General money
Engine code:
- 1595 cm3 - injection system Bosch Motronic 3.2, 74 kW (100 HP) — ADP
- 1595 cm3 Simos injection system, 74 kW (100 HP) — AHL
- 1781 cm3 Bosch Motronic injection system, 92 kW (124 HP) — ADR
- 1781 cm3 Bosch Motronic injection system. 88 kW (149 HP) — AFY
- 1781 cm3 Bosch Motronic injection system, 92 kW (124 HP) — APT
- 1781 cm3 Bosch Motronic - APW injection system
- 1781 cm3 Bosch Motronic injection system, 110 kW (149 HP) – AEV
- 1781 cm3 Bosch Motronic injection system, 132 kW (178 hp) — AJL
Cylinder diameter:
- ADR, AHL, ADP, APT, APW, AFY. AEB, AJI - 81.0 mm
Stroke:
- ADP, AHL - 77.4 mm
- ADR, APT, APW, AFY, AEB, AJL - 86.4 mm
Compression ratio:
- ADP — 10.3:1
- AHL — 10.2:1
- ADR — 10.3:1
- APT — 10.3:1
- APW — 10.3:1
- AFY — 9.2:1
- AEB — 9.5:1
- AJL — 9.5:1
Compression limits on a worn engine:
- ADP, AHL, ADR, AFY - 7.5 bar
- AEB, AJL APT, APW - 7.0 bar
Permissible compression difference between cylinders - 3.0 bar
The order of operation of the cylinders is 1-3-4-2
Cylinder #1 - Timing Belt Side
Lubrication system
Oil pump type:
- ADP, ADR, APT, APW, AFY, AEB, AJL - the pump is installed in a sump, driven by an auxiliary shaft
- AHL - the pump is installed in the sump, driven by a chain from the crankshaft
Oil pressure (oil temperature 80°C):
adp. ADR, APT, APW. AFY. AEB. AJL:
- At idle - 1.0-3.5 bar
- At 3000 min-1 - 5.0-7.0 bar
AHL:
- At idle - 2.0 bar
- At 2000 min-1 - 3.0-4.5 bar
Oil pump cover wear limit - 0.2 mm
The maximum allowable axial clearance of gears is 0.15 mm
Tightening torques for threaded connections Nm
Air conditioner drive belt tensioner - 20
Automatic camshaft adjuster bolt (DOHC engines) — 10
Bolts and nuts for connecting rod caps:
- Stage 1 - 30
- Stage 2 - Turn 90°
Camshaft bearing caps:
- All engines except AHL, ADP - 10
- AHL ADP engines - 20
Valve cover - 10
Camshaft sprocket:
- Engines AHL, ADP - 100
- Other engines - 65
Water pump pulley halves - 25
Front crankshaft seal housing:
- Bolts M6 - 10
- Bolts M8 - 25
Crankshaft rear oil seal housing:
- Bolts M6 - 10
- Bolts M8 - 20
Crankshaft sprocket:
- Stage 1 - 90
- Stage 2 - Turn 90°
Cylinder head bolts:
- AHL Engine:
- Stage 1 - 40
- Stage 2 - turn 180° (or 2 x 90°)
- Other engines:
- Stage 1 - 60
- Stage 2 - turn 180° (or 2X90°)
Faceplate mounting bolts:
- Stage 1 - 60
- Stage 2 - Turn 90°
Engine mount to subframe - 25
Bolts of fastening of the engine to the check point:
- M10 - 45
- M12 - 65
Downpipe to exhaust manifold - 30
Flywheel bolts:
- Stage 1 - 60
- Stage 2 - turn 180° (or 2 x 90°)
Hall sensor rotor to intake camshaft (ADR engines. AFY, AEB, AJL) — 25
Hall sensor to cylinder head - 10
Ignition coil (engines AEB, AJL) — 10
Intake manifold support bracket - 20
Intake manifold:
- Engines AHL, ADP - 20
- Other engines - 10
Auxiliary shaft flange - 25
Auxiliary shaft sprocket:
- ADP engines - 80
- Other engines - 65
Crankshaft bearing cap bolts:
- AHL Engines:
- Stage 1 - 40
- Stage 2 - Turn 90°
- Other engines;
- Stage 1 - 65
- Stage 2 - Turn 90°
Oil nozzles - 27
Oil pump seal (engines ADP, ADR, AFY, AEB, AJL) — 10
Oil pump:
- ADP, ADR, AFY engines. AEB, AJL - 25
- AHL engines - 15
Pressure reducing valve - 8
Pallet:
- ADP Engines:
- Short bolts in two stages up to - 20
- Long bolts (flywheel/faceplate side) — 45
- ADR engines. AFY, AEB, AJL:
- Short block/pallet bolts in two stages up to - 15
- Long pan/block bolts - 45
- Pan/gearbox bolts:
- M8 - 25
- M10 - 45
- ANS engines:
- Short bolts in two stages up to - 15
- Long bolts (flywheel/faceplate side) — 45
Rear Timing Belt Guard - 20
Timing belt tensioner (ADP engine) — 25
Timing Belt Tensioner Nut (AHL engine) — 15
Fan viscous coupling nut - 45
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