Description
Main structure of the engine
Diesel engine with direct injection
- 4 cylinders in line, turbocharging by variable geometry turbocharger with heat exchanger
- Integrated air intake system comprising the air inlet manifold, the air filter, the valve cover and the oil trap (oil vapour resuction)
- Cylinder head in aluminium alloy with 4 valves per cylinder, and with 2 overhead camshafts
- Cylinder head gasket composed of metal laminate
- Valve control by roller cam follower and hydraulic tappets
- Aluminium alloy cylinder block with cast iron liners inserted at the foundry
- Aluminium alloy bearing cap housing with cast iron bearing caps inserted during the casting process
- The aluminium alloy cylinder block incorporates the cast iron liners, inserted during casting
- Forged steel crankshaft
- Forged steel connecting rods
- "DELPHI" direct injection system with high pressure fuel pump driven by the timing belt
- Toothed timing belt with dynamic roller tensioner
- Coolant pump driven by the timing belt
- Driving of the accessories by a pulley having a vibration damper with flexible coupling
- Oxidation catalytic converter secured to the exhaust manifold outlet
- Oil filter with paper filter element (ecological type)
Data
| engine code | DV4TED4 |
|---|---|
| engine legislative type | 8HY |
| special feature | without |
| identification marking | - |
| number of cylinders | 4 |
| bore x stroke (mm) | 73,7 x 82 |
| capacity (cc) | 1398 |
| compression ratio | 18.4 / 1 |
| max. power (E.E.C.) | 66 kW |
| max. power (HP DIN) | 90 hp |
| max. power speed | 4000 rpm |
| max. torque (E.E.C.) | 20 daNm |
| max. torque speed | 2000 rpm |
| turbocharger | with variable capacity |
| air/air heat exchanger | yes |
| turbocharger pressure | 1 bar |
| injection system | HDI (*) |
| make | DELPHI |
| type | C6 |
| emission control standards | EURO 3 |
Note(*) High pressure Diesel injection (HDI)
Identification marking
Marking in "a"
- Engraving of the crankshaft bearings diameter category
- Bearing orientation (clutch to timing)
Marking in "b"
- Constructor's reference
- Legislation type
- Identification marking
- Serial number
Marking in "c"
- Machining reference
- Year of manufacture
Marking in "d": engine flywheel pegging hole
Cylinder block
"e" top of cylinder coolant hole diameter = 3,6 mm
Cylinder block
- Material: aluminium alloy
- Cast iron liners inserted during casting (foundry)
- Cylinder bore, diameter = 73,7 mm
Crankshaft main bearing cap casing
- Material: aluminium alloy
- 5 cast iron bearing caps inserted during casting
- Fixing: 26 bolts (10 M9 x 125 and 16 M6 x 100) 10 solid pins
Reciprocating gear
(1) crankshaft damping pulley
(2) sealing ring
(3) crankshaft half shells
(4) pistons
(5) conrods
(6) crankshaft endfloat thrust washers
(7) engine flywheel
Crankshaft
"f": timing pinion keyway
Marking in "g": crankshaft bearing class
Crankshaft
- Amount of bearings: 5
- Number of counterweights: 8
- Securing of the engine flywheel with 6 equidistant bolts
The sealing on the crankshaft is provided by a sealing ring on the timing side and on the engine flywheel side
The endfloat is adjusted by 2 thrust washers on bearing n°2 (only one thickness class)
Marking in "a": crankshaft bearing class
The pairing is carried out using 3 categories of smooth half-shells without centring lug
The correct bearing shell must be chosen using a matching table with the markings "g" and "a"
On the cylinder block side, there is only one category of grooved half-shells with centring lug
Conrods
"h": little end socket
(5) conrods
Conrods
- Material: forged steel
- Distance: A = 126,6 mm
- The connecting rod half-shells do not have a positioning lug
- Conrod/cap assembled using screws
- The big ends are known as "split" at "j"
NoteThe manufacturing process for "split" big ends consists of separating the conrod cap from the big end by means of a fracture line, obtained using a laser, which is then broken with an expanding drift
Pistons piston rings
Marking in "k": piston orientation
(4) aluminium alloy piston
(8) trapezoidal upper ring: containing word "TOP": thickness 2,5 mm
(9) tapered lower ring: containing word "TOP": thickness 1,95 mm
(10) trapezoidal scraper ring with spring: thickness 2,5 mm
NoteThe gudgeon pins are immobilised in translatory motion by two stop rings
Engine flywheel
Cast iron engine flywheel with a steel starter ring gear
Securing of the engine flywheel with 6 equidistant bolts
Blind holes for locking crankshaft in rotation (required for tightening and slackening the crankshaft pulley)
WarningThe blind holes are not pegging holes which are used when removing the timing belt
Sealing ring
The sealing rings provide the seal on the crankshaft on the oil pump side and on the flywheel side, as well as on the end of the camshaft on the timing pinion side
The sealing rings consist of a preformed Teflon lip
When the engine is started, the oil pressure exerts a force on the lip "l" which makes contact leaving a film of oil on the shaft thus creating sealing
WarningThe seal must remain on its support during fitting. if handled, place the ring back on its support and leave it for 30 minutes before fitting
WarningIf the lip is deformed, replace the sealing ring
Cylinder head assembly
(11) upper camshaft bearing cover
(12) cylinder head
Camshaft bearing cap casing
Material: aluminium alloy
Sealing between camshaft bearing cap casing and cylinder head: seal paste
The integrated air intake system is mounted by 8 bolts on the casing (11)
The casing (11) is fixed by means of 16 screws (M6 x 100) and 8 studs
Sealing of the inlet camshaft is by means of a sealing ring, at the camshaft pulley end
Cylinder head
Special features
- Material: aluminium alloy
- 4 valves per cylinder
- Air inlet manifold (fuel high pressure common injection rail)
- Exhaust manifold: oil filter side
- Valve seats: sintered steel
- Inlet valve guides: sintered steel
- Exhaust valve guides: sintered steel
- Height of the cylinder head: 124 mm ± 0,05 mm
Cylinder head mounted on the cylinder block by 10 TORX bolts
The exhaust manifold is retained by 10 studs and 10 copper-plated nuts with spacers
Cylinder head gasket
"n" thickness identification mark
"m" engine identification
Type: laminated metallic cylinder head gasket
Camshaft
Marking in "p": camshaft identification
(13) exhaust camshaft
(14) Induction camshaft
(15) timing chain and tensioner
Material: sintered steel
Cams fitted onto a steel tube
Vacuum pump drive on the end of the camshaft, flywheel side
Valve control
(16) roller valve rockers
(17) hydraulic tappets with automatic adjustment
Timing gear
Timing covers
(18) upper timing cover
(19) lower timing cover
Timing belt configuration
"q" timing belt pegging holes
(20) camshaft pulley
(21) roller tensioner
(22) timing belt
(23) crankshaft gear
(24) coolant pump
(25) dynamic roller tensioner
(26) fuel high pressure pump pulley
Data
- Timing belt width: 25,4 mm
- Number of teeth: 135
Crankshaft gear
The engine speed information is picked up by the sensor (27) on the crankshaft pinion (23) which has a magnetic track at "r"
Safety recommendations
- Wash your hands prior to any handling of the crankshaft pinion
- Avoid any impact or damage to the magnetic track use of sharp-edged tools is prohibited
- Never place magnetic tooling near to the crankshaft pinion
- Never use the magnetic track "r" as a support
- Do not bring force to bear on the target body
Lubrication
"s" upper engine supply channels
"t" vacuum pump channel
"u" oil pressure switch
"v" high pressure oil feed circuit
"w" high pressure oil rail in the cylinder head
(28) filter cartridge
(29) turbocharger lubrication
(30) coolant/oil heat exchanger
(31) filter gauze
(32) sump
(33) oil pump
(34) oil non-return valve
(35) underside of piston jet
Oil capacity
| engine legislative type | 8HY |
|---|---|
| lubrication system | 3,75 litres |
| sump | 3,6 litres |
| oil filter | 0,4 litre |
| capacity between min and max on the dipstick | 1,8 litre |
WarningAlways check the oil level using the dipstick
Draining intervals: refer to the maintenance schedule
Oil pump
The oil pump is located on the timing side on the cylinder block by 2 pins and driven by 2 flat spots at "x"
The seal between the oil pump and the cylinder block is provided by sealing compound
The seal between the oil pump outlet and the cylinder block channel is provided by a square-section elastomer O-ring (36)
The oil pressure relief valve is located at "y"
An oil pressure regulator located on the camshaft bearing lubrication channel limits the pressure in the upper engine
The non-return valve (34) maintains a reserve of oil in the upper engine for the hydraulic tappets
The electric sender is located on the inlet side of the sump in the cylinder block
Oil filter cartridge
"z" return valve to sump
The paper oil filter (ecological type) is located on an oil/water heat exchanger
Engine oil change
The engine can be drained by suction
The engine oil must be changed with the engine hot just after switching off the engine
The end of the dipstick guide tube has been enlarged, which enables a tube to be connected to a suction draining device (diameter 14 mm)
NoteIt is still possible to drain the engine by removing the drain plug from the sump
Air supply circuit
(37) the air filter assembly
(38) oil trap
(39) turbocompressor resonance attenuator
(40) turbocharger
(41) air/air intercooler
(42) air distributor
Integrated air intake system
The integrated air intake system consists of 2 parts (composite material)
Upper section
- Air filter unit
- The air filter element
- Air flow meter
Lower section
- Air inlet manifold
- Oil trap
- EGR pipe
Turbocharger
"aa" air intake inlet
"ab" air intake outlet
"ad" exhaust gas inlet
"ac" exhaust gas outlet
(43) turbocharging pressure regulator
Identification
- "ae" type of turbocharger
- "af" date of manufacture
- "ag" supplier's Part No.
| type | variable geometry turbocharger |
|---|---|
| make | IHI |
| reference | RHF3V |
| turbocharging pressure at idle speed | 0,5 bar |
| turbocharging pressure at full load | 1 bar |
| location | on the exhaust manifold |
Exhaust gas recycling
The EGR valve is located on the cylinder head (flywheel side)
The EGR valve is controlled by an electrovalve located on the cylinder head (exhaust side)
The electrovalve is controlled by the engine management ECU
Fuel supply system
Presentation
The engine is fitted with a "DELPHI C6" high pressure direct injection system
NoteThe "DELPHI C6" high pressure direct injection system does not have a low pressure pump
Fuel supply system
- (44) diesel fuel filter
- (45) transfer pump (pre-supply)
- (46) high pressure fuel pump
- (47) fuel flow actuator
- (48) diesel injectors
- (49) clogged fuel return pipe
- (50) high pressure fuel sensor
- (51) high pressure fuel supply common injection rail
- (52) fuel temperature sensor
- (53) venturi
- (54) manual fuel primer pump
- (55) fuel cooler
- (56) fuel tank
- (57) electric diesel fuel heater
Diesel fuel filter
"ah" fuel outlet to high pressure pump
"aj" fuel supply
(57) electric diesel fuel heater (removable)
(58) fuel filter release tab
(59) water bleed screw
(60) filter element
(61) fuel filter support
Filtration threshold: 5 microns
Engine cooling system
(30) coolant/oil heat exchanger
(62) expansion chamber
(63) coolant pump
(64a) assembly with drain plug (all countries except Extreme Cold climates)
(64b) assembly with thermoplungers
(65) oil / water heat exchanger
(66) heater matrix
(67) coolant outlet housing with thermostatic valve (integrated)
(68) engine cooling radiator
NoteFor Very Cold countries, the heater canister is located in place of the drain plug on the coolant inlet manifold
The coolant pump is driven by the timing belt
Driving the ancillaries
The ancillary drive belt is of the polyvee type
There are 2 possible assemblies (according to vehicle)
- Equipment (without air conditioning)
- Assembly with air conditioning
Equipment (without air conditioning)
(69) automatic roller tensioner
(70) alternator pulley
(71) roller tensioner
(72) crankshaft pulley
Equipment (WITH AIRCON)
(69) automatic roller tensioner
(70) alternator pulley
(72) crankshaft pulley
(73) air conditioning compressor