B1BB16K1 - 206 DW8 ENGINE

PRESENTATION DW8 (WJZ) ENGINE

1 - DESCRIPTION

1 - 1 - MAIN STRUCTURE OF THE DW8 ENGINE

Direct injection diesel engine :

- overhead camshaft driven by a toothed belt
- 4 cylinders in line ; 8 valves
- cylinder head with ADVANCED COMET RICARDO latest technology precombustion chamber (identical to engine TUD5)
- mechanical injection pump (driven by timing belt)
- coolant pump (driven by timing belt)
- upper cylinder head cover fitted with the oil separator and the oil filler hole
- oil sump with receptacle permitting draining by suction
- suction draining system
- engine fitted with an acoustic cover

1 - 2 - 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 .

2 - IDENTIFICATION

Engine type plate :

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

3 - DATA

engine type | DW8
--- | ---
engine code | WJZ
unit reference | vehicle specific
number of cylinders | 4
bore x stroke (mm) | 82,2 x 88
capacity (cm3) | 1868
compression ratio | 23/1
maximum power (EC) | 51 kW
maximum power (DIN) | 70 HP DIN
max engine speed with no load (rpm) | 4600
maximum torque (EC) | 12.5 da.Nm
turbocharger | -
turbocharger pressure | -
injection system | mechanical injection pump
make | BOSCH LUCAS VARITY
type | VE DPC
opacity of smoke | vehicle specific

4 - CYLINDER BLOCK

Water passage hole to promote cooling of the top of the cylinders .

Cast cylinder block (Casing not lined) :

- bore = diameter 82,2 mm
- the cylinder block is fitted with a piston head jet
- number of main bearings 5
- the coolant drain plug is in the rear face

NOTE : no. cylinder No. 1 : flywheel end .

5 - CRANKSHAFT AND CONNECTING RODS

5 - 1 - CRANKSHAFT

Engine crankshaft DW8 (Identical to XUD9A engine) :

- material: spheroidal graphite cast iron
- number of main bearings 5
- heat processing: surface hardening
- crankshaft sealing by lip seal

Crankshaft end float :

- the side clearance must be between 0,07 and 0,32 mm
- the side clearance is adjusted by 4 thrust washers on bearing no. 2 (2 on the cylinder head side, 2 on the crankshaft cap side)

5 - 2 - CRANKSHAFT HALF SHELLS

Smooth half shells (Cylinder block side) .

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

5 - 3 - CONNECTING RODS

Engine con rod (Identical to XUD9A engine) :

- the little end is fitted with a bronze ring (not drilled)
- distance between centres : 145 mm
- the big end half shells are smooth
- the half shells have a locating lug

6 - PISTONS

The pistons are made of a light alloy with the gudgeon pin offset by 0,03 mm .

Identification : Date code engraved on the top .

Direction of the clover leaf base : Oil filter side .

A single diameter category (Production size) .

A single diameter category (Repair size) .

Number of weight categories : 4 .

Maximum protrusion difference between the pistons: mm : 0,07 mm .

The gudgeon pins are immobilised in translatory motion by two stop rings .

6 - 1 - PISTON RINGS

Each piston has the following 3 rings :

- (1) upper sealing ring : compression ring (thickness 2 mm)
- (2) lower sealing ring : hooked ring (thickness 2 mm)

(3) Scraper ring : With spiral spring (Thickness 3 mm) .

6 - 2 - FLYWHEEL

Engine flywheel specific to the vehicle :

- material: lamellar graphite cast iron
- friction plate diameter : 200 mm
- 2 target wheels at 180

6 - 3 - ANCILLARIES DRIVE PULLEY

Ancillaries drive pulley hub (Secured to the crankshaft by 4 bolts) .

7 - CYLINDER HEAD ASSEMBLY

(e) Identification area .

(4) Upper cylinder head cover (Of a composite material) .

(5) Lower cylinder head cover .

(6) Cylinder head .

(7) Glow plugs .

(8) Injector holder .

(9) Fire ring .

(10) Camshaft .

7 - 1 - UPPER CYLINDER HEAD COVER (WITH INCORPORATED OIL SEPARATOR)

The seal is preformed and removable .

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

7 - 2 - CYLINDER-HEAD COVER

Material : Light alloy .

The seal is preformed and removable .

7 - 3 - CYLINDER HEAD

Component making it possible to obtain the best compromise between performance, noise and emission control standard :

- cylinder head with ADVANCED COMET RICARDO technology precombustion chambers
- diesel injector placed in front of the glow plug

(e) Identification area : 2 holes, diameter 9, below the injector housing (cylinder no. 1 and no. 3) .

NOTE : tightening is in a SPIRAL sequence .

7 - 4 - INJECTOR

The fire ring (9) is inside the injector holder .

NOTE : the injector carrier and cylinder head sealing washer must always be changed following every operation .

7 - 5 - CAMSHAFT

DW8 engine (Identical to XUD9A engine) :

- the camshaft is secured by 3 light alloy brackets
- the camshaft drives a vacuum pump (flywheel end)

The side clearance must be between 0,025 and 0,7 mm .

Identification of the camshaft by means of a blue paint ring between the intake and exhaust cams of cylinder no. 1 .

7 - 6 - CYLINDER HEAD GASKET

(1A) Engine identification .

(1B) Nominal dimension .

(1C) Repair size .

Number of categories : 5 .

Type : Cylinder head gasket of grooved metal sheets .

Select the thickness of the cylinder head gasket in relation to the protrusion of the pistons (Identical to XUD engine) .

engine code | WJZ
--- | ---
engine type | DW8
special features | CURTY or ELRING
engine identification (group 1A) | E - F
1st nominal dimension (group 1B) | N
2nd nominal dimension (group 1B) | N - O
3rd nominal dimension (group 1B) | N - O - P
4th nominal dimension (group 1B) | N - O - P - Q
5th nominal dimension (group 1B) | N - O - P - Q - R
6th nominal dimension (group 1B) | N - R
1st repair size (group 1C) | UNK.
2nd repair size (group 1C) | UNK.

7 - 7 - TAPPETS

Tappet with adjusting insert (Identical to XUD engine) .

7 - 8 - VALVES

Inlet valveDiameter 38,5 mm .

Exhaust valveDiameter 33 mm .

Valve stemDiameter 8 mm .

NOTE : the valve seats and guides are new and made from sintered steel .

7 - 9 - VALVE SPRING

External diameter : 29,4 mm .

Number of coils : 8 .

8 - TIMING

(11) Crankshaft gear .

(12) Roller tensioner .

(13) Coolant pump gear .

(14) Tensioner roller with cam .

(15) Camshaft hub (*) .

(16) Camshaft gear .

(17) Injection pump hub .

(18) Injection pump gear .

(19) Timing belt .

(*) Pinning on the cylinder head by bolts M8 (Identical to XUD9A engine) .

The timing cover is composed of the following 3 components :

- the top timing cover (4 bolts)
- the injection pump casing (2 bolts)
- the bottom timing cover (4 bolts)

8 - 1 - TIMING BELT

engine code | WJZ
--- | ---
engine type | DW8
width (mm) | 25,4
number of teeth | 140
material | HSN
supplier(s) | DAYCO
replacement interval for normal use (Km) | -
replacement interval for arduous conditions of use (Km) | -

NOTE : the belt tension is checked using the belt tension measuring equipment .

8 - 2 - INJECTION PUMP WITH HUB

The injection start point is defined by the position of the pump hub .

The injection pump hub permits setting of the timing and of the injection pump .

NOTE : setting of the pump is identical for the following suppliers : BOSCH, LUCAS VARITY .

9 - LUBRICATION

Crankcase breather system :

- the pipe (20) connects the cylinder block to the top of the cylinder head
- the upper cylinder head cover oil separator (4) recovers the oil vapours

9 - 1 - OIL CAPACITY

Depending on the vehicle, the installation of the engine may be inclined or upright (See : Data) .

9 - 2 - ENGINE INSTALLATION UPRIGHT

| engine code : WJZ
--- | ---
special features | with air conditioning (*) | without air conditioning (**)
with filter change | 4,75 litre(s) | 4,75 litre(s)
without filter change | - | -
capacity between min and max on the dipstick | 1,6 litre(s) | 1,6 litre(s)
(*) sump (aluminium) (**) sump (steel)

9 - 3 - ENGINE INSTALLATION INCLINED

| engine code : WJZ
--- | ---
special features | with air conditioning (*) | without air conditioning (**)
with filter change | 4,5 litre(s) | 4,75 litre(s)
without filter change | - | -
capacity between min and max on the dipstick | 1,5 litre(s) | 1,5 litre(s)
(*) sump (aluminium) (**) sump (steel)

IMPERATIVE : always check the oil level using the dipstick .

Oil change interval : Refer to the maintenance schedule .

9 - 4 - OIL FILTER CARTRIDGE

make | PURFLUX
--- | ---
type | LS 867A (first assembly) LS 867B (second assembly)
oil capacity | 0,32 litre(s)
over-pressure valve maximum pressure valve safety valve | 1,5 bar(s)

Replacement interval : Refer to the maintenance schedule .

9 - 5 - LUBRICATION SYSTEM

The piston bases are cooled by jets .

engine code | WJZ
--- | ---
check 1 pressure (bars) | 1000 rpm 1,8
check 2 pressure (bars) | 2000 rpm 3,7
check 3 pressure (bars) | 3000 rpm 4,3
check 4 pressure (bars) | 4000 rpm 4,5

9 - 6 - ENGINE OIL CHANGE

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

The engine can be drained by suction .

The end of the dipstick tube is opened out, to enable connection of a suction draining equipment nozzle (Diameter 14 mm) .

NOTE : it is still possible to drain the engines by removing the oil sump drain plug .

10 - AIR SUPPLY CIRCUIT

10 - 1 - AIR SYSTEM

(f) Intake of exterior air .

(g) Discharge of exhaust gas .

(h) Exhaust gas recirculation .

(21) Vacuum capsule .

(22) Exhaust gas recirculation tube .

(23) Inlet manifold (Of a composite material) .

(24) Inlet manifold (Aluminium) .

(25) Vacuum pump .

(26) Air cleaner .

(27) Resonator .

(28) EGR metering device .

(29) Valve .

(30) Solenoid valve .

The egr proportioner (28) is made up of the following components :

- (21) vacuum capsule
- (29) valve
- (30) solenoid valve

The Exhaust Gas Recirculation pipe is secured by :

- click clip on the egr regulator (front surface)
- 2 bolts on the exhaust manifold

10 - 2 - EXHAUST GAS RECIRCULATION

The exhaust gas recirculation (EGR) device allows the quantity of nitrous oxide (NOX) discharged by the exhaust to be reduced .

Recirculation is All or Nothing (The solenoid valve is open or closed) .

The recirculation valve is subjected to a vacuum from the vacuum pump and authorises recirculation of the exhaust gas towards the intake circuit .

First system .

The egr valve is opened in line with the following information :

- engine load below the limit given by the injection pump load switch
- engine coolant temperature below 48 degree(s)

Second system (See figure(s)) .

The opening of the egr valve is controlled by the ecu which receives the following information :

- engine load below the limit given by the injection pump load switch
- engine speed above 950 rpm
- engine coolant temperature below 48 degree(s)

Example of the second system .

(30) Solenoid valve .

(31) Load lever switch .

(32) According to specification :

- vehicle without air conditioning : tachometric relay type ecu (15-way brown)
- vehicle with air conditioning : egr air conditioning cut-off ecu (15-way grey)

(33) Air conditioning relay .

(34) Tdc sensor (1400) .

(35) Coolant thermistor (2-way green) .

There are 2 egr valve control systems: according to model and specification .

11 - PRE-POST HEATING

Pre-post heat box .

11 - 1 - PRE-HEATING

The pre-heat glow plugs and the warning light operate as soon as the ignition is switched on .

When the warning light goes out the glow plugs remain supplied to the maximum for 10 to 15 seconds, if the starter has not been operated .

NOTE : the warning light is no longer lit when the engine coolant temperature is higher than 80 °C .

11 - 2 - POST HEATING

The post-heating enables the operating phase of the plugs to be extended after the starting phase (For 3 minute(s)) .

The post-heat time delay starts as soon as the starter is released .

Parameters which could interrupt post-heating :

- coolant temperature greater than 60 degrees C
- load lever switch

12 - FUEL SUPPLY SYSTEM

12 - 1 - FILTRATION RESERVOIR ASSEMBLY

Diesel circulation (in the direction of the arrows) .

(36) Bleed screw .

(37) Filter bowl .

(38) Thermostatic element .

(39) Anti-return valve .

(40) Repriming pump .

(41) Fuel filter .

(42) O-ring .

(43) Filtered diesel outlet towards the injection pump .

(44) Cover .

(45) Air bleed valve .

(46) Opening / closing clip (without tools) .

(47) Decantation reservoir .

(48) Water detector .

12 - 2 - DIESEL HEATER

The fuel is heated by means of the cooling circuit .

The fuel is heated on contact with the water outlet housing .

The temperature of the fuel is regulated by a thermostatic element (incorporated in the filtration reservoir) .

12 - 3 - PHASES OF OPERATION : THERMOSTATIC ELEMENT (38)

Fuel temperature below 15 degrees C :

- the thermostatic component is detached from its seat
- the fuel is heated on contact with the water outlet housing

Fuel temperature between 15°c and 35°c :

- the thermostatic component is partially detached from its seat
- some of the fuel is heated

Fuel temperature above 35 °c :

- the thermostatic component is in contact with its seat
- the fuel passes directly towards the filter

12 - 4 - FUEL FILTER

Description : .

Elliptical section .

Supplier(s) : PURFLUX C446 .

Paper seal: surface dm2 : Surface area 40 dm2 .

Replacement .

Replacement interval : Refer to the maintenance schedule .

Refitting of the filter :

- fit the diesel filter (41) and cover (44) assembly in the filter bowl
- refit and tighten the clip (46)

Repriming of the fuel circuit .

The circuit is reprimed by operating the pump (40) until its operation becomes difficult (maximum 20 pump strokes) .

NOTE : the air in the circuit is bled to the injector return pipe through a valve calibrated at 400 mbars (clean bleed system) .

Water detector .

The filter bowl is fitted with a device for the detection of water in the fuel (48) (According to country) .

Maximum volume of water that can be decanted without danger : 80 cm3 .

The water presence warning light comes on when the decantation reservoir reaches a volume of (47) .

Water bleed procedure :

- open the bleed screw (36)
- press on the repriming pump (40) (allowing the water to flow)

13 - COOLING SYSTEM

(49) Radiator .

(50) Water/fluid heat exchanger .

(51) Coolant inlet manifold .

(52) Expansion chamber .

(53) Bleed screw .

(54) Heater matrix .

(55) Water outlet housing .

(56) Double acting thermostat .

Only use coolant sold by parts division (Identical to XUD engine) .

14 - INJECTION PUMP

14 - 1 - LUCAS VARITY EQUIPMENT

(57) Load lever .

(58) Damping .

(59) Idle adjustment bolt .

(60) Stop lever .

(61) Microswitch :

- EGR valve
- post heating

(62) Anti-stall adjustment screw (Residual flow) .

Mechanical diesel injection pump :

- supplier(s) : LUCAS VARITY
- type DPC
- with hub
- with mechanical over advance control
- with or without coded anti-start module

14 - 2 - BOSCH EQUIPMENT

(63)Fast idle adjustment screw .

(64) Idle adjustment bolt .

(65) Anti-stall adjustment screw (Residual flow) .

(66) Damping .

(67) Microswitch :

- EGR valve
- post heating

(68) Load lever .

(69) Stop lever .

Mechanical diesel injection pump :

- supplier(s) : BOSCH
- type VE
- with hub
- with or without coded anti-start module

15 - DRIVING THE ANCILLARIES

4 equipment possibilities (According to vehicle) :

- basic equipment (conventional steering)
- basic equipment (power steering)
- air conditioning equipment (conventional steering)
- air conditioning equipment (power steering)

15 - 1 - BASIC EQUIPMENT

Conventional steering .

Roller tensioner (Screw adjustment) .

Power steering .

(70) Roller tensioner (Screw adjustment) .

(71) Fixed roller .

15 - 2 - AIR CONDITIONING EQUIPMENT

Conventional steering .

Roller tensioner .

Power steering .

DW8 engine (Identical to XUD engine With air conditioning) :

- automatic roller tensioner
- eccentric reel roller