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