General data
Engine code:
- 1595 cm³ — Bosch Motronic 3.2 injection system, 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 injection system Bosch Motronic — APW
- 1781 cm³ Bosch Motronic injection system, 110 kW (149 hp) — AEB
- 1781 cm³ Bosch Motronic injection system, 132 kW (178 hp) — AJL
Cylinder diameter:
- ADR, AHL, ADP, APT, APW, AFY. AEB, AJI - 81.0 mm
Piston 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 for a worn engine:
- ADP, AHL, ADR, AFY - 7.5 bar
- AEB, AJL APT, APW - 7.0 bar
The permissible difference in compression values between cylinders is 3.0 bar
The firing order 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 the sump, driven by an auxiliary shaft
- AHL - the pump is installed in the sump, with a chain drive from the crankshaft
Oil pressure (oil temperature 80°C):
ADP, ADR, APT, APW, AFY, AEB, AJL:
- At idle speed - 1.0-3.5 bar
- At 3000 min⁻¹ – 5.0-7.0 bar
AHL:
- At idle speed - 2.0 bar
- At 2000 min⁻¹ – 3.0-4.5 bar
Oil pump cover wear limit is 0.2 mm
Maximum permissible axial clearance of gears is 0.15 mm
Tightening torques for threaded connections Nm
Air Conditioning Drive Belt Tensioner - 20
Automatic camshaft phase adjuster bolt (dOHC engines) — 10
Connecting rod cap bolts and nuts:
- Stage 1 - 30
- Stage 2 - turn 90°
Camshaft Bearing Caps:
- All engines except AHL, ADP - 10
- Engines AHL ADP - 20
Valve cover - 10
Camshaft Sprocket:
- Engines AHL, ADP - 100
- Other engines - 65
Water Pump Pulley Halves - 25
Front crankshaft oil 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 support to subframe - 25
Engine to gearbox mounting bolts:
- M10 - 45
- M12 - 65
Intake pipe to exhaust manifold - 30
Flywheel mounting 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 (aEB, AJL engines) — 10
Intake Manifold Support Bracket - 20
Intake manifold:
- Engines AHL, ADP - 20
- Other engines - 10
Auxiliary shaft flange - 25
Auxiliary shaft sprocket:
- ADP-80 Engines
- Other engines - 65
Crankshaft support cover mounting bolts:
- AHL Engines:
- Stage 1 - 40
- Stage 2 - turn 90°
- Other engines;
- Stage 1 - 65
- Stage 2 - turn 90°
Oil injectors - 27
Oil pump cat (engines ADP, ADR, AFY, AEB, AJL) — 10
Oil pump:
- Engines ADP, ADR, AFY. AEB, AJL — 25
- AHL Engines - 15
Pressure reducing valve - 8
Pallet:
- ADP Engines:
- Short bolts in two stages up to - 20
- Long bolts (from the flywheel/faceplate side) — 45
- ADR engines. AFY, AEB, AJL:
- Short block/pan 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 (from the flywheel/faceplate side) — 45
Rear timing belt shield - 20
Timing Belt Tensioner (aDP engine) — 25
Timing Belt Tensioner Nut (aHL engine) — 15
Fan viscous coupling nut - 45