2002 Land Rover Freelander

Powertrain Diagnostics & Repair / Engine / Mechanical / GENERAL DATA

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

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 - 118.95 - 119.05 mm (4.683 - 4.687 in) 118.95 mm (4.683 in)
minimum

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)  
General

→→ 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)*  
General

→→ 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
General

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 79.964 - 79.980 mm (3.1481 - 3.1488 in.)

Clearance in bore 20 mm (0.75 in.) 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 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
 General

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: 2° BTDC

→ Opens

→ Closes 54° ABDC

Exhaust valves: 50° BBDC

→ Opens

→ 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: 1.2 mm (0.05 in.)

→ Inlet valves

→ Exhaust valves 1.6 mm (0.06 in)

Seat face angle: 45°

→ Inlet valves

→ Exhaust valves 45°

Valve face angle: 45°

→ Inlet valves

→ 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 0.13 - 0.23 mm (0.0051 - 0.0091 in.)

→ Rotor body to drive gear 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 0.3 - 0.5 bar (4.4 - 7.3 lbf.in2
)
pressure

FUEL SYSTEM - KV6 PETROL

Different octane ratings (98 RON) may be defined nationally; 90 - 98 RON if re-tuned via Testbook/T4 programme. Leaded specifications
will be available in certain markets. Alternative fuel specification (23% ethanol) is available in certain markets.

Created/Modified Date: 10/21/2009 2:51:54 PM