B1BB1YK1 206 DW10TD ENGINE.doc

b1bb1yk1 - 206 dw10td engine data crankshaft dw10td enginedistance (mm)nominalrepair a0- 0,0879089,8 b0- 0,0236059,7 c0- 0,025049,7d 0,1526,5526,55e 0,224,524,5f 0,0226,226,5g+ 0,3026,126,1h 0,3526,0526,05dw10ated enginedistance (mm)nominalrepair a0- 0,0879089,8 b0- 0,0236059,7 c0- 0,025049,7d 0,1527,5527,55e 0,224,524,5f 0,0226,6326,93g+ 0,302727h 0,3527,327,3grinding of the joint face to - 0,2 mm (fitting of standard seal) .warning : when the grinding operation is carried out, the crankshaft must turn in the opposite direction to its usual direction of rotation in the engine, that is clockwise, seen from the flywheel end .warning : grinding of the crankpins and journals must be followed by a smoothing operation .1 - half shells crankshaft stop thrust washers .the bearing upper half-shells are grooved and drilled .distance (mm)nominalrepairi 0,0031,8421,992j 0,0031,8421,992k 0,0051,8331,983dw10 td enginedistance (mm)nominall1,83/1,88dw10 ated enginedistance (mm)nominall2,28/2,33b1kb04k1 - 206 emission control euro 3 - eobd 1 - introduction the european parliament has specified new measures to be taken against air pollution by motor vehicle emissions .this new (ec 98/69) directive is intended to introduce new requirements for petrol and diesel vehicles from 1st january 2000 .1 - 1 - reminder concerning designations old designationnew designationpsa designationvppsa designationvueuro 96euro 2l3w3euro 2000euro 3l4w4euro 2005euro 4l5w5this directive specifies : stricter limits for emission values according to homologation of exhaust pollutants stricter homologation procedure for measuring fuel evaporation the continuity of conformity checks of the production of new vehicles the production conformity check within the network the obligation to have an on-board diagnostics system (eobd) 1 - 2 - countries concerned germany, austria, belgium, denmark, spain, finland, france, greece, ireland, iceland, italy, luxemburg, norway, holland, portugal, united kingdom, sweden, switzerland .1 - 3 - tax incentives certain countries grant tax incentives in order to meet the future emission control standard before it comes into force .the designation is indicated by the symbol if joined to that of the anticipated standard (example : if l5 ) .another form of tax incentive is based on legislation which, in terms of strictness, is pitched between the existing standard and the future one : german standard d3 (intermediate between euro 2 and euro 3) german standard d4 (ditto euro 4 without eobd) 1 - 4 - application dates for private vehicles euro norm 3new modelsall modelspetrol / diesel *01/01/200001/01/2001(*) except vehicles whose weight exceeds 2500 kgeobdnew modelsall modelspetrol * 01/01/200001/01/2001diesel * 01/01/200301/01/2004(*) except vehicles whose weight exceeds 2500 kg2 - conformity in production and within the network the manufacturer must regularly be able to demonstrate to the authorities that he is taking measures to guarantee that production conforms to the approved model .it must also be possible to confirm that the emission control mechanisms function correctly during the normal life of the vehicle .the authorities regularly carry out audits at the manufacturers premises; the manufacturer must be able to supply support documents concerning : checks carried out according to the statistical rules of the directive the details recorded by the eobd systems for the vehicles tested the test failures and the faults found the measures adopted to correct vehicles in production and within the network the details of recall campaigns undertaken 2 - 1 - conformity in production conformity in production aims to check that the vehicles produced conform to the approved type .the tests concern : average exhaust emissions after a cold start the emission of carbon monoxide at idle the emission of crankcase gases emission by evaporation the on-board diagnostic equipment (eobd) 2 - 2 - conformity within the network conformity within the network aims to check that customers vehicles conform to fixed requirements for a minimum period, subject to maintenance of these vehicles being carried out correctly .the responsibility of the manufacturer last for 80000 km or 5 years in 2000 ; it is planned for 100000 km in 2005 .it comprises observation of the average level of exhaust emissions after a cold start and the functioning of the eobd .the vehicles will be withdrawn from second-hand vehicle parcs, from dealerships and subsidiaries, or by calling in the customer (by letter) .3 - development of the composition of fuels today, the harmful effects of lead on the system and on the environment are known to all .as from 01/01/2000, super leaded fuel will disappear and will be replaced by a super fuel containing a potassium additive of equivalent quality .in addition, all of the fuels marketed in france will be more environmentally friendly, because of a drop in the benzene and sulphur content .before 01/01/2000from 01/01/2000petrolsulphur500 ppm*sulphur150 ppm*petrolbenzene4%benzene1%dieselsulphur500 ppm*sulphur350 ppm*(*) parts per million .the petrol is divided as follows : unleaded 98 : 45 % of the market unleaded 95 : 25 % of the market note : as a concession for countries which had already made a justified request before 31/08/1999, distribution of super fuel can be authorised by the commission until 01/2005 .4 - eobd 4 - 1 - introduction eobd (european on board diagnostics) is a european regulation accompanying the euro norm 3 .the purpose of eobd is to indicate to the driver, by means of the engine diagnostics warning light, any fault affecting emission control because of a threshold being exceeded .obd is a monitoring software package incorporated in the engine management ecu and has two main functions : to detect the faults of the vehicle emission control equipment to indicate to the driver the faults which lead to an emission control threshold being exceeded, so that he can have the vehicle repaired 4 - 2 - elements monitored the ecu permanently monitors the elements essential for checking emissions : .a) petrol : misfiring the efficiency of the catalytic converter the condition of the oxygen sensors any component or system, the failure of which can cause the tolerated emission limits to be exceeded (air injection, egr, automatic gearbox) the continuity of the canister purge solenoid valve circuit b) diesel : the efficiency of the catalytic converter the functionality and reliability of the paticulate emission filter (if fitted) the continuity and total failure of the output and advance electronic actuators any component or system, the failure of which can cause the tolerated emission limits to be exceeded (egr, pre-heat, automatic gearbox) 4 - 3 - detection thresholds detection thresholds are determined according to each pollutant .in the event of exceeding the legislative threshold (failure), the engine diagnostics warning light comes on. the fault in question is memorised .4 - 4 - lighting of the engine diagnostics warning light (eobd) the engine diagnostics warning light indicates the failure of a component or a system relating to emissions, when this failure involves an increase in emissions with a level exceeding the legislative limits .misfiring threatening to damage the catalytic converter cause the engine diagnostics warning light to flash .the engine diagnostics warning light is only used where there is a risk of damage to the engine or a safety risk for the occupants of the vehicle .the light comes on at the end of 3 consecutive driving cycles (one driving cycle comprises starting the engine, a driving phase during which any malfunction would be detected, and switching off the engine) .the diagnostics warning light goes out after 3 consecutive driving cycles, during which the monitoring system responsible for activation no longer detects any malfunction; the fault changes to intermittent .the ecu can then clear the intermittent fault if, during 40 heating cycles, this fault has not reappeared .a heating cycle is a period of vehicle operation which is sufficient for the engine temperature to increase by at least 22 from starting the engine, and for it to reach a minimum temperature of 70 .intermittent faults can also be cleared using the diagnostic equipment diag 2000 .4 - 5 - access to the eobd fault codes access to the memorised fault codes is open to any professional technician having standardized diagnostic equipment called scantool whose ecu allows dialogue .access to the diagnostic modes is as follows : 01 : mode reading of the number of fault codes and the engine speed (dynamic) 02 : mode reading of the fixed info (associated variables) 03 : mode reading fault codes 04 : mode clearing of the fault codes 4 - 6 - clearing of the manufacturing and eobd fault codes for all the ecus fulfilling the emission control standard l4 with the eobd active, it us necessary to inform the service area when each request to clear the memorised fault codes is made .this signature is of the same type as the one which is stored in the identification zone of the ecu during downloading .this information can be looked at using the diagnostic equipment under the history heading : total number of operations counter date of operation mileage of the vehicle at the time of the operation equipment for carrying out work site of work being carried out total number of operations counter : this information is useful, since it enables the number of operations carried out on the vehicle to be established .type of clearing : this information allows the type of tool which has cleared the fault codes to be established, from which it is known whether the operation has been carried out within the network or by an independent repairer .5 - conclusion the directive 98/69 may be modified during the year 2000 .certain points are currently under discussion, in particular the eobd function for vehicles supplied with gas (lpg, gnv), as well as recording the mileage covered since the diagnostic warning light came on .the future standard applicable from euro 4, will impose even stricter measures (e.g. pollutant at measurement cycle at low temperature 01/2005) .b1bbm2k1 - 206 dw10td engine engine introduction dw10 1 - description main structure of the dw10 engine : diesel engine with direct injection power train angle (on new vehicles homologated from 1998, new standards relating to impacts impose a straightening of the engines in the front of vehicles) 1 overhead camshaft driven by a toothed belt 4 cylinders in line - 8 valves high pressure pump driven by a toothed timing belt coolant pump driven by a toothed timing belt oil filler hole incorporated in the cylinder head cover suction draining system engine fitted with an acoustic cover there are 2 versions of this engine : dw10 ated : with air/air exchanger dw10 td : with no exchanger the dw10 ated engine is an improved version of the dw10td engine, this power and torque improvement is obtained through management of the turbocharger pressures by the electronic injection ecu .2 - identification (a) identification marking comprising : (1) unit reference (2) legislation type (3) build order number 3 - data engine typedw10 ateddw10 tdengine coderhzrhyunit referencevehicle specificnumber of cylinders4bore x stroke (mm)85 x 88capacity (cm3)1996compression ratio18/1maximum power (kw - ec)8066maximum power (hp din)11090engine speed at max. power (r.p.m.)4000maximum torque (da.nm - ec)2520.5engine speed at max. torque (r.p.m.)2000turbochargervehicle specificair/air intercooleryesnoturbocharger pressure (2000 rpm)1 bar(s)turbocharger pressure (3000 rpm)1 bar(s)injection systemcommon railmakeboschtypeedc 15c2opacity of smoke (m - 1)specific to : vehicles4 - cylinder block cylinder block : in cast iron (not lined) 85 mm diameter barrels fitted with piston base jets fitted with 5 main bearing caps hollowed out at (b) to make the cylinder block lighter 8 mm thick inter-cylinder with coolant passage hole at (c) and coolant plate at (d) to assist cooling of the top of the barrels fitted with a coolant drain plug on the rear face the cylinder block is identical for both the dw10 ated and dw10td engines and is differentiated by the engine engraving (legislation type) .note : no. cylinder-number 1 : clutch end (flywheel) .5 - crankshaft and connecting rods (4) crankshaft .(5) top half shells .(6) bottom half shells .(7) end float thrust washer .(8) piston .(9) gudgeon pin .(10) stop ring .(11) connecting rod .(12) big end bearing shell .5 - 1 - crankshaft dw10 ated engine : crankshaft (identical to xud9te engine) in burnished steel with 5 bearings dw10 td engine : crankshaft (identical to xud7te engine) material : steel with 5 bearings front and rear sealing is by lip seals .the end float (between 0.07 and 0.32 mm) is adjusted on bearing no. 2 by 4 thrust washers (2 on the cylinder block side and 2 on the crankshaft cap side) .5 - 2 - crankshaft half shells crankshaft half shells : identical to xud9te engine smooth on the main bearing cap side grooved on the cylinder block side 5 - 3 - connecting rods new connecting rods (145 mm between centres) (identical to dw8 engine) : forged steel connecting rods the little end is fitted with a machined bronze bush in the shape of a snakes head smooth connecting rod half shells with tab 5 - 4 - pistons (e) : flywheel end .(f) : timing gear end .special pistons with dome and central cavity (bowl) necessary for the movement of the gases (swirl) .new light alloy pistons with valve cut-outs .the direction is given by the valve stamp (stamp on the side opposite the oil filter) .there is only one piston diameter category (series) .there is only one piston diameter category (repair) .one weight category, obtained by internal reworking of the pin .the floating gudgeon pin is retained by 2 rings .the piston has a steel insert to reinforce the compression ring groove .5 - 5 - piston rings the piston has 3 rings : upper sealing ring (13): double trapezoid compression ring (thickness = 3.5 mm) lower sealing ring (14): curved (thickness = 2 mm) scraper ring (15): with spiral spring (thickness = 3 mm) 5 - 6 - flywheel flywheel (adapted for each vehicle) : in cast iron with lamellar graphite friction plate diameter 275 mm the edge of the flywheel has 60 teeth of which 2 have been omitted to determine top dead centre 5 - 7 - accessories pulley a pulley for versions without air conditioning (damped hub with no torsion uncoupling step) .a pulley for versions with air conditioning (damped hub with torsion uncoupling step) .these pulleys are secured to the crankshaft by 1 bolt (identical to xud) .6 - cylinder head assembly 6 - 1 - cylinder-head cover (16) the cylinder head cover (16) is made from a composite material, it is fitted with a pre-formed removable seal .the oil filler hole is incorporated in the cylinder head cover .6 - 2 - camshaft bearing casting (17) the camshaft main bearing cap housing (17) is made from a light alloy .cap housing/cylinder head sealing is by caf 33 type sealing compound .the camshaft is positioned in the cylinder head by the studded cap housing, with 5 main bearings .the end float adjustment of the camshaft is on bearing no. 3 (bearing no. 1 on the flywheel end) .6 - 3 - cylinder head (18) a new cylinder head (18) : 2 valves per cylinder .height of new cylinder head : 133 mm .maximum cylinder head bow : 0.03 mm .the inlet ducts in the cylinder head are a complex helical shape to form the swirl .the valve seats and guides are new and made from sintered steel .note : tightening is in a spiral sequence .6 - 4 - injectors the base of each injector resembles the conventional multi-hole model (with specifications adapted to the engine version, for example: 5 holes, 0.16 mm in diameter or 5 x 0.20 or 6 x 0.15) .there is a control solenoid valve on the top .note : always replace the copper seal, installed in the cylinder head (after repair) .6 - 5 - the camshaft the camshaft : this drives the vacuum pump (flywheel end) it engages the roller cam followers which operate the valves the hydraulic tappets permit wear take-up maintaining a zero clearance between the camshaft, the cam followers and the valves .lubrication is via a longitudinal channel .side channels direct the oil to the bearings and cams .end float value : 0.07 mm to 0.38 mm .6 - 6 - cylinder head gasket (g) : thickness identification .there are 5 categories of laminated metal cylinder gaskets .the cylinder head gasket fits both dw10 ated and dw10 td engines .method for selecting the gasket by measuring the piston protrusion (identical to dw8 engine) .piston protrusion measurements (mm)thickness (mm)notch(es) number of holes at (g)0.47 to 0.6041.30 0.0610.605 to 0.6541.35 0.0620.655 to 0.7041.40 0.0630.705 to 0.7541.45 0.0640.755 to 0.831.50 0.0656 - 7 - tap