Engine - K1.8 Petrol

GENERAL SPECIFICATION - 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 cm³ (109.59 in³ )
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 &ohm;
→ Secondary resistance (typical)	10 &ohm;
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.in² )
→ Fuel flow rate	117g/min. @ 3.0 bar (4.13 fl.oz/min. @ 43.5 lbf. in² )
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/in² )
Pressure at 2500 rev/min (hot)	375 kPa (3.75 bar, 54.4 lbf/in² )
Relief valve opening pressure	410 kPa (59.5 lbf/in² )
Low oil pressure switch opening pressure	20 - 58 kPa (3.0 - 8.5 lbf/in² )
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	≈ 900 mV
→ Sensor voltage - Low	≈ 40 mV
Throttle potentiometer:
→ Make / Type	CTS-MJC 100020
→ Total track resistance	4 k&ohm; ± 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