Engine - KV6 Petrol

GENERAL SPECIFICATION - 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 cm³ (152.37 in³ )
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.in² )
Pressure at 3000 rev/min.	3.0 bar (43.5 lbf.in² )
Relief valve opening pressure	4.1 bar (59.5 lbf.in² )
Low oil pressure switch opening pressure	0.3 - 0.5 bar (4.4 - 7.3 lbf.in² )