Engine - TD4 Diesel
GENERAL SPECIFICATION - 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 cm3 (119.05 in3 ) |
| 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.in2 ) |
| Oil pressure at idle: | |
| → Cold-1000 rev/min. | 1.5 bar (21.8 lbf.in2 ) |
| → Operating temperature (minimum) | 0.5 bar (7.3 lbf.in2 ) |
| → Regulated pressure | 4.2 ± 0.5 bar (60.9 ± 7.3 lbf.in2 ) |
| → Pressure at 3500 rev/min (hot) | 3.0 - 4.5 bar (43.5 - 65.3 lbf.in2 ) |
| Relief valve opening pressure | 4.2 bar (60.9 lbf.in2 ) |
| Low oil pressure switch opening pressure | 0.2-0.5 bar (2.9-7.3 lbf.in2 ) |
| 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.) |