Engine identification
Petrol engines:
- 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 (119 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, 110kW (149 HP) – AEV
- 1781 cm3 injection system Bosch Motronic, 132 kW (178 HP) — AJL
Diesel engines:
- Direct injection with electronic control and turbocharging, 66 k W (90 l. With.) — 1Z
- Direct fuel injection with electronic control and turbocharging, 81 kW (110 l. With.) — AFN
- Direct fuel injection with electronic control and turbocharging, 55 kW (75 l. With.) — AFF
- Direct fuel injection with electronic control and turbocharging, 66 kW (90 l. With.) — AHU
- Direct fuel injection with electronic control and turbocharging, 66 kW (90 l. With.) – ANN
Note: To find the engine code marking, see "Vehicle identification" at the end of this guide.
Cylinder head
Maximum allowable curvature of the mating surface:
- All engines - 0.1 mm
Minimum allowable head height:
- Gasoline engines ADP, AHL - 132.6 mm
- Gasoline engines ADR, AFY, AEB, AJL - 139.25 mm
- Diesel engines - grinding is not allowed
Choice of gasket thickness (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 single-punch gasket is not recommended.
Minimum allowable distance from the heel of the valve stem to the top surface of the head:
Inlet | High school graduation | |
ADP petrol engines. AHL | 33.8mm | 34.1 mm |
Gasoline engines ADR, AFY, AEB, AJL | 34.0 mm (external) | 34.4 mm |
33.7mm (center.) | ||
Diesel engines | 35.8mm | 36.1mm |
Pistons and rings
Piston diameter:
- ADP, ADR, AFY, AEB, AJL petrol engines:
- 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
Gap between ring and piston groove:
- 4-cylinder gasoline 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
- Meslosemnoe 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 lock of the ring (the ring is installed in the cylinder 15 mm from the surface):
- ADP, AHL, ADR, AFY, AEB, AJL petrol engines:
- 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
- Meslosemny ring — 0.25...0.50 mm
- Extremely worn ring - 1.0 mm
Valves
Rod diameter: | Inlet | High school graduation |
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 "reel" valve discs (the heel of the rod is flush with the end face of the guide bush): | ||
ADP, AHL | 1.0 mm | 1.3mm |
ADR, AFY, AEB, AJL | 0.80 mm | 0.80 mm |
1Z, AHU, ANN, AFN, AFF | 1.3mm | 1.3mm |
Camshaft
Maximum allowable 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 the camshaft bearings:
- Engines ADP, AHL ADR, AFY, AEB, AJL - 0.10 mm
- Engines 1Z, AHU, ANN, AFN, AFF - 0.11 mm
Auxiliary shaft
Maximum allowable axial clearance:
- ADP, ADR, AFY, AEB, AJL, 1Z, AHU, ANN, AFN, AFF - 0.25 mm
Cylinder block
Cylinder diameter:
- ADR, AHL, ADR, AFY, AEB, AJL engines:
- Standard - 81.01 mm
- Repair size - 81.51 mm
- The maximum allowable wear is 0.08 mm
- Engines 1Z, AHU, ANN, AFN, AFF:
- Standard - 79.51 mm
- 1st repair - 79.76 mm
- 2nd repair - 80.01 mm
- The maximum allowable wear is 0.10 mm
Connecting rods
Clearances in connecting rod bearings (maximum):
- ADR, AHL, ADR, AFY, AEB, AJL - 0.40 mm
- 1Z, AHU, ANN, AFN, AFF - 0.37 mm
Crankshaft
Needle bearing seating depth - 1.5 mm
Axial clearance:
- New:
- Gasoline engines ADP, ADR, AFY, AEB, AJL - 0.07...0.23 mm
- AHL petrol engines - 0.07...0.21 mm
- Diesel engines - 0.07...0.17 mm
- Extremely worn:
- Gasoline engines ADP, AHL, ADR, AFY, AEB, AJL - 0.30 mm
- Diesel engines - 0.37 mm
Clearances in main bearings:
- New:
- Gasoline 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:
- Gasoline engines ADP, AHL, ADR, AFY, AEB, AJL - 0.15 mm
- Diesel engines - 0.17 mm
Main bearing journal diameter:
- ADP, ADR, AFY, AEB, AJL petrol engines:
- 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 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:
- Gasoline 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.
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