Page 78 of 1007

GENERAL DATA
04-15
* New metal dowels supplied with gasket must be fitted
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 - 0.0013 in.)
⇒ Service limit 0.11 mm (0.0043 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
⇒ Exhaust valves1.2 mm (0.05 in.)
1.6 mm (0.06 in)
Seat face angle:
⇒ Inlet valves
⇒ Exhaust valves45°
45°
Valve face angle:
⇒ Inlet valves
⇒ Exhaust valves45°
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.in
2)
Pressure at 3000 rev/min. 3.0 bar (43.5 lbf.in
2)
Relief valve opening pressure 4.1 bar (59.5 lbf.in
2)
Low oil pressure switch opening pressure 0.3 - 0.5 bar (4.4 - 7.3 lbf.in
2) General
Page 83 of 1007
GENERAL DATA
04-20
Clutch
Type Maintenance free hydraulic system
Pressure plate diameter (all variants) 228 mm (8.976 in.)
Drive plate diameter (all variants) 228 mm (8.976 in.)
Clutch plate friction material Valeo F808
Diaphragm finger height when clamped on a thick
gauge plate28.58 - 31.54 mm (1.125 - 1.242 in.)
Diaphragm finger clearance (service limit) 1.0 mm (0.039 in)
Clutch plate thickness under 6600 N (1484 lb) axial
load:
⇒ New 6.9 - 7.5 mm (0.272 - 0.295 in.)
⇒ Service limit (K1.8/PG1) 5.60 mm (0.220 in.)
⇒ Service limit (Td4/Getrag) 5.60 mm (0.220 in.)
Rivet depth:
⇒ New 1.2 mm (0.047 in.) above rivet head
⇒ Service limit 0.20 mm (0.008 in.) above rivet head
Clutch plate run-out:
⇒ New 0.4 mm (0.016 in.)
⇒ Service limit 0.4 mm (0.016 in.)
Pressure plate warpage (Service limit):
⇒ K1.8 engine with PG1 gearbox 0.18 mm (0.0071 in.)
⇒ Td4 engine with Getrag gearbox 0.18 mm (0.0071 in.)
Page 90 of 1007

GENERAL DATA
04-27
Steering
* The steering geometry settings are given in degrees and minutes, decimal parts of a degree and millimetres.
Steering and suspension geometry settings are for a vehicle at unladen weight.
Type Power assisted rack and pinion
Steering column Height adjustable by 3.5° or 30 mm vertical movement of steering
wheel
Turns - lock to lock 3.20
Turning circle: 11.38 m (37 ft 1.2 in) - with a 215/65 tyre
Overall ratio 19.5: 1
Wheel alignment*
Front
⇒ Camber angle (negative): -0° 15' ± 0° 45' (-0.25° ± 0.75°)
⇒ Cross camber angle 1° (1°) Maximum
⇒ Castor angle: 3° 30' ± 1° (3.92° ± 1.0°)
⇒ Cross castor angle 1° (1°) Maximum
⇒ King pin inclination 12° 18' (12.3°)
⇒ Front wheel alignment - total toe-out: - 0° 14' ± 0° 14' (- 0.23° ± 0.23°)
Rear
⇒ Camber angle (negative): -0° 30' ± 0° 45' (0.5° ± 0.75°)
⇒ Cross camber angle 1° (1°) Maximum
⇒ Thrust angle: 0° 0' ± 0° 6' (0° ± 0.10°)
⇒ Rear wheel alignment - total toe-in: 0° 20' ± 0° 15' (0.3° ± 0.25°)
Power assisted steering
Maximum Operating Pressure ( limited by pressure
relief valve in pump):
⇒ K1.8 90 - 100 bar (1305 - 1450 lbf/in
2)
⇒ KV6 & Td4 90 - 100 bar (1305 - 1450 lbf/in
2)
Pressure at idle 5 - 7 bar (72.5 - 101.5 lbf/in
2)
Maximum flow 5.5 ± 0.5 litres/min. (1.45 ± 0.13 US gal/min), limited by flow control
valve in pump
Page 91 of 1007

GENERAL DATA
04-28
Front Suspension
Type Independent, MacPherson struts with coil springs, lower "L" shaped
arms and anti-roll bar
Nominal height to wheel arch from hub centre* 453 mm (17.83 in)
Road spring identification (colour code):
Td4 with manual gearbox
⇒ Colour code YELLOW / BLUE
⇒ Total coils 6
⇒ Active coils 5
⇒ Wire diameter 14.87 mm (0.585 in)
⇒ Free length 367 mm (14.45 in)
Td4 with automatic gearbox, non air conditioning
⇒ Colour code YELLOW / WHITE
⇒ Total coils 6
⇒ Active coils 5
⇒ Wire diameter 14.87 mm (0.585 in)
⇒ Free length 367 mm (14.445 in)
Td4 with automatic gearbox and air conditioning
⇒ Colour code YELLOW / BROWN
⇒ Total coils 6
⇒ Active coils 5
⇒ Wire diameter 14.866 mm (0.5853 in)
⇒ Free length 375 mm (14.76 in)
K1.8 without air conditioning
⇒ Colour code YELLOW / PINK
⇒ Total coils 5.5
⇒ Active coils 4.5
⇒ Wire diameter 14.03 mm (0.552 in)
⇒ Free length 359 mm (14.13 in)
K1.8 with air conditioning
⇒ Colour code YELLOW / GREY
⇒ Total coils 5.5
⇒ Active coils 4.5
⇒ Wire diameter 14.03 mm (0.552 in)
⇒ Free length 359 mm (14.13 in)
KV6 without air conditioning
⇒ Colour code YELLOW / BLUE
⇒ Total coils 6
⇒ Active coils 5
⇒ Wire diameter 14.87 mm (0.585 in)
⇒ Free length 367 mm (14.45 in)
KV6 with air conditioning
⇒ Colour code YELLOW / WHITE
⇒ Total coils 6
⇒ Active coils 5
⇒ Wire diameter 14.87 mm (0.585 in)
⇒ Free length 371 mm (14.61 in)
Page 93 of 1007
GENERAL DATA
04-30
Rear Suspension
* At unladen weight
Type Independent, MacPherson struts with coil springs and lower
"trapezoidal links"
All models, except those with Sports
Suspension:Nominal height to wheel arch from hub
centre*463 mm (18.228 in) ± 10 mm (0.39)
Models with Sports Suspension only:Nominal height
to wheel arch from hub centre*433 mm (17.047 in)
Road spring identification:
All models except Sports Suspension
⇒ Colour code WHITE / GREEN
Total coils 6.42
Active coils 4.7
Wire diameter 13.825 mm (0.5443 in)
Free length 349.86 (13.774 in)
Models with Sports Suspension, (fitted from 04MY)
⇒ Colour code ORANGE / ORANGE
⇒ Total coils 6.8
⇒ Active coils 5.6
⇒ Wire diameter 13.97
⇒ Free length 311
Page 98 of 1007
GENERAL DATA
04-35
Dimensions
* At EEC kerb weight
Overall length (inc. 195/80 spare wheel/tyre):
⇒ K1.8 4368 mm (14 ft 4 in)
⇒ KV6 4433 mm (14 ft 7 in)
⇒ Td4 4368 mm (14 ft 4 in)
Overall width (including mirrors 2.068 m (6 ft 9.4 in)
Overall height (including roof bars and cross rails)* 1.708 m (5 ft 7.2 in)
Overall height (including roof bars and cross rails)*
⇒ 3 door 1.808 m (5 ft 11.2 in)
⇒ 5 door 1.828 m (5 ft 11.9 in)
Ground clearance (minimum)*: 186 mm (7.3 in)
Wading depth (maximum) 400 mm (15.7 in)
Wheelbase 2.557 m (8 ft 4.7 in)
Maximum approach angle
*30.5°
Maximum departure angle (with towbar)
*24°
Maximum departure angle (without towbar)
*33.9°
Maximum breakover angle 24°
Track:
⇒ Front
⇒ Rear1534 mm (60.4 in)
1545 mm (60.8 in)
Page 128 of 1007

TORQUE WRENCH SETTINGS
06-25
Steering
* Tighten with weight of vehicle on suspension
TORQUE DESCRIPTION METRIC IMPERIAL
Ball joint to steering arm nuts 55 Nm 41 lbf.ft
Coolant rail to cylinder block bolts (KV6) 9 Nm 7 lbf.ft
Gear change linkage to bulkhead bolts (Td4 manual) 25 Nm 18 lbf.ft
Heatshield nuts (KV6) 25 Nm 18 lbf.ft
Interlock cable to column lock union (JATCO) 4 Nm 3 lbf.ft
IRD hose clip bolt (Td4) 25 Nm 18 lbf.ft
Key cable clamp bolt (JATCO) 6 Nm 4.5 lbf.ft
PAS pipe clip to engine lifting eye bolt 10 Nm 7.5 lbf.ft
PAS high pressure pipe clip bolt 8 Nm 6 lbf.ft
PAS fluid pipe bracket bolts 10 Nm 7.5 lbf. ft
PAS outlet hose to pump banjo bolt (KV6 & K1.8) 20 Nm 15 lbf.ft
PAS outlet hose to pump banjo bolt (Td4) 25 Nm 18 lbf.ft
PAS outlet pipe clip bolt 22 Nm 16 lbf.ft
PAS pipe to clamp bolt 22 Nm 16 lbf. ft
PAS pipe to engine front mounting plate bolt (KV6) 25 Nm 18 lbf.ft
PAS pipe support bracket to RH hydramount nut (KV6) 85 Nm 63 lbf.ft
PAS pipe to RH turret clip bolt 10 Nm 7.5 lbf.ft
PAS pump high pressure pipe union 25 Nm 18 lbf.ft
PAS pump pulley bolts 10 Nm 7.5 lbf.ft
PAS pump to mounting bracket bolts (KV6 & K1.8) 25 Nm 18 lbf.ft
PAS pump to mounting bracket bolts (Td4):
⇒ M610 Nm 7.5 lbf.ft
⇒ M825 Nm 18 lbf.ft
PAS pump mounting to cylinder block bolts 45 Nm 33 lbf.ft
PAS rack fluid feed pipe union nut 18 Nm 13 lbf. ft
PAS rack fluid return pipe union nut 22 Nm 16 lbf. ft
PAS rack mounting and clamp to bulkhead bolts 45 Nm 33 lbf. ft
Ram feed pipe union nuts:
⇒ Small (6mm) diameter 18 Nm 13 lbf.ft
⇒ Large (10 mm) diameter 24 Nm 18 lbf.ft
Steering column height adjuster clamp bolt and nut 10 Nm 7.5 lbf.ft
Steering column height adjuster clamp bolt and nut 12 Nm 9 lbf.ft
Steering column bracket side support bolt 10 Nm 7.5 lbf.ft
Steering column lock bolt SHEAR
Steering column to fascia support rail (Nyloc) nuts and bolts 14 Nm 10 lbf.ft
Steering column to PAS rack pinion clamp pinch bolt
132 Nm 24 lbf. ft
Steering wheel nut 45 Nm 33 lbf.ft
Track-rod ends to steering arm nuts 55 Nm 41 lbf.ft
Track-rod end pinch bolt * 28 Nm 21 lbf.ft
Track-rod to rack bolts 100 Nm 74 lbf.ft
Turnbuckle lock nuts 90 Nm 66 lbf.ft
Page 134 of 1007

TORQUE WRENCH SETTINGS
06-31
Seat belts (3-door models)
Front seat belt loop to 'B' post bolt 31 Nm 23 lbf.ft
Front seat belt pre-tensioner and buckle to seat frame Torx bolt 32 Nm 24 lbf.ft
Front seat belt reel bolt 31 Nm 23 lbf.ft
Front seat belt slider bar bolts 40 Nm 30 lbf.ft
Front seat belt lower mounting Torx bolts 40 Nm 30 lbf.ft
Front seat belt upper mounting Torx bolt 31 Nm 23 lbf.ft
Rear seat belt and buckle to frame Torx bolts 32 Nm 24 lbf.ft
Rear seat belt lower fixing to body bolt 50 Nm 37 lbf.ft
Rear seat belt reel to squab nut 32 Nm 24 lbf.ft
Rear seat belt upper mounting bolt 32 Nm 24 lbf.ft
Rear seat squab lock Torx screws 20 Nm 15 lbf.ft
Seat belt pre-tensioner to seat bolt 32 Nm 24 lbf.ft
Seat belts (5-door models)
Front seat belt adjuster to 'B' post Torx bolts 26 Nm 19 lbf.ft
Front seat belt upper anchorage to adjuster mounting nut 31 Nm 23 lbf.ft
Front seat belt lower fixing to 'B' post bolt 40 Nm 30 lbf.ft
Front seat belt pre-tensioner and buckle to seat frame Torx bolt 32 Nm 24 lbf.ft
Front seat belt reel bolt 31 Nm 23 lbf.ft
Rear centre seat belt reel to seat squab nut 32 Nm 24 lbf.ft
Rear seat belt and buckle bolts 32 Nm 24 lbf.ft
Rear side seat belt lower fixing bolt 40 Nm 30 lbf.ft
Rear side seat belt reel bolt 50 Nm 37 lbf.ft
Rear side seat belt buckle to catch assembly bolt 32 Nm 24 lbf.ft
Rear side seat belt upper mounting bolt 32 Nm 24 lbf.ft
Seat belt height adjuster bolts 26 Nm 19 lbf.ft
Screens
Sun roof side rail Torx bolts 22 Nm 16 lbf.ft TORQUE DESCRIPTION METRIC IMPERIAL