B1BT08K1 - 206 DW8 ENGINE

MODIFICATION DW8 ENGINE

The removal/refitting of these new units does not present any particular difficulty .

The cylinder head cover sealing function has changed and must be carried out with care .

1 - DRIVING THE ANCILLARIES

The ancillaries pulley (1) is made of stamped metal with integrated vibration damper .

This pulley differs in the shape of the exterior crown wheel .

There is complete interchangeability between a part of the previous design and a new part .

2 - SEALING OF BEARING NO. 1

The appearance of the seal has not changed, only the material is different .

There is complete interchangeability between a part of the previous design and a new part .

3 - CYLINDER HEAD

3 - 1 - CYLINDER HEAD GASKET

Addition of a cylinder head gasket to accommodate better the range of piston protrusion .

IMPERATIVE : select the cylinder head gasket in relation to the protrusion of the pistons .

(A) Engine identification .

(B) Thickness identification .

DW8 engine
piston protrusion (*) | gasket thickness compressed | number of holes at A | number of holes at B
--- | --- | --- | ---
0.51 to 0.55 mm | 1.26 ± 0.04 mm | 2 | 1
0.55 to 0.59 mm | 1.30 ± 0.04 mm | 2 | 2
0.59 to 0.63 mm | 1.34 ± 0.04 mm | 2 | 3
0.63 to 0.67 mm | 1.38 ± 0.04 mm | 2 | 4
0.67 to 0.71 mm | 1.42 ± 0.04 mm | 2 | 5
0.71 to 0.79 mm | 1.46 ± 0.04 mm | 2 | 3
(*) : use the highest piston as a reference

3 - 2 - SEALING OF THE CYLINDER HEAD COVER

The cylinder head assembly consists of 3 components :

- 1 plastic cylinder head cover (2)
- 1 cylinder-head cover (3)
- the cylinder head (4)

These 3 components are now sealed by type E7 sealing compound .

The cylinder head covers (2) and (3) no longer have a recess for a pre-formed gasket .

4 - REMOVAL

DW8 ENGINE

REMOVE THE CYLINDER HEAD ASSEMBLY .

NOTE : the use of sealing compound may make separation of the components difficult .

WARNING : clean the joint faces with an approved descaling product ; do not use abrasives or sharp tools on the joint faces ; the joint faces must not have any trace of knocks or scores .

The dry sealing compound can be removed easily from the flat surfaces of the casings .

However, for precise cleaning, use a wooden or plastic spatula .

5 - REFITTING

DW8 ENGINE

REFIT THE CYLINDER HEAD .

Apply sealing compound (a) in an even bead of approximately E7 mm diameter round the edge of the cylinder head cover 3.5 .

Refit the lower cylinder head cover on the cylinder head .

Once the components are in contact, engage the mounting bolts and tighten them to a torque of 0.5 ± 0.1 dan.m starting with the centre bolt .

Apply sealing compound (a) in an even bead of approximately E7 mm diameter round the edge of the cylinder head cover 3.5 .

Refit the plastic cylinder head cover .

Engage the mounting bolts .

Pre-tighten the bolts to 0.8 ± 0.1 m.daN ; Angular tightening 50° (+0° ; +5°) .

IMPERATIVE : proceed bolt by bolt in the order shown .

WARNING : to prevent damage to the sealing compound on refitting, avoid any movement of the components while bolting the assembly .

NOTE : the plastic cylinder head cover mounting bolts are self-cutting. refitting them in the holes already cut does not present any difficulties but it is recommended that the bolts are engaged as straight and as deeply as possible ; clean the bolts before refitting .

6 - CYLINDER HEAD BOLT

The cylinder head bolts are male torx recess bolts with captive washer .

IMPERATIVE : before reusing the cylinder head bolts, check their length .

X = Maximum length below head .

Length of reusable bolts X = 125.5 mm .

IMPERATIVE : do not re-use cylinder head bolts if they are longer than 125.5 mm .

NOTE : pass a tap M12 X 150 into the internal screw threads of the cylinder block receiving the cylinder head bolts .

Fit the cylinder head bolts coated with MOLYKOTE G RAPID PLUS on the threads and under the bolt heads .

IMPERATIVE : do not lubricate the new bolts .

DW8 ENGINE

TIGHTEN THE CYLINDER HEAD .

Tightening procedure :

- pre-tighten : 2 ± 0.2 da.Nm
- tightening torque: 6 ± 0.6 da.Nm
- angular tightening 180°

There is complete interchangeability between a part of the previous design and a new part .

Combining the bolts is permitted .

6 - 1 - VALVE STEM SEALS

Valve stem seals : Brown .

There is complete interchangeability between a part of the previous design and a new part .

6 - 2 - VALVE SPRINGS

The valve springs are painted yellow to enable them to be identified .

There is complete interchangeability between a part of the previous design and a new part .

7 - TIMING BELT TENSIONER ROLLER

Tensioner roller with steel pulley .

There is complete interchangeability between a part of the previous design and a new part .

8 - LUBRICATION

The moulded body of the piston head coolers has changed to a mechanical welded tube body .

There is complete interchangeability between a part of the previous design and a new part .

9 - COOLING SYSTEM

The coolant pump turbine is made of brown plastic .

The new turbine/coolant pump pinion assembly is interchangeable with the previous design .