ENGINE - TD4 DIESEL
| General | |
|---|---|
| Type | 2.0 litre in-line direct injection diesel, 16-valve, DOHC, turbocharged and inter cooled |
| Cylinder arrangement | 4 in-line, transverse, No.1 cylinder at front of engine |
| Bore | 84.00 mm (3.307 in.) |
| Stroke | 88.00 mm (3.465 in.) |
| Capacity | 1951 cm 3 (119.05 in 3 ) |
| Firing order | 1-3-4-2 |
| Compression ratio | 18:1 ± 0.5:1 |
| Direction of rotation | Clockwise, viewed from the front of the engine |
| Maximum power: --> Up to 03 Model Year-Manual and automatic gearbox | 82 kW (112 bhp) @ 4000 rev/min. |
| > 03 Model Year onwards - Manual gearbox | 82 kW (112 bhp) @ 4000 rev/min |
| > 03 Model Year onwards - Automatic gearbox | 80 kW (107 bhp) @ 4000 rev/min |
| Maximum torque | 260 Nm (192 lbf.ft) @ 1750 rev/min. |
| Maximum governed speed | 4800 rev/min. |
| Maximum overrun speed | 5250 rev/min |
| Idle speed | 780 ± 30 rev/min |
| Dimensions: --> Length | 482 mm (19.0 in) |
| > Width | 634 mm (25.0 in) |
| > Height | 697 mm (27.4 in) |
| Glow plugs | 4 off, one per cylinder arranged centrally on inlet side between inlet valves |
| Turbocharger | Garrett GT2 |
| Fuel injection system | Common rail, direct injection fed by Bosch high pressure delivery pump |
| Injection timing | Controlled by ECM |
| Emissions standard | ECD3 |
| Valve timing | |
| Inlet valves: --> Opens | 8° BTDC |
| > Closes | 28° ABDC |
| Exhaust valves: --> Opens | 38° BBDC |
| > Closes | 4° ATDC |
| Lubrication | |
| Type | Wet aluminium die-cast sump, pressure fed |
| Oil filter | Disposable canister with full flow bypass |
| Oil cooler | Integral with oil filter assembly, connected to vehicle cooling system |
| Oil pump | |
| > Type | Crankshaft driven, eccentric rotor |
| > Oil flow rate | 30 litres / min. (6.625 gallons/min.) |
| > Outer rotor to body clearance | 0.080 - 0.158 mm (0.0031 - 0.062 in.) |
| > Peak pressure | Up to 20 bar (290 lbf.in 2 ) |
| Oil pressure at idle | |
| > Cold-1000 rev/min. | 1.5 bar (21.8 lbf.in 2 ) |
| > Operating temperature (minimum) | 0.5 bar (7.3 lbf.in 2 ) |
| > Regulated pressure | 4.2 ± 0.5 bar (60.9 ± 7.3 lbf.in 2 ) |
| > Pressure at 3500 rev/min (hot) | 3.0 - 4.5 bar (43.5 - 65.3 lbf.in 2 ) |
| Relief valve opening pressure | 4.2 bar (60.9 lbf.in 2 ) |
| Low oil pressure switch opening pressure | 0.2-0.5 bar (2.9-7.3 lbf.in 2 ) |
| Cylinder block | |
| Type | Grey cast iron with hollow beam structure |
| Cylinder head warp -maximum | 0.03 mm (0.001 in.) |
| Cylinder head bore | |
| > Standard | 84.000 - 84.018 mm (3.3071 - 3.3078 in) |
| >--> Wear limit | 84.040 mm (3.3087 in) |
| > Intermediate | 84.080 - 84.098 mm (3.3102 - 3.3109 in) |
| >--> Wear limit | 84.120 mm (3.3118) |
| > 1 st. Oversize (Grinding dimension) | 84.250 - 84.268 mm (3.3169 - 3.3176 in) |
| >--> Wear limit | 84.290 mm (3.3185 in) |
| Cylinder bore ovality (permitted roundness deviation) | 0.01 mm (0.0004 in) |
| > Wear limit | 0.04 mm (0.0016 in) |
| Cylinder bore taper (permitted conicity) | 0.01 mm (0.0004 in) |
| > Wear limit | 0.04 mm (0.0016 in) |
| Measurements at top centre and bottom of bore | |
| Crankshaft | |
| Main journal diameter | 60 mm (2.36 in.) |
| Crankpin journal diameter | 44.975 - 45.009 mm (1.7707 -1.7720 in) |
| End float | 0.08 - 0.163 mm (0.0031 - 0.0064 in.) |
| Maximum out of round | 0.15 mm (0.006 in.) |
| Crankshaft seal | PTFE |
| At centre main journal; crankshaft supported on outer bearing pins | |
| Main bearings | |
| Quantity | 5 (4 main, 1 thrust) |
| Type | Grooved shells in crankshaft, plain shells in main bearing caps |
| Ground sizes of main bearing journals | |
| Standard | |
| > Yellow | 59.977 - 59.983 mm (2.3613 - 2.3615 in) |
| > Green | 59.970 - 59.976 mm (2.3610 - 2.3613 in) |
| > White | 59.964 - 59.970 mm (2.3608 - 2.3610 in) |
| 1st Undersize (0.25) | |
| > Yellow | 59.727 - 59.733 mm (2.3515 - 2.3517 in) |
| > Green | 59.720 - 59.726 mm (2.3512 - 2.3514 in) |
| > White | 59.714 - 59.720 mm (2.3509 - 2.3512 in) |
| 2nd Undersize (0.50) | |
| > Yellow | 59.477 - 59.483 mm (2.3416 - 2.3418 in) |
| > Green | 59.470 - 59.476 mm (2.3413 - 2.3416 in) |
| > White | 59.464 - 59.469 mm (2.3411 - 2.3413 in) |
| Crankshaft radial bearing play | 0.027 - 0.063 mm (0.0011 - 0.0025 in) |
| Connecting Rods | |
| Type | Forged H-sections, horizontally split big-end, plain small-end |
| Distance between centres | 135 mm (5.32 in.) |
| Parallel deviation | 0.05 mm (0.002 in) |
| Parallel distortion | 0.5 mm (0.02 in) |
| Big-end bearings | |
| Quantity | 4 |
| Material | Sputter bearing on rod end halves |
| Gudgeon pins | |
| Type | Fully floating, retained by circlips |
| Bush bore diameter | 30.008-30.015 mm (1.1814-1.1817 in.) |
| Fit in connecting rod | Press fit |
| Length | 65 mm (2.56 in.) |
| Pistons | |
| Type | Graphite compound skirt with recessed combustion chamber in crown and oil cooling channel |
| Piston running clearance | 0.036 - 0.072 mm (0.0014 - 0.0028 in) |
| Maximum clearance in cylinder bore (engine run in) | 0.15 mm (0.006 in) |
| Piston diameter | |
| > Standard | 83.950 ± 0.009 mm (3.3051 ± 0.0004 in) |
| > Intermediate | 84.030 ± 0.009 mm (3.3083 ± 0.0004 in) |
| > 1st Oversize | 84.200 ± 0.009 mm (3.3150 ± 0.0004 in) |
| Measured 12 mm (0.47 in) from bottom of skirt and 90° to gudgeon pin | |
| Piston rings | |
| Type | 2 compression, 1 oil control |
| > Top compression ring | Barrel edge, chrome plated |
| > 2nd compression ring | Taper faced |
| > Oil control ring | Bevelled ring with spring |
| New ring to groove clearance (axial play) | |
| > Top compression ring | Does not have to be measured |
| > 2nd compression ring | 0.05 - 0.09 mm (0.0020 - 0.0035 in.) |
| > Oil control ring | 0.03 - 0.07 mm (0.0012 - 0.0028 in.) |
| New ring fitted gap 30 mm (1.2 in) from top of bore | |
| > Top compression ring | 0.20 - 0.35 mm (0.008 - 0.014 in.) |
| > 2nd compression ring | 0.30 - 0.45 mm (0.012 - 0.018 in.) |
| > Oil control ring | 0.20 - 0.40 mm (0.008 - 0.016 in.) |
| Cylinder head | |
| Type | Aluminium alloy gravity die casting |
| Port configuration | Cross flow |
| Intake ports | 1 x helical, 1 x tangential |
| Cylinder head gasket | |
| > Type | Multi-layer steel |
| > Selection | |
| >--> 1 hole | Piston protrusion up to 0.91 mm (0.036 in) |
| >--> 2 hole | Piston protrusion 0.92 -1.03 mm (0.036 - 0.041 in) |
| >--> 3 hole | Piston protrusion over 1.03 mm (0.041 in) |
| Camshaft | |
| Type | DOHC made from clear chill casting, hollow cast, negative cam radius; vacuum pump driven from exhaust camshaft |
| Bearings | 5 per camshaft |
| Drive | Simplex chain |
| Radial runout | 0.047 - 0.088 mm (0.0019 - 0.0035 in) |
| End float | 0.15 - 0.33 mm (0.006 - 0.013 in.) |
| Bearing clearance | 0.011 - 0.034 mm (0.0004 - 0.0013 in.) |
| Tappets | |
| Type | Hydraulic valve adjusters with roller finger levers |
| Valves | |
| Stem diameter | |
| > Inlet | 5.97 ± 0.01 mm (0.235 ± 0.0004 in.) |
| > Exhaust | 5.97 ± 0.01 mm (0.235 ± 0.0004 in.) |
| Valve stem to guide clearance | 0.025 - 0.054 mm (0.0010 - 0.0021 in.) |
| Valve head stand down | |
| > Inlet | 0.73 ± 0.1 mm (0.029 ± 0.004 in.) |
| > Exhaust | 0.56 ± 0.1 mm (0.022 ± 0.004 in.) |
| Head diameter | 25.9 ± 0.1 mm (1.02 ± 0.004 in.) |
| Valve seat angle | 45° |
| Valve seat width | |
| > Inlet | 1.20 ± 0.15 mm (0.047 ± 0.006 in) |
| > Exhaust | 1.45 ± 0.15 mm (0.057 ± 0.006 in) |
| Valve springs | |
| Type | Parallel, single coil |
| Free length | 47.5 mm (1.87 in.) |
| Fitted length | 32 mm (1.26 in.) |
GENERAL SPECIFICATION - ENGINE - TD4 DIESEL
Scheme 13
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Scheme 16
ENGINE - KV6 PETROL
| General | |
|---|---|
| Type: --> Up to 03 Model Year | 2.5 litre V6, 24 valve, air assisted direct fuel injection petrol, water cooled, transverse mounted |
| > From 03 Model Year | 2.5 litre V6, 24 valve, direct fuel injection petrol, water cooled, transverse mounted |
| Cylinder arrangement | 90° V6, numbered from the front of the engine |
| > Left bank | Cylinders 1, 3 and 5 |
| > Right bank | Cylinders 2, 4 and 6 |
| Bore (nominal) | 80 mm (3.15 in.) |
| Stroke | 82.8 mm (3.26 in.) |
| Capacity | 2497 cm 3 (152.37 in 3 ) |
| Firing order | 1-6-5-4-3-2 |
| Compression ratio | 10.5: 1 ± 0.5: 1 |
| Direction of rotation | Clockwise viewed from front of engine |
| Maximum power | 130 kW (177 bhp) @ 6500 rev/min. |
| Maximum torque | 240.0 Nm (177 lbf.ft) @ 4000 rev/min. |
| Maximum engine speed | |
| > Continuous | 6500 rev/min. |
| > Intermittent | 6750 rev/min. |
| Idle speed | 750 rev/min. ± 50 rev/min. |
| Weight (fully dressed, wet) | 154 kg (340 lb) |
| Dimensions (dressed) | |
| > Length (nominal) | 770 mm (30.3 in.) |
| > Width (nominal) | 750 mm (29.5 in.) |
| > Height (nominal) | 750 mm (29.5 in.) |
| Valve operation | Self-adjusting lightweight hydraulic tappets operated directly by the camshafts |
| Fuel injection system | |
| > Make - Up to 03 Model Year | Siemens engine management system |
| > Make - From 03 Model Year | Siemens engine management system |
| > Type - Up to 03 Model Year | Multi-point, air assisted fuel injection controlled by ECM, electro-mechanical injectors with twin sprays targeted on to back of inlet valves |
| > Type - From 03 Model Year | Multi-point fuel injection controlled by ECM, electro-mechanical injectors with quadruple sprays targeted on to back of inlet valves |
| Inlet manifold | Variable geometry |
| Spark plugs --> Type | NLP 100290 |
| > Plug gap | 1.0 mm ± 0.05 mm (0.039 in. ± 0.002 in.) |
| Coils: --> Make - Up to 03 Model Year | BREMR |
| > Make - From 03 Model Year | Champion BAE 403H |
| > Type - Up to 03 Model Year | 6 x coils (3 x plug top, 3 x remote mounted) |
| > Type - From 03 Model Year | 6 x coils (6 x plug top) |
| Emissions standard | ECD3 |
| Cylinder head | |
| Type | Aluminium alloy |
| Cylinder head gasket * | Multi-layer steel |
| Cylinder head warp: --> Lateral | 0.025 mm (0.001 in) |
| > Longitudinal | 0.080 mm (0.003 in) |
| Cylinder head height Reface height -minimum | 118.95 - 119.05 mm (4.683 - 4.687 in) 118.95 mm (4.683 in) |
| Cylinder block | |
| Type | Cosworth cast aluminium alloy with bearing ladder bolted to bottom of block |
| Cylinder liner type | Damp, bottom half stepped - sliding fit into lower part of cylinder block |
| Cylinder liner bore | |
| > RED grade A | 80.000 - 80.015 mm (3.1496 - 3.1502 in.) |
| > BLUE grade B | 80.015 - 80.030 mm (3.1502 - 3.1508 in.) |
| Crankshaft | |
| Material / Type | Cast spheroidal graphite iron with cold rolled fillets on all journals except outer mains |
| Crankshaft end-float --> Service limit | 0.10 - 0.30 mm (0.004 - 0.012 in.) 0.40 mm (0.016 in.) |
| Main journal diameter | |
| > Grade 1 | 67.743 - 67.749 mm (2.6670 - 2.6673 in.) |
| >--> Grade A (Green) | |
| >--> Grade B (Yellow) | |
| >--> Grade C (Black) | |
| > Grade 2 | 67.737 - 67.743 mm (2.6668 - 2.6670 in.) |
| >--> Grade A (Blue) | |
| >--> Grade B (Green) | |
| >--> Grade C (Yellow) | |
| > Grade 3 | 67.731 - 67.737 mm (2.6666 - 2.6668 in.) |
| >--> Grade A (Red) | |
| >--> Grade B (Blue) | |
| >--> Grade C (Green) | |
| Maximum out of round | 0.010 mm (0.0004 in.) |
| Main housing diameter | |
| > Grade A | 71.600 - 71.593 mm (2.8189 - 2.8186 in.) |
| > Grade B | 71.593 - 71.586 mm (2.8186 - 2.8183 in.) |
| > Grade C | 71.586 - 71.579 mm (2.8183 - 2.8181 in.) |
| Big-end journal diameter | |
| > Grade A | 54.049 - 54.055 mm (2.1279 - 2.1281 in.) |
| > Grade B | 54.043 - 54.049 mm (2.1277 - 2.1279 in.) |
| > Grade C | 54.037 - 54.043 mm (2.1274 - 2.1277 in.) |
| > Maximum out of round | 0.010 mm (0.0004 in.) |
| Big-end housing diameter | |
| > Grade 7 | 57.677 - 57.671 mm (2.2707 - 2.2705 in.) |
| >--> Grade A (Green)* | |
| >--> Grade B (Blue)* | |
| >--> Grade C (Red)* | |
| > Grade 8 | 57.671 - 57.665 mm (2.2705 - 2.2703 in.) |
| >--> Grade A (Yellow)* | |
| >--> Grade B (Green)* | |
| >--> Grade C (Blue)* | |
| > Grade 9 | 57.665 - 57.659 mm (2.2703 - 2.2700 in.) |
| >--> Grade A (Black)* | |
| >--> Grade B (Yellow)* | |
| >--> Grade C (Green) | |
| Cylinder block / bearing ladder bore diameter grades * Crankshaft big-end journal grades | |
| Main bearings | |
| Quantity | 4 |
| Material / type | Glacier AS15 - oil grooves in upper half shells, plain lower half shells |
| Clearance in bearings | 0.021 - 0.039 mm (0.0008 - 0.0015 in.) |
| Thrust washers | |
| > Type / position | Glacier AS15 - thrust washer halves at top and bottom of rear main bearing, oil grooves in top and bottom halves |
| > Thrust washer halves thickness | 2.61 - 2.65 mm (0.103 - 0.104 in.) |
| Main bearing thickness | |
| > Red | 1.930 - 1.927 mm (0.0760 - 0.0759 in.) |
| > Blue | 1.927 - 1.924 mm (0.0759 - 0.0757 in.) |
| > Green | 1.924 - 1.921 mm (0.0757 - 0.0756 in.) |
| > Yellow | 1.921 - 1.918 mm (0.0756 - 0.0755 in.) |
| > Black | 1.918 - 1.915 mm (0.0755 - 0.0754 in.) |
| Big-end bearings | |
| Material / Type | Glacier AS15 - plain upper and lower half shells with locating tags |
| Clearance in bearings | 0.022 - 0.040 mm (0.0009 - 0.0016 in.) |
| Big-end bearing thicknesses | |
| > Red | 1.803 - 1.800 mm (0.0710 - 0.0709 in.) |
| > Blue | 1.800 - 1.797 mm (0.0709 - 0.0707 in.) |
| > Green | 1.797 - 1.794 mm (0.0707 - 0.0706 in.) |
| > Yellow | 1.794 - 1.791 mm (0.0706 - 0.0705 in.) |
| > Black | 1.791 - 1.788 mm (0.0705 - 0.0704 in.) |
| Big-end end-float | 0.19 - 0.29 mm (0.007 - 0.011 in.) |
| Connecting rods | |
| Type | Forged steel H-sections with horizontally split big-ends |
| Distance between centres | 151.31 - 151.41 mm (5.957 - 5.961 in.) |
| Gudgeon pins | |
| Type | Semi-floating offset towards thrust side |
| Fit in connecting rods | Interference |
| > Diameter - Red coded | 17.997 - 18.000 mm (0.7085 - 0.7087 in.) |
| > Diameter - Green coded | 17.994 - 17.997 mm (0.7084 - 0.7085 in.) |
| > Length | 52.3 - 52.6 mm (2.059 - 2.071 in.) |
| > Clearance in piston | 0.011 mm (0.0004 in.) |
| Pistons | |
| Type | Aluminium alloy, tin plated, thermal expansion with offset gudgeon pin |
| Piston diameter (measured from thrust to non-thrust sides of piston) | 79.964 - 79.980 mm (3.1481 - 3.1488 in.) |
| Clearance in bore 20 mm (0.75 in.) from bottom of cylinder liner | 0.034 - 0.035 mm (0.0013 - 0.0014 in.) |
| Piston rings | |
| Type | |
| > Top compression ring | Chrome plated steel |
| > 2nd compression ring | Chrome plated cast iron |
| > Oil control ring | Stainless steel top and bottom rails with expander ring |
| New ring to groove clearance | |
| > Top compression ring | 0.05 - 0.08 mm (0.0020 - 0.0031 in.) |
| > 2nd compression ring | 0.04 - 0.07 mm (0.0012 - 0.0024 in.) |
| > Oil control ring | 0.010 - 0.180 mm (0.0004 - 0.0071 in.) |
| Ring fitted gap 20 mm (0.75 in) from top of bore | |
| > Top compression ring | 0.20 - 0.35 mm (0.008 - 0.014 in.) |
| > 2nd compression ring | 0.28 - 0.45 mm (0.011 - 0.018 in.) |
| > Oil control ring | 0.25 -1.00 mm (0.010 - 0.039 in.) |
| Piston ring width | |
| > Top compression ring | 3.1 ± 0.15 mm (0.122 ± 0.006 in.) |
| > 2nd compression ring | 3.15-3.45 mm (0.124-0.136 in.) |
| > Oil control ring | 2.286 - 2.438 mm (0.090 - 0.096 in.) |
| Camshaft | |
| Type | Twin camshafts on each cylinder bank retained by camshaft carrier, line bored with cylinder head. Reluctor for camshaft sensor mounted on left hand inlet camshaft |
| Camshaft identification | |
| > Inlet | Orange paint mark |
| > Exhaust | Blue paint mark |
| Bearings | 5 per camshaft |
| Drive | Toothed belt driven from crankshaft to front of inlet camshafts, 2 x short toothed belts from rear of inlet camshafts to exhaust camshafts |
| Camshaft end-float | 0.06 - 0.19 mm (0.002 - 0.007 in.) |
| > Service limit | 0.3 mm (0.012 in.) |
| Bearing clearance | 0.025 - 0.059 mm (0.0010 - 0.0023 in.) |
| > Service limit | 0.1 mm (0.004 in.) |
| Tappets | |
| Type | Hydraulic self-adjusting, directly operated from camshafts |
| Tappet outside diameter | 32.959 - 32.975 mm (1.2976 - 1.2982 in.) |
| Valve timing | |
| Inlet valves: --> Opens | 2° BTDC |
| > Closes | 54° ABDC |
| Exhaust valves: --> Opens | 50° BBDC |
| > Closes | 14°ATDC |
| Valve maximum lift | |
| Inlet valves | 8.2 mm (0.32 in.) |
| Exhaust valves | 8.8 mm (0.35 in.) |
| Valves | |
| Stem diameter | |
| > Inlet valves | 5.952 - 5.967 mm (0.2343 - 0.2349 in.) |
| > Exhaust valves | 5.947 - 5.962 mm (0.2341 - 0.2347 in.) |
| Stem to guide clearance | |
| Inlet valves | 0.033 - 0.073 mm (0.0012 - 0.0028 in.) |
| Exhaust valves | 0.038 - 0.078 mm (0.0015 - 0.0030 in.) |
| Valve stem fitted height | |
| > New | 38.93 - 39.84 mm (1.533 - 1.569 in.) |
| > Service limit | 40.10 mm (1.579 in.) |
| Valve guide fitted height | 6.0 mm (0.24 in.) |
| Valve guide inside diameter | 6.000 - 6.025 mm (0.2362 - 0.2372 in.) |
| Head diameter | |
| > Inlet valves | 31.4 - 31.6 mm (1.236 -1.244 in.) |
| > Exhaust valves | 27.3 - 27.5 mm (1.075 -1.083 in.) |
| Valve seat width: --> Inlet valves | 1.2 mm (0.05 in.) |
| > Exhaust valves | 1.6 mm (0.06 in) |
| Seat face angle: --> Inlet valves | 45° |
| > Exhaust valves | 45° |
| Valve face angle: --> Inlet valves | 45° |
| > Exhaust valves | 45° |
| Valve springs | |
| Free length | 47.6 mm (1.874 in.) |
| Fitted length | 37.0 mm (1.457 in.) |
| Load at fitted length | 210 ± 13 N |
| Load at top of lift | 440 ± 22 N |
| Lubrication | |
| Type | Cast aluminium, wet sump with full flow filtration |
| Oil pump | Crankshaft driven, high pressure die cast body |
| > Outer rotor end-float | 0.04 - 0.09 mm (0.0016 - 0.0035 in.) |
| > Inner rotor end-float | 0.04 - 0.09 mm (0.0016 - 0.0035 in.) |
| > Inner rotor tip | 0.05 - 0.13 mm (0.002 - 0.005 in) |
| > Outer rotor to body diameterical clearance | 0.13 - 0.23 mm (0.0051 - 0.0091 in.) |
| > Rotor body to drive gear clearance (pump not fitted) | 0.15 - 0.25 mm (0.0059 - 0.0098 in.) |
| Relief valve spring free length | 38.90 mm (1.531 in) |
| Oil filter | Full-flow disposable cartridge |
| Oil cooler | Partial flow type |
| Pressure at idle (min.) | 1.0 bar (14.5 lbf.in 2 ) |
| Pressure at 3000 rev/min. | 3.0 bar (43.5 lbf.in 2 ) |
| Relief valve opening pressure | 4.1 bar (59.5 lbf.in 2 ) |
| Low oil pressure switch opening pressure | 0.3 - 0.5 bar (4.4 - 7.3 lbf.in 2 ) |
GENERAL SPECIFICATION - ENGINE - KV6 PETROL
ENGINE - K1.8 PETROL
| General | |
|---|---|
| Type | 1.8 litre petrol, 16-valve DOHC |
| Cylinder arrangement | 4 in-line, transverse, No.1 cylinder at front of engine |
| Bore | 80.00 mm (3.150 in.) |
| Stroke | 89.30 mm (3.516 in.) |
| Capacity | 1796 cm 3 (109.59 in 3 ) |
| Firing order | 1-3-4-2 |
| Compression ratio | 10.5:1 ± 0.5:1 |
| Direction of rotation | Clockwise viewed from the front of the engine |
| Maximum power | 88 kW (118 bhp) @ 5500 rev/min. |
| Maximum torque | 165 Nm (223.7 lbf.ft) @ 2750 rev/min. |
| Idle speed | 775 ± 50 rev/min. |
| Maximum intermittent engine speed | 6750 rev/min. |
| Weight (fully dressed, wet) | 108 kg (238 lb) |
| Dimensions | |
| > Length (nominal) | 654 mm (25.75 in.) |
| > Width (nominal) | 600 mm (23.62 in.) |
| > Height (nominal) | 615 mm (24.21 in.) |
| Spark plugs | |
| > Type | NLP 100290 |
| > Gap | 1.0 mm ± 0.05 mm (0.039 in. ± 0.002 in.) |
| Ignition coils | |
| > Make | Nippon Denso - NEC 100730 |
| > Type | 2 x twin output coils, plug top mounted; cylinders 1 & 4 and 2 & 3 |
| > Primary resistance (typical) | 0.7 Ω |
| > Secondary resistance (typical) | 10 Ω |
| Fuel injection system | |
| Type | Returnless fuel rail, multi-point fuel injection, electronically controlled from ECM |
| Controller | MEMS 3 breaker less, electronic, fully mapped engine management system |
| Injectors | |
| > Operating pressure | 3.5 bar (50.8 lbf.in 2 ) |
| > Fuel flow rate | 117g/min. @ 3.0 bar (4.13 fl.oz/min. @ 43.5 lbf. in 2 ) |
| Valve operation | Self-adjusting, lightweight hydraulic tappets operated directly by camshafts |
| Emissions standard | ECD3 |
| Cylinder block | |
| Material | Aluminium alloy |
| Cylinder liner type | Damp, bottom half stepped -sliding fit into lower part of cylinder block |
| Cylinder liner bore | |
| > RED grade A | 80.000-80.015 mm (3.1496-3.1501 in.) |
| > BLUE grade B | 80.016-80.030 mm (3.1502-3.1508 in.) |
| Cylinder head | |
| Material | Aluminium alloy |
| Cylinder head warp -maximum | 0.05 mm (0.002 in) |
| Cylinder head height | |
| > New | 118.95-119.05 mm (4.683-4.687 in.) |
| > Reface limit | 0.20 mm (0.008 in.) |
| Crankshaft | |
| Crankshaft end-float | 0.10 - 0.25 mm (0.004 - 0.010 in.) |
| > Service limit | 0.34 mm (0.013 in.) |
| Main journal diameter | 47.986 - 48.007 mm (1.8892 -1.8900 in.) |
| > Maximum out of round | 0.010 mm (0.0004 in.) |
| Main journal tolerance | |
| > Grade 1 | 48.000 - 48.007 mm (1.8898 -1.8900 in.) |
| > Grade 2 | 47.993-48.000 mm (1.8895-1.8898 in.) |
| > Grade 3 | 47.986-47.993 mm (1.8892-1.8895 in.) |
| Big-end journal diameter | 47.986-48.007 mm (1.8892-1.8900 in.) |
| > Maximum out of round | 0.010 mm (0.0004 in.) |
| Big-end journal tolerance | |
| > Grade A | 48.000-48.007 mm (1.8898-1.8900 in.) |
| > Grade B | 47.993-48.000 mm (1.8895-1.8898 in.) |
| > Grade C | 47.986-47.993 mm (1.8892-1.8898 in.) |
| Main bearings | |
| Quantity | 5 |
| Type | Steel backed, aluminium/tin lined, oil grooves in upper halves, plain in bearing caps |
| Clearance in bearings | 0.02 - 0.05 mm (0.0008 - 0.0020 in.) |
| Thrust washers | Halves at No.3 main bearing |
| Thrust washer halves thickness | 2.61 -2.65 mm (0.1028-1.043 in.) |
| Big-end bearings | |
| Clearance in bearings | 0.021 - 0.049 mm (0.0008 -0.0019 in.) |
| Big-end end-float | 0.10 - 0.25 mm (0.004 - 0.010 in.) |
| Connecting rods | |
| Type | Horizontally split big-end, plain small end |
| Distance between centres | 133.05-133.15 mm (5.238-5.242 in.) |
| Gudgeon pins | |
| Type | Semi-floating off-set towards thrust side |
| > Fit in connecting rod | Interference |
| > Diameter (RED) | 17.997-18.000 mm (0.7085-0.7087 in.) |
| > Diameter (GREEN) | 17.994 -17.997 mm (0.7084 -0.7087 in.) |
| > Length | 52.3 - 52.6 mm (2.06 - 2.07 in.) |
| Pistons | |
| Type | Aluminium alloy, tin plated, thermal expansion with offset gudgeon pin |
| Piston diameter (measured from thrust to non-thrust sides of piston) | 79.975 - 79.990 mm (3.1486 -3.1492 in.) |
| Clearance in bore | 0.01 - 0.04 mm (0.0004 - 0.0016 in.) |
| Maximum ovality | 0.30 mm (0.012 in.) |
| Piston rings | |
| Type | 2 compression, 1 oil control |
| > Top compression ring | Barrel faced, granulite coated |
| > 2nd compression ring | Tapered, phosphate coated |
| > Oil control ring | Nitrided ring with radii and spring |
| New ring to groove clearance | |
| > Top compression ring | 0.040-0.072 mm (0.0016-0.0028 in.) |
| > 2nd compression ring | 0.030-0.062 mm (0.0012-0.0024 in.) |
| > Oil control ring | 0.010-0.180 mm (0.0004-0.0071 in.) |
| Ring fitted gap 20 mm (0.75 in) from top of bore | |
| > Top compression ring | 0.20 - 0.35 mm (0.008 - 0.014 in.) |
| > 2nd compression ring | 0.28 - 0.48 mm (0.011 - 0.019 in.) |
| > Oil control ring | 0.15 - 0.40 mm (0.006 - 0.016 in.) |
| Piston ring width | |
| > Top compression ring | 0.978 - 0.990 mm (0.0385 -0.0390 in.) |
| > 2nd compression ring | 1.178-1.190 mm (0.0464-0.0469 in.) |
| > Oil control ring | 0.33 - 0.38 mm (0.0130 - 0.0150 in.) |
| Camshaft | |
| Type | DOHC acting directly on tappets, incorporates target/reluctor for camshaft sensor |
| Bearings | 6 per camshaft, direct line bored |
| Drive | Toothed belt driven from crankshaft gear, automatically tensioned |
| Camshaft end-float | 0.06 - 0.19 mm (0.002 - 0.007 in.) |
| > Service limit | 0.30 mm (0.012 in.) |
| Bearing clearance | 0.060 - 0.094 mm (0.0024 -0.0037 in.) |
| > Service limit | 0.15 mm (0.006 in.) |
| Tappets | |
| Type | Self-adjusting lightweight hydraulic tappets, operated directly from camshafts |
| Tappet outside diameter | 32.959 - 32.975 mm (1.2976 -1.2982 in.) |
| Valve timing | |
| Inlet valves: --> Opens | 12° BTDC |
| > Closes | 52° ABDC |
| > Maximum lift | 8.8 mm (0.35 in.) |
| Exhaust valves: --> Opens | 52° BBDC |
| > Closes | 12° ATDC |
| > Maximum lift | 8.8 mm (0.35 in.) |
| Valves | |
| Stem diameter | |
| > Inlet valves | 5.952 - 5.967 mm (0.2343 -0.2349 in.) |
| > Exhaust valves | 5.947 - 5.962 mm (0.2341 -0.2347 in.) |
| Stem to guide clearance | |
| > Inlet valves | 0.033-0.063 mm (0.0013-0.0025 in.) |
| >--> Service limit | 0.07 mm (0.0028 in.) |
| > Exhaust valves | 0.038-0.078 mm (0.0015-0.0031 in.) |
| >--> Service limit | 0.11 mm (0.0043 in.) |
| Valve stem fitted height | |
| > New | 38.93-39.84 mm (1.5327-1.5685 in.) |
| > Service limit | 40.10 mm (1.5787 in.) |
| Head diameter | |
| > Inlet valves | 27.6 - 27.8 mm (1.087 - 1.094 in.) |
| > Exhaust valves | 24.0 - 24.2 mm (0.945 - 0.953 in.) |
| Valve seat width | |
| > Inlet | 1.0- 1.4 mm (0.039-0.055 in) |
| > Exhaust | 1.4-1.8 mm (0.055-0.071 in) |
| Seat face angle - Inlet and Exhaust | 45° |
| Valve face angle - Inlet and Exhaust | 45° |
| Valve springs | |
| Free length | 50.0 mm (1.97 in.) |
| Fitted length | 37.0 mm (1.46 in.) |
| Load at fitted length | 250 ± 12 N |
| Load at valve open length | 450 ± 18 N |
| Lubrication | |
| Type | Cast aluminium wet sump |
| Pump type | Crankshaft driven, eccentric rotor |
| > Outer rotor to housing clearance | 0.28 - 0.36 mm (0.011 - 0.014 in.) |
| > Inner rotor tip clearance | 0.05 - 0.13 mm (0.002 - 0.005 in.) |
| > Rotor end-float | 0.02 - 0.06 mm (0.001 - 0.002 in.) |
| Relief valve spring free length | 38.90 mm (1.531 in.) |
| Oil filter | Full flow disposable screw-on canister |
| Pressure at idle (min.) | 100 kPa (14.5 lbf/in 2 ) |
| Pressure at 2500 rev/min (hot) | 375 kPa (3.75 bar, 54.4 lbf/in 2 ) |
| Relief valve opening pressure | 410 kPa (59.5 lbf/in 2 ) |
| Low oil pressure switch opening pressure | 20 - 58 kPa (3.0 - 8.5 lbf/in 2 ) |
| Sensors | |
| Crankshaft sensor | Siemens NSC 100630, Hall effect acting on profiled target on flywheel |
| Camshaft sensor | |
| > Make / Type | ITT NSC 100610 +0, Hall effect acting on camshaft reluctor ring |
| > Ring | TGN 100050 |
| Oxygen sensor | |
| > Make / Type | NTK-MHK 100720 |
| > Heating element (nominal) | 7 Watts |
| > Sensor voltage - High | Approx. 900 mV |
| > Sensor voltage - Low | Approx. 40 mV |
| Throttle potentiometer | |
| > Make / Type | CTS-MJC 100020 |
| > Total track resistance | 4 kΩ ± 20% |
| > Sensor supply voltage | 5V ± 4% |
| TMAP sensor | |
| > Make / Type | Motorola - MHK 100820 |
| > Sensor supply voltage | 5V ± 4% |
| Coolant temperature sensor | |
| > Make / Type | AB Electronik - MEK 100170; NTC thermistor bead |
| Oil temperature sensor | |
| > Make / Type | AB Elektronik - MEK100170; NTC thermistor bead |
GENERAL SPECIFICATION - ENGINE - K1.8 PETROL
Scheme 17
Different octane ratings (98 RON) may be defined nationally; 90 & 98 RON if re-tuned via Testbook/T4 programme. Leaded specifications will be available in certain markets. Alternative fuel specification (23% ethanol) is available in certain markets.
Scheme 18
Different octane ratings (98 RON) may be defined nationally; 90 - 98 RON if re-tuned via Testbook/T4 programme. Leaded specifications will be available in certain markets. Alternative fuel specification (23% ethanol) is available in certain markets.
Scheme 19
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WHEELS AND TYRES
| WARNING | Inner tubes MAY NOT be fitted with any of these tyres. |
Scheme 39
*Snow chains may be fitted with these tyres
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Scheme 48
To increase stability, it is recommended that the nose weight is adjusted to the maximum limit, when loading to the maximum trailer weight.
*If the vehicle trailer weight exceeds 1800 kg the vehicle payload must be restricted to less than the Gross Vehicle Weight to ensure the loaded combination is within the Gross Train Weight limit.
**The Gross Towing Weight must be reduced by 300 kg (662 lb) when the following conditions exist: climbing steep hills and mountains with air temperatures above 30 °C/86 °F. altitudes of 1000 metres (3280 feet) and above.