EW10J4

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B1BBM7K1 - 206 EW10J4 ENGINE
ENGINE INTRODUCTION
1 - DESCRIPTION
New engine : EW10J4 engine .
EW engines are progressively replacing XU engines .
Special features :
z 4 cylinders in line - 16 valves

z 2 overhead camshafts driven by toothed timing belt
z multipoint injection system
z engine with reduced fuel consumption (raised output)
NOTE : the engine is prepared for future emission control standards .
The engine output is improved due to the following factors :
z reduction of mechanical losses

z reduction of weight
z optimisation of induction and exhaust ducts
z controlled exhaust gas recirculation valve (reduction in fuel consumption)
1 - 1 - 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 .
1 - 2 - DATA
http://www.peugeot206cc.co.uk/repair-206/206/info/gb/b1bbm7k3.htm 26/09/2010
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Engine type plate :
z (a) : legislation type

z (b) : unit reference
z (c) : build order number
2 - DATA
engine type EW10J4

legislation type RFR
unit reference vehicle specific
number of cylinders 4
bore x stroke (mm) 85 x 88
capacity (cm3) 1997
compression ratio 10,8
maximum power (EC) 99 kW
maximum power (HP DIN) 138
engine speed at max. power (r.p.m.) 6000 rpm
maximum torque (EC) 19 da.Nm
engine speed at maximum torque (rpm) 4100 rpm
injection system multipoint
make MAGNETI MARELLI
type MMDCM 4.8P
3 - CYLINDER BLOCK ASSEMBLY
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(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 :
z bore = ø 85 mm
z number of main bearings = 5
z 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 .
NOTE : no. 1 cylinder : flywheel end .
The sealing between the following components is ensured by sealing compound :
z cylinder block
z bearing cap cover
z sump
4 - CRANKSHAFT AND CONNECTING RODS
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(6) Crankshaft .
(7) Compression ring .
(8) Lower sealing ring .
(9) Scraper ring .
(10) Piston .
(11) Gudgeon pin .
(12) Connecting rod .
(13) Big end bearing shell .
(14) Crankshaft end float washers .
(15) Top half shells .
(16) Lower half-shell .
(d) Lubrication hole .
4 - 1 - CRANKSHAFT
New crankshaft :
z material : cast iron

z lighter counterweights
z number of main bearings : 5
z number of counterweights : 8
z crankshaft sealed by a lip seal
Crankshaft end float :
Page 5 of 24
z the end float should be 0,06 to 0,15 mm

z the end float is determined by 2 half washers on main bearing no. 2 (2 cylinder block side)
4 - 2 - CRANKSHAFT HALF SHELLS
(6) Crankshaft .
(1) Cylinder block .
(e) Marking of category of main bearings - To crankshaft (Paint) :
z bar code used in plant

z marking of diameter category (main bearing 1 to main bearing 5)
(f) Marking of category of main bearings - To cylinder block (Cold stamped inscription) :
z marking of diameter category (main bearing 1 to main bearing 5)

z 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) .
NOTE : there is only one category of upper half shell .
4 - 3 - CONNECTING RODS
Connecting rods :
z material : forged steel

z distance between centres = 139 mm
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z the big end half shells are smooth

z the half shells have a locating lug
z 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 .
NOTE : the big end half shells (top and bottom) are drilled .
4 - 4 - CONNECTING ROD HALF SHELLS
(6) Crankshaft .
(12) Connecting rod .
(g) Crankshaft marking (A B C D) :
z bar code used in plant

z diameter category marking (crank pin 1 to crank pin 5)
(h) Marking on the connecting rod (Cold stamped inscription) :
z weight category marking (XX)

z diameter category marking (A)
z Factory markings (X)
The big ends and crank pins are matched by references .
Matching is by using 3 categories of (lower) half-shells .
NOTE : there is only one category of upper half shell .
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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) .
4 - 5 - PISTONS
Material : Light alloy .
There is only one piston diameter category (Production size) .
There is only one piston diameter category (Repair size) .
4 - 6 - PISTON RINGS
The piston has 3 rings :
z upper sealing ring : thickness 1,2 mm

z lower sealing ring : thickness 1,5 mm
z scraper ring : thickness 2,5 mm
4 - 7 - FLYWHEEL
Flywheel (Vehicle specific) :
z material : cast iron

z friction plate 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 .
4 - 8 - THE ANCILLARY DRIVE PULLEY
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Special features :
z secured to the crankshaft by 4 bolts

z damped hub with declutching in torsion stage
5 - 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 .
5 - 1 - 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 .
NOTE : tightening is in a SPIRAL sequence .
5 - 2 - CAMSHAFT BEARING CASTING
Material: aluminium alloy .
Sealing between camshaft bearing cap casing and cylinder head: sealing compound .
In service : Use AUTOJOINT OR sealing compound .
The camshaft end float is controlled at no. 5 cylinder head bearing (bearing no. 1, flywheel end) .
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5 - 3 - CYLINDER HEAD
4 valves per cylinder (2 inlet, 2 exhaust) with clearance adjustment by hydraulic tappets .
Height of 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 .
5 - 4 - 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 pressure lubricated and the cams by oil bath .
NOTE : the rotor (21) is not removable .
5 - 5 - CYLINDER HEAD GASKET
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(22) Cylinder head gasket .
(k) Engine identification : hole .
(l) Machined cylinder head gasket identification .
Special features :
z number of categories : 1
z thickness : 0,8 mm
z type : laminated metal gasket (3 layers)
5 - 6 - HYDRAULIC TAPPET
The hydraulic tappets automatically adjust valve clearance .
Design identical to the tappets used in the XU engines .
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Diameter : 28,4 mm .
5 - 7 - VALVES
Inlet valve : ø 33,3 mm .
Exhaust valve : 29 mm .
Valve stem seal : 6 mm .
Valve stem seal with integral cup .
5 - 8 - VALVE SPRINGS
Special features :
z conical shape
z mark : paint mark(s)
z external diameter 1 : ø 26,7 mm
z external diameter 2 : ø 15,1 mm
6 - TIMING
(23) Securing bolt(s) .
(25) Camshaft gear : Exhaust .
(26) Camshaft gear : Inlet .
(27) Dynamic tensioner roller .
(28) Roller tensioner .
(29) Crankshaft gear .
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(30) Coolant pump gear .
The timing cover is composed of the following 2 components :
z (24) the top timing cover (5 fastening points)

z (31) the bottom timing cover (5 fastening points)
6 - 1 - TIMING BELT
legislation type RFR

engine type EW10J4
width mm 25,4 mm
number of teeth 153
material HSN
manufacturer GATES
identification markings -
replacement interval with normal refer to the maintenance
use schedule
6 - 2 - CAMSHAFT GEAR
(25) Camshaft gear .
(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 .
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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 :
z improved accuracy of timing

z better distribution of belt tension between the different runs
Camshaft hub identification :
z stamping on the camshaft hub

z reference number
7 - LUBRICATION
Pressure lubrication by an internally driven dual eccentric rotor pump .
The oil filter cartridge is separate from the cylinder block .
7 - 1 - 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) .
7 - 2 - OIL CAPACITY
engine EW10J4
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special features without

4.25 litre
oil capacity with replacement of the oil filter
(s)
oil capacity, drainage by suction with replacement of
-
filter cartridge
oil capacity without replacement of the oil filter 4.0 litre(s)
capacity between min and max on the dipstick -
always check the oil level using the dipstick
Capacity between min and max on the dipstick : 1,7 litre(s) .
IMPERATIVE : always check the oil level using the dipstick .
Oil change interval : Refer to the maintenance schedule .
7 - 3 - OIL FILTER
oil filter 1st fitting 2nd fitting

make PURFLUX PURFLUX
type LS867A LS867B
oil capacity 0.32 litre(s)
safety valve 1.5 bar(s)
Replacement interval with normal use : Refer to the maintenance schedule .
Oil pressure .
engine EW10J4
check 1 at 1000 rpmminimum pressure (bars) 3.4
check 4 at 4000 rpmminimum pressure (bars) -
the values given are in bars for an engine which is run in, at an
oil temperature of 80 ° C
7 - 4 - 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) .
NOTE : it is still possible to drain the engine by removing the drain plug from the sump .
8 - AIR SUPPLY CIRCUIT
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8 - 1 - AIR SYSTEM
(37) The air inlet hose .
(38) Injectors supply rail .
(39) Exhaust gas recirculation tube .
(40) Inlet manifold .
(41) Throttle housing : Aluminium alloy .
(42) Jubilee clip .
(n) Access to the screw .
Special features - Inlet manifold :
z material : composite materials

z resonator integral with the air inlet manifold
z exhaust gas recirculation tube take-off
z the seal is preformed and removable
Special features , Throttle housing :
z material : light alloy

z 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) .
8 - 2 - ADJUSTMENT OF EXHAUST GASES
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Arrows : Direction of exhaust gas circulation .
(39) Exhaust gas recirculation tube .
(40) Inlet manifold .
(41) Throttle housing .
(43) Exhaust manifold .
(44) Exhaust gas recirculation (EGR) valve .
(45) Water 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 :
z coolant temperature
z engine speed (rpm)
z engine load
8 - 3 - EXHAUST GAS RECIRCULATION (EGR) VALVE
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Special features :
z proportional solenoid valve controlled by the injection ECU
8 - 4 - EXHAUST MANIFOLD
(43) Exhaust manifold .
(46) Internal ducts (1 per cylinder) .
(47) External envelope .
Material : Steel .
The exhaust manifold is made up of the following components :
z 4 ducts
z 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 .
9 - FUEL SUPPLY SYSTEM
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(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 (Activated 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 :
z injector supply rail without fuel return circuit

z petrol pressure regulator mounted in the fuel tank
z fuel pressure : 3,5 bar(s)
9 - 1 - SCHRADER VALVE
The schrader valve is of the tyre valve type .
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Functions :
z depressurising the circuit

z pressure check
z delivery check
NOTE : access to the schrader valve requires prior removal of the engine styling cover .
9 - 2 - FUEL FILTER
The fuel filter filters impurities above 15 - 20 microns .
Replacement interval : Refer to the maintenance schedule .
10 - COOLING SYSTEM
(58) Heater matrix .
(59) Bleed screw .
(60) Thermostat .
(61) Radiator .
(62) Expansion chamber .
(63) Coolant inlet manifold - Coolant pump .
Special features :
z expansion chamber separate from radiator
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z double valve thermostat
10 - 1 - COOLANT PUMP
Special features :
z material : composite materials

z driven by timing belt
z the coolant pump is outside the cylinder block
IMPERATIVE : the centralising dowels must always be refitted when fitting the coolant pump .
10 - 2 - THERMOSTAT
Double action thermostat .
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(a1) To coolant inlet manifold .
(a2) Coolant outlet from the cylinder head .
(a3) Outlet to the radiator .
(t) Operation : Cold .
(u) Operation : In warm up phase .
(v) Operation : 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) Operation - Cold : The coolant circulates in the following components :
z engine (loop circulation)

z heater matrix
(u) In warm up phase : The coolant circulates in the following components :
z engine (loop circulation)

z heater matrix
z radiator
(v) Operation - Hot : The coolant circulates in the following components :
z engine
z heater matrix
z radiator
11 - ANCILLARIES DRIVE
2 equipment possibilities (According to vehicle) :
z vehicle with power steering

z vehicle with power steering + air conditioning
11 - 1 - WITHOUT AIR CONDITIONING
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(66) Power steering pump .
(67) Alternator .
(69) Belt drive pulley .
11 - 2 - WITH AIR CONDITIONING
(66) Power steering pump .
(67) Alternator .
(69) Belt drive pulley .
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(70) Air conditioning compressor .
12 - INJECTION SYSTEM
Manufacturer : MAGNETI MARELLI .
Type : MMDCM 4.8P .
12 - 1 - INJECTION
Special features :
z the control unit is of the Pressure-Engine Speed type

z this injection system manages injection and ignition mainly from information on inlet air
pressure and engine speed
z multipoint injection (4 electro-mechanical injectors)
z multipoint sequential injection
z programmed injector opening time (mapping)
12 - 2 - IGNITION
Special features :
z integral electronic ignition

z twin static type ignition
z mapping advance
The coils are part of a compact unit attached to the cylinder head (BBC 2.2) .
Ignition coil unit (BBC) :
z manufacturer : SAGEM BBC 2.2

z primary winding resistance : 0,5 Ω
z secondary winding resistance : 12,5 kΩ
Spark plugs :
z manufacturer : EYQUEM RFC 52LZDP

z flat seat
z electrode gap : 1 mm
z tightening torque : 2,5 da.Nm
Replacement interval with normal use : Refer to the maintenance schedule .
12 - 3 - DOWNLOADING
This injection/ignition control unit has a Flash Eprom memory .
Special features of the Flash Eprom memory :
z 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
z the operation consists of downloading the program into the memory of the ECU
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12 - 4 - INJECTION CONTROL UNIT
Special features :
z new connections
z connectors locked by plastic yoke
Allocation of the 128 control unit ways through 3 connectors .
The control unit manages the following functions :
z the air - petrol supply

z ignition system
z autodiagnosis
z mixture regulation
z idle speed regulation
z knock regulation
z engine cooling system
z exhaust gas recirculation
z engine speed (tachometer)
z immobiliser

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Page 1 of 24

B1BBM7K1 - 206 EW10J4 ENGINE

New engine : EW10J4 engine .

EW engines are progressively replacing XU engines .

z 4 cylinders in line - 16 valves

NOTE : the engine is prepared for future emission control standards .

The engine output is improved due to the following factors :

z reduction of mechanical losses

1 - 1 - POWER TRAIN INSTALLATION

Engine type plate :

z (a) : legislation type

engine type EW10J4

3 - CYLINDER BLOCK ASSEMBLY

(1) Cylinder block .

(2) Crankshaft bearing cap casing .

(4) Oil pump .

(5) Cast iron cylinder liner(s) .

The liners are of the dry type .

Light alloy crankcase incorporating 5 cast iron main bearing caps .

NOTE : no. 1 cylinder : flywheel end .

The sealing between the following components is ensured by sealing compound :

4 - CRANKSHAFT AND CONNECTING RODS

(7) Compression ring .

(8) Lower sealing ring .

(9) Scraper ring .

(11) Gudgeon pin .

(12) Connecting rod .

(13) Big end bearing shell .

(14) Crankshaft end float washers .

(15) Top half shells .

(16) Lower half-shell .

(d) Lubrication hole .

z material : cast iron

Crankshaft end float :

z the end float should be 0,06 to 0,15 mm

4 - 2 - CRANKSHAFT HALF SHELLS

(1) Cylinder block .

(e) Marking of category of main bearings - To crankshaft (Paint) :

z bar code used in plant

z marking of diameter category (main bearing 1 to main bearing 5)

Matching is by means of 4 classes of smooth half shells .

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

Grooved half shells (Cylinder block side) .

NOTE : there is only one category of upper half shell .

z material : forged steel

z the big end half shells are smooth

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

4 - 4 - CONNECTING ROD HALF SHELLS

(12) Connecting rod .

(g) Crankshaft marking (A B C D) :

z bar code used in plant

(h) Marking on the connecting rod (Cold stamped inscription) :

z weight category marking (XX)

The big ends and crank pins are matched by references .

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

NOTE : there is only one category of upper half shell .

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

Material : Light alloy .

There is only one piston diameter category (Production size) .

There is only one piston diameter category (Repair size) .