4-cylinder petrol engines
| |
1781 cm3, Bosch Motronic 3.2 injection system, 92 kW |
ADR |
1984 cm3, Bosch Mono-Motronic injection system, 74 kW |
AAE |
1984 cm3, Bosch KE-Motronic injection system, 103 kW |
ACE
|
1984 cm3, Volkswagen Digifant injection system, 85 kW |
ABK
|
1984 cm3, Bosch KE-Motronic injection system, 85 kW |
AAD
|
5-cylinder petrol engines
| |
2226 cm3, Motronic injection system, 169 kW |
AAN
|
2309 cm3, Bosch KEIII Jetronic injection system,
98 kW |
AAR
|
4 cylinder diesel engine
| |
1896 cm3, direct injection, turbo, 66 kW, 1Z |
AHU
|
5-cylinder diesel engines
| |
2370cm3, direct injection, normal suction, 64 kW |
AAS
|
2460cm3, direct injection, turbocharger, 85 kW, ABP |
AAT
|
2460cm3, direct injection, turbocharger, 103 kW |
AEL
|
cylinder head
| |
Maximum deformation of the surface of the cylinder head: | |
All types of engines except diesel engines AAS, AAT, ABP, AEL |
0.1 mm
|
Diesel engines AAS, AAT, ABP, AEL |
0.2mm
|
Minimum cylinder head height: | |
ADR petrol engine |
139.25 mm
|
Petrol AAE, ABK, AAD |
132.6 mm
|
Petrol ACE, |
118.1 mm
|
Petrol AAR, AAN |
132.75 mm
|
Diesel engines |
Reprocessing not possible
|
Selection of cylinder head gasket (diesel 1Z, AHU): | |
Piston protrusion 0.91 - 1.00 mm |
1 hole
|
Piston protrusion 1.01 - 1.10 mm |
2 holes
|
Piston protrusion 1.11 - 1.10 mm |
3 holes
|
Selection of cylinder head gasket (diesel AAS): | |
Piston protrusion 0.66 - 0.86 mm |
1 hole (thickness 1.53 mm)
|
Piston protrusion 1.01 - 1.10 mm |
2 hole (1.57mm)
|
Piston protrusion 1.11 - 1.20 mm |
3 hole (1.61 mm)
|
Selection of cylinder head gasket (diesel ABP, AAT, AEL): | |
Piston protrusion 0.76 - 0.01 mm |
1 hole (thickness 1.53 mm)
|
Piston protrusion 1.02 - 1.05 mm |
2 hole (1.57mm)
|
Piston protrusion 1.06 - 1.13 mm |
3 hole (1.61 mm)
|
Minimum distance from the center of the valve stem to the surface heads: |
Inlet valve/ Exhaust valve
|
– Petrol ADRs |
33.2 mm/ 33.0 mm
|
– Petrol AAE, ABK, AAD, AAR, AAN |
33.8 mm/ 34.1 mm
|
– Petrol ACE |
34.4 mm/ 34.7 mm
|
– Diesel engines |
35.8 mm/ 36.1 mm
|
Pistons and piston rings
| |
Piston diameter: | |
– Petrol ADRs: | |
Standard |
80.985 mm
|
Enlarged, after the first bore of the cylinder |
81.235 mm
|
Enlarged after second boring |
81.485 mm
|
Maximum deviation |
0.04mm
|
– Petrol AAE, ACE, ABK, AAD, AAR, AAN: | |
Standard |
82.480 mm
|
Enlarged, after the first bore of the cylinder |
82.730 mm
|
Enlarged after second boring |
82.980 mm
|
Maximum deviation |
0.04mm
|
– Diesel 1Z, AHU: | |
Standard |
79.170 mm
|
Enlarged, after the first bore of the cylinder |
79.720 mm
|
Enlarged after second boring |
79.970 mm
|
Maximum deviation |
0.04mm
|
– Diesel AAS: | |
Standard |
79.480 mm
|
Enlarged, after the first bore of the cylinder |
79.730 mm
|
Enlarged after second boring |
79.980 mm
|
Maximum deviation |
0.04mm
|
– Diesel ABP, AAT, AEL: | |
Standard |
80.960 mm
|
Enlarged, after the first bore of the cylinder |
81.210 mm
|
Maximum deviation |
0.04mm
|
Gap between piston rings and ring grooves: | |
4 cylinders, petrol ADR: | |
– New: | |
Compression rings |
0.02 - 0.07 mm
|
Oil scraper ring |
0.02 - 0.06 mm
|
Maximum wear |
0.12 mm
|
4 cylinders, petrol AAE, ABK, AAD: | |
– New: | |
Compression rings and oil scraper ring |
0.02 - 0.50 mm
|
Maximum wear |
0.15 mm
|
4 cylinders, petrol ACE: | |
– New: | |
Compression rings |
0.02 - 0.07 mm
|
Oil scraper ring |
0.02 - 0.06 mm
|
Maximum wear |
0.15 mm
|
5 cylinders, petrol AAR, AAN: | |
– New: | |
Compression rings |
0.02 - 0.07 mm
|
Oil scraper ring |
0.02–0.06 mm
|
Maximum wear |
0.12 mm
|
4 cylinders, diesel 1Z, AHU: | |
– New: | |
Top compression ring |
0.06 - 0.09 mm
|
Second compression ring |
0.05 - 0.08 mm
|
Oil scraper ring |
0.03 - 0.06 mm
|
Maximum wear: | |
Compression rings |
0.25 mm
|
Oil scraper ring |
0.15 mm
|
5 cylinders diesel AAS: | |
– New: | |
Top compression ring |
0.09 - 0.12 mm
|
Second compression ring |
0.05 - 0.08 mm
|
Oil scraper ring |
0.03 - 0.06 mm
|
Maximum wear: | |
Compression rings |
0.25 mm
|
Oil scraper ring |
0.15 mm
|
5 cylinders, diesel AAT: | |
– New: | |
Top compression ring |
0.07 - 0.105 mm
|
Second compression ring |
0.05 - 0.075 mm
|
Oil scraper ring |
0.03 - 0.065 mm
|
Maximum wear: | |
Compression rings |
0.25 mm
|
Oil scraper ring |
0.15 mm
|
Pistons and piston rings (continuation) | |
Piston ring end clearances
| |
4 cylinders, petrol ADR: | |
– New: | |
Compression rings |
0.15 - 0.40 mm
|
Oil scraper ring |
0.25 - 0.50 mm
|
3 piece ring |
less than 1.00 mm
|
Maximum wear: | |
Compression rings |
0.80 mm
|
Oil scraper ring |
1.0 mm
|
3 piece ring |
1.30 mm
|
4 cylinders, petrol AAE, ABK, AAD: | |
– New: | |
Compression rings |
0,30– 0,45
|
Oil scraper ring |
0.25 - 0.45 mm
|
Maximum wear |
1.0mm
|
4 cylinders, petrol ACE: | |
– New: | |
Compression rings |
0.20 - 0.40 mm
|
Oil scraper ring |
0.2 - -0.50 mm
|
Maximum wear |
1.0mm
|
5 cylinders, petrol AAR, AAN: | |
– New: | |
Compression rings |
0.02 - 0.07 mm
|
Oil scraper ring |
0.02 - 0.06 mm
|
Maximum wear |
0.15 mm
|
4 cylinders, diesel 1Z, AHU: | |
– New: | |
Compression rings |
0.20 - 0.40 mm
|
Oil scraper ring |
0.25 - 0.50 mm
|
Maximum wear |
1.0mm
|
5 cylinders diesel AAS: | |
– New: | |
Compression rings |
0.20 - 0.40 mm
|
Oil scraper ring |
0.25 - 0.50 mm
|
Maximum wear: | |
Top compression ring |
1.20 mm
|
Second compression ring |
0.60 mm
|
Oil scraper ring |
1.20 mm
|
5 cylinders, diesel ABP, AAT, AEL: | |
– New: | |
Top compression ring |
0.25 - 0.45 mm
|
Second compression ring |
0.20 - 0.40 mm
|
Oil scraper ring |
0.25 - 0.50 mm
|
Maximum wear |
1.0mm
|
valves
| |
Valve stem diameter: | |
intake: | |
ADR |
5.95-5.97mm
|
AAE, ABK, AAD, AAR, 1Z, AHU, AAS, ABP, AAT, AEL, AAN |
7.97 mm
|
ACE |
6.97 mm
|
graduation: | |
ADR |
5.94 - 5.95 mm
|
AAE, ABK, AAD, AAR, 1Z, AHU, AAS, ABP, AAT, AEL, AAN |
7.95 mm
|
ACE |
6.94 mm
|
Maximum valve head deflection: | |
intake: | |
ADR |
0.8mm
|
AAE, ACE, ABK, AAD, AAR, AAN |
1.0 mm
|
1Z, AHU, AAS, ABP, AAT, AEL |
1.3mm
|
graduation: | |
ADR |
0.8mm
|
AAE, ACE, ABK, AAD, AAR, AAN |
1.3mm
|
1Z, AHU, AAS, ABP, AAT, AEL |
1.3 mm
|
Camshaft
| |
Maximum free play: | |
intake: | |
AAE, ACE, ABK, AAD, AAR, 1Z, AHU, AAS, ABP, AAT, AEL, AAN |
0.15 mm
|
ADR |
0.20 mm
|
beat (all types) |
0.01mm
|
Maximum lubrication clearance (all models) |
1.10mm
|
intermediate shaft
| |
Maximum free play: | |
ADR, AAE, ACE, ABK, AAD, 1Z, AHU |
0.25 mm
|
Cylinder block
| |
Cylinder diameter: | |
ADR: | |
Standard |
81.01 mm
|
Enlarged, after the first boring |
81.26 mm
|
Enlarged, after the second boring |
81.51 mm
|
Maximum cylinder wear |
0.10 mm
|
AAE, ACE, ABK, AAD, AAR, AAN: | |
Standard |
82.51 mm
|
Enlarged, after the first boring |
82.76 mm
|
Enlarged, after the second boring |
83.01 mm
|
Maximum cylinder wear |
0.08mm
|
1Z, AHU, AAS: | |
Standard |
79.51 mm
|
Enlarged, after the first boring |
79.76 mm
|
Enlarged, after the second boring |
80.01 mm
|
Maximum cylinder wear: | |
1Z, AHU |
0.10 mm
|
AAS |
0.08mm
|
ABP, AAT, AEL: | |
Standard |
81.01 mm
|
Enlarged, after the first boring |
81.26 mm
|
Maximum cylinder wear |
0.08 mm
|
connecting rods
| |
Lateral clearance of the lower head of the connecting rod: | |
AAE, ACE, ABK, AAD, 1Z, AHU |
0.37 mm
|
ACE, AAR, AAS, ABP, AAT, AEL, AAN |
0.4mm
|
Crankshaft
| |
Depth of centering needle bearing |
1.5mm
|
Free move: | |
Denomination: | |
Petrol ADR, AAR, AAN |
0.07 - 0.23 mm
|
Petrol AAE, ABK, AAD |
0.017 - 0.17 mm
|
Petrol ACE |
0.07 - 0.17 mm
|
Diesel 1Z, AHU |
0.07 - 0.17 mm
|
Diesel AAS, ABP, AAT, AEL |
0.07 - 0.18 mm
|
Maximum wear: | |
Petrol ADRs |
0.30 mm
|
Petrol AAR, AAN |
0.25 mm
|
Petrol AAE, ABK, AAD, ACE |
0.25 mm
|
Diesel 1Z, AHU |
0.37 mm
|
Diesel AAS, ABP, AAT, AEL |
0.25 mm
|
Main bearing lubrication gap: | |
Petrol ADR, AAE, ACE, ABK, AAD |
0.17 mm
|
Petrol AAR, AAN |
0.10 mm
|
Diesel 1Z, AHU |
0.17 mm
|
Diesel AAS, ABP, AAT, AEL |
0.16 mm
|
Main bearing journal diameter: | |
4 cylinders, petrol ADR, AAE, ACE, ABK, AAD: | |
Standard |
54.00 mm
|
Reduced, after the first turning |
53.75 mm
|
Reduced, after the second turning |
53.50 mm
|
Reduced, after the third turning |
53.25 mm
|
5 cylinders, petrol AAR, AAN: | |
Standard |
58.00 mm
|
Reduced, after the first turning |
57.75 mm
|
Reduced, after the second turning |
57.50 mm
|
Reduced, after the third turning |
57.25 mm
|
4 cylinders, diesel 1Z, AHU: | |
Standard |
54.00 mm
|
Reduced, after the first turning |
53.75 mm
|
Reduced, after the second turning |
53.50 mm
|
Reduced, after the third turning |
53.25 mm
|
5 cylinders, diesel AAS, ABP, AAT, AEL: | |
Standard |
58.00 mm
|
Reduced, after the first turning |
57.75 mm
|
Reduced, after the second turning |
57.50 mm
|
Reduced, after the third turning |
57.25 mm
|
Connecting rod diameter: | |
All engines: | |
Standard |
47.80 mm
|
Reduced, after the first turning |
47.55 mm
|
Reduced, after the second turning |
47.30 mm
|
Reduced, after the third turning |
47.05 mm
|
Maximum ovality |
0.03mm
|
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