Engine Overhaul Specifications (Audi A4 B5)

Engine identification

Petrol engines:

• 1595 cm³ Bosch Motronic injection system 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 (119 hp) — AFY
• 1781 cm³ Bosch Motronic injection system, 92 kW (124 hp) — APT
• 1781 cm³ Bosch Motronic injection system — APW
• 1781 cm³ Bosch Motronic injection system, 110 kW (149 hp) — AEB
• 1781 cm³ Bosch Motronic injection system, 132 kW (178 hp) — AJL

Diesel engines:

• Direct fuel injection with electronic control and turbocharging, 66 kW (90 hp) - 1Z
• Direct fuel injection with electronic control and turbocharging, 81 kW (110 hp) - AFN
• Electronically controlled direct fuel injection with turbocharging, 55 kW (75 hp) — AFF
• Direct fuel injection with electronic control and turbocharging, 66 kW (90 hp) - AHU
• Direct fuel injection with electronic control and turbocharging, 66 kW (90 hp) - ANN

Note: To locate the engine code marking, see "Vehicle Identification" at the end of this manual.

Cylinder head

Maximum permissible curvature of the mating surface:

• All motors - 0.1mm

Minimum allowable head height:

• Gasoline engines ADP, AHL - 132.6 mm
• Petrol engines ADR, AFY, AEB, AJL - 139.25 mm
• Diesel engines - grinding is not allowed

Selecting the thickness of the gasket (diesel engines):

• Piston protrusion 0.91...1.00 mm — 1 hole/notch*
• Piston protrusion 1.01...1.10 mm — 2 holes/notches*
• Piston protrusion 1.11...1.20 mm — 3 holes/notches*

* The use of a gasket with one notch is not recommended.

Minimum allowable distance from the heel of the valve stem to the top surface of the head:

	Inlet	Outlet
Gasoline engines ADP. AHL	33.8 mm	34.1 mm
Petrol engines ADR, AFY, AEB, AJL	34.0 mm (outside)	34.4 mm
	33.7 mm (center)
Diesel engines	35.8 mm	36.1 mm

Pistons and rings

Piston diameter:

• Petrol engines ADP, ADR, AFY, AEB, AJL:
• Standard - 80.975 mm
• 1st repair size - 81.475 mm
• Permissible wear - 0.04 mm
• AHL petrol engine:
• Standard - 80.965 mm
• 1st repair size - 81.465 mm
• Permissible wear - 0.04 mm
• Diesel engines:
• Standard - 79.470 mm
• 1st repair size - 79.720 mm
• 2nd repair size - 79.970 mm
• Permissible wear - 0.04 mm

Clearance between ring and piston groove:

• 4-cylinder petrol engines ADP, AHL, ADR, AEB, AJL:
• First compression ring - 0.06...0.09 mm
• Second compression ring - 0.05...0.08 mm
• Oil scraper ring — 0.03...0.06 mm
• Wear limit:
• Compression rings - 0.20 mm
• Removable ring - 0.15 mm
• 4-cylinder diesel engines:
• First compression ring - 0.06...0.09 mm
• Second compression ring - 0.05...0.08 mm
• Oil scraper ring — 0.03...0.06 mm
• Wear limit:
• Compression rings - 0.25 mm
• Oil scraper ring - 0.15 mm

Gap in the ring lock (the ring is installed in the cylinder 15 mm from the surface):

• Petrol engines ADP, AHL, ADR, AFY, AEB, AJL:
• New:
• Compression rings - 0.20...0.40 mm
• Oil scraper ring — 0.25...0.50 mm
• Extremely worn - 0.8 mm
• Diesel engines:
• New:
• Compression rings - 0.20...0.40 mm
• Oil ring - 0.25...0.50 mm
• Extremely worn ring - 1.0 mm

Valves

Rod diameter:	Inlet	Outlet
ADP, AHL	6.918...6.922 mm	6.918...6.922 mm
ADR, AFY, AEB, AJL	5.950...5.970 mm	5.940...5.950 mm
1Z, AHU, ANN, AFN, AFF up to 3/1998	7.970 mm	7.950 mm
1Z, AHU, ANN, AFN, AFF after 4/1998	6.963 mm	6.943 mm
Maximum allowable "wobble" of the valve plate (the heel of the rod is flush with the end of the guide sleeve):
ADP, AHL	1.0 mm	1.3 mm
ADR, AFY, AEB, AJL	0.80 mm	0.80 mm
1Z, AHU, ANN, AFN, AFF	1.3 mm	1.3 mm

Camshaft

Maximum permissible axial clearance:

• ADP, AHL, 1Z, AHU, ANN, AFN, AFF - 0.15 mm
• ADR, AFY, AEB, AJL - 0.20 mm

Maximum allowable runout (all engines) — 0.01 mm

Maximum allowable clearance in camshaft bearings:

• ADP, AHL ADR, AFY, AEB, AJL engines — 0.10 mm
• Engines 1Z, AHU, ANN, AFN, AFF — 0.11 mm

Auxiliary shaft

Maximum permissible axial clearance:

• ADP, ADR, AFY, AEB, AJL, 1Z, AHU, ANN, AFN, AFF - 0.25 mm

Cylinder block

Cylinder diameter:

• Engines ADR, AHL, ADR, AFY, AEB, AJL:
• Standard - 81.01 mm
• Repair size - 81.51 mm
• Maximum wear limit is 0.08 mm
• Engines 1Z, AHU, ANN, AFN, AFF:
• Standard - 79.51 mm
• 1st repair - 79.76 mm
• 2nd repair - 80.01 mm
• Maximum wear tolerance is 0.10 mm

Connecting rods

Connecting rod bearing clearances (maximum):

• ADP, AHL, ADR, AFY, AEB, AJL - 0.40 mm
• 1Z, AHU, ANN, AFN, AFF - 0.37 mm

Crankshaft

Needle bearing seating depth is 1.5 mm

Axial clearance:

• New:
• Petrol engines ADP, ADR, AFY, AEB, AJL — 0.07...0.23 mm
• Gasoline engines AHL — 0.07...0.21 mm
• Diesel engines - 0.07...0.17 mm
• Extremely worn:
• Petrol engines ADP, AHL, ADR, AFY, AEB, AJL - 0.30 mm
• Diesel engines - 0.37 mm

Main bearing clearances:

• New:
• Petrol engines ADP, ADR, AFY, AEB, AJL — 0.02...0.04 mm
• Gasoline engines AHL — 0.01...0.04 mm
• Diesel engines - 0.03...0.08 mm
• Extremely worn:
• Petrol engines ADP, AHL, ADR, AFY, AEB, AJL - 0.15 mm
• Diesel engines - 0.17 mm

Main bearing journal diameter:

• Petrol engines ADP, ADR, AFY, AEB, AJL:
• Standard - 54.00 mm_-0.017-0.037
• 1st repair size - 53.75 mm_-0.017-0.037
• 2nd repair size - 53.50 mm_-0.017-0.037
• 3rd repair size - 53.25 mm_-0.017-0.037
• AHL petrol engines:
• Standard - 54.00 mm_-0.022-0.042
• 1st repair size - 53.75 mm_-0.022-0.042
• 2nd repair size - 53.50 mm_-0.022-0.042
• 3rd repair size - 53.25 mm_-0.022-0.042
• Diesel engines 1Z, AHU, ANN, AFN, AFF:
• Standard - 54.00 mm_-0.022-0.042
• 1st repair size - 53.75 mm_-0.022-0.042
• 2nd repair size - 53.50 mm_-0.022-0.042
• 3rd repair size - 53.25 mm_-0.022-0.042

Connecting rod bearing journal diameter:

• All engines, petrol and diesel:
• Standard - 47.80 mm_-0.022-0.042
• 1st repair size - 47.55 mm_-0.022-0.042
• 2nd repair size - 47.30 mm_-0.022-0.042
• 3rd repair size - 47.05 mm_-0.022-0.042

Connecting rod bearing clearance:

• New:
• Gasoline engines - 0.01...0.05 mm
• Diesel engines - 0.03...0.08 mm
• Extremely worn:
• Petrol engines - 0.12 mm
• Diesel engines - 0.08 mm
• Permissible out-of-roundness - 0.03 mm

Tightening torques for threaded connections

See Chapter 2A or 2B.

This article was copied from the website AUDImanual.ru