Presentation: engine (EW10J4) Peugeot 607 I

Description

New engine: EW10J4 engine

EW engines are progressively replacing XU engines

Special features

• 4 cylinders in line - 16 valves
• 2 overhead camshafts driven by toothed timing belt
• Multipoint injection system
• Engine with reduced fuel consumption (raised output)

The engine output is improved due to the following factors

• Reduction of mechanical losses
• Reduction of weight
• Optimisation of induction and exhaust ducts
• Controlled exhaust gas recirculation valve (reduction in fuel consumption)

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

Data

Engine type plate

• (a): legislation type
• (b): identification marking
• (c): production serial number

Data

Cylinder block assembly

(1) cylinder block

(2) crankshaft bearing cap casing

(3) sump

(4) oil pump

(5) cast iron cylinder liner(s)

The light alloy cylinder block has cast iron liners fitted on assembly (foundry)

The liners are of the dry type

Light alloy crankcase incorporating 5 cast iron main bearing caps

Special features

• Bore = ø 85 mm
• Amount of bearings = 5
• The coolant drain plug is in the rear face

The sump is new, with stiffening ribs to improve the rigidity of the connection to the gearbox

The sealing between the following components is ensured by sealing compound

• Cylinder block
• Bearing cap cover
• Sump

Reciprocating gear

(6) crankshaft

(7) compression ring

(8) lower sealing ring

(9) scraper ring

(10) piston

(11) the piston shaft

(12) connecting rod

(13) big end bearing shell

(14) crankshaft end float washers

(15) top half shells

(16) lower half-shell

(d) lubrication hole

Crankshaft

New crankshaft

• Material: cast iron
• Lighter counterweights
• Amount of bearings: 5
• Number of counterweights: 8
• Crankshaft sealing by lip seal

Crankshaft end float

• There should be an endfloat of 0,06 to 0,15 mm
• The end float is determined by 2 half washers on main bearing no. 2 (2 cylinder block side)

Crankshaft half shells

(6) crankshaft

(1) cylinder block

(e) marking of category of main bearings - to crankshaft (paint)

• Bar code used in plant
• Marking of diameter category (main bearing 1 to main bearing 5)

(f) 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

The crankshaft bearings (cylinder block + main bearing caps) and the crankshaft journals are matched by references on the cylinder block and the crankshaft

Matching is by means of 4 classes of smooth half shells

Selection of the appropriate half shell is by means of a matching table (see corresponding operation) with the markings (e) and (f)

Smooth half shells (on the main bearing cap side)

Grooved half shells (cylinder block side)

Conrods

Conrods

• Material: forged steel
• Distance between centres = 139 mm
• The big end half shells are smooth
• The half shells have a locating lug
• Number of weight categories: 4

The gudgeon pins are fitted tight in the connecting rods, and free in the pistons

The half shells are identified by a dab of paint on the edge

The connecting rods are drilled to lubricate the base of the liner

Connecting rod half shells

(6) crankshaft

(12) connecting rod

(g) crankshaft marking (A B C D)

• Bar code used in plant
• Diameter category marking (crank pin 1 to crank pin 5)

(h) marking on the connecting rod (cold stamped inscription)

• Weight category marking (XX)
• Diameter category marking (A)
• Factory markings (X)

The big ends and crank pins are matched by references

Matching is by using 3 categories of (lower) half-shells

The half shells are identified by a dab of paint on the edge

Selection of the appropriate half shell is by means of a matching table (see corresponding operation) with the markings (g) and (h)

Pistons

Material: aluminium alloy

There is only one piston diameter category (production size)

There is only one piston diameter category (repair size)

Piston rings

The piston has 3 rings

• Upper sealing ring: thickness 1,2 mm
• Lower sealing ring: thickness 1,5 mm
• Scraper ring: thickness 2,5 mm

Engine flywheel

Engine flywheel (vehicle specific)

• Material: cast iron
• Clutch diameter: 230 mm

The edge of the flywheel has 60 teeth of which 2 have been omitted to determine Top Dead Centre

A special tool (-).0189-C enables immobilisation of the crankshaft by a hole drilled in the cylinder block and flywheel

The ancillary drive pulley

Special features

• Secured to the crankshaft by 4 bolts
• Damped hub with declutching in torsion stage

Cylinder head assembly

(17) cylinder head cover (composite materials)

(18) camshaft bearing cap cover

(19) cylinder head

(i) exhaust gas recirculation channels cast into the cylinder head (foundry)

(j) cylinder head identification boss

Cylinder head cover

Two cylinder head covers (top cylinder head cover with an oil drain and oil filler opening)

Material: composite materials

The oil filler hole is incorporated in the cylinder head cover

The seal is preformed and removable

Camshaft bearing casting

Material: aluminium alloy

Sealing between camshaft bearing cap casing and cylinder head: sealing compound

At repair: use AUTOJOINT OR sealing compound

The camshaft end float is controlled at no. 5 cylinder head bearing (bearing no. 1, flywheel end)

Cylinder head

4 valves per cylinder (2 inlet, 2 exhaust) with clearance adjustment by hydraulic tappets

Height of a new cylinder head = 137 mm

Exhaust valve guides: sintered steel = 0,2 mm

Maximum permissible bow = 0,03 mm

The valve seats and guides are new and made from sintered steel

Maximum allowable machining

Inlet valve guide: brass

Part of the exhaust gas recirculation channels is incorporated in the cylinder head

Camshaft

(20) camshaft

(21) rotor driven by the camshaft

New cast iron camshafts with 8 cams and 5 bearings

The camshaft reference cylinder sensor rotor is fitted to the exhaust camshaft

The camshaft bearings are lubricated under pressure and the cams by oil baths

Cylinder head gasket

(22) cylinder head gasket

(k) engine identification: hole

(l) machined cylinder head gasket identification

Special features

• Number of categories: 1
• Thickness: 0,8 mm
• Type: laminated metal gasket (3 layers)

Hydraulic tappet

The hydraulic tappets automatically adjust valve clearance

Design identical to the tappets used in the XU engines

Diameter: 28,4 mm

Valves

Inlet valve: ø 33,3 mm

Exhaust valve: 29 mm

Valve stem seal: 6 mm

Valve stem seal with integral cup

Valve springs

Special features

• Conical shape
• Mark: paint mark(s)
• External diameter 1: ø 26,7 mm
• External diameter 2: ø 15,1 mm

Timing gear

(23) fixing screws

(25) camshaft pinion: exhaust

(26) camshaft pinion: inlet

(27) dynamic roller tensioner

(28) roller tensioner

(29) crankshaft gear

(30) coolant pump gear

The timing cover is composed of the following 2 components

• (24) the top timing cover (5 fastening points)
• (31) the bottom timing cover (5 fastening points)

Timing belt

Camshaft pinion

(25) camshaft pinion

(32) camshaft hub

(33) setting hole

(34) oblong hole

The camshaft is set through the hubs (32) keyed to the camshafts

The gears are attached to their hubs by 3 bolts

When the 3 fastening bolts are slackened, the gears are free to rotate (within the limits of the oblong holes)

This type of assembly makes possible

• Improved accuracy of timing
• Better distribution of belt tension between the different runs

Camshaft hub identification

• Stamping on the camshaft hub
• Reference number

Lubrication

Pressure lubrication by an internally driven dual eccentric rotor pump

The oil filter cartridge is separate from the cylinder block

Oil pump

(4) oil pump

(35) oil pump external rotor

(36) oil pump internal rotor

(6) crankshaft

(m) flats

The oil pump is driven from the end of the crankshaft by means of two flats (m)

Relief valve setting: 7 bar(s)

Oil capacity

Capacity between min and max on the dipstick: 1,7 litres

Oil change interval: refer to the maintenance schedule

Oil filter

Replacement interval with normal use: refer to the maintenance schedule

Oil pressure

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 tube is flared, which makes it possible to connect a suction drainage nozzle (diameter 14 mm)

Air supply circuit

Air circuit

(37) the air entry union

(38) injectors supply rail

(39) exhaust gas recirculation tube

(40) inlet manifold

(41) throttle butterfly housing: aluminium alloy

(42) Jubilee clip

(n) access to the screw

Special features - inlet manifold

• Material: composite materials
• Resonator integral with the air inlet manifold
• Exhaust gas recirculation tube take-off
• The seal is preformed and removable

Special features, throttle butterfly housing

• Material: aluminium alloy
• Idle regulation by stepper motor

Removal of the air inlet connector from the throttle housing requires slackening of its attachment collar (42) via access (n)

Exhaust gas recycling

Arrows: direction of exhaust gas circulation

(19) cylinder head

(39) exhaust gas recirculation tube

(40) inlet manifold

(41) throttle butterfly housing

(43) exhaust manifold

(44) exhaust gas recycling valve (EGR)

(45) coolant outlet housing

Exhaust gas recirculation is used to reduce the pumping effect (reduction in fuel consumption)

The recirculation is of the progressive type managed by mapping

The opening of the EGR valve is controlled by the EGR solenoid valve which is managed by the engine management control unit which receives the following data

• Coolant temperature
• Engine speed (rpm)
• Engine load

Exhaust gas recycling valve (EGR)

Special features: proportional solenoid valve controlled by the injection ECU

Exhaust manifold

(43) exhaust manifold

(46) internal ducts (1 per cylinder)

(47) external envelope

Material: panel

The exhaust manifold is made up of the following components

• 4 ducts
• 1 pressed steel envelope

A space between the exhaust ducts and the half shells provides good heat insulation

This exhaust manifold makes possible rapid warming up of the catalytic converter on cold starts

Fuel supply system

(p) direction of fuel circulation

(q) direction of petrol vapour circulation

(r) to petrol vapour recycling pipes

(s) to fuel supply pipes

(38) injectors supply rail

(48) canister (active carbon filter)

(49) fuel filter

(50) schrader valve

(51) fuel return pipes

(52) click-on connector

(53) petrol injector(s)

(54) petrol vapour reaspiration pipes

(55) fuel supply pipes

(56) fuel pressure regulator

(57) fuel pump submerged in the fuel tank

Special features

• Injector supply rail without fuel return circuit
• Petrol pressure regulator mounted in the fuel tank
• Fuel pressure: 3,5 bar(s)

Schrader valve

The schrader valve is of the tyre valve type

Functions

• Depressurising the circuit
• Pressure check
• Delivery check

Fuel filter

The fuel filter filters impurities above 15 - 20 microns

Replacement interval: refer to the maintenance schedule

Cooling system

(19) cylinder head

(45) coolant outlet housing

(58) heater matrix

(59) bleed screw(s)

(60) thermostat

(61) radiator

(62) expansion chamber

(63) coolant inlet manifold - coolant pump

Special features

• Expansion chamber separate from radiator
• Double valve thermostat

Coolant pump

Special features

• Material: composite materials
• Driven by timing belt
• The coolant pump is outside the cylinder block

Thermostat

Double action thermostat

(45) coolant outlet housing

(a1) to coolant inlet manifold

(a2) coolant outlet from the cylinder head

(a3) outlet to the radiator

(t) function: cold

(u) function: in warm up phase

(v) function: hot

(63) - (64) valve

The thermostat has two valves (63) and (64)

When the valve (64) is open: the coolant circulates through the radiator

When the valve (63) is open: the coolant is directed to the coolant inlet manifold (loop circulation)

(t) function - cold: the coolant circulates in the following components

• Engine (loop circulation)
• Heater matrix

(u) in warm up phase: the coolant circulates in the following components

• Engine (loop circulation)
• Heater matrix
• Radiator

(v) function - hot: the coolant circulates in the following components

• Engine
• Heater matrix
• Radiator

Ancillaries drive

2 equipment possibilities (according to vehicle)

• Vehicle with power steering
• Vehicle with power steering + air conditioning

Without air conditioning

(65) dynamic roller tensioner

(66) power-assisted steering pump

(67) alternator

(68) roller tensioner

(69) belt drive pulley

With air conditioning

(65) dynamic roller tensioner

(66) power-assisted steering pump

(67) alternator

(68) roller tensioner

(69) belt drive pulley

(70) air conditioning compressor

Injection system

Make: MAGNETI MARELLI

Type: MMDCM 4.8P

Injection

Special features

• The control unit is of the Pressure-Engine Speed type
• This injection system manages injection and ignition mainly from information on inlet air pressure and engine speed
• Multipoint injection (4 electro-mechanical injectors)
• Multipoint sequential injection
• Programmed injector opening time (mapping)

Ignition system

Special features

• Integral electronic ignition
• Twin static type ignition
• Mapping advance

The coils are part of a compact unit attached to the cylinder head (BBC 2.2)

Ignition coil unit (BBC)

• Make: SAGEM BBC 2.2
• Résistance de l'enroulement primaire: 0,5 ohms
• Résistance de l'enroulement secondaire: 12500 ohms

Sparking plugs

• Make: EYQUEM RFC 52LZDP
• Flat seat
• Electrode gap: 1 mm
• Tightening torque: 2,5 daNm

Replacement interval with normal use: refer to the maintenance schedule

Downloading

This injection/ignition control unit has a Flash Eprom memory

Special features of the Flash Eprom memory

• This type of memory makes it possible, if there is a calibration modification, to modify the contents of the control unit memory without either removing or replacing the control unit
• The operation consists of downloading the program into the memory of the ECU

Injection electronic control unit

Special features

• New connections
• Connectors locked by plastic yoke

Allocation of the 128 control unit ways through 3 connectors

The control unit (7) manages the following functions

• The air - petrol supply
• Ignition system
• Autodiagnosis
• Mixture regulation
• Regulation of idle speed
• Knocking regulation
• Engine cooling
• Exhaust gas recycling
• Engine speed (tachometer)
• Immobiliser