Petrol engine KV6 (Freelander 1)

General information

Type:
- Up to model year 2003	V-shaped, 6-cylinder, 24-valve, 2.5 liter displacement, turbocharged, direct fuel injection, liquid-cooled, transversely mounted
- Starting with the 2003 model year	V-shaped, 6-cylinder, 24-valve, 2.5 liter displacement, direct fuel injection, liquid-cooled, transversely mounted
Cylinder arrangement	90 → V6, cylinder numbering from the front end of the engine
- Left lane	Cylinders 1, 3 and 5
- Right lane	Cylinders 2, 4 and 6
Cylinder diameter (nominal)	80 mm (3.15 in)
Piston stroke	82.8 mm (3.26 in)
Working volume	2497 cm³ (152.371 in³)
Operating procedure	1-6-5-4-3-2
Compression ratio	10,5: 1±0,5: 1
Direction of rotation	Clockwise when viewed from the front of the engine
Maximum power	130 kW (177 hp) at 6500 rpm
Maximum torque:	240.0 Nm (177 lb-ft) at 4000 rpm
Maximum engine shaft speed
- In long-term mode	6500 rpm
- Short-term mode	6750 rpm
Idle speed	750 rpm ±50 rpm
Weight (with full equipment, filled lubrication and cooling systems)	154 kg (340 in)
Dimensions (with installed equipment)
- Length (nominal)	770 mm (30.3 in)
- Width (nominal)	750 mm (29.5 in)
- Height (nominal)	750 mm (29.5 in)
Valve drive	Self-adjusting, low-mass hydraulic tappets driven directly by the camshafts
Fuel injection system
- Manufacturer - up to 2003 model year	Siemens Engine Management System
- Manufacturer - since 2003 model year	Siemens Engine Management System
- Type - up to 2003 model year	Multipoint injection with boost, controlled by the electronic control unit ECM, electro-mechanical injectors with a dual jet directed to the rear surface of the intake valves
- Manufacturer - since 2003 model year	Multipoint injection with boost, controlled by the electronic control unit ECM, electro-mechanical injectors with a quadruple jet directed to the rear surface of the intake valves
Intake manifold	Variable Geometry
Spark plugs
- Type	NLP 100290
- Gap between electrodes	1.0 mm ±0.05 mm (0.039 in ±0.002 in)
Ignition coils
- Manufacturer - up to 2003 model year	BREMR
- Manufacturer - since 2003 model year	Champion BAE 403H
- Type - up to 2003 model year	6 ignition coils (3 directly connected to spark plugs, 3 remotely mounted)
- Manufacturer - since 2003 model year	6 ignition coils connected to spark plugs
Standards for the content of harmful substances in exhaust gases	ECD3

Cylinder head

Type	Aluminum alloy
Gas joint laying *	Multilayer, steel
Cylinder head deformation:
- In the transverse direction	0.025 mm (0.001 in)
- In the longitudinal direction	0.2 mm (0.08 in)
Cylinder head height:	118.95 - 119.05 mm (4.683 - 4.687 in)
Height after reprocessing is minimal	118.95 mm (4.683 in)

Cylinder block

Type	Aluminium Cosworth casting with crankshaft bearing housing bolted to the bottom of the block
Cylinder liner type	Wet, with a ribbed lower part, installed on a sliding fit in the lower part of the cylinder block
Cylinder liner diameter:
- Class A with red marking	80,000 - 80,015 mm (3.1496 - 3.1502 in)
- Class B with blue marking	80.015 - 80.030 mm (3.1502 - 3.1508 in)

Crankshaft

Material / Type	Cast iron with spheroidal graphite, with cold rolled dumbbells on all journals except the outer main ones
Crankshaft axial clearance	0.10 - 0.30 mm (0.004 - 0.012 in)
- Allowed without replacement	0.40 mm (0.016 in)
Main journal diameter
- Class 1	67.743 - 67.749 mm (2.6670 - 2.6673 in)
-- Class A (Green Marking)**
-- Class B (With yellow marking)**
-- Class C (With black marking)**
- Class 2	67.737 - 67.743 mm (2.6668 - 2.6670 in)
-- Class A (With blue marking)**
-- Class B (Green Marking)**
-- Class C (With yellow marking)**
- Class 3	67.731 - 67.737 mm (2.6666 - 2.6668 in)
-- Class A (with red marking)**
-- Class B (With blue marking)**
-- Class C (Green Marking)**
- Maximum deviation from circular shape	0.010 mm (0.0004 in)
Main journal diameter
- Class A	71.600 - 71.593 mm (2.8189 - 2.8186 in)
- Class B	71.593 - 71.586 mm (2.8186 - 2.8183 in)
- Class C	71.586 - 71.579 mm (2.8183 - 2.8181 in)
Diameter of crankshaft connecting rod journals
- Class A	54.049 - 54.055 mm (2.1279 - 2.1281 in)
- Class B	54.043 - 54.049 mm (2.1277 - 2.1279 in)
- Class C	54.037 - 54.043 mm (2.1274 - 2.1277 in)
- Maximum deviation from circular shape	0.010 mm (0.0004 in)
Diameter of crankshaft connecting rod journals
- Class 7	57.677 - 57.671 mm (2.2707 - 2.2705 in)
-- Class A (Green Marking)**
-- Class B (With blue marking)**
-- Class C (with red marking)*
- Class 8	57.671 - 57.665 mm (2.2705 - 2.2703 in)
-- Class A (With yellow marking)*
-- Class B (Green Marking)*
-- Class B (With blue marking)*
- Class 9	57.665 - 57.659 mm (2.2703 - 2.2700 in)
-- Class A (Black Marking)*
-- Class B (With yellow marking)*
-- Class C (Green Marking)*

* Crankpin classes

**Cylinder Block / Bearing Support Diameter Classes

Crankshaft main bearings

Quantity	4
Material / Type	Glacier AS15 - oil grooves in the upper bearing, connecting rod cap bearing - smooth
Bearing clearance	0.021 - 0.039 mm (0.0008 - 0.0015 in)
Thrust washers
- Type / location	Glacier AS15 - Thrust washer halves in the upper and lower parts of the rear main bearing, oil grooves in the upper and lower half of the bearing.
- Thickness of the halves of the thrust washer	2.61 - 2.65 mm (0.103 - 0.104 in)
Thickness of main bearing liners
- With red marking	1.930 - 1.927 mm (0.0760 - 0.0759 in)
- With blue markings	1.927 - 1.924 mm (0.0759 - 0.0757 in)
- With green marking	1.924 - 1.921 mm (0.0757 - 0.0756 in)
- With yellow marking	1.921 - 1.918 mm (0.0756 - 0.0755 in)
- With black markings	1.918 - 1.915 mm (0.0755 - 0.0754 in)

Big end bearings

Material / Type	Glacier AS15 - smooth upper and lower liners with locking tabs
Bearing clearance	0.022 - 0.040 mm (0.0009 - 0.0016 in)
Crankshaft connecting rod journal bearings
- With red marking	1.803 - 1.800 mm (0.0710 - 0.0709 in)
- With blue markings	1.800 - 1.797 mm (0.0709 - 0.0707 in)
- With green marking	1.797 - 1.794 mm (0.0707 - 0.0706 in)
- With yellow marking	1.794 - 1.791 mm (0.0706 - 0.0705 in)
- With black markings	1.791 - 1.788 mm (0.0705 - 0.0704 in)
Connecting rod bearing axial play	0.19 - 0.29 mm (0.007 - 0.011 in)

Connecting rods

Type	Forged steel, H-shaped profile, with horizontal lower head split
Distance between the axes of the upper and lower heads	151.31 - 151.41 mm (5.957 - 5.961 in)

Piston pins

Type	Semi-floating type, with a projection in the thrust part. Fitting in the upper head of the connecting rod
Size groups
- Diameter - With red marking	17.997 - 18.000 mm (0.7085 - 0.7087 in)
- Diameter - With green marking	17.994 - 17.997 mm (0.7084 - 0.7085 in)
- Length	52.3 - 52.6 mm (2.059 - 2.071 in)
- Piston clearance	0.010 mm (0.0004 in)

Pistons

Type	Made of aluminum alloy, tin plated, connection with piston pin projection by thermal expansion
Piston diameter (measured in a plane perpendicular to the axis of the piston pin at a distance of 10 mm (0.4 in) from the bottom of the piston skirt
- Class A	79.965 - 79.980 mm (3.1482 - 3.1488 in)
- Class B	79.981 - 79.995 mm (3.1489 - 3.1494 in)
Cylinder gap at 20mm (0.75 in) from cylinder edge	0.034 - 0.035 mm (0.0013 - 0.0014 in)
Maximum deviation from circular shape	0.3 mm (0.012 in)

Piston rings

Type:
- Upper compression ring	Chromed steel
- Lower compression ring	Chrome plated cast iron
- Oil scraper ring	Upper and lower stainless steel belt with intermediate ring
Clearance in the mating of the new piston ring and the groove on the piston:
- Upper compression ring	0.05 - 0.08 mm (0.0020 - 0.0031 in)
- Lower compression ring	0.04 - 0.07 mm (0.0012 - 0.0024 in)
- Oil scraper ring	0.010 - 0.180 mm (0.0004 - 0.0071 in)
The ring groove is located 20 mm (0.75 in) from the top of the piston
- Upper compression ring	0.20 - 0.35 mm (0.008 - 0.0014 in)
- Lower compression ring	0.28 - 0.45 mm (0.011 - 0.0018 in)
- Oil scraper ring	0.25 - 1.00 mm (0.010 - 0.039 in)
Piston ring width:
- Upper compression ring	3.1±0.15 mm (0.122±0.006 in)
- Lower compression ring	3.15 - 3.45 mm (0.124 - 0.136 in)
- Oil scraper ring	2.286 - 2.438 mm (0.090 - 0.096 in)

Camshaft

Type	Two camshafts for each cylinder bank, located in bearings machined in one installation together with the cylinder head. Magnetic marker for the position sensor is located on the left camshaft of the intake valves
Camshaft designation
- Inlet valve	Marking with orange paint
- Exhaust valve	Marking with blue paint
Bearings	Five supports for each shaft
Drive	Toothed belt drive from crankshaft pulley to pulleys at front ends of intake camshafts and 2 short toothed belt drives from rear ends of intake camshafts to exhaust camshafts
Axial clearance of the camshaft	0.06 - 0.19 mm (0.002 - 0.007 in)
- Allowed without replacement	0.3 mm (0.012 in)
Bearing clearance	0.025 - 0.059 mm (0.0010 - 0.0023 in)
- Allowed without replacement	0.1 mm (0.004 in)

The material was taken from the specified website [lrman.ru]

Valve lifters

Type	Hydraulic, self-adjusting, driven directly from the camshaft
Outside diameter of pushers	32.959 - 32.975 mm (1.2976 - 1.2982 in)

Valve timing

Inlet valves:
- Opening:	2° before TDC
- Closing	54° after BDC
Exhaust valves:
- Opening:	50° before BDC
- Closing	14° after TDC
Maximum valve lift:
- Inlet valves	8.2 mm (0.32 in)
- Exhaust valves	8.8 mm (0.35 in)

Valves

Rod 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)
Valve stem - guide clearance:
Intake valves	0.033 - 0.063 mm (0.0013 - 0.0025 in)
- Allowed without replacement	0.07 mm (0.0028 in)
Exhaust valves	0.038 - 0.078 mm (0.0015 - 0.0013 in)
- Allowed without replacement	0.11 mm (0.0043 in)
Height of valve stem when assembled
- New	38.93 - 39.84 mm (1.533 - 1.569 in)
- Allowed without replacement	40.10 mm (1.579 in)
Height of valve guide when assembled	6.0 mm (0.24 in)
Inner diameter of valve guides:	6.000 - 6.025 mm (0.2362 - 0.2372 in)
Plate 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)
Width of the sealing cone (chamfer) of the valve seats:
- Inlet valves	1.2 mm (0.05 in)
- Exhaust valves	1.6 mm (0.06 in)
Valve seat chamfer angle
- Inlet valves	45°
- Exhaust valves	45°
Valve seat chamfer angle
- Inlet valves	45°
- Exhaust valves	45°

Valve springs

Length in free state	47.6 mm (1.874 in)
Length when assembled	37.0 mm (1.457 in)
Load at assembled length	210±13N
Load at end of valve lift	440±22 N

Lubrication system

Type	Wet sump with cast aluminum pan, full flow filtration
Oil pump	Crankshaft driven, die cast housing
- Axial clearance of the outer rotor	0.04 - 0.09 mm (0.0016 - 0.0035 in)
- Axial clearance of the inner rotor	0.04 - 0.09 mm (0.0016 - 0.0035 in)
- Deviation from the vertical of the inner rotor	0.05 - 0.13 mm (0.002 - 0.005 in)
- Radial clearance between the outer rotor and the housing	0.13 - 0.23 mm (0.0051 - 0.0091 in)
- Clearance between rotor body and drive gear (pump not installed)	0.15 - 0.25 mm (0.0059 - 0.0098 in)
Length of the relief valve spring in free state	38.90 mm (1.531 in)
Oil filter	Full flow, with replaceable element
Oil cooler	Included in the lubrication system in parallel
System pressure at idle (minimum)	1.0 bar (14.5 psi)
Pressure at 3000 rpm	3.0 bar (43.5 psi)
Pressure at which the safety valve starts to open	4.1 bar (59.5 psi)
Oil pressure alarm response pressure	0.3 - 0.5 bar (4.4 -7.3 psi)

New metal keys supplied with the gasket must be installed.