B1BBM7K1 - 406D9 EW10J4 ENGINE

ENGINE INTRODUCTION

1 - DESCRIPTION

New engine : EW10J4 engine .

EW engines are progressively replacing XU engines .

Special features :

• 4 cylinders in line - 16 valves
• 2 overhead camshafts driven by toothed timing belt
• multipoint injection system
• engine with reduced fuel consumption (raised output)

NOTE : the engine is prepared for future emission control standards .

The engine output is improved due to the following factors :

• reduction of mechanical losses
• reduction of weight
• optimisation of induction and exhaust ducts
• controlled exhaust gas recirculation valve (reduction in fuel consumption)

1 - 1 - POWER TRAIN INSTALLATION

The new crash protection standards impose a correction to the inclination of the power train in the front section for new vehicles homologated from 1998 .

1 - 2 - DATA

Engine type plate :

• (a) : legislation type
• (b) : unit reference
• (c) : build order number

2 - DATA

3 - CYLINDER BLOCK ASSEMBLY

(1) Cylinder block .

(2) Crankshaft bearing cap casing .

(3) Sump .

(4) Oil pump .

(5) Cast iron cylinder liner(s) .

The light alloy cylinder block has cast iron liners fitted on assembly (Foundry) .

The liners are of the dry type .

Light alloy crankcase incorporating 5 cast iron main bearing caps .

Special features :

• bore = ø 85 mm
• number of main bearings = 5
• the coolant drain plug is in the rear face

The sump is new, with stiffening ribs to improve the rigidity of the connection to the gearbox .

NOTE : no. 1 cylinder : flywheel end .

The sealing between the following components is ensured by sealing compound :

• cylinder block
• bearing cap cover
• sump

4 - CRANKSHAFT AND CONNECTING RODS

(6) Crankshaft .

(7) Compression ring .

(8) Lower sealing ring .

(9) Scraper ring .

(10) Piston .

(11) Gudgeon pin .

(12) Connecting rod .

(13) Big end bearing shell .

(14) Crankshaft end float washers .

(15) Top half shells .

(16) Lower half-shell .

(d) Lubrication hole .

4 - 1 - CRANKSHAFT

New crankshaft :

• material : cast iron
• lighter counterweights
• number of main bearings : 5
• number of counterweights : 8
• crankshaft sealed by a lip seal

Crankshaft end float :

• the end float should be 0,06 to 0,15 mm
• the end float is determined by 2 half washers on main bearing no. 2 (2 cylinder block side)

4 - 2 - CRANKSHAFT HALF SHELLS

(6) Crankshaft .

(1) Cylinder block .

(e) Marking of category of main bearings - To crankshaft (Paint) :

• bar code used in plant
• marking of diameter category (main bearing 1 to main bearing 5)

(f) Marking of category of main bearings - To cylinder block (Cold stamped inscription) :

• marking of diameter category (main bearing 1 to main bearing 5)
• Factory markings

The crankshaft bearings (cylinder block + main bearing caps) and the crankshaft journals are matched by references on the cylinder block and the crankshaft .

Matching is by means of 4 classes of smooth half shells .

Selection of the appropriate half shell is by means of a matching table (see corresponding operation) with the markings (e) and (f) .

Smooth half shells (On the main bearing cap side) .

Grooved half shells (Cylinder block side) .

NOTE : there is only one category of upper half shell .

4 - 3 - CONNECTING RODS

Connecting rods :

• material : forged steel
• distance between centres = 139 mm
• the big end half shells are smooth
• the half shells have a locating lug
• number of weight categories : 4

The gudgeon pins are fitted tight in the connecting rods, and free in the pistons .

The half shells are identified by a dab of paint on the edge .

The connecting rods are drilled to lubricate the base of the liner .

NOTE : the big end half shells (top and bottom) are drilled .

4 - 4 - CONNECTING ROD HALF SHELLS

(6) Crankshaft .

(12) Connecting rod .

(g) Crankshaft marking (A B C D) :

• bar code used in plant
• diameter category marking (crank pin 1 to crank pin 5)

(h) Marking on the connecting rod (Cold stamped inscription) :

• weight category marking (XX)
• diameter category marking (A)
• Factory markings (X)

The big ends and crank pins are matched by references .

Matching is by using 3 categories of (lower) half-shells .

NOTE : there is only one category of upper half shell .

The half shells are identified by a dab of paint on the edge .

Selection of the appropriate half shell is by means of a matching table (see corresponding operation) with the markings (g) and (h) .

4 - 5 - PISTONS

Material : Light alloy .

There is only one piston diameter category (Production size) .

There is only one piston diameter category (Repair size) .

4 - 6 - PISTON RINGS

The piston has 3 rings :

• upper sealing ring : thickness 1,2 mm
• lower sealing ring : thickness 1,5 mm
• scraper ring : thickness 2,5 mm

4 - 7 - FLYWHEEL

Flywheel (Vehicle specific) :

• material : cast iron
• friction plate diameter : 230 mm

The edge of the flywheel has 60 teeth of which 2 have been omitted to determine Top Dead Centre .

A special tool (-).0189-C enables immobilisation of the crankshaft by a hole drilled in the cylinder block and flywheel .

4 - 8 - THE ANCILLARY DRIVE PULLEY

Special features :

• secured to the crankshaft by 4 bolts
• damped hub with declutching in torsion stage

5 - CYLINDER HEAD ASSEMBLY

(17) Cylinder-head cover (Composite materials) .

(18) Camshaft bearing cap cover .

(19) Cylinder head .

(i) Exhaust gas recirculation channels cast into the cylinder head (foundry) .

(j) Cylinder head identification boss .

5 - 1 - CYLINDER-HEAD COVER

Two cylinder head covers (top cylinder head cover with an oil drain and oil filler opening) .

Material : Composite materials .

The oil filler hole is incorporated in the cylinder head cover .

The seal is preformed and removable .

NOTE : tightening is in a SPIRAL sequence .

5 - 2 - CAMSHAFT BEARING CASTING

Material: aluminium alloy .

Sealing between camshaft bearing cap casing and cylinder head: sealing compound .

In service : Use AUTOJOINT OR sealing compound .

The camshaft end float is controlled at no. 5 cylinder head bearing (bearing no. 1, flywheel end) .

NOTE : tightening is in a SPIRAL sequence .

5 - 3 - CYLINDER HEAD

4 valves per cylinder (2 inlet, 2 exhaust) with clearance adjustment by hydraulic tappets .

Height of new cylinder head = 137 mm .

Exhaust valve guides: sintered steel = 0,2 mm .

Maximum permissible bow = 0,03 mm .

The valve seats and guides are new and made from sintered steel .

Maximum allowable machining .

Inlet valve guide: brass .

NOTE : tightening is in a SPIRAL sequence .

Part of the exhaust gas recirculation channels is incorporated in the cylinder head .

5 - 4 - CAMSHAFT

(20) Camshaft .

(21) Rotor driven by the camshaft .

New cast iron camshafts with 8 cams and 5 bearings .

The camshaft reference cylinder sensor rotor is fitted to the exhaust camshaft .

The camshaft bearings are pressure lubricated and the cams by oil bath .

NOTE : the rotor (21) is not removable .

5 - 5 - CYLINDER HEAD GASKET

(22) Cylinder head gasket .

(k) Engine identification : hole .

(l) Machined cylinder head gasket identification .

Special features :

• number of categories : 1
• thickness : 0,8 mm
• type : laminated metal gasket (3 layers)

5 - 6 - HYDRAULIC TAPPET

The hydraulic tappets automatically adjust valve clearance .

Design identical to the tappets used in the XU engines .

Diameter : 28,4 mm .

5 - 7 - VALVES

Inlet valve : ø 33,3 mm .

Exhaust valve : 29 mm .

Valve stem seal : 6 mm .

Valve stem seal with integral cup .

5 - 8 - VALVE SPRINGS

Special features :

• conical shape
• mark : paint mark(s)
• external diameter 1 : ø 26,7 mm
• external diameter 2 : ø 15,1 mm

6 - TIMING

(23) Securing bolt(s) .

(25) Camshaft gear : Exhaust .

(26) Camshaft gear : Inlet .

(27) Dynamic tensioner roller .

(28) Roller tensioner .

(29) Crankshaft gear .

(30) Coolant pump gear .

The timing cover is composed of the following 2 components :

• (24) the top timing cover (5 fastening points)
• (31) the bottom timing cover (5 fastening points)

6 - 1 - TIMING BELT

6 - 2 - CAMSHAFT GEAR

(25) Camshaft gear .

(32) Camshaft hub .

(33) Setting hole .

(34) Oblong hole .

The camshaft is set through the hubs (32) keyed to the camshafts .

The gears are attached to their hubs by 3 bolts .

When the 3 fastening bolts are slackened, the gears are free to rotate (within the limits of the oblong holes) .

This type of assembly makes possible :

• improved accuracy of timing
• better distribution of belt tension between the different runs

Camshaft hub identification :

• stamping on the camshaft hub
• reference number

7 - LUBRICATION

Pressure lubrication by an internally driven dual eccentric rotor pump .

The oil filter cartridge is separate from the cylinder block .

7 - 1 - OIL PUMP

(4) Oil pump .

(35) Oil pump external rotor .

(36) Oil pump internal rotor .

(6) Crankshaft .

(m) Flats .

The oil pump is driven from the end of the crankshaft by means of two flats (m) .

Relief valve setting : 7 bar(s) .

7 - 2 - OIL CAPACITY

Capacity between min and max on the dipstick : 1,7 litre(s) .

IMPERATIVE : always check the oil level using the dipstick .

Oil change interval : Refer to the maintenance schedule .

7 - 3 - OIL FILTER

Replacement interval with normal use : Refer to the maintenance schedule .

Oil pressure .

7 - 4 - ENGINE OIL CHANGE

The engine can be drained by suction .

The engine oil must be changed with the engine hot just after switching off the engine .

The end of the dipstick tube is flared, which makes it possible to connect a suction drainage nozzle (diameter 14 mm) .

NOTE : it is still possible to drain the engine by removing the drain plug from the sump .

8 - AIR SUPPLY CIRCUIT

8 - 1 - AIR SYSTEM

(37) The air inlet hose .

(38) Injectors supply rail .

(39) Exhaust gas recirculation tube .

(40) Inlet manifold .

(41) Throttle housing : Aluminium alloy .

(42) Jubilee clip .

(n) Access to the screw .

Special features - Inlet manifold :

• material : composite materials
• resonator integral with the air inlet manifold
• exhaust gas recirculation tube take-off
• the seal is preformed and removable

Special features , Throttle housing :

• material : light alloy
• idle regulation by stepper motor

Removal of the air inlet connector from the throttle housing requires slackening of its attachment collar (42) via access (n) .

8 - 2 - ADJUSTMENT OF EXHAUST GASES

Arrows : Direction of exhaust gas circulation .

(19) Cylinder head .

(39) Exhaust gas recirculation tube .

(40) Inlet manifold .

(41) Throttle housing .

(43) Exhaust manifold .

(44) Exhaust gas recirculation (EGR) valve .

(45) Water outlet housing .

Exhaust gas recirculation is used to reduce the pumping effect (reduction in fuel consumption) .

The recirculation is of the progressive type managed by mapping .

The opening of the EGR valve is controlled by the EGR solenoid valve which is managed by the engine management control unit which receives the following data :

• coolant temperature
• engine speed (rpm)
• engine load

8 - 3 - EXHAUST GAS RECIRCULATION (EGR) VALVE

Special features :

• proportional solenoid valve controlled by the injection ECU

8 - 4 - EXHAUST MANIFOLD

(43) Exhaust manifold .

(46) Internal ducts (1 per cylinder) .

(47) External envelope .

Material : Steel .

The exhaust manifold is made up of the following components :

• 4 ducts
• 1 pressed steel envelope

A space between the exhaust ducts and the half shells provides good heat insulation .

This exhaust manifold makes possible rapid warming up of the catalytic converter on cold starts .

9 - FUEL SUPPLY SYSTEM

(p) Direction of fuel circulation .

(q) Direction of petrol vapour circulation .

(r) To petrol vapour recycling pipes .

(s) To fuel supply pipes .

(38) Injectors supply rail .

(48) Canister (Activated carbon filter) .

(49) Fuel filter .

(50) Schrader valve .

(51) Fuel return pipes .

(52) Click-on connector .

(53) Petrol injector(s) .

(54) Petrol vapour reaspiration pipes .

(55) Fuel supply pipes .

(56) Fuel pressure regulator .

(57) Fuel pump submerged in the fuel tank .

Special features :

• injector supply rail without fuel return circuit
• petrol pressure regulator mounted in the fuel tank
• fuel pressure : 3,5 bar(s)

9 - 1 - SCHRADER VALVE

The schrader valve is of the tyre valve type .

Functions :

• depressurising the circuit
• pressure check
• delivery check

NOTE : access to the schrader valve requires prior removal of the engine styling cover .

9 - 2 - FUEL FILTER

The fuel filter filters impurities above 15 - 20 microns .

Replacement interval : Refer to the maintenance schedule .

10 - COOLING SYSTEM

(19) Cylinder head .

(45) Water outlet housing .

(58) Heater matrix .

(59) Bleed screw .

(60) Thermostat .

(61) Radiator .

(62) Expansion chamber .

(63) Coolant inlet manifold - Coolant pump .

Special features :

• expansion chamber separate from radiator
• double valve thermostat

10 - 1 - COOLANT PUMP

Special features :

• material : composite materials
• driven by timing belt
• the coolant pump is outside the cylinder block

IMPERATIVE : the centralising dowels must always be refitted when fitting the coolant pump .

10 - 2 - THERMOSTAT

Double action thermostat .

(45) Water outlet housing .

(a1) To coolant inlet manifold .

(a2) Coolant outlet from the cylinder head .

(a3) Outlet to the radiator .

(t) Operation : Cold .

(u) Operation : In warm up phase .

(v) Operation : Hot .

(63) - (64) Valve .

The thermostat has two valves (63) and (64) .

When the valve (64) is open : The coolant circulates through the radiator .

When the valve (63) is open : The coolant is directed to the coolant inlet manifold (Loop circulation) .

(t) Operation - Cold : The coolant circulates in the following components :

• engine (loop circulation)
• heater matrix

(u) In warm up phase : The coolant circulates in the following components :

• engine (loop circulation)
• heater matrix
• radiator

(v) Operation - Hot : The coolant circulates in the following components :

• engine
• heater matrix
• radiator

11 - ANCILLARIES DRIVE

2 equipment possibilities (According to vehicle) :

• vehicle with power steering
• vehicle with power steering + air conditioning

11 - 1 - WITHOUT AIR CONDITIONING

(65) Dynamic tensioner roller .

(66) Power steering pump .

(67) Alternator .

(68) Roller tensioner .

(69) Belt drive pulley .

11 - 2 - WITH AIR CONDITIONING

(65) Dynamic tensioner roller .

(66) Power steering pump .

(67) Alternator .

(68) Roller tensioner .

(69) Belt drive pulley .

(70) Air conditioning compressor .

12 - INJECTION SYSTEM

Manufacturer : MAGNETI MARELLI .

Type : MMDCM 4.8P .

12 - 1 - INJECTION

Special features :

• the control unit is of the Pressure-Engine Speed type
• this injection system manages injection and ignition mainly from information on inlet air pressure and engine speed
• multipoint injection (4 electro-mechanical injectors)
• multipoint sequential injection
• programmed injector opening time (mapping)

12 - 2 - IGNITION

Special features :

• integral electronic ignition
• twin static type ignition
• mapping advance

The coils are part of a compact unit attached to the cylinder head (BBC 2.2) .

Ignition coil unit (BBC) :

• manufacturer : SAGEM BBC 2.2
• primary winding resistance : 0,5 Ω
• secondary winding resistance : 12,5 kΩ

Spark plugs :

• manufacturer : EYQUEM RFC 52LZDP
• flat seat
• electrode gap : 1 mm
• tightening torque : 2,5 da.Nm

Replacement interval with normal use : Refer to the maintenance schedule .

12 - 3 - DOWNLOADING

This injection/ignition control unit has a Flash Eprom memory .

Special features of the Flash Eprom memory :

• this type of memory makes it possible, if there is a calibration modification, to modify the contents of the control unit memory without either removing or replacing the control unit
• the operation consists of downloading the program into the memory of the ECU

12 - 4 - INJECTION CONTROL UNIT

Special features :

• new connections
• connectors locked by plastic yoke

Allocation of the 128 control unit ways through 3 connectors .

The control unit manages the following functions :

• the air - petrol supply
• ignition system
• autodiagnosis
• mixture regulation
• idle speed regulation
• knock regulation
• engine cooling system
• exhaust gas recirculation
• engine speed (tachometer)
• immobiliser