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303-01D Engine - 1.6L Duratorq-TDCi (DV) Diesel|Description and Operation > < Engine - Vehicles With: Automatic Transaxle

C-MAX 2003.75 (06.2003-)

Engine - 1.6L Duratorq-TDCi (DV) Diesel - Specifications C-MAX 2003.75 (06/2003-)

Engine Data

Description
Engine code G8DA G8DB HHDA
Emission code level Stage III Stage IV + DPF Stage IV
Firing order 1-3-4-2 1-3-4-2 1-3-4-2
Bore diameter 75 mm 75 mm 75 mm
Stroke 88.3 mm 88.3 mm 88.3 mm
Displacement 1560 cc 1560 cc 1560 cc
Compression ratio 18:1 18:1 18:1
Power output at 4000 rpm 80 kW (109 PS) 80 kW (109 PS) 66 kW (90 PS)
Torque at 2000 rpm 230 Nm 230 Nm 215 Nm
Idle speed 750 rpm 750 rpm 750 rpm
Maximum oil consumption 0.1 L/1000km 0.1 L/1000km 0.1 L/1000km

Lubricants, Fluids, Sealers and Adhesives

Item Specification
Engine oil - 5W-30 WSS-M2C913-B
Coolant WSS-M97B44-D
Silicone sealant WSE-M4G323-A4

Engine Oil Capacity

Description Liters
Initial fill including oil filter 4.20
Service fill including oil filter 3.80
Service fill without oil filter 3.40

Cylinder Block

Description mm
Cylinder bore diameter 75.000 - 75.018
Main bearing parent bore diameter 49.98
Main bearing clearance - radial 0.017 - 0.043

Pistons

Description mm
Piston diameter 74.905 - 74.920
Piston clearance in cylinder 0.079 - 0.112
Piston ring end gaps
- upper compression ring 0.200 - 0.350
- lower compression ring 0.200 - 0.400
- oil control ring 0.800 - 1.000

Piston ring gap position: The piston ring gaps must be distributed evenly around the circumference of the piston. This also applies to the oil control ring elements. Align the piston ring gaps at 120 degrees to each other.

Crankshaft

Description mm
Main bearing journal end float 0.100 - 0.300
Main bearing journal diameter 49.962 - 49.981

Connecting Rod

Description mm
Big end bore diameter 48.655 - 48.671
Small end bore diameter 25.000
Connecting rod bearing clearance 0.024 - 0.070

Piston Pin

Description mm
Piston pin length 59.700 - 60.000
Piston pin diameter 24.995 - 25.000

Camshaft

Description mm
Camshaft end float 0.195 - 0.300
Camshaft bearing journal diameter 23.959 - 23.980

Valves

Description mm
Valve stem to valve guide clearance - intake valve 0.103 - 0.118
Valve stem to valve guide clearance - exhaust valve 0.113 - 0.128

Cylinder Head

Description mm
Thickness of cylinder head gasket with piston protrusion of 0.533 - 0.634 1.25 (two notches)
Thickness of cylinder head gasket with piston protrusion of 0.634 - 0.684 1.30 (three notches)
Thickness of cylinder head gasket with piston protrusion of 0.684 - 0.734 1.35 (one notch)
Thickness of cylinder head gasket with piston protrusion of 0.734 - 0.784 1.40 (four notches)
Thickness of cylinder head gasket with piston protrusion of 0.784 - 0.886 1.45 (five notches)
Maximum distortion - measured longitudinally and diagonally 0.025

Oil Pressure Specifications

Description bar
Oil pressure at idle speed 1.0 - 2.0
Oil pressure at 2000 rpm 2.3 - 3.7

Torque Specifications

Description Nm lb-ft lb-in
Transaxle retaining bolts 47 35 -
Engine rear mount retaining nuts 48 35 -
Engine rear mount center retaining bolt 148 109 -
Engine front mount retaining nuts 80 59 -
Engine front mount retaining bolts 90 66 -
Engine support insulator to transaxle bolts 48 35 -
Engine rear mount center nut 148 109 -
Engine support insulator to front axle crossmember bolts 48 35 -
Lower arm ball joint retaining nuts 52 38 -
Intermediate shaft center bearing cap locknuts 25 18 -
Thermostat housing retaining bolts 7 - 62
Crankshaft pulley retaining bolt a) - -
Flywheel retaining bolts a) - -
Lower crankcase to cylinder block (Crankshaft main bearing cap retaining bolts) a) - -
Lower crankcase to cylinder block (M6) a) - -
Connecting rod bearing cap retaining bolts a) - -
Piston cooling oil spray nozzles 20 15 -
Fuel filter bracket retaining bolts 7 - 62
Engine rear lifting eye 20 15 -
Fuel pump retaining bolts 22 16 -
Fuel pump front support bracket retaining bolts 20 15 -
Fuel pump rear support bracket retaining bolts 10 - 89
Fuel pump pulley retaining nut 50 37 -
Noise, vibration and harshness (NVH) shield retaining bolts 20 15 -
Fuel injection supply manifold retaining bolts 22 16 -
Fuel injector retaining bracket a) - -
High pressure fuel supply line to fuel injectors nuts a) - -
High-pressure fuel supply line to fuel injection supply manifold nuts a) - -
Clutch disc and pressure plate retaining bolts 20 15 -
Fuel filter shield 9 - 80
Camshaft housing retaining bolts a) - -
Camshaft position (CMP) sensor retaining bolt 4 - 35
Timing belt idler pulley stud 7 - 62
Timing belt idler pulley nut 37 27 -
Timing belt tensioner retaining bolt 30 22 -
Throttle body retaining bolts 8 - 71
Exhaust gas recirculation (EGR) tube to intake manifold retaining bolts 6 - 53
Brake vacuum pump retaining bolts 20 15 -
Camshaft pulley retaining bolt 43 32 -
Water pump retaining bolts 10 - 89
Oil pump pickup tube to oil pump retaining bolts 12 9 -
Oil pump pickup tube to ladder frame retaining bolts 9 - 80
Oil cooler retaining bolts 10 - 89
Oil pump retaining bolts 10 - 89
Oil pan drain plug 34 25 -
Oil pan studs 7 - 62
Oil pan retaining bolts and nuts 10 - 89
Oil pressure switch 30 22 -
Oil cooler 10 - 89
Oil level indicator tube retaining bolt 9 - 80
Cylinder head bolts a) - -
Timing belt upper cover 5 - 45
Timing belt lower cover 5 - 45
Exhaust manifold studs 10 - 89
Exhaust manifold retaining nuts 25 18 -
Exhaust manifold heat shield 7 - 62
Glow plugs 8 - 71
Glow plug wiring loom 2 - 18
Generator retaining bolts 47 35 -
Generator mounting bracket retaining bolts 25 18 -
Air conditioning (A/C) compressor retaining bolt 25 18 -
AC compressor bracket retaining bolt 25 18 -
Intake manifold/oil separator assembly retaining bolts and studs 10 - 89
Turbocharger retaining nuts 25 18 -
Turbocharger studs to exhaust manifold 10 - 89
Turbocharger oil return tube retaining bolts 10 - 89
Turbocharger oil supply line union bolt to turbocharger 27 20 -
Turbocharger heat shield retaining bolts 7 - 62
Crankshaft position (CKP) sensor retaining bolt 8 - 71
Starter motor retaining bolts 35 26 -
Exhaust flexible pipe to muffler and tailpipe assembly nuts 47 35 -
Exhaust flexible pipe clamp nut 47 35 -

a) Refer to the procedure in this section.

303-01D Engine - 1.6L Duratorq-TDCi (DV) Diesel|Description and Operation > < Engine - Vehicles With: Automatic Transaxle