B1BBMEK1 - 206 TU5JP4 ENGINE

ENGINE INTRODUCTION

New engine : TU5JP4 EURO 3 (L4) (From TU5J4) .

Special features :

- 4 cylinders in line - 16 valves
- 2 overhead camshafts driven by toothed timing belt
- BOSCH multipoint injection system
- engine suspension located in centre of timing gear (special timing covers)

Improvement in engine performance is obtained by :

- reduction of the weights
- optimisation of induction and exhaust ducts

1 - DATA - IDENTIFICATION

Engine type plate (1) :

- (a) engine code
- (b) unit reference
- (c) build order number

engine code | NFU
--- | ---
unit reference | vehicle specific
number of cylinders | 4
bore x stroke (mm) | 78.5 x 82
capacity (cm3) | 1587
compression ratio | 10.8/1
maximum power (KW - EC) | 87
maximum power (HP DIN) | 110
engine speed at max. power (r.p.m.) | 6600
maximum torque (da.Nm - EC) | 14.5
engine speed at max. torque (r.p.m.) | 5200
injection system | multipoint
make | BOSCH
type | M7.4.4 - ME7.4.4

2 - DESCRIPTION

2 - 1 - CYLINDER BLOCK ASSEMBLY

(2) Cylinder block .

(3) Fixings for oil filter brackets .

The cast cylinder block is specific to the engine TU5JP4 .

The drain plug for the coolant is fitted on the intake side .

The dipstick tube is glued into the main bearing cap casting (removal of the seal) .

The oil filter is new ; it is fastened by 3 screws (3) .

The oil pressure switch is now fitted to the oil filter bracket, its old location is plugged .

2 - 2 - CRANKSHAFT AND CONNECTING RODS

(4) Crankshaft .

(5) Upper sealing ring (Thickness 1,2 mm) .

(6) Lower compression ring (Thickness 1,5 mm) .

(7) Scraper ring (Thickness 2,5 mm) .

(8) Piston .

(9) Gudgeon pins shrink fit in the little ends .

(10) Connecting rod .

Components common to the engine TU5J4 :

- (11) connecting rod half shells
- (12) crankshaft end float washers
- (A) jet for lubricating the liner

Crankshaft .

Material : cast steel with non-hardened surfaces .

Lighter counterweights .

Number of main bearings : 5 .

Number of counterweights : 8 .

Centering of the gearbox primary shaft in the crankshaft has been modified to accommodate the strengthened gearbox MA .

Identification of parts .

The input shaft splines are lengthened by 2,5 mm .

Assembly with the TU5J4 engine .

Assembly with the TU5JP4 engine .

It is possible to differentiate between the crankshafts by the diameter of the centre bore :

- engine crankshaft TU5J4 : the centre bore diameter is 34 mm
- engine crankshaft TU5JP4 : the centre bore diameter is 41 mm

Crankshaft half shells .

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

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

(15) 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

3 - CYLINDER HEAD ASSEMBLY

The cylinder head is of aluminium alloy .

The cylinder head is a special one ; the inside and outside diameters for the valve spring thrust washer housing differ from the TU5J4 cylinder head .

The hydraulic tappets are common with those of the TU5J4 engine .

The seals of the cylinder head covers are pre-formed and can be replaced in service .

The cylinder head covers, the valves, housings and spring thrust washers assembly and springs, as well as the valve seats are special ones .

4 - TIMING ASSEMBLY

Adjustment of the belt tension is made by a special dynamic tensioner roller .

The intake camshaft (16) and the exhaust camshaft (17) are fitted with lighter pulleys .

Camshafts are specific (Increased seal bearing) .

4 - 1 - CAMSHAFT IDENTIFICATION

(18) After-sales identification zone (by micro-impact etching) comprising :

- cam identification no. 1 to 6
- team no. (A - B - C)
- day/year no. (3 figures / 2 figures)

The timing cases are special ones (captive bolts and incidence of the new engine suspension on the timing side) .

5 - LUBRICATION

The cartridge filter is fitted on a bracket located on the exhaust side of the engine and protected from the heat of the manifold/catalytic converter by a heat shield .

The engine is fitted to the drain pipe by suction .

The end of the dipstick is adapted to accommodate a 14 mm diameter adaptor to carry out draining by suction (Ditto TU5J4) .

The option of draining the engine by gravity is retained .

Oil capacity :

- with filter change : 3.25 litre(s)
- without filter change : 3 litre(s)
- between min and max : 1.5 litre(s)

The oils recommended for the TU5JP4 EURO3 engine correspond to the ACEA A3 standards .

The TU5JP4 EURO3 engine is suitable for fuel economy oils .

5 - 1 - OIL PRESSURE

engine | TU5JP4
--- | ---
check 1 at 1000 rpm minimum pressure (bars) | 1.5
check 2 at 2000 rpm minimum pressure (bars) | 3
check 3 at 4000 rpm minimum pressure (bars) | 4
the values given are in bars for an engine which is run in, at an oil temperature of 80 ° C

6 - AIR SUPPLY CIRCUIT

6 - 1 - AIR SYSTEM

(20) Injectors' supply rail .

(24) Injectors .

(19) Air inlet union .

(21) Valve for pressure take-off and fuel output .

(22) Inlet manifold .

(23) Motorised throttle housing .

(25) Pressure sensor .

Regulation of the idle is by a stepper motor .

7 - FUEL SUPPLY SYSTEM

(26) Injectors' supply rail .

(27) Canister .

(29) Valve for pressure take-off and fuel output .

(30) Fuel return pipes .

(31) Click-on connector .

(32) Petrol vapour reaspiration pipes .

(33) Fuel supply pipes .

(27) Canister .

(28) Fuel filter (incorporated in the pumpgauge unit) .

(30) Fuel return pipes .

(34) Fuel pressure regulator .

(35) Fuel pump submerged in the fuel tank .

7 - 1 - SPECIAL FEATURES

Injector supply rail without fuel return circuit .

Fuel pressure regulator fitted in the pump/gauge module .

Fuel pressure : 3.5 bar(s) .

The supply rail for the injectors is fitted with a valve (29) to carry out the following operations :

- switching off the current to the injectors supply rail
- fuel pressure check
- delivery check

The fuel filter of the pump/gauge module provides filtration of 15 - 20 microns .

8 - EXHAUST MANIFOLD

The exhaust manifold is a special one .

The catalytic converter is fitted directly onto the manifold (parallel to the front surface of the engine) .

The exhaust manifold is fitted with a heat shield protecting the oil filter .

9 - COOLING SYSTEM

(36) Bleed screw .

(37) Expansion chamber .

(38) Coolant pump .

(39) Heater matrix .

(40) Radiator .

(41) Water outlet housing .

(42) Gearbox .

(43) Engine .

(44) Coolant/engine oil exchanger (With automatic gearbox equipment) .

9 - 1 - SPECIAL FEATURES

Expansion chamber separate from radiator .

Opening of the thermostat at 89 °c, the temperature of the warning threshold on the instrument panel being 118 °c .

10 - DRIVING THE ANCILLARIES

Polyvee type belts with dynamic or mechanical belt tensioner, according to specification .

(45) Alternator .

(46) Belt drive pulley .

(47) Belt tensioning bolt(s) .

AIR CONDITIONING

(54) Manual tension roller .

(55) Alternator .

(56) Ancillaries drive pulley .

(57) Air conditioning compressor .

POWER STEERING AIR CONDITIONING

(58) Dynamic tensioner roller .

(59) Alternator .

(60) Roller tensioner .

(61) Ancillaries drive pulley .

(62) Air conditioning compressor .

(63) Power steering pump .

ALL MODELS

11 - INJECTION SYSTEM

Supplier(s) : BOSCH .

Type ME7.4.4 .

Phased sequential multipoint injection .

12 - IGNITION

Integral electronic ignition is of the twin static type (with coil pack housing .

12 - 1 - IGNITION COILS

The coils are integral with a compact housing (64) installed and fastened on the cylinder head (Supplier(s) SAGEM - ELECTRIFIL) .

12 - 2 - SPARK PLUGS

Supplier(s) : BOSCH - SAGEM .

Electrode gap : 0.9 mm ± 0.5 .

Tightening torque : 0.28 da.Nm .

Flat seat plugs of the type :

- SAGEM EYQUEM RFN58LZ
- BOSCH SUPER BNA R13-318