B1BBM2K1 - 206 MOTOR DW10TD

PRESENTATION OF THE DW10 ENGINE

1 - DESCRIPTION

Main architecture of the DW10 engine:

direct injection diesel engine

GMP inclination (in new vehicles homologated since 1998, the
new rules concerning collisions impose a restoration of the
engines in the front block of the vehicles
1 overhead camshaft driven by a toothed belt
4 inline cylinders - 8 valves
high-pressure pump driven by a toothed timing belt
water pump driven by toothed timing belt
integrated oil fill hole in the valve cover
oil suction draining device
motor equipped with an acoustic cover

This engine is available in 2 versions:

DW10 ATED: with air/air exchanger

DW10 TD: without exchanger

The DW10 ATED engine is an improved version of the DW10TD engine, This improvement of
power and torque is obtained through the management of the turbocharger pressures by
the electronic injection calculator.

2 - IDENTIFICATION
Identification marking includes:

(1) brand organ

regulatory type
(3) manufacturing order number

3 - CHARACTERISTICS

DW10 DW10
engine code
ATED TD
engine type approval RHZ RHY
brand organ specific vehicle
number of cylinders 4
diameter_x_travel_mm 85 x 88
engine displacement (cm3) 1996
compression relationship 18/1
maximum power (kw - CEE) 80 66
maximum power (DIN hp) 110 90
maximum power regime (r/min.) 4000
by maxi (m.daN - CEE) 25 20.5
maximum regime (r/mn.) 2000
turbocharger specific vehicle
air/air exchanger yes no
supercharging pressure (2000
1 bar
r/mn
boost pressure (3000
1 bar
r/mn)
injection system COMMON RAIL
brand BOSCH
type EDC 15C2
 opacity of the smoke (m - 1) specific: vehicles

4 - CYLINDER CARTER

Cylinder casing:

in a fade (not a camouflage)

cylinders with a diameter of 85 mm
equipped with piston back sprayers
equipped with 5 bench covers emptied in (B) to lighten the cylinder crankcase
intercylinders of thickness 8 mm with water passage drill in (C) and sheet of
water in (D) to promote the cooling of the top part of the cylinders
equipped with a coolant drain plug installed in the
rear end

The cylinder block is identical between a DW10 ATED and DW10TD engine and is distinguished
by the motor engraving (Regulatory type).

NOTE: cylinder-number: 1: clutch side (flywheel).

5 - MOBILE COUPLING
Crankshaft.

Upper semi-housings.

(6) Lower semi-caps.

Longitudinal top valve.

Piston.

Bolt.

Brake ring.

White.

Semi-sleeve of the connecting rod head.

5 - 1 - CRANKSHAFT

Motor DW10 ATED:

crankshaft (identical to the XUD9TE engine)

in polished steel
of 5 supports

DW10 TD engine:

crankshaft (identical to engine XUD7TE)

steel
of 5 supports

The front and rear sealing is ensured by seals.

The adjustment of the longitudinal clearance (ranging from 0.07 to 0.32 mm) is carried out in
Support No. 2 for 4 washers (2 on the crankcase side and 2 on the crankshaft cover side).

5 - 2 - CRANKSHAFT SEMI-BUSHINGS

Crankshaft semi-bearings:

identical to the XUD9TE engine

sheets side covers bench
grooves on the cylinder block side

5 - 3 - RODS

New cranks (center-to-center 145 mm) (Identical to the DW8 engine) :

forged steel connecting rods

 the connecting rod foot is equipped with a machined bronze bushing in the shape of
snake head
smooth connecting rod semi-sleeves with a notch

5 - 4 - PISTONS

(E): Flywheel side engine.

Distribution side.

Specific pistons with a raised feature and central cavity (BOWL) necessary for turbulence
of the gases (SWIRL).

New lightweight alloy pistons with notches for the valves.

The orientation is provided by the notch of the valves (notch side opposite to the filter)
oil) .

There is only one class of piston diameter (Series).

There is only one class of piston diameter (Repair).

A class of weights, obtained by interior adjustment of the bolt.

The floating piston bolt is held by 2 retainers.

The piston has a steel insert to reinforce the short-fire segment collar.
.

5 - 5 - SEGMENTATION

The piston has 3 rings:

upper sealing segment (13): double trapezoidal firewall (thickness

3.5 mm
lower sealing segment (14): eagle peak (thickness = 2 mm)
scratching segment (15): with spiral spring (thickness = 3 mm)
5 - 6 - FLYWHEEL

Flywheel (Adapted to each vehicle):

in melted with laminar graphite

friction diameter 275 mm
the flywheel includes 60 teeth on its perimeter of which 2 have been
suppressed in order to determine the Upper Break-even Point

5 - 7 - PULLEY ACCESSORIES

A pulley for the versions without air conditioning (damped moyú without step of
twist cut) .

A pulley for the versions with air conditioning (dampered moyu with step in
twisting).

These pulleys are secured with 1 screw on the crankshaft (Identical XUD).

6 - BUTTSTOCK SET

6 - 1 - ROCKER COVER (16)

The rocker cover (16) is made of composite material, it has a sealing gasket.
preformed and is removable.

The oil filler hole is integrated into the valve cover.

6 - 2 - CAMSHAFT SUPPORT PLATE CARTER (17)

The camshaft support cover (17) is made of lightweight alloy.

The sealing of the sump cover/cylinder head is done using CAF 33 type gasket paste.

The camshaft is positioned in the cylinder head by the cover pan, has a gear, and has 5
supports.
The longitudinal machining of the camshaft is carried out at support No. 3 (Support No. 1 side
flywheel.

6 - 3 - BUTT (18)

A new cylinder head (18): 2 valves per cylinder.

Height of the new cylinder head: 133 mm.

Maximum deformation of the cylinder head plane: 0.03 mm.

The intake ducts in the cylinder head have a complex helical shape to allow
the formation of the SWIRL.

The seats and valve guides are new and made of sintered steel.

NOTE: the tightening method is done on a SCREW.

6 - 4 - INJECTORS

The bottom part of each injector looks like the classic multi-slot model (of
characteristics adapted to the engine version, for example: 5 holes of ø 0.16 mm,
5 X 0.20 or 6 X 0.15.

The vertex is mounted on an electromagnetic control valve.

NOTE: systematically replace the copper gasket located in the cylinder head (after
the intervention) .

6 - 5 - THE CAMSHAFT

The camshaft :

move the vacuum pump (flywheel side)

attack the roller ingots that operate the valves

Hydraulic tappets allow for wear recovery while maintaining zero clearance.
between the camshaft, the ingots, and the valves.

Lubrication is ensured by a longitudinal channel.

The lateral channels direct the oil to the bearings and the cams.

Longitudinal clearance value: 0.07 mm to 0.38 mm.

6 - 6 - CYLINDER HEAD
Mark thickness.

There are 5 types of multi-layer metal head gaskets.

The cylinder head is equipped interchangeably on the DW10 ATED and DW10 TD engines.

Method of determining the joint by measuring the piston leveling (Identical

to the DW8 engine.

values of thickness flush notch(es) number of

piston (mm) (mm) drills in (G)
1.30 ±
0.47 to 0.604 1
0.06
1.35 ±
0.605 to 0.654 2
0.06
1.40 ±
0.655 to 0.704 3
0.06
1.45 ±
0.705 to 0.754 4
0.06
1.50 ±
0.755 to 0.83 5
0.06

6 - 7 - STUNS (FUNCTIONING)
Roller ingot.

Hydraulic jack.

Patella.

Piston.

Valve.

Recovery pier.

Recovery dock.

Body.

Lower chamber.

Upper chamber.

The hydraulic tappets are for automatic play recovery with a diameter of 12 mm.

Slack recovery phase of valve lever (H - I):

when there is clearance, the pulley (21) lifts under the action of the spring (25);
this causes a depression in the lower chamber (27), which makes the valve open
(23)
there is a pressure balance between the two chambers (27) and (28); the valve (23) is
closes under the action of the spring (24), the two chambers are isolated

Compression phase (valve lift) (J) :

 when the lever rests on the ingot, the pressure rises to the lower chamber (27), the
valve (23) is adjusted in its seat; the hydraulic tappet is at limit function, the
the movement is transmitted entirely to the valve

6 - 8 - VALVES

Specific valves:

admission (diameter 35.6 mm)

escape (diameter 33.8 mm)

Valve stem (Diameter 5.978 mm) .

6 - 9 - VALVE SPRINGS

Outer diameter: 20.9 mm.

Number of turns: 9.

7 - DISTRIBUTION

7 - 1 - CHARACTERISTICS

pinion with 21 teeth of the crankshaft.

Water pump pinion (20 teeth).

Camshaft gear (42 teeth) .

Camshaft bearing

High-pressure pump gear (42 teeth).

Roller winder (Outer diameter: 60 mm).

Manual tension roller (Diameter 60 mm and eccentric radius 7 mm).

Timing belt.

Timing cover in 3 parts fixed by 9 screws:

(37) upper cover (4 fixation points)

high pressure pump housing (3 mounting points)
lower case (5 fixing points)

7 - 2 - TIMING BELT

engine homologation type RHZ RHY

engine code DW10 ATED DW10 TD
width (mm) 25.4
number of teeth 141
provider(s) DAYCO
material HSN
brand registration -
change frequency (km)
160,000
a normal use
change periodicity (km)
120,000
under severe use

NOTE: The tension of the belt is adjusted by mounting the manual tension roller.
(eccentric) requiring the assembly of the tension control tool SEEM.

7 - 3 - HIGH PRESSURE PUMP

The high-pressure radial three-piston pump is driven by the distribution of

unsynchronized manner.

8 - LUBRICATION
Low pressure oil return circuit.

Steam oil descending circuit from the top of the engine.

High pressure oil rising circuit.

Low pressure oil descent circuit.

Oil vapor descent circuit from the top of the engine.

Oil high pressure ascension circuit.

8 - 1 - OIL CAPACITY

DEPENDING ON THE VEHICLE APPLICATION, THE ENGINE MAY GO

INCLINED OR STRAIGHT: ADAPTATION TO EACH VEHICLE.
 engine homologation type RHY - RHZ RHY - RHZ
air without air
particularities
air-conditioned air-conditioned
oil capacity (with
4.5 4.5
filter
oil capacity (without
4.2 4.2
filter

engine homologation type RHY - RHZ RHY - RHZ

air without air
particularities
air-conditioned conditioned
oil capacity (with
4.25 4.25
filter)
oil capacity (without
4 4
filter)

IMPERATIVE: systematically check the oil level with the dipstick.

manual.

Change periodicity (Engine oil): See maintenance documents.

8 - 2 - ENGINE OIL FILTER CARTRIDGE

Oil filter cartridge (First installation):

PURFLUX LS 867A (diameter 76 mm)

Oil filter cartridge (Replacement) :

PURFLUX LS 867B (diameter 76 mm, valve: 1.5 bar(s))

Change frequency (Motor oil filter cartridge): See documents for

maintenance.

8 - 3 - LUBRICATION CIRCUIT

The cooling of the piston bottom is ensured by sprayers.

Engine oil pressure 80°C measured at the location and site of the pressure switch.

engine homologation type RHZ RHY

control 1 1000 r/min 1000 r/min
minimum pressure (bar(s)) 2 2
control 2 2000 r/mn 2000 r/min
 minimum pressure (bar(s)) 2.8 2.8
control 3 3000 r/month 3000 r/month
minimum pressure (bar(s)) 3.8 3.8
control 4 4000 r/min 4000 r/mn
minimum pressure (bar(s)) 4 4

8 - 4 - ENGINE DRAINING

The draining must be done hot as soon as the engine stops.

It is possible to drain the engine using a suction device (Terminal ø 14

It is always possible to drain the engine by removing the oil pan drain plug.

9 - AIR SUPPLY CIRCUIT

9 - 1 - THE AIR CIRCUIT

Exhaust collector (Cast)

(41) Admission distributor (Aluminum alloy).

EGR Valve.

Union sleeve distributor/EGR valve.

The air intake manifold (Aluminum alloy).

Vacuum pump.

The Exhaust Gas Recycling tube is fixed with:

1 clamp click on the EGR valve (42)

 2 screws in the air inlet fitting (44)

The EGR valve (42) is secured with 2 screws to the exhaust manifold (40).

9 - 2 - RECYCLING OF EXHAUST GASES

The EGR device functions to reduce the amount of nitrogen oxide.

(NOx) expelled by exhaust gases.

Nitrogen oxides are produced by the combination of nitrogen and oxygen from the
air of emission under the effect of a very high temperature (above 1800 °C).

The EGR decreases the amount of oxygen in certain operational phases.

available in the cylinder.

The EGR valve (42) is subjected to a depression coming from the vacuum pump (45)
fixed at the end of the camshaft and allows the recycling of exhaust gases
towards the air sleeve (44).

The recycling is of a progressive type directed by mapping.

The opening of the EGR valve (42), commanded by the EGR solenoid valve, which is
directed by the motor control calculator receives the following information:

engine water temperature

engine operating regime
cargamotor (the position of the accelerator pedal)

9 - 3 - PRESSURE REGULATION SOLENOID VALVE TURBO-

COMPRESSOR

EGR Valve.

Vacuum pump.

Electrovalve pressure regulation turbo-compressor.

EGR solenoid valve.

Turbocharger.

Turbo regulation valve.

Mandated by the controller, this solenoid valve allows you to regulate the intake pressure.
through the turbo regulation valve (49).

10 - PRE-POST WARM-UP

Preheating box.

Glow plugs.

(1320) Motor control calculator.

Preheating indicator light.

10 - 1 - PREHEATING

Since the contact is established: The motor control calculator powers the spark plugs of
preheating and sends the warning light of the combination, of the panel
instruments, based on the temperature of the water engine; The time of
Preheating varies depending on the engine water temperature.

NOTE: The combination indicator only lights up during the phase of

preheating; the lighting time is identical to the preheating time.

preheating time
engine water temperature
second(s)
-30°C 20
 -10°C 5
0°C 0.5
+-18°C 0

After the warning light goes off, if not requested at startup, the spark plugs of
preheating is kept powered for a maximum of 10 seconds.

During the start-up phase, the glow plugs are powered in the
following conditions :

The engine water temperature is below 20 °C

the engine spins at more than 70 rpm for 0.2 second(s)

10 - 2 - POST-WARM-UP

The post-heating consists of prolonging the operation of the glow plugs in a

maximum duration of 60 seconds from the end of the startup phase.

Parameters that can interrupt post-heating:

water temperature engine above 20 °C

caudal injected greater than 35 mm3
motor regime above 2000 rpm

11 - FUEL CIRCUIT

11 - 1 - PRESENTATION

This engine is equipped with a new COMMON RAIL direct injection system.
from the brand BOSCH.

Fuel deposit.

Priming pump.
Diesel filter.

High-pressure pump.

Common rail.

Injector.

Gas oil pressure sensor.

(57) Diesel temperature sensor.

(58) Third piston deactivator.

High pressure diesel regulator.

Towards the water outlet box.

11 - 2 - FILTRATION BOWL SET

Diesel input coming from the tank.

Diesel entry that comes from the water outlet box.

Diesel output: Towards the water outlet box.

Output of the diesel: Towards the high pressure pump.

Output of the diesel towards the tank (return circuit).

Purge screw (Water in the diesel).

Low pressure regulator.

(62) Filtration element.

Thermostatic element.
Filtration of impurities above 5 microns.

Frequency of change (Gasoline filter cartridge): See maintenance documents.

11 - 3 - DIESEL HEATER

The fuel is heated through the cooling circuit (in the outlet box of
water) .

The fuel temperature is regulated by a thermostatic element (63)

(integrated into the filtration bowl).

11 - 4 - OPERATING PHASE (THERMOSTATIC ELEMENT)

The thermostatic element (63) is a bimetal that deforms based on the

fuel temperature.

Fuel temperature below 15°C:

the bi-lamina (63) blocks the direct path to the filter

the fuel is directed toward the engine's water outlet box to
warm up before filtering

Temperature ranging from 15 °C to 25 °C:

the bi-lamina (63) divides the incoming flow: a part of the fuel passes
directly towards the filtering element (62), the other continues to heat up

Temperature above 25°C :

the bimetallic (63) closes the direct path to the heating circuit: everything
the fuel is directed towards the filtering element

11 - 5 - LOW PRESSURE REGULATOR

The priming pump (51) generates a feed pressure of 2.25 ± 0.25 bars.
The low-pressure regulator (61) regulates the pressure after filtering the diesel to 1.25 ±
0.25 bars.

12 - REFRIGERATION CIRCUIT

12 - 1 - PRINCIPLE SCHEMA

De-gassing box.

aerothermal

Water outlet box.

Water inlet box.

Water pump (In crankcase-cylinders).

Purge screw.

The cooling radiator.

Heat exchanger water/oil (12 plates).

Water circuit reheater (Additional heating).

13 - MOVEMENT OF THE ACCESSORIES

2 equipment are available (depending on the vehicle and level of equipment):

power steering equipment +- alternator

air conditioning equipment +- power steering +- alternator

13 - 1 - ASSISTED DIRECTION EQUIPMENT +- ALTERNATOR

Crankshaft pulley.

Dynamic tension roller.

Power steering pump.

Alternator.

Stabilizer roller.

(78) Roller reel (The tension adjustment for mounting the belt is performed by
the means of an eccentric) .

13 - 2 - AIR CONDITIONING EQUIPMENT +- POWER STEERING

Alternator

Crankshaft pulley.

Dynamic tension roller.

Power steering pump.

Alternator.
Air conditioning compressor.

(84) Roller wind-up (The mounting tension adjustment of the belt is done by
middle of an eccentric) .