperature-stressed sliding connections as well as plastic seal rings19 70 20690 167 353
Special greaseInstallation of oxygen sensor19 48 60290 295 397

Coolant System

Engine4JA1T4JA1TC4JG2T
Coolant capacityl7.08.48.6
Fan
TypeVisco-clutch fan driveVisco-clutch fan driveVisco-clutch fan drive
Number of Blades8
Radiator Cap
Opening pressurebar/psi0.88 to 1.17/13 to 170.88 to 1.17/13 to 170.88 to 1.17/13 to 17
Coolant pump
DesignCentrifugal pumpCentrifugal pumpCentrifugal pump
Delivery rate150 ltr/min @ 2800 rpm
Thermostat
DesignWax pellet with jiggle pinWax pellet with jiggle pinWax pellet with jiggle pin
Start of opening° C828282
Fully open° C959595

Drive Belts

Engine4JA1T4JA1TC4JG2T
Alternator
Depressionmm8 - 12*8 - 12*8 - 12*
Power steering
Depressionmm13 - 16*13 - 16*13 - 16*
Air Conditioning
Depression newmm7 - 10*7 - 10*7 - 10*
usedmm7 - 8*7 - 8*7 - 8*
* with thumb pressure of approx. 98 N.* with thumb pressure of approx. 98 N.*with thumb pressure of approx. 98 N.
Timing
Tensionkg10 - 12-10 - 12
using tension adjustment lever-using tension adjustment lever

Oil Circuit

Engine4JA1T4JA1TC4JG2T
Engine oil quality
single andCCMC-PD2 also in conjunctionACEA B2—B3CCMC-PD2 also in conjunction
multi-grade oilswith API-../CD ifSAE 10W30with API-../CD if
CMC-PD2 is also specified-CCMC-PD2 is also specified
Engine oil viscosity
single-grade oils
SAE 10W°Cminus 25 to 0minus 25 to 0minus 25 to 0
SAE 20 20W°Cminus 15 to 15minus 15 to 15minus 15 to 15
SAE 30°C0 to 300 to 300 to 30
SAE 40 50°Cover 25over 25over 25
multi-grade oils
SAE 5W - 30°Cbelow minus 10below minus 10below minus 10
SAE 10W - 30°Cminus 25 to 30minus 25 to 30minus 25 to 30
SAE 15W - 40° Cminus 15 to over 30minus 15 to over 30minus 15 to over 30
SAE 20W - 40°Cminus 15 to over 30minus 15 to over 30minus 15 to over 30
SAE 2-W - 50°Cminus 15 to over 30minus 15 to over 30minus 15 to over 30

Oil Circuit (Continued)

Engine Oil Filling Quantity

Engine4JA1T4JA1TC4JG2T
Two wheel driveFour wheel driveTwo wheel driveFour wheel drive
Initial filll5.56.57.35.57.1
With oil filter changel4.54.56.0
Without oil filter changel3.53.55.0

Oil Pump

Engine4JA1T4JA1TC4JG2T
Clearances
Gear teeth and pump bodymm0.14 to 0.200.14 to 0.200.14 to 0.20
Gears and pump covermm0.06 to 0.150.06 to 0.150.06 to 0.15

Adjustment Values/checking Values

Engine4JA1T4JA1TC4JG2T
Valve clearance (cold)mm0.40.40.4
AdjustmentAdjusting screw with locknutAdjusting screw with locknutAdjusting screw with locknut
Compressionbar/psiDifference in pressure individual cylinders in engine must not exceed 1.0/14.5Difference in pressure individual cylinders in engine must not exceed 1.0/14.5Difference in pressure individual cylinders in engine must not exceed 1.0/14.5
Compression pressurebar/psi30/435 at 200 rpm31/440 at 200 rpm30/435 at 200 rpm
Pressure loss checkPressure loss per cylinder with engine in perfect condition approx. 25%Pressure loss per cylinder with engine in perfect condition approx. 25%Pressure loss per cylinder with engine in perfect condition approx. 25%
Pressure deviation between individual cylinders approx. 10%Pressure deviation between individual cylinders approx. 10%Pressure deviation between individual cylinders approx. 10%
Idle speed:
Lowerrpm744 - 795705 - 755696 - 745
Upperrpm4 700 - 4 9004 0004 500 - 4 700
Increaserpm850 - 950835 - 885850 - 950
Charge pressurebar/psi1.15/171.15/171.15/17
Injection pump timing12 ° BTDC12 ° BTDCTDC

Cylinder Head

Cylinder Head Gasket

Engine4JA1T4JA1TC4JG2T
Cylinder head gasket new:
Thicknessmm1.501.501.50
1.551.551.55
1.601.601.60
Identificationmm1 notch1 notch1 notch
2 notches2 notches2 notches
3 notches3 notches3 notches
Piston projectionmm0.718 - 0.7730.718 - 0.7730.658 - 0.712
0.773 - 0.8190.773 - 0.8190.713 - 0.758
0.819 - 0.8740.819 - 0.8740.759 - 0.813

Cylinder Head (Continued)

Cylinder Head Dimensions

Engine4JA1T4JA1TC4JG2T
Deviation of plane surfacemm0.05 - 0.200.05 - 0.200.05 - 0.20
Height of cylinder head (sealing surface to sealing surface)mm91.95 - 92.0591.95 - 92.05
Grinding allowance for plane surface maximummm0.30Not permitted
Deviation of sealing surfaces for manifold attachmentmm0.05 - 0.200.05 - 0.200.55 - 0.20
Grinding allowance for manifold sealing surface maximummm0.40.40.4
Valve indentation of sealing surface:
Intakemm0.73 - 1.281.1 - 1.6
Exhaustmm0.7 - 1.21.1 - 1.6
Swirl chamber depressionmm0 - 0.02-0 - 0.02

Cylinder Head (Continued)

Valve Seat Reworking

Engine4JA1T4JA1TC4JG2T
Valve correction angle4545
Lower correction angle1515
Upper correction angle7475
Valve seat width:
Intakemm1.7 standard1.7 standard
mm2.2 (limit)2.2 (limit)
Exhaustmm2.0 (standard)2.0 (standard
mm2.5 (limit)2.5 (limit)

Cylinder Head (Continued)

Valve Dimensions

Engine4JA1T4JA1TC4JG2T
StandardLimitStandardLimitStandardLimit
Stem diameter:
Intakemm7.946 - 7.9617.887.946 - 7.9617.88
Exhaustmm7.921 - 7.9367.857.921 - 7.9367.85
Thickness:
Intakemm1.81.51.341.1
Exhaustmm1.81.51.381.1
Stem play in bore:
Intakemm0.039 - 0.0690.20.039 - 0.0690.2
Exhaustmm0.064 - 0.0930.250.064 - 0.0930.25
Valve guide heightmm1313

Valve Springs

Engine4JA1T4JA1TC4JG2T
Free heightmm44.4 - 45.3 mm (inner spring)44.4 - 45.3 mm (inner spring)47.1 - 48.0
mm48.2 - 49.7 mm (outer spring)48.2 - 49.7 mm (outer spring)
Out of parallel maximummm3 mm (inner spring)3 mm (inner spring)1.7
3.2 mm (outer spring)3.2 mm (outer spring)
Tension at installed heightN49 - 57.9 at 37 mm (inner spring)49 - 57.9 at 37 mm (inner spring)257.7 - 296 at 38 mm
N117.4 - 205 at 39 mm (outer spring)117.4 - 205 at 39 mm (outer spring)

Cylinder Head (Continued)

Rockershaft and Arms

Engine4JA1T4JA1TC4JG2T
Rockershaft radial runout maximummm0.30.30.3
Rockershaft diametermm18.90 - 1918.90 - 1918.90 - 19
Rocker arm inside diametermm19.036 - 19.119.036 - 19.119.036 - 19.1
Clearance between rockershaft and rocker armmm0.01 - 0.20.01 - 0.20.01 - 0.2
Push-rod curvature maximummm0.30.30.3

Camshaft and Followers

Camshaft

Engine4JA1T4JA1TC4JG2T
Radial runoutmm0.02 - 0.100.02 - 0.100.02 - 0.10
End playmm0.08 - 0.20.05 - 0.20.08 - 0.2
Lobe heightmm41.65 - 42.0841.65 - 42.0841.65 - 42.08
Journal diametermm49.6 - 49.97549.6 - 49.97549.6 - 49.975
Bearing inside diametermm50 - 50.0850 - 50.0850 - 50.08
Clearance between journal and bearingmm0.05 - 0.120.05 - 0.120.05 - 0.12

Cam Followers

Engine4JA1T4JA1TC4JG2T
Stem diametermm12.95 - 12.9912.95 - 12.9912.95 - 12.99
Clearance between cam follower and cylinder blockmm0.03 - 0.10.03 - 0.10.03 - 0.1

Crank Drive

Cylinder Liner

Engine4JA1T4JA1TC4JG2T
Bore diametermm93.021 (standard)93.021 (standard)95.404 (standard)
mm93.1 (limit)93.1 (limit)95.470 (limit)
Projection above sealing surfacemm0.010.010.01
Difference in projection between individual cylinders maximummm0.030.030.03
Interference fitmm0.01 - 0.0190.01 - 0.0190.01 0 .019

Piston

Engine4JA1T4JA1TC4JG2T
Installation positionMark points to timing gear case cover
Piston clearance in boremm0.025 - 0.0450.025 - 0.0450.056 - 0.065
Piston pin hole diametermm31.002 - 31.01034.002 - 34.010

Crank Drive (Continued)

Piston Rings

StandardLimit
1st compression ring:
Gapmm0.2 - 0.41.5
Clearance between ring and piston groovemm0.09 - 0.1250.15
2nd compression ring:
Gapmm0.2 - 0.41.5
Clearance between ring and piston groovemm0.05 - 0.0750.15
Oil ring:
Gapmm0.1 - 0.31.5
Clearance between ring and piston groovemm0.03 - 0.070.15

Piston Pins

Engine4JA1T4JA1TC4JG2T
TypeFloating bearing in con-rod and piston 2 circlips in position bushing in con-rod
InstallationSliding seat
Diametermm30.97 - 3133.97 - 34
Play:
In pistonmm0.002 - 0.0150.002 - 0.015
In con-rodmm0.008 - 0.02 (standard)0.008 - 0.02 (standard)
0.05 (limit)0.05 (limit)

Crank Drive (Continued)

Con-Rod

Engine4JA1T4JA1TC4JG2T
Distortionmm0.08 - 0.20.08 - 0.20.08 - 0.2
Parallelismmm0.05 - 0.150.05 - 0.150.05 - 0.15

Crank Drive (Continued)

Selection Table for Main Bearing Shells

Illustration

Cylinder block main bearing identification (size mark A in following tables).

  1. 1. Front bearing
  2. 2. Second bearing
  3. 3. Centre and pilot bearings
  4. 4. Fourth bearing
  5. 5. Rear bearing

(A) is inset coding bar of bearing bore size in the block at each location.

Crankshaft main bearing identification (size mark B in following tables)

  1. 1. Front bearing
  2. 2. Second bearing
  3. 3. Centre and pilot bearings
  4. 4. Fourth bearing
  5. 5. Rear bearing

At location (B) is given coding number of each crankshaft journal size.

Crank Drive (Continued)

Selection Table for Main Bearing Shells - 4JA1T

Bearing bore in cylinder blockMain bearing journalShell colour codeBearing play mm
Size mark 'A'Diameter (mm)Diameter (mm)Size mark 'B'
163.987 - 59.92759.222 - 59.9271 or -Black
59.922 - 59.9272 or -Blue0.031-0.064 (standard) 0.11 (limit)
59.917 - 59.9223 or -
263.975 - 63.98759.927 - 59.9321 or -Green
59.922 - 59.9272 or -0.031-0.064 (standard) 0.11 (limit)
59.917 - 59.9223 or -Black

Selection Table for Main Bearing Shells - 4JA1TC

Bearing bore in cylinder blockMain bearing journalShell colour codeBearing play mm
Size mark 'A'Diameter (mm)Diameter (mm)Size mark 'B'
11 or -
2 or -
3 or -
21 or -
2 or -
3 or -

Crank Drive (Continued)

Selection Table for Main Bearing Shells - 4JG2T

Bearing bore in cylinder blockMain bearing journalShell colour codeBearing play mm
Size mark 'A'Diameter (mm)Diameter (mm)Size mark 'B'
173.987 - 74.069.927 - 69.9321 or -Black
69.922 - 69.9272 or -Blue0.031-0.064 (standard) 0.11 (limit)
69.917 - 69.9223 or -
273.975 - 73.98769.92 - 73.9871 or -Green
69.922 - 69.9272 or -0.031-0.064 (standard) 0.11 (limit)
69.917 - 69.9223 or -Black

Crankshaft Drive (Continued)

Crankshaft

Engine4JA1T4JA1TC4JG2T
Crankshaft and con-rod journals:
Main journal diametermm59.91 - 59.369.91 - 69.93
Con-rod journal diametermm52.90 - 52.9352/90 - 52.93
Uneven wear limitmm0.080.08
Radial run-outmm0.05 - 0.080.05 - 0.08
Axial playmm0.1 - 0.30.1 - 0.3
Main bearing playmm0.031 - 0.1100.031 - 0.110
Con-rod bearing playmm0.029 - 0.10.029 - 0.1
Con-rod lateral playmm0.023 - 0.350.023 - 0.35

Crank Drive (Continued)

Flywheel

Enginemm4JA1T4JA1TC4JG2T
Starter ring gearmmHeat ring gear to 200° maximum before fitting
Friction surface depth 'A;mm20 - 2120 - 2118 - 19
Surface roughnessmmLess than 0.006Less than 0.006Less than 0.006

Cylinder Block

Engine4JA1T4JA1TC4JG2T
Deviation of plane surfacemm0.05 - 0.200.05 - 0.200.05 - 0.20
Height of cylinder block (sealing surface to sealing surface)mm244.945 - 245.055269.945 - 270.055

Mechanical Injection System

Injection Pump

Engine4JA1T4JA1TC4JG2T
TypeBosch VE distributorBosch VP44 distributorBosch VE distributor

Injectors

Engine4JA1T4JA1TC4JG2T
Typehole with 5 jetshole with 5 jets — double spring typePintaux
Opening pressurebar/psi181.43/2.631195/2830 1ste stage 338/4906 2nd stage147.1/2134

Quick on Start Pre Heating System

Engine4JA1T4JG2T4JA1TC
ControlElectronic-
Glow plug resistanceohmApprox. 0.9 at 25 °C-
Coolant temperature sensor resistork ohm12 at - 15 °C12 at - 15 °C-
6 at 0 °C6 at 0 °C-
3.6 at 10 °C3.6 at 10 °C-
2.45 at 20 °C2.45 at 20 °C-
1.1 at 40 °C1.1 at 40 °C-
0.6 at 60 °C0.6 at 60 °C-
0.3 at 80 °C0.3 at 80 °C-
Dropping resistorohm-225 - 225 at-
-approx. 25 °C-

Quick Warming Up System

Engine4JA1T4JG2T4JA1TC
Idling speed under quickEngine coolant temperature less than 80 °C-
warming up systemAmbient air temperature less than 15 °C-
conditionsQuick warming up system on 900 rpm-
Quick warming up system switch off 720 rpm - 4JG2T-
Quick warming up system switch off 770 rpm - 4JA1T-
Quick warming up systemNo load engine speed more than 1750 rpm-
cancellation conditionsAcceleration opening more than 55% - 4JA1T-
Engine coolant temperature more than 80 °C-
Ambient air temperature more than 15 °C-
Ambient temperature switch:
Off to on°C88-
On to off°CApprox. 15Approx. 15-
Vacuum switch valve resistanceohm40 at 20 °C40 at 20 °C-
Intake throttle valve clearancemm1.01.0-
Exhaust throttle valve clearance:
At 0.53 bar/8 psimm0.150.15-
At 0.35 bar/5 psimm1.151.15-

Starter

Identification Data

Engine4JA1T4JA1TC4JG2T
TypeHitachiHitachi S14-03
Opel Part No.94 433 91294 387 653

Test Data

Engine4JA1T4JA1TC4JG2T
Idle speed checkCurrentamps160 or less
Speedrmp3900 or more
Voltagevolts11
On load speed checkCurrentamps300
Speedrmp200 or more
Voltagevolts10.85
TorqueNm7.4 or more
Short circuit checkCurrentamps1300 or less
Voltagevolts3
TorqueNm36 or more
CommutatorDiameter minimummm3436.5
Runoutmm0.02-0.0530.05-0.1
Insulator depthmm0.20.2-0.8
BrushesLengthmm9.5-14.511-18
Spring tensionN28-35
Pinion travelmm0.3-1.30.3-1.3

Alternator

Test Data

Engine4JA1T4JA1TC4JG2T
Nominal voltagevolts121212
Current output maximumamps50 at 5000 rpm60 at 5000 rpm60 at 6000 rpm
Slip rings diametermm30.6-31.630.6-31.6
Brush lengthmm6-206-20
Excitation winding resistanceohm4.2 at 20 °C4.2 at 20 °C
Stator winding resistanceohm0.10.1

Alternator (Continued)

Vacuum Pump

Engine4JA1T4JA1TC4JG2T
Housing inside diametermm57-57.157-57.160-60.1
Vane lengthmm12.5-13.512.5-13.514.2-15.2
Diesel Engine4JA1T4JA1TC4JG2T
NmNmNm
Air conditioning compressor595959
Alternator:
Adjuster plate bolt191919
Pivot bolt404040
Pulley nut505050
Through bolts666
Axle mounting bolts152152152
Camshaft:
Gear to camshaft bolt-108-
Oil seal retainer bolts18-18
Pulley centre boss bolt64-64
Pulley to centre boss bolts8-8
Pulley flange bolts8-8
Thrust washer plate bolts-19-
Con-rod bearing cap to con-rod838329 + 45°
Diesel Engine4JA1T4JA1TC4JG2T
NmNmNm
Coolant temperature sensor343434
Coolant pipes to intake manifold191919
Clutch slave cylinder bolts284045
Crankshaft:
Main bearing caps167167167
Damper pulley bolts19-19
Pulley boss bolt206206206
Cylinder head cover bolts131313
Cylinder head to cylinder block bolts49 +60 to 75° +60 to 75°49 +60 to 75° +60 to 75°49 +60 to 75° +60 to 75°
Dipstick tube bolts191919
Engine damping block to engine:
Small bolts404040
Large bolts117117117
Diesel Engine4JA1T4JA1TC4JG2T
NmNmNm
Exhaust gas recirculation:
Exhaust manifold side nut and bolt262426
Exhaust gas recirculation valve nut242424
EGR cooler bracket to cylinder head-19-
EGR cooler to brackets-19-
Exhaust manifold::
Exhaust manifold to cylinder head nuts and bolts:262626
Heat shield bolts-19-
Flywheel to crankshaft118118118
Front exhaust pipe to turbocharger adapter676767
Glow plugs232323
Idler gear bolts-19-
Injection pump:
Adjusting bolt19-19
Head plug17-17
Diesel Engine4JA1T4JA1TC4JG2T
NmNmNm
Heat shield bolts-19-
Lower s upport bracket bolts194019
Pulley nut64not allowed64
Timing gear case mounting bolts-19-
Upper support bracket bolts-25-
Injector:
Retaining bolt3737-
Setting screw--64
Body nut306930
Leak off pipe-1769
Injector pipe nuts292929
Intake manifold to cylinder head191919
Intercooler:
Brackets to intake manifold and cylinder head-20-
Cover plate bolts-20-
Diesel Engine4JA1T4JA1TC4JG2T
NmNmNm
Intercooler to mounting brackets-20-
Intercooler pipe-22-
Oil cooler centre bolt222222
Oil filter housing:
Pressure relief valve202020
Retaining bolts191919
Oil pan:
Bolts191919
Nuts242424
Drain plug444444
Oil pump:
Bolts191919
Sleeve nut252525
Strainer/cover bolts161616
Power steering pump:
Diesel Engine4JA1T4JA1TC4JG2T
NmNmNm
Lock bolt373737
Suction pipe bolts212121
Pressure hose nut202020
Rear plate cylinder block828282
Rockershaft bolts545454
Scissor gear:
Gear to hub bolt-108-
Lock bolt-74-
Starter:
Mounting bolts696969
Terminal B999
Terminal M999
Solenoid switch bolts777
Through bolts666
Thermostat housing bolts191919
Diesel Engine4JA1T4JA1TC4JG2T
NmNmNm
Timing belt tensioner centre bolt76-76
Timing cover bolts8198
Timing gear case bolts-19-
Timing pulley housing bolts1919
Track rod:
Nuts to relay arm595959
Nuts to pitman arm and outer rods989898
Turbocharger:
Nuts262626
Exhaust adapter bolts262626
Coolant connection block-8-
Oil feed pipe bolts :
Cylinder block end295429
Turbocharger end222222
Retaining clip181818
Oil return pipe bolts888
Diesel Engine4JA1T4JA1TC4JG2T
NmNmNm
Vacuum pump screws777
Valve clearance lock nut151515
Visco-clutch and fan assembly888
Water pump to cylinder block202020