Freelander 1. Manual - part 10

 

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Freelander 1. Manual - part 10

 

 

GENERAL DATA

04-1

GENERAL DATA

Engine – Td4 Diesel

General

Type

2.0 litre in-line direct injection diesel, 16-valve, DOHC, turbocharged 
and intercooled

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

82 kW (112 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

 Width

 Height

482 mm (19.0 in)
634 mm (25.0 in)
697 mm (27.4 in)

Glow plugs:

4 off, one per cylinder arranged centrally on inlet side between inlet 
valves

Turbocharger

Mitsubishi MR1 TD025L3 - 08T - 3.3

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

 Closes

8

°

 BTDC

28

°

 ABDC

Exhaust valves:

 Opens

 Closes

38

°

 BBDC

4

°

 ATDC

Lubrication

Type

Wet aluminium die-cast sump, pressure fed

Oil filter

Disposable canister with full flow by-pass

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

)

GENERAL DATA

04-2

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)

 1st.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

GENERAL DATA

04-3

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

GENERAL DATA

04-4

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.)

 

 

 

 

 

 

 

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