Audi 100/A6

1990-1997 of release

Repair and car operation



Audi 100/A6
+ 1. The maintenance instruction
+ 2. Maintenance service
+ 3. Engines
+ 3.2. Diesel engines
- 3.3. Removal and a partition of engines
   - 3.3.2. Technical characteristics
      3.3.2.2. The inhaling moments
   3.3.3. Repair work, possible without engine dismantle
   + 3.3.4. Major repairs
   3.3.5. Removal and engine installation
   3.3.6. An engine partition
   + 3.3.7. A head of cylinders
   3.3.8. Pistons and rods
   + 3.3.9. A cranked shaft
   3.3.10. An intermediate shaft
   3.3.11. The block of cylinders
   3.3.12. Radical bearings and bearings of rods
   3.3.13. Piston rings
   3.3.14. The first start of the engine after a partition
+ 4. Cooling system
+ 5. Heating and ventilation
+ 6. Fuel system
+ 7. An exhaust system
+ 8. Systems of start, ignition
+ 9. Transmission
+ 10. Brake system
+ 11. Suspension brackets, a steering
+ 12. A body
+ 13. An electric equipment
+ 14. A good advice



3.3.2. Technical characteristics

3.3.2.1. Codes of engines
THE GENERAL DATA

Codes of engines

4-cylinder petrol engines
1781 sm3, инжекторная system Bosch Motronic 3.2, 92 kw

ADR

1984 sm3, инжекторная system Bosch Mono-Motronic, 74 kw

AAE

1984 sm3, инжекторная system Bosch KE-Motronic, 103 kw
ACE
1984 sm3, инжекторная system Volkswagen Digifant, 85 kw
ABK
1984 sm3, инжекторная system Bosch KE-Motronic, 85 kw
AAD
5-cylinder petrol engines
2226 sm3, инжекторная system Motronic, 169 kw
AAN
2309 sm3, инжекторная system Bosch KEIII Jetronic, 98 kw
AАR
The 4-cylinder diesel engine
1896 sm3, direct injection, turbo-supercharging, 66 kw, 1Z
AHU
5-cylinder diesel engines
2370см3, direct injection, normal всасывание, 64 kw
AAS
2460см3, direct injection, турбонагнетатель, 85 kw, ABP
AAT
2460см3, direct injection, турбонагнетатель, 103 kw
AEL
Head of cylinders
The maximum deformation of a surface of a head of cylinders:
All types of engines except diesel engines AAS, AAT, ABP, AEL
0,1 mm
Diesel engines AAS, AAT, ABP, AEL
0,2 mm
The minimum height of a head of cylinders:
Petrol engine ADR
139,25 mm
Petrol AAE, ABK, AAD
132,6 mm
Petrol ACE,
118,1 mm
Petrol AAR, AAN
132,75 mm
Diesel engines
Repeated processing is impossible
Selection of a lining of a head of cylinders (a diesel engine 1Z, AHU):
Ledge of the piston 0,91 – 1,00 mm
1 aperture
Ledge of the piston 1,01 – 1,10 mm
2 apertures
Ledge of the piston 1,11 – 1,10 mm
3 apertures
Selection of a lining of a head of cylinders (diesel engine AAS):
Ledge of the piston 0,66 – 0,86 mm
1 aperture (a thickness of 1,53 mm)
Ledge of the piston 1,01 – 1,10 mm
2 aperture (1,57 mm)
Ledge of the piston 1,11 – 1,20 mm
3 aperture (1,61 mm)
Selection of a lining of a head of cylinders (diesel engine ABP, AAT, AEL):
Ledge of the piston 0,76 – 0,01 mm
1 aperture (a thickness of 1,53 mm)
Ledge of the piston 1,02 – 1,05 mm
2 aperture (1,57 mm)
Ledge of the piston 1,06 – 1,13 mm
3 aperture (1,61 mm)
The minimum distance from the centre of a rod of the valve to a head surface:
The inlet valve / the Final valve
 – Petrol ADR
33,2 mm / of 33,0 mm
 – Petrol AAE, ABK, AAD, AAR, AAN
33,8 mm / of 34,1 mm
 – Petrol ACE
34,4 mm / of 34,7 mm
 – Diesel engines
35,8 mm / of 36,1 mm
Pistons and piston rings
Diameter of the piston:
 – Petrol ADR:
The standard
80,985 mm
Increased, after the first расточки the cylinder
81,235 mm
Increased after the second расточки
81,485 mm
The maximum deviation
0,04 mm
 – Petrol AAE, ACE, ABK, AAD, AAR, AAN:
The standard
82,480 mm
Increased, after the first расточки the cylinder
82,730 mm
Increased after the second расточки
82,980 mm
The maximum deviation
0,04 mm
 – A diesel engine 1Z, AHU:
The standard
79,170 mm
Increased, after the first расточки the cylinder
79,720 mm
Increased after the second расточки
79,970 mm
The maximum deviation
0,04 mm
 – Diesel engine AAS:
The standard
79,480 mm
Increased, after the first расточки the cylinder
79,730 mm
Increased after the second расточки
79,980 mm
The maximum deviation
0,04 mm
 – Diesel engine ABP, AAT, AEL:
The standard
80,960 mm
Increased, after the first расточки the cylinder
81,210 mm
The maximum deviation
0,04 mm
Backlash between piston rings and flutes of rings:
4 cylinders, petrol ADR:
 – New:
Kompressionnye rings
0,02 – 0,07 mm
Maslosemnoe ring
0,02 – 0,06 mm
The maximum deterioration
0,12 mm
4 cylinders, petrol AAE, ABK, AAD:
 – New:
Kompressionnye rings and маслосъемное a ring
0,02 – 0,50 mm
The maximum deterioration
0,15 mm
4 cylinders, petrol ACE:
 – New:
Kompressionnye rings
0,02 – 0,07 mm
Maslosemnoe ring
0,02 – 0,06 mm
The maximum deterioration
0,15 mm
5 cylinders, petrol AAR, AAN:
 – New:
Kompressionnye rings
0,02 – 0,07 mm
Maslosemnoe ring
0,02 0,06 mm
The maximum deterioration
0,12 mm
4 cylinders, diesel engine 1Z, AHU:
 – New:
Top компрессионное a ring
0,06 – 0,09 mm
The second компрессионное a ring
0,05 – 0,08 mm
Maslosemnoe ring
0,03 – 0,06 mm
The maximum deterioration:
Kompressionnye rings
0,25 mm
Maslosemnoe ring
0,15 mm
5 cylinders, diesel engine AAS:
 – New:
Top компрессионное a ring
0,09 – 0,12 mm
The second компрессионное a ring
0,05 – 0,08 mm
Maslosemnoe ring
0,03 – 0,06 mm
The maximum deterioration:
Kompressionnye rings
0,25 mm
Maslosemnoe ring
0,15 mm
5 cylinders, diesel engine AAT:
 – New:
Top компрессионное a ring
0,07 – 0,105 mm
The second компрессионное a ring
0,05 – 0,075 mm
Maslosemnoe ring
0,03 – 0,065 mm
The maximum deterioration:
Kompressionnye rings
0,25 mm
Maslosemnoe ring
0,15 mm
Pistons and piston rings (continuation)
Trailer backlashes of piston rings
4 cylinders, petrol ADR:
 – New:
Kompressionnye rings
0,15 – 0,40 mm
Maslosemnoe ring
0,25 – 0,50 mm
Ring from 3 parts
Less than 1,00 mm
The maximum deterioration:
Kompressionnye rings
0,80 mm
Maslosemnoe ring
1,0 mm
Ring from 3 parts
1,30 mm
4 cylinders, petrol AAE, ABK, AAD:
 – New:
Kompressionnye rings
0,30 0,45
Maslosemnoe ring
0,25 – 0,45 mm
The maximum deterioration
1,0 mm
4 cylinders, petrol to ASYA:
 – New:
Kompressionnye rings
0,20 – 0,40 mm
Maslosemnoe ring
0,2–0,50 mm
The maximum deterioration
1,0 mm
5 cylinders, petrol AAR, AAN:
 – New:
Kompressionnye rings
0,02 – 0,07 mm
Maslosemnoe ring
0,02 – 0,06 mm
The maximum deterioration
0,15 mm
4 cylinders, diesel engine 1Z, AHU:
 – New:
Kompressionnye rings
0,20 – 0,40 mm
Maslosemnoe ring
0,25 – 0,50 mm
The maximum deterioration
1,0 mm
5 cylinders, diesel engine AAS:
 – New:
Kompressionnye rings
0,20 – 0,40 mm
Maslosemnoe ring
0,25 – 0,50 mm
The maximum deterioration:
Top компрессионное a ring
1,20 mm
The second компрессионное a ring
0,60 mm
Maslosemnoe ring
1,20 mm
5 cylinders, diesel engine ABP, AAT, AEL:
 – New:
Top компрессионное a ring
0,25 – 0,45 mm
The second компрессионное a ring
0,20 – 0,40 mm
Maslosemnoe ring
0,25 – 0,50 mm
The maximum deterioration
1,0 mm
Valves
Diameter of a rod of the valve:
The inlet:
ADR
5,95-5,97 mm
AAE, ABK, AAD, AAR, 1Z, AHU, AAS, ABP, AAT, AEL, AAN
7,97 mm
ACE
6,97 mm
The final:
ADR
5,94 – 5,95 mm
AAE, ABK, AAD, AAR, 1Z, AHU, AAS, ABP, AAT, AEL, AAN
7,95 mm
ACE
6,94 mm
The maximum deviation of a head of the valve:
The inlet:
ADR
0,8 mm
AAE, ACE, ABK, AAD, AAR, AAN
1,0 mm
1Z, AHU, AAS, ABP, AAT, AEL
1,3 mm
The final:
ADR
0,8 mm
AAE, ACE, ABK, AAD, AAR, AAN
1,3 mm
1Z, AHU, AAS, ABP, AAT, AEL
1,3 mm
Camshaft
The maximum free wheeling:
The inlet:
AAE, ACE, ABK, AAD, AAR, 1Z, AHU, AAS, ABP, AAT, AEL, AAN
0,15 mm
ADR
0,20 mm
Palpation (all types)
0,01 mm
The maximum lubricant backlash (all models)
1,10мм
Intermediate shaft
The maximum free wheeling:
ADR, AAE, ACE, ABK, AAD, 1Z, AHU
0,25 mm
The block of cylinders
Diameter of the cylinder:
ADR:
The standard
81,01 mm
Increased, after the first расточки
81,26 mm
Increased, after the second расточки
81,51 mm
The maximum deterioration of the cylinder
0,10 mm
AAE, ACE, ABK, AAD, AAR, AAN:
The standard
82,51 mm
Increased, after the first расточки
82,76 mm
Increased, after the second расточки
83,01 mm
The maximum deterioration of the cylinder
0,08 mm
1Z, AHU, AAS:
The standard
79,51 mm
Increased, after the first расточки
79,76 mm
Increased, after the second расточки
80,01 mm
The maximum deterioration of the cylinder:
1Z, AHU
0,10 mm
AAS
0,08 mm
ABP, AAT, AEL:
The standard
81,01 mm
Increased, after the first расточки
81,26 mm
The maximum deterioration of the cylinder
0,08 mm
Rods
Lateral backlash of the bottom head of a rod:
AAE, ACE, ABK, AAD, 1Z, AHU
0,37 mm
ACE, AAR, AAS, ABP, AAT, AEL, AAN
0,4 mm
Cranked shaft
Depth of the aligning needle bearing
1,5 mm
Free wheeling:
Face value:
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 engine 1Z, AHU
0,07 – 0,17 mm
Diesel engine AAS, ABP, AAT, AEL
0,07 – 0,18 mm
The maximum deterioration:
Petrol ADR
0,30 mm
Petrol AAR, AAN
0,25 mm
Petrol AAE, ABK, AAD, ACE
0,25 mm
Diesel engine 1Z, AHU
0,37 mm
Diesel engine AAS, ABP, AAT, AEL
0,25 mm
Lubricant backlash of the radical bearing:
Petrol ADR, AAE, ACE, ABK, AAD
0,17 mm
Petrol AAR, AAN
0,10 mm
Diesel engine 1Z, AHU
0,17 mm
Diesel engine AAS, ABP, AAT, AEL
0,16 mm
Diameter of a neck of the radical bearing:
4 cylinders, petrol ADR, AAE, ACE, ABK, AAD:
The standard
54,00 mm
Reduced, after the first grinding
53,75 mm
Reduced, after the second grinding
53,50 mm
Reduced, after the third grinding
53,25 mm
5 cylinders, petrol AAR, AAN:
The standard
58,00 mm
Reduced, after the first grinding
57,75 mm
Reduced, after the second grinding
57,50 mm
Reduced, after the third grinding
57,25 mm
4 cylinders, diesel engine 1Z, AHU:
The standard
54,00 mm
Reduced, after the first grinding
53,75 mm
Reduced, after the second grinding
53,50 mm
Reduced, after the third grinding
53,25 mm
5 cylinders, diesel engine AAS, ABP, AAT, AEL:
The standard
58,00 mm
Reduced, after the first grinding
57,75 mm
Reduced, after the second grinding
57,50 mm
Reduced, after the third grinding
57,25 mm
Diameter of a neck of a rod:
All engines:
The standard
47,80 mm
Reduced, after the first grinding
47,55 mm
Reduced, after the second grinding
47,30 mm
Reduced, after the third grinding
47,05 mm
The maximum ovality
0,03 mm