DW 10 TD

B1BB1YK1 - 206 DW10TD ENGINE
DATA CRANKSHAFT
DW10TD engine
distance (mm)
nominal
repair
A
0
- 0,087
90
89,8
B
0
- 0,023
60
59,7
C
0
- 0,02
50
49,7
D
0,15
26,55
26,55
E
0,2
24,5
24,5
F
0,02
26,2
26,5
G
+ 0,3
0
26,1
26,1
H
0,35
26,05
26,05
DW10ATED engine
distance (mm)
1/152
nominal
repair
A
0
- 0,087
90
89,8
B
0
- 0,023
60
59,7
C
0
- 0,02
50
49,7
D
0,15
27,55
27,55
E
0,2
24,5
24,5
F
0,02
26,63
26,93
G
+ 0,3
0
27
27
H
0,35
27,3
27,3
Grinding of the joint face to - 0,2 mm (fitting of standard seal) .

WARNING : when the grinding operation is carried out, the crankshaft must turn in the opposite
direction to its usual direction of rotation in the engine, that is clockwise, seen from the flywheel end .
WARNING : grinding of the crankpins and journals must be followed by a smoothing operation .
1 - HALF SHELLS
Crankshaft stop thrust washers .

The bearing upper half-shells are grooved and drilled .
distance (mm)
2/152
nominal
repair
I
0,003
1,842
1,992
J
0,003
1,842
1,992
1,833
1,983
0,005
DW10 TD engine
distance (mm)
nominal
1,83/1,88
DW10 ATED engine
distance (mm)
nominal
2,28/2,33
B1KB04K1 - 206
EMISSION CONTROL EURO 3 - EOBD
1 - INTRODUCTION
The european parliament has specified new measures to be taken against air pollution by motor
vehicle emissions .
This new (ec 98/69) directive is intended to introduce new requirements for petrol and diesel vehicles
from 1st january 2000 .
1 - 1 - REMINDER CONCERNING DESIGNATIONS
old
designation
EURO 96
new
designation
psa
designation
VP
psa
designation
VU
EURO 2
L3
W3
EURO 2000 EURO 3
L4
W4
EURO 2005 EURO 4
L5
W5
This directive specifies :
stricter limits for emission values according to homologation of exhaust pollutants

stricter homologation procedure for measuring fuel evaporation
the continuity of conformity checks of the production of new vehicles
the production conformity check within the network
the obligation to have an on-board diagnostics system (eobd)
1 - 2 - COUNTRIES CONCERNED
Germany, Austria, Belgium, Denmark, Spain, Finland, FRANCE, Greece, Ireland, Iceland, Italy,
Luxemburg, Norway, Holland, Portugal, United Kingdom, Sweden, Switzerland .
1 - 3 - TAX INCENTIVES
Certain countries grant tax incentives in order to meet the future emission control standard before it
comes into force .
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The designation is indicated by the symbol IF joined to that of the anticipated standard (Example : IF
L5 ) .
Another form of tax incentive is based on legislation which, in terms of strictness, is pitched between
the existing standard and the future one :
german standard D3 (intermediate between euro 2 and euro 3)
german standard D4 (ditto euro 4 without eobd)
1 - 4 - APPLICATION DATES FOR PRIVATE VEHICLES

euro norm 3
new models
petrol / Diesel *
01/01/2000
all models
01/01/2001
(*) except vehicles whose weight exceeds 2500 kg

EOBD
new models
all models
petrol *
01/01/2000
01/01/2001
Diesel *
01/01/2003
01/01/2004
(*) except vehicles whose weight exceeds 2500 kg
2 - CONFORMITY IN PRODUCTION AND WITHIN THE NETWORK

The manufacturer must regularly be able to demonstrate to the authorities that he is taking measures
to guarantee that production conforms to the approved model .
It must also be possible to confirm that the emission control mechanisms function correctly during the
normal life of the vehicle .
The authorities regularly carry out audits at the manufacturer's premises; the manufacturer must be
able to supply support documents concerning :
checks carried out according to the statistical rules of the directive

the details recorded by the eobd systems for the vehicles tested
the test failures and the faults found
the measures adopted to correct vehicles in production and within the network
the details of recall campaigns undertaken
2 - 1 - CONFORMITY IN PRODUCTION
Conformity in production aims to check that the vehicles produced conform to the approved type .
The tests concern :
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average exhaust emissions after a cold start

the emission of carbon monoxide at idle
the emission of crankcase gases
emission by evaporation
the on-board diagnostic equipment (EOBD)
2 - 2 - CONFORMITY WITHIN THE NETWORK

Conformity within the network aims to check that customers' vehicles conform to fixed requirements
for a minimum period, subject to maintenance of these vehicles being carried out correctly .
The responsibility of the manufacturer last for 80000 km or 5 years in 2000 ; it is planned for 100000
km in 2005 .
It comprises observation of the average level of exhaust emissions after a cold start and the
functioning of the eobd .
The vehicles will be withdrawn from second-hand vehicle parcs, from dealerships and subsidiaries, or
by calling in the customer (by letter) .
3 - DEVELOPMENT OF THE COMPOSITION OF FUELS
Today, the harmful effects of lead on the system and on the environment are known to all .
As from 01/01/2000, super leaded fuel will disappear and will be replaced by a super fuel containing
a potassium additive of equivalent quality .
In addition, all of the fuels marketed in france will be more environmentally friendly, because of a drop
in the benzene and sulphur content .
before 01/01/2000
petrol
sulphur
500 ppm*
from 01/01/2000
sulphur
150 ppm*
petrol benzene
4%
benzene
1%
diesel sulphur
500 ppm*
sulphur
350 ppm*
(*) Parts per million .

The petrol is divided as follows :
unleaded 98 : 45 % of the market

unleaded 95 : 25 % of the market
NOTE : as a concession for countries which had already made a justified request before 31/08/1999,
distribution of super fuel can be authorised by the commission until 01/2005 .
4 - EOBD
4 - 1 - INTRODUCTION
Eobd (european on board diagnostics) is a european regulation accompanying the euro norm 3 .
The purpose of eobd is to indicate to the driver, by means of the engine diagnostics warning light, any
fault affecting emission control because of a threshold being exceeded .
Obd is a monitoring software package incorporated in the engine management ecu and has two main
functions :
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to detect the faults of the vehicle emission control equipment
to indicate to the driver the faults which lead to an emission control threshold being exceeded,
so that he can have the vehicle repaired
4 - 2 - ELEMENTS MONITORED
The ecu permanently monitors the elements essential for checking emissions : .
A) Petrol :
misfiring
the efficiency of the catalytic converter
the condition of the oxygen sensors
any component or system, the failure of which can cause the tolerated emission limits to be
exceeded (air injection, egr, automatic gearbox)
the continuity of the canister purge solenoid valve circuit
B) Diesel :
the efficiency of the catalytic converter

the functionality and reliability of the paticulate emission filter (if fitted)
the continuity and total failure of the output and advance electronic actuators
any component or system, the failure of which can cause the tolerated emission limits to be
exceeded (egr, pre-heat, automatic gearbox)
4 - 3 - DETECTION THRESHOLDS
Detection thresholds are determined according to each pollutant .
In the event of exceeding the legislative threshold (failure), the engine diagnostics warning light
comes on. the fault in question is memorised .
4 - 4 - LIGHTING OF THE ENGINE DIAGNOSTICS WARNING LIGHT (EOBD)
The engine diagnostics warning light indicates the failure of a component or a system relating to
emissions, when this failure involves an increase in emissions with a level exceeding the legislative
limits .
Misfiring threatening to damage the catalytic converter cause the engine diagnostics warning light to
flash .
The engine diagnostics warning light is only used where there is a risk of damage to the engine or a
safety risk for the occupants of the vehicle .
The light comes on at the end of 3 consecutive driving cycles (one driving cycle comprises starting
the engine, a driving phase during which any malfunction would be detected, and switching off the
engine) .
The diagnostics warning light goes out after 3 consecutive driving cycles, during which the monitoring
system responsible for activation no longer detects any malfunction; the fault changes to intermittent .
The ecu can then clear the intermittent fault if, during 40 heating cycles, this fault has not
reappeared .
A heating cycle is a period of vehicle operation which is sufficient for the engine temperature to
increase by at least 22 from starting the engine, and for it to reach a minimum temperature of 70 .
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Intermittent faults can also be cleared using the diagnostic equipment DIAG 2000 .
4 - 5 - ACCESS TO THE EOBD FAULT CODES
Access to the memorised fault codes is open to any professional technician having standardized
diagnostic equipment called SCANTOOL whose ecu allows dialogue .
Access to the diagnostic modes is as follows :
01 : mode reading of the number of fault codes and the engine speed (dynamic)
02 : mode reading of the fixed info (associated variables)
03 : mode reading fault codes
04 : mode clearing of the fault codes
4 - 6 - CLEARING OF THE MANUFACTURING AND EOBD FAULT CODES

For all the ecus fulfilling the emission control standard L4 with the eobd active, it us necessary to
inform the service area when each request to clear the memorised fault codes is made .
This signature is of the same type as the one which is stored in the identification zone of the ecu
during downloading .
This information can be looked at using the diagnostic equipment under the history heading :
total number of operations counter

date of operation
mileage of the vehicle at the time of the operation
equipment for carrying out work
site of work being carried out
Total number of operations counter : This information is useful, since it enables the number of
operations carried out on the vehicle to be established .
Type of clearing : This information allows the type of tool which has cleared the fault codes to be
established, from which it is known whether the operation has been carried out within the network or
by an independent repairer .
5 - CONCLUSION
The directive 98/69 may be modified during the year 2000 .
Certain points are currently under discussion, in particular the eobd function for vehicles supplied with
gas (lpg, gnv), as well as recording the mileage covered since the diagnostic warning light came on .
The future standard applicable from EURO 4, will impose even stricter measures (e.g. pollutant at
measurement cycle at low temperature 01/2005) .
B1BBM2K1 - 206 DW10TD ENGINE
ENGINE INTRODUCTION DW10
1 - DESCRIPTION
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Main structure of the DW10 engine :
diesel engine with direct injection

power train angle (on new vehicles homologated from 1998, new standards relating to impacts
impose a straightening of the engines in the front of vehicles)
1 overhead camshaft driven by a toothed belt
4 cylinders in line - 8 valves
high pressure pump driven by a toothed timing belt
coolant pump driven by a toothed timing belt
oil filler hole incorporated in the cylinder head cover
suction draining system
engine fitted with an acoustic cover
There are 2 versions of this engine :
DW10 ATED : with air/air exchanger

DW10 TD : with no exchanger
The DW10 ATED engine is an improved version of the DW10TD engine, This power and torque
improvement is obtained through management of the turbocharger pressures by the electronic
injection ECU .
2 - IDENTIFICATION
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(A) Identification marking comprising :

(1) unit reference
(2) legislation type
(3) build order number
3 - DATA
engine type
DW10 ATED DW10 TD
engine code
RHZ
unit reference
RHY
vehicle specific
number of cylinders
bore x stroke (mm)
85 x 88
capacity (cm3)
1996
compression ratio
18/1
maximum power (KW - EC)
80
66
maximum power (HP DIN)
110
90
engine speed at max. power (r.p.m.) 4000

maximum torque (da.Nm - EC)
25
20.5
engine speed at max. torque (r.p.m.) 2000

turbocharger
air/air intercooler
vehicle specific
yes
no
turbocharger pressure (2000 rpm) 1 bar(s)

turbocharger pressure (3000 rpm) 1 bar(s)
injection system
make
BOSCH
type
EDC 15C2
opacity of smoke (m - 1)
9/152
COMMON RAIL
specific to : vehicles
4 - CYLINDER BLOCK
Cylinder block :
in cast iron (not lined)

85 mm diameter barrels
fitted with piston base jets
fitted with 5 main bearing caps hollowed out at (B) to make the cylinder block lighter
8 mm thick inter-cylinder with coolant passage hole at (C) and coolant plate at (D) to assist
cooling of the top of the barrels
fitted with a coolant drain plug on the rear face
The cylinder block is identical for both the DW10 ATED and DW10TD engines and is differentiated by
the engine engraving (Legislation type) .
NOTE : no. cylinder-number 1 : clutch end (flywheel) .
5 - CRANKSHAFT AND CONNECTING RODS
(4) Crankshaft .
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(5) Top half shells .

(6) Bottom half shells .
(7) End float thrust washer .
(8) Piston .
(9) Gudgeon pin .
(10) Stop ring .
(11) Connecting rod .
(12) Big end bearing shell .
5 - 1 - CRANKSHAFT
DW10 ATED engine :
crankshaft (identical to XUD9TE engine)

in burnished steel
with 5 bearings
DW10 TD engine :
crankshaft (identical to XUD7TE engine)

material : steel
with 5 bearings
Front and rear sealing is by lip seals .

The end float (between 0.07 and 0.32 mm) is adjusted on bearing no. 2 by 4 thrust washers (2 on the
cylinder block side and 2 on the crankshaft cap side) .
5 - 2 - CRANKSHAFT HALF SHELLS
Crankshaft half shells :
identical to XUD9TE engine

smooth on the main bearing cap side
grooved on the cylinder block side
5 - 3 - CONNECTING RODS
New connecting rods (145 mm between centres) (Identical to DW8 engine) :
forged steel connecting rods

the little end is fitted with a machined bronze bush in the shape of a snake's head
smooth connecting rod half shells with tab
5 - 4 - PISTONS
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(E) : Flywheel end .

(F) : Timing gear end .
Special pistons with dome and central cavity (BOWL) necessary for the movement of the gases
(SWIRL) .
New light alloy pistons with valve cut-outs .
The direction is given by the valve stamp (stamp on the side opposite the oil filter) .
There is only one piston diameter category (Series) .
There is only one piston diameter category (Repair) .
One weight category, obtained by internal reworking of the pin .
The floating gudgeon pin is retained by 2 rings .
The piston has a steel insert to reinforce the compression ring groove .
5 - 5 - PISTON RINGS
The piston has 3 rings :
upper sealing ring (13): double trapezoid compression ring (thickness = 3.5 mm)
lower sealing ring (14): curved (thickness = 2 mm)
scraper ring (15): with spiral spring (thickness = 3 mm)
5 - 6 - FLYWHEEL
Flywheel (Adapted for each vehicle) :
in cast iron with lamellar graphite

friction plate diameter 275 mm
the edge of the flywheel has 60 teeth of which 2 have been omitted to determine Top Dead
Centre
5 - 7 - ACCESSORIES PULLEY
A pulley for versions without air conditioning (damped hub with no torsion uncoupling step) .
A pulley for versions with air conditioning (damped hub with torsion uncoupling step) .
12/152
These pulleys are secured to the crankshaft by 1 bolt (Identical to XUD) .

6 - CYLINDER HEAD ASSEMBLY
6 - 1 - CYLINDER-HEAD COVER (16)

The cylinder head cover (16) is made from a composite material, it is fitted with a pre-formed
removable seal .
The oil filler hole is incorporated in the cylinder head cover .
6 - 2 - CAMSHAFT BEARING CASTING (17)
The camshaft main bearing cap housing (17) is made from a light alloy .
Cap housing/cylinder head sealing is by CAF 33 type sealing compound .
The camshaft is positioned in the cylinder head by the studded cap housing, with 5 main bearings .
The end float adjustment of the camshaft is on bearing no. 3 (Bearing no. 1 on the flywheel end) .
6 - 3 - CYLINDER HEAD (18)
A new cylinder head (18) : 2 valves per cylinder .
Height of new cylinder head : 133 mm .
Maximum cylinder head bow : 0.03 mm .
The inlet ducts in the cylinder head are a complex helical shape to form the SWIRL .
The valve seats and guides are new and made from sintered steel .
NOTE : tightening is in a SPIRAL sequence .
6 - 4 - INJECTORS
The base of each injector resembles the conventional multi-hole model (with specifications adapted
to the engine version, for example: 5 holes, 0.16 mm in diameter or 5 X 0.20 or 6 X 0.15) .
There is a control solenoid valve on the top .
NOTE : always replace the copper seal, installed in the cylinder head (after repair) .
13/152
6 - 5 - THE CAMSHAFT
The camshaft :
this drives the vacuum pump (flywheel end)
it engages the roller cam followers which operate the valves
The hydraulic tappets permit wear take-up maintaining a zero clearance between the camshaft, the
cam followers and the valves .
Lubrication is via a longitudinal channel .
Side channels direct the oil to the bearings and cams .
End float value : 0.07 mm to 0.38 mm .
6 - 6 - CYLINDER HEAD GASKET
(G) : Thickness identification .

There are 5 categories of laminated metal cylinder gaskets .
The cylinder head gasket fits both DW10 ATED and DW10 TD engines .
Method for selecting the gasket by measuring the piston protrusion (Identical to DW8 engine) .
piston protrusion
measurements (mm)
thickness
(mm)
notch(es) number
of holes at (G)
0.47 to 0.604
1.30 0.06
0.605 to 0.654
1.35 0.06
0.655 to 0.704
1.40 0.06
0.705 to 0.754
1.45 0.06
0.755 to 0.83
1.50 0.06
14/152
6 - 7 - TAPPETS (OPERATION)
(19) Roller cam follower .

(20) Hydraulic tappet .
(21) Ball joint .
(22) Piston .
(23) Valve .
(24) Return spring .
(25) Return spring .
(26) Barrel .
(27) Lower chamber .
(28) Upper chamber .
The 12 mm diameter hydraulic tappets have automatic clearance take-up .
Cam - valve clearance take-up phase (H - I) :
if there is a clearance, the ball joint (21) lifts under the action of the spring (25); this results in a
vacuum in the lower chamber (27), which opens the valve (23)
the pressure between the two chambers (27) and (28) is equal; the valve (23) closes under the
action of the spring (24), the two chambers are isolated
Compression phase (valve lift) (J) :

15/152
as soon as the cam presses on the cam follower, the pressure increases in the lower chamber
(27), the valve (23) is pressed against its seat; the hydraulic tappet is in stop function mode,
the movement is transmitted in its entirety to the valve
6 - 8 - VALVES
Special valves :
inlet (diameter 35.6 mm)

exhaust (diameter 33.8 mm)
Valve stem (Diameter 5.978 mm) .

6 - 9 - VALVE SPRINGS
External diameter : 20.9 mm .
Number of coils : 9 .
7 - TIMING
7 - 1 - DATA
(29) crankshaft gear (21) teeth .

(30) Coolant pump gear (20 teeth) .
(31) Camshaft gear (42 teeth) .
(32) Camshaft hub .
(33) High pressure pump pinion (42 teeth) .
(34) Roller tensioner (External diameter : 60 mm) .
(35) Manual tensioner roller (60 mm diameter and eccentric radius 7 mm) .
(36) Timing belt .
16/152
Timing cover in 3 sections secured by 9 bolt(s) :
(37) upper cover (4 fastening points)

(38) high pressure pump casing (3 fastening points)
(39) lower cover (5 fastening points)
7 - 2 - TIMING BELT
engine code
RHZ
engine type
DW10 ATED
width (mm)
25.4
number of teeth
141
supplier(s)
material
identification mark
RHY
DW10 TD
DAYCO
HSN
-
replacement interval (km)

in normal conditions of use
160 000
replacement interval (km)

in arduous conditions of use
120 000
NOTE : the belt is tensioned on fitting by the manual tensioner roller (eccentric) requiring the fitting of
the SEEM tension checking equipment .
7 - 3 - HIGH PRESSURE PUMP
The high pressure pump has three radial pistons and is driven in a non synchronous manner by the
timing .
8 - LUBRICATION
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(K) : Low pressure oil descent circuit .

(L) : Oil vapour descent circuit from the top of the engine .
(M) : High pressure oil ascent circuit .
(N) : Low pressure oil descent circuit .

(O) : Oil vapour descent circuit from the top of the engine .
(P) : High pressure oil ascent circuit .
8 - 1 - OIL CAPACITY
18/152
depending on the use of the vehicle, the engine can be tilted or straightened: adaptation to each
vehicle .
straight engine
engine code
RHY - RHZ
special features
air conditioning
RHY - RHZ
without air
conditioning
oil capacity (with filter) 4.5
4.5
oil capacity (without

4.2
filter)
4.2
tilted engine
engine code
RHY - RHZ
special features
air conditioning
oil capacity (with filter) 4.25

oil capacity (without
4
filter)
RHY - RHZ
without air
conditioning
4.25
4
IMPERATIVE : always check the oil level using the dipstick .

Oil change interval (Engine oil) : Refer to the maintenance documents .
8 - 2 - ENGINE OIL FILTER CARTRIDGE
Oil filter cartridge (First assembly) :
PURFLUX LS 867A (diameter 76 mm)
Oil filter cartridge (Spare) :
PURFLUX LS 867B (diameter 76 mm, valve : 1.5 bar(s))
Replacement interval (Engine oil filter cartridge) : Refer to the maintenance documents .
8 - 3 - LUBRICATION SYSTEM
The piston bases are cooled by jets .
Engine oil pressure at 80C measured in place of the pressure switch .
engine code
RHZ
RHY
check 1
minimum pressure (bar(s))
1000 rpm
2
1000 rpm
2
check 2
2000 rpm
2.8
2000 rpm
2.8
check 3
3000 rpm
3.8
3000 rpm
3.8
check 4
4000 rpm
4
4000 rpm
4
19/152
8 - 4 - 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 (End piece 14 mm) .
It is still possible to drain the engine by removing the drain plug from the sump .
9 - AIR SUPPLY CIRCUIT
9 - 1 - THE INDUCTION CIRCUIT
(40) Exhaust manifold (Cast iron) .

(41) Inlet manifold (Aluminium alloy) .
(42) EGR valve .
(43) EGR valve/manifold connection pipe .
(44) The air inlet hose (Aluminium alloy) .
(45) Vacuum pump .
The Exhaust Gas Recirculation pipe is secured by :
1 clic clip(s) on the EGR valve (42)

2 bolt(s) on the air inlet union (44)
The EGR valve (42) is secured by 2 bolts on the exhaust manifold (40) .
9 - 2 - EXHAUST GAS RECIRCULATION
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The role of the EGR system is to reduce the amount of nitrous oxide (NOx) expelled in the exhaust
gases .
The nitrous oxides are produced by the combination of the nitrogen and the oxygen in the intake air
under the effect of a very high temperature (greater than 1800 degrees C) .
During certain phases of operation the EGR reduces the amount of oxygen available in the cylinder .
The EGR valve (42) is subjected to a vacuum from the vacuum pump (45) secured at the end of the
camshaft and this authorises recirculation of the exhaust gases to the air union (44) .
The recirculation is of the progressive type managed by mapping .
The opening of the EGR valve (42) 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
engine load (the position of the accelerator pedal)
9 - 3 - TURBOCHARGER PRESSURE REGULATION SOLENOID VALVE
(42) EGR valve .

(45) Vacuum pump .
(46) Turbocharger pressure regulation solenoid valve .
(47) EGR solenoid valve .
(48) Turbocharger .
(49) Turbo regulation valve .
Controlled by the ECU, this solenoid valve enables it to regulate the intake pressure via the turbo
regulation valve (49) .
10 - PRE-POST HEATING
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(1150) Pre-heat control unit .

(1160) Glow plugs .
(1320) Engine management control unit .
(V1150) Pre-heat warning lamp .
10 - 1 - PRE-HEATING
As soon as ignition is switched on : The engine management control unit supplies the glow plugs and
controls the lighting of the warning light on the instrument panel, depending on the coolant
temperature; The pre-heating time varies depending on the coolant temperature .
NOTE : the warning light on the instrument panel only comes on during the pre-heating phase; it
comes on for the duration of the pre-heating .
pre-heating time
(second(s))
coolant temperature
-30C
20
-10C
0C
+18C
0.5
0
If the starter is not operated, when the warning light goes out, the glow plugs remain supplied for a
maximum of 10 seconds .
During the starting phase, the glow plugs are supplied under the following conditions :
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the coolant temperature is below 20 degrees C

the engine runs at more than 70 rpm for 0.2 second(s)
10 - 2 - POST HEATING
Post-heating consists of prolonging the operation of the glow plugs for a maximum of 60 seconds
from the end of the starting phase .
Parameters which could interrupt post-heating :
coolant temperature greater than 20 degrees C

flow injected greater than 35 mm3
engine speed above 2000 rpm
11 - FUEL SYSTEM
11 - 1 - PRESENTATION
This engine is fitted with a new COMMON RAIL direct injection system from BOSCH .
(50) Fuel tank .

(51) Scavenge pump .
(52) Fuel filter .
(53) High pressure pump .
(54) Common rail .
(55) Injector .
(56) Diesel pressure sensor .
(57) Diesel temperature sensor .
(58) Third piston de-activator .
(59) Diesel high pressure regulator .
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(Q) To coolant outlet housing .

11 - 2 - FILTRATION RESERVOIR ASSEMBLY
(E1) Diesel inlet from tank .

(E2) Diesel inlet from coolant outlet housing .
(S1) Diesel outlet : To coolant outlet housing .
(S2) Diesel outlet : To high pressure pump .
(S3) Diesel outlet to tank (return circuit) .
(60) Bleed screw (Water in diesel fuel) .
(61) Low pressure regulator .
(62) Filtering element .
(63) Thermostatic element .
Filtration of impurities bigger than 5 microns .
Replacement interval (Diesel filter cartridge) : Refer to the maintenance documents .
11 - 3 - DIESEL HEATER
The fuel is heated by the cooling circuit (on the coolant outlet housing) .
The temperature of the fuel is regulated by a thermostatic element (63) (incorporated in the filtration
reservoir) .
11 - 4 - OPERATING PHASE (THERMOSTATIC ELEMENT)
The thermostatic element (63) is a bimetallic strip which deforms according to the temperature of the
fuel .
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Fuel temperature below 15 degrees C :
the bimetallic strip (63) closes the direct passage to the filter
the fuel is directed to the coolant outlet housing to be heated before filtering
Temperature between 15 and 25 degrees C :
the bimetallic strip (63) divides the intake flow: one part of the fuel passes directly towards the
filtering element (62), the other continues to be heated
Temperature above 25 degrees C :
the bimetallic strip (63) closes the direct passage to the heating circuit: all the fuel is directed
to the filtering element
11 - 5 - LOW PRESSURE REGULATOR

The scavenge pump (51) generates a supply pressure of 2.25 0.25 bars .
The low pressure regulator (61) regulates the pressure after filtration of the diesel to 1.25 0.25
bars .
12 - COOLING SYSTEM
12 - 1 - SCHEMATIC DIAGRAM
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(64) Expansion chamber .

(65) heater matrix .
(66) Water outlet housing .
(67) Water inlet housing .
(68) Coolant pump (To cylinder block) .
(69) Bleed screw .
(70) The cooling radiator .
(71) Water/fluid heat exchanger (12 blades) .
(72) Water circuit heater (Additional heating) .
13 - DRIVING THE ANCILLARIES
There are 2 possibilities (depending on the vehicle and the level of specification) :
power steering + alternator

air conditioning + power steering + alternator
13 - 1 - POWER STEERING + ALTERNATOR
26/152
(73) Crankshaft pulley .

(74) Dynamic tensioner roller .
(75) Power steering pump .
(76) Alternator .
(77) Stabiliser roller .
(78) Roller tensioner (The belt fitting tension is adjusted by means of a cam ring) .
13 - 2 - AIR CONDITIONING + POWER STEERING + ALTERNATOR
(79) Crankshaft pulley .

(80) Dynamic tensioner roller .
(81) Power steering pump .
(82) Alternator .
(83) Air conditioning compressor .
(84) Roller tensioner (The belt fitting tension is adjusted by means of a cam ring) .
B2CB4GK1 - 206 MA GEARBOX
IDENTIFICATION CENTERING OF THE GEARBOX INPUT SHAFT IN THE CRANKSHAFT
27/152
From the reinforced gearboxes MA, the crankshafts have a modified primary shaft .
1 - EARLIER ASSEMBLY
A = 13 minimum .
B = 40 maximum .
2 - LATER ASSEMBLY
C = 15 minimum .
D = 40 maximum .
28/152
The input shaft splines are lengthened by 2,5 mm .

It is possible to differentiate between the crankshafts by the diameter of the centre bore :
earlier assembly : the centre bore diameter is 34 mm

later assembly : the centre bore diameter is 41 mm
3 - INTERCHANGEABILITY
The old gearboxes are compatible with the new crankshafts .
The old crankshafts are not compatible with the new gearboxes .
B1BB1WK1 - 206 DW10TD ENGINE
IDENTIFICATION ENGINE
1 - IDENTIFICATION
(A) Identification marking comprising :
(1) unit reference

(2) legislation type
(3) build order number
engine type
engine code
DW10ATED
RHZ
unit reference 10CYCZ - 10DYAA 10DYAB

10DYAC - 10DYAD 10DYAE
10DYAM - 10DYAN
10DYAV - 10DYAW 10DYAX
29/152
DW10TD
RHY
10DYAF - 10DYAG 10DYAH
10DYAJ - 10DYAK 10DYAL
10DTAR - 10DYAS 10DYAT
10DYAU - 10DYBA -
10DYBL - 10DYBM 10DYBX

10DYBZ - 10DYCN 10DYCP
10DYCQ - 10DYDA 10DYDB
10DYDS - 10DYDT
number of
cylinders
10DYBB
10DYBC - 10DYBD 10DYBE
10DYBF - 10BYBG 10DYBH
10DYBR - 10DYBS 10DYCA
10DYCB - 10DYCC 10DYCD
10DYCE - 10DYCF 10DYCJ
10DYCK - 10DYCW 10DYCX
10DYDL - 10DYDM 10DYDN
10DYDP - 10DYEM 10DYEN
10DYEP - 10DYEQ 10DYET
10DYEU
bore x stroke
85 x 88
(mm)
capacity (cm3) 1996
E5AB1DK1 - 206 DW10TD ENGINE
PRESENTATION TOOLING ENGINE
kit for engine(s) DW

reference
description
reference reference
[1]
kit
[1a]
timing side crankshaft seal

(-).0188 fitting drift
A1
(drift)
(-).0188 - A
[1b]
timing side crankshaft seal (-).0188 -
(-).0188 - A
30/152
(-).0188-ZX (-).0188
fitting drift
(cone)
A2
[1c]
engine flywheel side

crankshaft seat fitting drift
(cone)
(-).0188 B1
(-).0188 - B
[1d]
engine flywheel side

crankshaft seat fitting drift
(drift)
(-).0188 B1
(-).0188 - B
[1e]
camshaft seal fitting drift

(cone)
(-).0188 C1
(-).0188 - C
[1f]

(drift)
(-).0188
-C1
(-).0188 - C
[1g]
single engine flywheel

setting pin
(-).0188 - D (-).0188 - D
[1h]
bolt(s) M8 x 125 length 45

mm
(-).0188 - E (-).0188 - E
(overhead camshaft setting
rod)
[1i]
flywheel stop
(-).0188 - F (-).0188 - F
[1j]
tensioner roller setting rod
(-).0188 - G -
[1k]
injection pump setting pin
(-).0188 - H -
[1l]
tension lever
square 8 mm
square 7 mm
(-).0188 J1
(-).0188 J2
[1m]
belt retaining clip
(-).0188 - K -
[1n]
cylinder head releasing

levers
(quantity 2)
(-).0188 - L (-).0188 - L
[1p]
camshaft setting rod
(-).0188 - M -
(-).0188 - J
kit for engine(s) DW (continued)

reference
31/152
description
reference reference
kit
(-).0188 ZX
[1q]

(drift) (cone)
(-).0188 - N (-).0188 - N
[1r]
crankshaft pulley extractor (-).0188 - P (-).0188 - P
[1s]
dynamic tensioner roller

pins
(pin 4) (pin 2)
(-).0188 - Q (-).0188 - Q
[1t]
kit for detaching the high

pressure pump
(-).0188 - R (-).0188 - R
[1u]
set of plugs
(-).0188 - T (-).0188 - T
[1v]
compression checking kit
(-).0188 - U (-).0188 - U
[1w]
pulley immobilisation pin
(-).0188 - V (-).0188 - V
[1x]
valve stem seal fitting tool (-).188 - W
[1y]
double engine flywheel

setting pin
(-).0188 - X (-).0188 - X
[1z]
flywheel setting rod
(-).0188 - Y (-).0188 - Y
[1Aa]
dynamic tensioner
compression lever
(-).0188 - Z (-).0188 - Z
[1]
reference
description
reference
(-).0188
(-).0188 W
reference
[2]
tension measuring
equipment
(-).0192
[3]
angular locking cotter
FACOM D360
4069-T
type
[4]
cylinder head bolt

socket
(-).0185
32/152
(-).0192
FACOM STX
14
reference
description
reference
reference
[5]
pin + dial gauge support (-).0504
5602 - T
[6]
bearing no. 1 side seals

(-).0153-A
fitting tool
7004-T.F
[7]
dial gauge with securing

(-).01504
lug
2437-T
[8]
dial gauge support rod
[9]
dial gauge carrier
reference
description
(-).0113 - EZ +
1132-T
FZ
reference
reference
[10]
pipe spanner
(-).1603 -
4220-T.D
[11]
pipe spanner
(-).1603 - G
4220-T.C
33/152
reference description
[12]
reference
[13]
34/152
valve lifter
cup press
reference
FACOM
U43 - LA+
U43 - LA16 - 21
description
valve stem oil seal
pliers
reference
FACOM
U43 - LA+
U43 - LA16 - 21
reference
reference
(-).0170-A
4517-T (kit 4507T)
reference
description
reference
reference
[14]
crankshaft spanner
(-).0117-EZ
XXX
[15]
dial gauge support
(-).0110-H
1754 - T bis
reference
reference
reference
[16]
35/152
description
stand
DESVIL
2509 - T
reference description
[17]
adaptor
reference
[18]
reference
reference
(-).0132 - ALZ 7002 - TA/9015 - T
description
valve stem oil seal drift
reference
reference
(-).0132 - W 4511 - T
B1FD06K1 - 206
CHECK : OIL TIGHTNESS OF THE ENGINES AND GEARBOXES
The purpose of this general procedure is to make the location of any oil leaks from the engines,
gearboxes and final drives easier. it can be applied on the vehicle or the unit in the workshop .
1 - SPECIAL TOOLS
36/152
[1] - [2] - [3] Engine and/or gearbox oil leak checking kit (-).1523 (Part No. 9780.43) .
[1] Pressure release valve assembly, consisting of :
[A] pressure limiting pressure release valve calibrated to 0.5 bar(s)

[A1] adaptor for connection to the air circuit
[A2] adaptor for connection to the air circuit
[2] Set of adaptors, for the units, consisting of :
[B] M21 x1,50 for 1580 SPI engine

[C] M16 x 1,50 for BE3/MA/MG/ME gearbox ; engines ES/ZPJ/DK/DJ/TU/TUD and final drives
[D] M14 x 1,25 for XU/XUD/DW/TUD engines
[E] M14 x 1,00 for BE3 gearbox
[F] M10 x 1,50 for ME/MG gearbox
[G] M8 x 1,00 for transfer box
[H1] front seat not comfortable (diameter 14 mm)
[H2] front seat not comfortable (diameter 16 mm)
[3] Set of plugs for the engine oil vapours recirculation circuit, for the gearbox breather, consisting of
the following plugs :
[J] 23 mm diameter plug : for the oil breather circuit

[K] 20 mm diameter plug : for the oil breather circuit
[L] 16 mm diameter plug : for MA/BE gearbox
[M] gearbox breather plug
[4]Aerosol can of leak detection product (Part No. 9733.07) .

Check .
WARNING : the application of this method, following repair of the unit in question using sealing
compound, necessitates waiting until the compound has polymerised (that is 2 hours minimum) .
2 - CHECKING AN ENGINE
Drain the engine oil .
37/152
Close the oil vapours recirculation circuit using the plugs [3] provided for this purpose .
In place of the drain plug or dipstick, fit the adaptor [2] provided for this purpose .
Connect the pressure release valve [1] to the adaptor [2] .
3 - CHECKING A GEARBOX OR A FINAL DRIVE
Drain the gearbox or the final drive .
NOTE : the check can only be carried out with the drive shafts in place .
38/152
Close the gearbox breather using a plug [3] provided for this purpose .
In place of the drain plug, fit the adaptor [2] provided for this purpose .
Connect the pressure release valve [1] to the adaptor [2] .
4 - CHECKING PROCEDURE
Connect the pressure reducer to the compressed air network using the adaptor [A1] or [A2]. the
pressure should be 0.5 bar(s) maximum .
Spray the leak detection product [4] on the areas at risk (dipstick tube, filler tube, unions, joint faces,
rotary seals etc.) .
Check for the formation of bubbles in these areas, these identify a possible oil leak .
Cut off the supply of air by disconnecting the pressure release valve [1] from the adaptor [2] .
Reduce the air pressure in the unit being checked, either by pulling the dipstick in the case of an
engine or by unplugging the breather in the case of gearboxes and final drives .
Make the necessary repairs .
Repeat the checking procedure .
Remove the tools .
Fill with oil .
B1BG0YK1 - 206 DW10TD ENGINE
REASSEMBLY ENGINE (CYLINDER BLOCK)
1 - REASSEMBLY
Place the cylinder block on the stand .
Carefully clean all the seal surfaces using scouring product .
39/152
Clean the threads and taps .

Do not use sharp or abrasive tools .
The joint faces must not have any trace of knocks or scores .
Fit :
40/152
the oil level sensor (1) : tightening torque 2.7 da.Nm

the oil pressure sensor (2) : tightening torque 3.2 da.Nm
the oil pipe plugs (3) and their seals : tightening torque 3.4 da.Nm
Refit the piston base spray jets (4), Tighten the bolts to 1 da.Nm .
Fit the grooved main bearing half-shells (5), on the cylinder block side .
Lubricate the crankshaft main bearings .

Fit :
the crankshaft (6)

the side stop thrust washers (7), grooved surface in contact with the crankshaft
NOTE : THICKNESS OF THE STOP THRUST WASHERS .
APPLY (E10) SEALING COMPOUND TO THE CORNERS AND ENDS (A) OF MAIN BEARING NO.
1.
41/152
PLACE TOOL [6] ON THE CAP OF BEARING NO. 1 :
the shim slide (8) must be in the extension of surface (9) of the bearing cap
tighten the clamp (10)
Refit the side seals (11) in the groove of the main bearing cap, with the minimum protrusion at (B) .
Lubricate the two surfaces of the feelers (12) .
PLACE THE FEELERS (12) ON TOOL [6] ABOVE THE HEEL (13) OF THE MAIN BEARING CAP .
The side seals (11) must have a minimum protrusion of approximately 1.5 mm (Maximum = 4 mm) .
42/152
Engage the cap/side seal assembly in the cylinder block, by tilting the assembly .
Position the main bearing on the centralising bushes .
Tighten the 2 bolts (14) .

REMOVE THE TOOL [6] SIDEWAYS .
IMPERATIVE : the new side seals are supplied to the correct length and must not be cut, if the
protrusion is too great, repeat the fitting operation .
43/152
Position :
the side stop thrust washers grooved surface in contact with the crankshaft
the bearing caps (15)
IMPERATIVE : MARKING AND DETERMINING OF THE BEARING HALF SHELLS .

Tighten :
the bolts (16) to 2.5 da.Nm + 60
FIT THE DIAL GAUGE [7] USING TOOLS [8] - [9] .

This end float should be between 0.07 and 0.32 mm .
Adjust the clearance by adjusting the thickness of the side stop thrust washers .
44/152
FIT A NEW OIL SEAL (16) USING THE TOOL [1C + 1D] .
Refit the seal by tapping with a mallet to the limit .
Remove the tool with a rotating movement .
IMPERATIVE : the outer face of the lip seal must be free of all traces of oil .
Con rod positioning .

Check that the new main bearing shell is fitted on the con rod big end .
MARKING AND DETERMINING OF THE BEARING HALF SHELLS .
IMPERATIVE : piston and pin must match .
Assemble the connecting rods and pistons directing the notches (17) to the side opposite the
recesses (18) on the pistons .
Fit :
45/152
the oiled gudgeon pins
the new retaining rings
Ensure that the con rods turn freely on their pins .

Fit the rings using piston ring pliers .
IMPERATIVE : turn the word TOP stamped on the rings to face upwards .
Position the ring gaps at 120 degrees to the scraper ring gap .
IMPERATIVE : direct the recesses (18) to the side opposite the oil filter fixing (19) .
Oil the piston rings and cylinder jackets .
Insert the con rod/piston assembly in the corresponding cylinder using a ring compressor .
Fit the big end cap with a new oiled main bearing shell .
IMPERATIVE : line up the cap bearing shell notch (20) with the con rod bearing shell notch (17) .
46/152
IMPERATIVE : always fit new connecting rod cap nuts .

Clean : The bolts, The nuts .
COAT THE BIG END NUTS (THREAD AND CONTACT SURFACE) WITH G10 .
Tightening is carried out in two stages .
Stage 1 :
tighten the nuts to 20 da.Nm
Stage 2 :
finally tighten by turning through 70 , USING THE TOOL [3]
(X) = 10 mm .
Clean the checking surfaces .
FIT THE DIAL GAUGE [7] ON THE BRACKET [15] .
47/152
Turn the crankshaft .

Place the needle of the dial gauge on one of the checking points (Checking point C) .
Continue turning the crankshaft until the piston reaches TDC ; Read the value .
Turn a quarter turn backwards .
Move the piston to the Top Dead Centre value without ever exceeding it .
Zero the dial gauge .
MOVE THE DIAL GAUGE/BRACKET ASSEMBLY [7] AND [15] OVER THE CYLINDER BLOCK .
Read the value .
Place the needle of the dial gauge on one of the checking points (Checking point D) .
Zero the dial gauge .
Read the value .
Calculate the average of the 2 values measured .
Continue in the same way for the other three cylinders .
NOTE : maximum gap between 2 pistons : = 0.07 mm .
WARNING : the highest average value determines the thickness of the gasket .
Fit :
the cotter (22)

the drive pinion (24) for the oil pump on the crankshaft
the oil pump by placing the chain on the gears
Tighten the bolts to 1.6 da.Nm .

Fit :
48/152
the dipstick tube (25)
TIGHTEN THE BOLT : 0.9 da.Nm + E3 .
COAT THE PLATE (26) WITH E10 SEALING COMPOUND .

Fit :
the seal carrier plate (26)

tightening torque : 1.5 da.Nm
FIT A NEW OIL SEAL (27) USING THE TOOL [1B] + [1C] .
FIT A NEW LIP SEAL USING TOOL [1B] + [1C] + Bolt (28) .
Remove the tool with a rotary movement .
IMPERATIVE : the outer face of the lip seal must be free from all traces of oil .
Fit the pump (29) using a new seal .
Tighten the bolts to 1.5 da.Nm .
49/152
1 - 1 - ALUMINIUM OIL SUMP

NOTE : for engines fitted with an aluminium oil sump, check that the dowel pin (30) is present .
COAT THE SUMP GASKET SURFACE WITH A BEAD OF (E10) SEALING COMPOUND .
IMPERATIVE : ensure that the bead of sealing compound goes right round each of the threaded
holes in order to guarantee a tight seal .
Fit the sump, Tightening torque : 1.6 da.Nm .

SCREW THE TWO THREADED RODS OF THE TOOL [1K] INTO THE CRANKSHAFT .
Check that the centralising pin is present .
Refit the flywheel (32) .
RETAIN THE ENGINE FLYWHEEL (32) IN PLACE USING THE CENTRING PINS AND FASTENERS
OF THE TOOL (1K) .
INSERT THE FLYWHEEL STOP [1I] .
CLEAN AND COAT WITH (E3) THE BOLTS .
1st fitting : Single engine flywheel .
CLEAN AND COAT WITH (E3) THE BOLTS .
Tightening torque : 4.75 da.Nm .
2nd fitting : Double flywheel .
IMPERATIVE : following any work: when disassembling the double flywheel from the crankshaft,
always replace the double flywheel bolts .
Fit the pre-coated bolts .
Tightening torque : 4.8 da.Nm .
50/152
C5HG2HK1 - 206 DW10TD ENGINE

REMOVAL - REFITTING ANCILLARY DRIVE BELT
WARNING : different methods depending on the case encountered .
1 - SPECIAL TOOLS
DW10TD ENGINE
[1] Tension lever (-).0188-J2 .
[2] setting rod for dynamic roller 4 mm (-).0188-Q1 .
[3] setting rod for dynamic roller 2 mm (-).0188-Q2 .
[4] Dynamic tensioner compression lever (-).0188-Z .
2 - DYNAMIC TENSIONER FEATURES
(A) Setting hole DW10 .

(B) Belt wear check mark (fixed on engine) .
(C) Zero wear mark .
51/152
(D) Maximum wear mark .

This marking system enables belt wear to be checked; coinciding of marks (D) and (B) means that
the belt must be replaced .
Tightening torque(s) :
bolt(s) (1) to 4.3 m.daN
3 - REMOVAL
Remove the front right-hand wheel .
Move aside the right-hand front mud shield .
Remove the shield under the power train .
Release the fastener (2) .

Turn the eccentric roller (3) using tool [1] until the setting rod [2] 4 mm is in place in the setting hole
(A) .
Move the eccentric roller (3) towards the rear .
Slightly tighten the bolt (2) .
Remove the belt .
IMPERATIVE : check that the rollers (3) and (4) turn freely (no play and no tight spots) .
4 - REFITTING
52/152
Fit the belt ending with the dynamic tensioner roller (4) .
Turn the eccentric roller (3) using tool [1] clockwise to free tool [2] from the setting hole (A) .
Without altering the position of the roller, Tighten the fastener (2) to 4.3 daN.m. .
IMPERATIVE : take care that the belt is correctly located in the grooves of the various pulleys .
Remove the tool [1] .
Turn the engine 4 revolutions .
Check that marks (B), (C) coincide :
the setting rod [3] must fall into position easily, otherwise resume adjustment
DW10TD ENGINE
Continue the fitting operations in the reverse order to removal .
Tighten the wheel bolts to 8.5 da.Nm .
B1BG11K1 - 206 DW10TD ENGINE
REMOVAL - REFITTING POWER UNIT
1 - SPECIAL TOOLS
53/152
[1] Load balancer Type NAUDER .
[2] Final drive output oil seal fitting drifts (-).0317-T/(-).0317-U .

[3] Flywheel stop (-).0188-F .
54/152
[4] Tool for unclipping the ball joints (-).0317-AC .
[5] Pulley extractor (-).0188-P .
55/152
[6] Set of plugs (-).0188-T .
[7] Socket for the removal of the gearbox shaft (-).0317-AB .

2 - REMOVAL
Disconnect the battery .
POSITION THE RODS FOR RETAINING THE SUSPENSION SPRINGS .
The power unit is removed from above .
Remove the shields under the power train .
56/152
Drain :
the cooling system

the gearbox
the engine (if necessary)
Remove :
the wheels
the mud shields
the drive shafts
THE ANCILLARY DRIVE BELT
IMPERATIVE : remove the exhaust pipe to avoid damaging the flexible hose; this cannot withstand
the torsion, traction or bending tensions caused by the removal of one of the power train supports .
AIR CONDITIONING
RemoveThe eccentric roller of the ancillaries drive belt .
ALL MODELS
Without disconnecting the hoses, move aside and clamp the air conditioning compressor .
Unclip the power steering pipe (2) .
Remove :
the clutch housing closing plate
Lock the flywheel with the stop [3] .

Remove :
57/152
the ancillary drive pulley (using the tool [5])
Remove : The torque reaction link (3) .
Remove : The style cover (4) .

Move aside : The assembly (5) .
Disconnect and move aside the harnesses and cables attached to the assembly (5) .
Remove the battery .
Disconnect, unclip and move aside the harnesses attached to the battery tray .
Remove :
the battery container (6)

the assembly support (5)
the expansion chamber (7)
the radiator
Protect the condenser with a panel of strong cardboard .

Mark the position of the pipes (8) on the solenoid valves (9) .
Remove : The solenoid valves bracket .
Move aside The brake servo vacuum pipe (10) .
Move aside :
the ECU (11) and its support

the fuel pipes (12)
Plug the holes using tool [6] .
58/152
Move aside the harness (13) .

Remove :
the fuse box cover (14)

the air duct (15)
Disconnect, unclamp and remove the harnesses from the fuse box .
Move aside The clutch control .
Move aside :
59/152
the heater matrix hoses (16)

the earth cable (chassis leg)
the heater assembly (17)
Uncouple the gearbox control rods (Using the tool [4]) .

WARNING : pressure must be applied to the tools to unclip the ball joints; they must not be used as
levers as this may bend the connecting rods .
Without disconnecting the hoses, move aside and clamp the power steering pump .
Remove the alternator (19) .
Remove the assembly (20) .

Unclamp the air conditioning pipes (Front right chassis leg) .
AIR CONDITIONING
Move aside the buffer tank (21) without disconnecting the pipes .
60/152
ALL MODELS
Fit the tool [1] .

Remove :
61/152
the connecting plate (23)

the stop (24)
the right-hand engine mounting (25)
Remove :
62/152
the fasteners (26)

the battery tray support (27)
the gearbox shaft nut (28) and its washer
the mounting bolts (29)
the gearbox flexible mounting (30)
the bolts (31)
the bracket (32)
the spacer (33)
the shaft (34) (using the tool [7])
the bolts (35)
the bracket (36)
Remove the power unit from above .

3 - REFITTING
Always renew :
the Nyloc nuts

the exhaust clip
Use the drifts [2] to fit the final drive oil seals, having greased the space between the seal lips .
Position the power train .
Refit the right-hand engine mounting (25) .

Tighten :
the bolts (37) to 4,5 da.Nm

the bolt (38) to 4,5 da.Nm
Fit :
63/152
the stop (24); tightening torque 3,2 da.Nm

the connecting plate (23); tightening torque 2,15 da.Nm
Fit :
the bracket (36)

the bolts (35); tightening torque 6 da.Nm
the shaft (34); tightening torque 5 da.Nm +
the spacer (33)
the gearbox shaft bracket (32)
the bolts (31); tightening torque 1,9 da.Nm
the mounting bolts (29) (without tightening)
WARNING : centralise the power train before tightening the flexible mounting securing bolts .
Tighten :
the bolts (29) to 3 da.Nm

the nut (28) to 6,5 da.Nm
Fit :
64/152

the fasteners (26); tightening torque 1.9 da.Nm
Refit the alternator (19) .

Firstly tighten the bolts on the crankshaft pulley side to 4,1 da.Nm then the bolts on the oil filter side
to 3,9 da.Nm .
Refit the torque reaction link (3) .

Tighten :
the bolt (39) to 5 da.Nm

AIR CONDITIONING
65/152
Check the presence of the two spacers (41) .

WARNING : the anti-rotation nut (42) secures the compressor at its upper rear end .
Refit the compressor in the order of assembly shown above .
Firstly tighten the bolts on the crankshaft pulley side to 4.2 da.Nm then the bolts on the oil filter side
to 4.1 da.Nm .
Re-connect the connector .
ALL MODELS
Refit the drive shafts .
Tighten the drive shaft nuts to 32.5 m.daN .
Fit : The ancillary drive pulley .
Clean the threads of the bolt of the pulley in the crankshaft by using a M16 X 150 tap .
Cleanthe thread of the bolt .
Tighten the bolt to 4 da.Nm + .
Finally tighten by turning through 51 (Using a FACOM D360 type tool) .
Check the tightening : 19.5 da.Nm .
66/152
Refit the pump respecting the order of assembly of the components .

Tighten (In order) :
the bolt (43) to 2.5 da.Nm

the bolt (44) to 2.5 da.Nm +

Refill :
the gearbox

Fill and bleed the cooling system .
Initialise the various ECUs .
B1BG11K1 - 206 DW10TD ENGINE
REMOVAL - REFITTING POWER UNIT
1 - SPECIAL TOOLS
67/152
[1] Load balancer Type NAUDER .
[2] Final drive output oil seal fitting drifts (-).0317-T/(-).0317-U .

[3] Flywheel stop (-).0188-F .
68/152
[4] Tool for unclipping the ball joints (-).0317-AC .
[5] Pulley extractor (-).0188-P .
69/152
[6] Set of plugs (-).0188-T .
[7] Socket for the removal of the gearbox shaft (-).0317-AB .

2 - REMOVAL
POSITION THE RODS FOR RETAINING THE SUSPENSION SPRINGS .
The power unit is removed from above .
Remove the shields under the power train .
70/152
Drain :
the cooling system

the gearbox
Remove :
the wheels
the mud shields
the drive shafts
THE ANCILLARY DRIVE BELT
IMPERATIVE : remove the exhaust pipe to avoid damaging the flexible hose; this cannot withstand
the torsion, traction or bending tensions caused by the removal of one of the power train supports .
AIR CONDITIONING
RemoveThe eccentric roller of the ancillaries drive belt .
ALL MODELS
Without disconnecting the hoses, move aside and clamp the air conditioning compressor .
Unclip the power steering pipe (2) .
Remove :
the clutch housing closing plate
Lock the flywheel with the stop [3] .

Remove :
71/152
the ancillary drive pulley (using the tool [5])
Remove : The torque reaction link (3) .
Remove : The style cover (4) .

Move aside : The assembly (5) .
Disconnect and move aside the harnesses and cables attached to the assembly (5) .
Remove the battery .
Disconnect, unclip and move aside the harnesses attached to the battery tray .
Remove :
the battery container (6)

the assembly support (5)
the expansion chamber (7)
the radiator
Protect the condenser with a panel of strong cardboard .

Mark the position of the pipes (8) on the solenoid valves (9) .
Remove : The solenoid valves bracket .
Move aside The brake servo vacuum pipe (10) .
Move aside :
the ECU (11) and its support

the fuel pipes (12)
Plug the holes using tool [6] .
72/152
Move aside the harness (13) .

Remove :
the fuse box cover (14)

the air duct (15)
Disconnect, unclamp and remove the harnesses from the fuse box .
Move aside The clutch control .
Move aside :
73/152
the heater matrix hoses (16)

the earth cable (chassis leg)
the heater assembly (17)
Uncouple the gearbox control rods (Using the tool [4]) .

WARNING : pressure must be applied to the tools to unclip the ball joints; they must not be used as
levers as this may bend the connecting rods .
Without disconnecting the hoses, move aside and clamp the power steering pump .
Remove the alternator (19) .

Unclamp the air conditioning pipes (Front right chassis leg) .
AIR CONDITIONING
Move aside the buffer tank (21) without disconnecting the pipes .
74/152
ALL MODELS
Fit the tool [1] .

Remove :
75/152
the connecting plate (23)

the stop (24)
the right-hand engine mounting (25)
Remove :
76/152
the fasteners (26)

the mounting bolts (29)
the bolts (31)
the bracket (32)
the spacer (33)
the shaft (34) (using the tool [7])
the bolts (35)
the bracket (36)
Remove the power unit from above .

3 - REFITTING
Always renew :
the Nyloc nuts

the exhaust clip
Use the drifts [2] to fit the final drive oil seals, having greased the space between the seal lips .
Position the power train .
Refit the right-hand engine mounting (25) .

Tighten :
the bolts (37) to 4,5 da.Nm

Fit :
77/152
the stop (24); tightening torque 3,2 da.Nm

the connecting plate (23); tightening torque 2,15 da.Nm
Fit :
the bracket (36)

the bolts (35); tightening torque 6 da.Nm
the shaft (34); tightening torque 5 da.Nm +
the spacer (33)
the gearbox shaft bracket (32)
the bolts (31); tightening torque 1,9 da.Nm
the mounting bolts (29) (without tightening)
WARNING : centralise the power train before tightening the flexible mounting securing bolts .
Tighten :

the nut (28) to 6,5 da.Nm
Fit :
78/152

the fasteners (26); tightening torque 1.9 da.Nm
Refit the alternator (19) .

Firstly tighten the bolts on the crankshaft pulley side to 4,1 da.Nm then the bolts on the oil filter side
to 3,9 da.Nm .
Refit the torque reaction link (3) .

Tighten :
the bolt (39) to 5 da.Nm

AIR CONDITIONING
79/152
Check the presence of the two spacers (41) .

WARNING : the anti-rotation nut (42) secures the compressor at its upper rear end .
Refit the compressor in the order of assembly shown above .
Firstly tighten the bolts on the crankshaft pulley side to 4.2 da.Nm then the bolts on the oil filter side
to 4.1 da.Nm .
Re-connect the connector .
ALL MODELS
Refit the drive shafts .
Tighten the drive shaft nuts to 32.5 m.daN .
Fit : The ancillary drive pulley .
Clean the threads of the bolt of the pulley in the crankshaft by using a M16 X 150 tap .
Cleanthe thread of the bolt .
Tighten the bolt to 4 da.Nm + .
Finally tighten by turning through 51 (Using a FACOM D360 type tool) .
Check the tightening : 19.5 da.Nm .
80/152
Refit the pump respecting the order of assembly of the components .

Tighten (In order) :
the bolt (44) to 2.5 da.Nm +

Refill :
the gearbox

Fill and bleed the cooling system .
B1FI02V1 - 206
ENGINE CAPACITIES
106 - petrol
capacities in litres
engine type
without filter with filter
TU (not TU5J4) gravity draining 2,90
3,20
TU (not TU5J4) suction draining -
3,25
TU5J4 gravity draining
2,90
3,20
TU5J4 suction draining
3,10
3,40
imperative : in every case, check the level and top-up if

necessary
106 - Diesel
engine type
TUD3
81/152
with filter
3,50
TUD5
4,50

necessary
206 - petrol
engines
engine
code
capacities in capacities in
litres
litres
engines
engine type
with filter
between min
and max
dipstick
HFX - HFY
HFZ - K6C - TU (not TU5JP4 )
3,00
KFW
gravity draining
KFX - NFZ
1,50
HFX - HFY
HFZ - K6C - TU (not TU5JP4)
3,25
KFW
suction draining
KFX - NFZ
1,50
TU5JP4
N6A - NFU gravity draining /
suction draining
3,25
1,50
RFN - RFR EW10J4
4,25
1,70

necessary
206 - diesel
engines
engine
code
engines
engine type with filter
WJY - WJZ DW8

RHY
capacities in
litres
DW10TD
between min and
max
dipstick
4,75
1,60
4,50
1,40

necessary
306 - petrol
engine type
without
filter
with
filter
XU10J4R air con.
3,95
4,25
XU10J4R no air conditioning
4,45
4,75
XU10J2C air con.
3,95
4,25
XU10J2C no air conditioning
4,20
4,50
XU7JP air con.
3,95
4,25
XU7JP no air conditioning
4,45
4,75
XU10J4D air con.
3,95
4,25
82/152
XU10J4D no air conditioning
4,20
4,50
XU7JP4 air con. (dipstick handle colour : orange)
3,95
4,25
XU7JP4 air con. (dipstick handle colour : yellow)
4,50
XU7JP4 no air conditioning (dipstick

4,45
handle - colour : orange)
4,75

handle - colour : yellow)
5,00
XU10J4RS
4,25
TU gravity draining
2,90
3,20
TU suction draining
3,25

necessary
306 - Diesel
-
engine type
with filter
XUD9A air con.
4,00
XUD9A no air conditioning
4,50
XUD9TE air con.
4,00
XUD9TE no air conditioning
4,50
XUD7 air con.
4,00
XUD7 no air conditioning
4,50
DW8 air con.
4,50
DW8 no air conditioning
4,75
DW10TD air con.
4,25
DW10TD no air conditioning
4,50

necessary
406 - petrol
engine type
capacities in
litres
with filter
XU5JP/XU7JP air con.
4,25
XU5JP/XU7JP steel sump
4,75
XU7JP4 air con. (dipstick handle - colour :

4,25
orange)
XU7JP4 air con. (dipstick handle - colour :
4,50
yellow)
handle - colour : orange)
4,75

handle - colour : yellow)
5,00
83/152
XU10J4R air con.
4,25
XU10J4R no air conditioning
4,75
XU10J2CTE air con.
4,50
XU10J2CTE no air conditioning
4,75
ES9 suction draining
5,25
ES9 gravity draining
4,75
XU7JB air con.
4,50
XU7JB no air conditioning
5,00
EW7J4
4,25
EW10J4
4,25
EW12J4
4,25

necessary
406 - Diesel
-
engine type
XUD9BTF/XUD9TF air con.
with filter
4,00
XUD9BTF/XUD9TF no air conditioning 4,50

XUD11BTE air con.
4,75
XUD11BTE no air conditioning
5,25
XUD9SD air con.
4,25
XUD9SD no air conditioning
4,00
DW10ATED
4,50
DW10TD
4,50
DW12TED4
4,75

necessary
806 - petrol
engine type
with filter
XU10J2C air con.
4,50
XU10J2C no air conditioning
4,75
XU10J2CTE air con.
4,50
XU10J2CTE no air conditioning
4,75
XU7JP air con.
4,25
XU7JP no air conditioning
4,75
XU10J4R
4,25
EW10J4
4,25

necessary
84/152
806 - Diesel
engine type
with filter
XUD9TF air con.
4,00
XUD9TF no air conditioning
4,25
XUD9BTF air con.
4,00
XUD9BTF no air conditioning
4,25
XUD11BTE air con.
4,25
XUD11BTE no air conditioning
4,75
DW10ATED
4,50
DW10ATED4
4,75

necessary
B1FB0IK1 - 206
RECOMMENDATIONS LUBRICANTS
1 - OIL QUALITIES
The engine lubrication oils are categorised in accordance with 3 quality levels :
mineral oil(s) (ESSO UNIFLO, TOTAL ACTIVA/QUARTZ 5000)

semi-synthetic oil(s) (ESSO ULTRA, TOTAL ACTIVA/QUARTZ 7000)
synthetic oil(s) (ESSO ULTRON, TOTAL ACTIVA/QUARTZ 9000)
In addition to the existing range of oils, for vehicles from model year 2000, an "energy saving" oil is
available; This oil contributes to the objective of resolving the problem of fuel consumption, which is
Peugeot's aim .
IMPERATIVE : the energy saving oil must not be used in engines prior to 2000 Model Year, nor in
engines XU10J4RS, DW12TED4, EW12J4, 1580 SPI or SOFIM engines ; likewise, 0W30 oil must
not be used in the above mentioned engines .
Automobiles PEUGEOT recommends the quality of lubricants to use in the owner's documentation :
handbook
warranty and maintenance record
WARNING : for vehicles sold from model year 1999, in accordance with the normal maintenance
plan, the use of an approved semi-synthetic oil is imperative .
Organisations categorise the oils in accordance with their performance and give them a quality label
which is visible on the packaging :
API : American Petroleum Institute

ACEA : European Automobile Manufacturers' Association
NLGI : National Lubrication Grease Institute
The grade (viscosity index) must be selected in accordance with the climate of the country of use .
85/152
2 - RECOMMENDED LUBRICANTS AND PERFORMANCE SPECIFICATIONS FOR INDIVIDUAL

UNITS
2 - 1 - PUMPS
units
ESSO
KF - KF1 - KF2 KF6 - KF5 - XN2

petrol injection
pump
ESSOLUBE
X101 10W
Part No.
9730.GA (1)
API
ACEA
standards standards
SC/CC
vacuum pump (with

separate
ESSO UNIFLO
SJ
lubrication)
10W40
PIERBURG
A2
vacuum pump (with

separate
ESSO GEAR
GL5
lubrication)
OIL GX 80W90
SAGINAW
power steering
pump
ESSO ATF D
(1)
Part No.
9730.94
(1) marketed by Parts Department in 2 litre cans
units
TOTAL
KF - KF1 - KF2 - TOTAL RUBIA S

KF5 - KF6 - XN2 10W
petrol injection TOTAL RUBIA H
pump
10W
vacuum pump
(with separate
lubrication)
PIERBURG
86/152
CCMC/
API
standards
standards
ACEA
CD/SF
CC/SF
TOTAL ACTIVA 7000

10W40
SJ/CF
TOTAL QUARTZ
7000 10W40
D2
D1
A3/B3
TOTAL
TRANSMISSION TM
vacuum pump
MULTIGRADE
(with separate
80W90
GL5
lubrication)
TOTAL
SAGINAW
TRANSMISSION TM
80W90
power steering TOTAL FLUIDE

pump
AT42
API
standards
units
power
steering
pump
PENTOSIN CHF
11 S
Part No. 9979.64
(1) (2)
ACEA
standards
-

(2) for cold climates only, this oil cannot be mixed with
other oils; it is therefore necessary to completely drain the
system and to rinse it before filling with this oil
2 - 2 - GEARBOX FINAL DRIVE - TRANSFER BOX

units
ESSO
BC3
GX 80W90
ACEA
standards
SJ
A2
ATF 4HP20/AL4
Part No.
9736.22 (1) (3)
4HP14 - 4HP18 - ESSO ATF D

MB3 automatic Part No.
gearbox
9730.94 (1) (3)
4HP20/AL4
automatic
gearbox
API
standards
ESSO GEAR
manual gearbox OIL BV 75W80
MA-BE-ME-ML- (1) (3)
BA7-BA10
Part No.
9736.41
specific to
Peugeot
ESSO GEAR
OIL BT 80W90
405 x 4 transfer
(1)
box
Part No.
9736.19
GL5

(3) never use any other grade of oil
units
BC3
TM 80W90
4HP14 - 4HP18 TOTAL FLUIDE

- MB3
AT42
87/152
API
ACEA
standards standards
TOTAL
SJ/CF
A3/B3
automatic
gearbox
4HP20 - AL4
automatic gearbox
manual
gearbox MABE-ME-MLBA7-BA10
specific to
Peugeot
TOTAL
TRANSMISSION
BV 75W80
(4) new formula
TOTAL
405 x 4
TRANSMISSION X4 GL5
transfer box
80W90
(4) if another oil has been used, drain and rinse but Never
Mix the oils
2 - 3 - REAR FINAL DRIVE

units
ESSO
API/PEUGEOT
standards
conventional rear ESSO GEAR OIL

specific to Peugeot
axle
VT (5)
conventional hypoid
ESSO GEAR OIL
rear axle
BT 80W90 (1)
GL5
with limited slip and
Part No. 9736.19
405 x 4
(5) if there is no ESSO GEAR OIL VT oil available, use
ESSO GEAR OIL GP90 or GX-80W90 after emptying and
rinsing the final drive, but never mix the two oils
units
TOTAL
API/PEUGEOT
standards
TOTAL
TRANSMISSION TM
MULTIGRADE 80W90
conventional rear
(4)
GL5
axle
TOTAL
TRANSMISSION TM
80W90
conventional
TOTAL
hypoid rear axle
TRANSMISSION X4
with limited slip
80W90
and 405 x 4
GL5
Mix the oils
2 - 4 - SUSPENSION
units
88/152
ESSO
API/PEUGEOT
standards
hydraulic
suspension
units
hydraulic
suspension
ESSO LHM
EXTRA
specific to Peugeot
API/PEUGEOT
standards
TOTAL
TOTAL LHM
PLUS
specific to Peugeot
2 - 5 - REAR SUSPENSION
units
ESSO
ESSO GEAR OIL BT

80W90 (1)
rear suspension J7 Part No. 9736.19
J9
ESSO GEAR OIL GX
80W90
API
standards
GL5

units
TOTAL
TOTAL TRANSMISSION TM
rear suspension MULTIGRADE 80W90
J7 - J9
80W90
API
standards
GL5
2 - 6 - STEERING
units
ESSO
API
standards
ESSO GEAR OIL

BT 80W90 (1)
J7 - J9 steering systems
Part No. 9736.19 GL5
except J9 power steering
ESSO GEAR OIL
GX 80W90
units
TOTAL
API
standards
TOTAL TRANSMISSION
J7 - J9 steering
TM MULTIGRADE 80W90
systems except J9
GL5
TOTAL TRANSMISSION
power steering
TM 80W90
2 - 7 - SHOCK ABSORBERS
89/152
units
ESSO
front shock
absorbers
API standards
ESSO OLEOFLUID PA
specific to
(1)
Peugeot
Part No. 9730.27
2 - 8 - MECHANICAL UNITS
units
NLGI
standards
ESSO
mechanical
units
ESSO MULTIPURPOSE
GREASE 4746
units
TOTAL
NLGI2
NLGI standards
mechanical units TOTAL MULTIS 2
NLGI2
2 - 9 - AIR CONDITIONING COMPRESSORS

units
products packaging Part No.
compressors for R12

refrigerant
LUNARIA-S
125 ml
(*)
9735.H8
compressors SANDEN
SANDEN
with fixed displacement for
SP20
R134a refrigerant
40 ml
250 ml
9735.C8
9735.C6
compressors SANDEN
SANDEN
with variable displacement
SP10
for R134a refrigerant
40 ml
250 ml
9735.C5
9735.C4
40 ml
250 ml
9979.41
9979.40
compressors DELPHIHARRISON for V5

refrigerant
UCON 488
(*) do not use LUNARIA-S in compressors made by

SANDEN or DELPHI
NOTE : for vehicles manufactured and sold in countries where ESSO and TOTAL products are not
available, use PEUGEOT locally recommended lubricants .
3 - OILS FOR PETROL ENGINES
3 - 1 - EUROPE
Country
Germany
Austria
Belgium
Spain
FRANCE
90/152
ESSO
ESSO
UNIFLO
ESSO
ULTRA
ESSO
grade
API
standards
15W40
10W40
5W40
0W30
5W30
SJ
SJ/SH EC-I
SJ/SH EC-I
SJ/SH EC-II
-
ACEA
standards
A2
A3
A3
A3
Great Britain
Greece
Hungary
Italy
Ireland
Luxemburg
Netherlands
Poland
Portugal
Czech
Republic
Slovakia
Switzerland
Rumania
Russia
Denmark
Finland
Norway
Sweden
ULTRON
ESSO
ULTRON (6)
ESSO
ULTRA (6)
specific to
Peugeot
ESSO
UNIFLO
ESSO
10W40
ULTRA
10W40
ESSO
5W40
ULTRON
0W30
ESSO
5W30
ULTRON (6)
ESSO
ULTRA (6)
SJ
SJ/SH EC-I
SJ/SH EC-I
SJ/SH EC-II
-
A2
A3
A3
A3
specific to
Peugeot
(6) this energy saving oil can only be used with engines
designed to receive it (from my 2000)
Country
FRANCE
Germany
Austria
Belgium
Belorussia
Bosnia
Croatia
Denmark
Estonia
Finland
Great Britain
Hungary
Ireland
Italy
Latvia
91/152
TOTAL
grade
TOTAL
ACTIVA 5000
TOTAL
15W40
ACTIVA 7000
10W40
TOTAL
5W40
ACTIVA 9000
0W40
5W30
TOTAL
ACTIVA 9000
(6)
TOTAL
QUARTZ
5000
TOTAL
QUARTZ
7000
TOTAL
QUARTZ
9000
TOTAL
QUARTZ
9000
TOTAL
API
standards
SJ
SJ
SJ
ACEA
standards
A2
A3
A3
SJ EC
specific to
Peugeot
15W40
10W40
5W40
0W40
SJ
SJ
SJ
SJ
A2
A3
A3
A3
5W30
SJ EC
specific to
Peugeot
Lithuania
Luxemburg
Macedonia
Norway
Netherlands
Poland
QUARTZ
Czech
9000 (6)
Republic
Russia
Slovenia
Sweden
Switzerland
TOTAL
QUARTZ
5000
TOTAL
QUARTZ
7000
TOTAL
QUARTZ
7000
TOTAL
QUARTZ
9000
TOTAL
QUARTZ
9000
Bulgaria
Cyprus
Spain
Greece
Malta
Portugal
Rumania
15W40
15W50
10W40
5W40
0W40
SJ
SJ
SJ
SJ
SJ
5W30
SJ EC
A2
A3
A3
A3
A3
specific to
Peugeot
TOTAL
QUARTZ
9000 (6)
3 - 2 - AFRICA
Country
ESSO
grade
API
standards
ESSO SUPER
20W50 SJ
OIL (7)
Tunisia
15W50 SJ
ESSO ULTRA
5W40 SJ/SH EC-I
ESSO ULTRON
ACEA
standards
A2
A3
A3
(7) mineral oil(s)

Country
TOTAL
grade
API
standards
TOTAL
QUARTZ 5000
20W50 SJ
all
TOTAL
15W50 SJ
countries QUARTZ 7000
5W40 SJ
TOTAL
QUARTZ 9000
92/152
ACEA
standards
A2
A3
A3
3 - 3 - SOUTHERN EUROPE
Country
grade
API
standards
20W50
15W50
5W40
0W40
SJ
SJ
SJ
SJ/SH EC-II
TOTAL
TOTAL
QUARTZ
5000
TOTAL
QUARTZ
7000
Turkey
TOTAL
QUARTZ
9000
TOTAL
QUARTZ
9000
CCMC/ACEA
standards
A2
A3
A3
A3
3 - 4 - FRENCH OVERSEAS TERRITORIES

Country
ESSO
ESSO
UNIFLO
French West
ESSO
Indies
ULTRA
Reunion
ESSO
ULTRON
Country
TOTAL
TOTAL
ACTIVA 5000
TOTAL
Caribbean ACTIVA 5000
Pacific TOTAL
Polynesia ACTIVA 7000
Reunion TOTAL
ACTIVA 7000
TOTAL
ACTIVA 9000
API
standards
grade
ACEA
standards
15W40 SJ
A2
10W40 SJ/SH EC-I A3
5W40 SH/SH EC-I A3
API
standards
grade
20W50
15W40
15W50
10W40
5W40
SJ
SJ
SJ
SJ
SJ
ACEA
standards
A2
A2
A3
A3
A3
3 - 5 - MIDDLE EAST
Country
ESSO
grade
API
standards
ACEA
standards
Bahrain ESSO
10W40 SJ/SH EC-I A3
United Arab RACING OIL
Emirates (8)
Kuwait
93/152
Lebanon
Oman
Qatar
Yemen
(8) semi-synthetic oil(s)
Country
TOTAL
Bahrain
United Arab
Emirates
Kuwait
Lebanon
Oman
Qatar
Yemen
TOTAL
QUARTZ
5000
TOTAL
QUARTZ
7000
TOTAL
QUARTZ
9000
Country
TOTAL
Iran
API
standards
grade
20W50 SJ
15W50 SJ
5W40 SJ
grade
API
standards
TOTAL
20W50 SJ
QUARTZ 5000
ACEA
standards
A2
A3
A3
ACEA
standards
A2
3 - 6 - SOUTH-EAST ASIA
Country
Australia
China
Korea
Hong
Kong
India
Indonesia
Malaysia
Singapore
Taiwan
Thailand
Vietnam
ESSO
ESSO
ULTRAFLO
ESSO
ULTRON
Australia ESSO
Thailand SUPERFLO
JAPAN
Hong
Kong
94/152
grade
API
standards
ACEA
standards
10W40 SJ/SH EC-I A3

5W40 SJ/SH EC-I A3
20W50 SJ
A2
ESSO
ULTRAFLO
ESSO
ULTRON
UNOIL GX-7
UNOIL GX-6
10W40
5W40
5W40
10W40
A3
A3
A3
A2
ESSO
ULTRON
0W30 SJ/SH EC-II A3
SJ/SH EC-I
SJ/SH EC-I
SI/S4 EC-I
SJ/S4 EC-I
Country
TOTAL
grade
TOTAL
China
QUARTZ 5000
India
TOTAL
Indonesia
20W50
QUARTZ 5000
JAPAN
15W40
TOTAL
Malaysia
15W50
QUARTZ 7000
Singapore
10W40
TOTAL
Taiwan
5W40
QUARTZ 7000
Thailand
TOTAL
Vietnam
QUARTZ 9000
API
standards
SJ
SJ
SJ
SJ
SJ
ACEA
standards
A2
A2
A3
A3
A3
3 - 7 - SOUTH AMERICA
Country
ESSO
grade
API
standards
ACEA
standards
Brazil
ESSO
ULTRA
ESSO
ULTRON
15W50 SJ
5W40 SJ/SH EC-I
A3
A3
Argentina
Bolivia
Paraguay
Uruguay
ESSO
UNIFLO
ESSO
ULTRA
ESSO
ULTRON
15W40 SJ
10W40 SJ/SH EC-I
5W40 SJ/SH EC-I
A2
A3
A3
Chile
Columbia ESSO
Ecuador ULTRON
Surinam
5W40 SJ/SH EC-I
A3
API
standards
Country
TOTAL
grade
Argentina
Chile
Bolivia
Brazil
Paraguay
Uruguay
TOTAL
QUARTZ 5000
TOTAL
QUARTZ 5000
TOTAL
QUARTZ 7000
TOTAL
QUARTZ 7000
TOTAL
QUARTZ 9000
20W50
15W40
15W50
10W40
5W40
SJ
SJ
SJ
SJ
SJ
grade
API
standards
Country
TOTAL
Cuba TOTAL
20W50 SJ
QUARTZ 5000 15W50 SJ
TOTAL
5W40 SJ
QUARTZ 7000
95/152
ACEA
standards
A2
A2
A3
A3
A3
ACEA
standards
A2
A3
A3
TOTAL
QUARTZ 9000
3 - 8 - CENTRAL AMERICA AND THE CARIBBEAN

Country
ESSO
Bahamas
Barbados
Belize
Guatemala
Haiti
Honduras
Jamaica
ESSO
Mexico
ULTRON
Panama
Puerto Rico
Dominican
Republic
Salvador
Trinidad and
Tobago
grade
API
standards
ACEA
standards
5W40 SJ/SH EC-I A3
4 - OILS FOR DIESEL ENGINES

4 - 1 - EUROPE
Country
ESSO
grade
API
standards
ACEA
standards
Germany
Austria
Belgium
Spain
FRANCE
Great Britain
Greece
Ireland
Italy
Luxemburg
Netherlands
Portugal
Russia
Switzerland
ESSO
UNIFLO
DIESEL
ESSO
ULTRA
DIESEL
ESSO
ULTRON
DIESEL
ESSO
ULTRA (6)
15W40
10W40
5W40
5W30
CF
CF
CF
-
B2
B3
B3
specific to
Peugeot
Hungary
Norway
Poland
Czech
Republic
Rumania
Slovakia
ESSO
UNIFLO
DIESEL
ESSO
ULTRA
DIESEL
ESSO
ULTRA (6)
15W40 CF
10W40 CF
5W30 -
B2
B3
specific to
Peugeot
96/152
Finland
Denmark
Sweden
ESSO
ULTRA
DIESEL
ESSO
ULTRA (6)
10W40 CF
5W30 -
B3
specific to
Peugeot
API
standards
Country
TOTAL
grade
FRANCE
TOTAL
ACTIVA
DIESEL 5000
TOTAL
ACTIVA
DIESEL 7000
TOTAL
ACTIVA
DIESEL 9000
TOTAL
ACTIVA 9000
(6)
15W40
10W40
5W40
5W30
CF
CF
CF
CF
15W40
10W40
5W40
5W30
CF
CF
CF
CF
Germany
Austria
Belgium
Belorussia
Bosnia
Bulgaria
Cyprus
Croatia
Denmark
Spain
Estonia
Finland
Great Britain
Greece
Hungary
Ireland
Italy
Latvia
Lithuania
Luxemburg
Macedonia
Malta
Norway
Netherlands
Poland
Portugal
Czech
Republic
Rumania
Russia
97/152
TOTAL
QUARTZ
DIESEL 5000
TOTAL
QUARTZ
DIESEL 7000
TOTAL
QUARTZ
9000
TOTAL
QUARTZ
9000 (6)
ACEA
standards
B2
B3
B3
specific to
Peugeot
B2
B3
B3
specific to
Peugeot
Slovenia
Sweden
Switzerland
4 - 2 - AFRICA
Country
Tunisia
ESSO
grade
API
standards
ESSO ULTRON
5W40 CF
DIESEL
Country
TOTAL
grade
ACEA
standards
B3
API
standards
TOTAL
QUARTZ
DIESEL 5000
15W40 CF
all
TOTAL
15W50 CF
countries QUARTZ
5W40 CF
DIESEL 7000
TOTAL
QUARTZ 9000
ACEA
standards
B2
B3
B3
Country
TOTAL
grade
API
standards
TOTAL QUARTZ
DIESEL 5000
15W40 CF
TOTAL QUARTZ
Turkey
15W50 CF
DIESEL 7000
5W40 CF
TOTAL QUARTZ
9000
ACEA
standards
B2
B3
B3

Country
ESSO
grade
API
standards
ESSO
UNIFLO
DIESEL
French
15W40 CF
ESSO ULTRA
West Indies
10W40 CF
DIESEL
Reunion
5W40 CF
ESSO
ULTRON
DIESEL
98/152
ACEA
standards
B2
B3
B3
Country
TOTAL
TOTAL ACTIVA
DIESEL 5000
Caribbean TOTAL ACTIVA
Pacific DIESEL 7000
Polynesia TOTAL ACTIVA
Reunion DIESEL 7000
TOTAL ACTIVA
DIESEL 9000
grade
15W40
15W50
10W40
5W40
API
standards
ACEA
standards
CF
CF
CF
CF
B2
B3
B3
B3
4 - 5 - MIDDLE EAST
Country
TOTAL
Bahrain
United Arab
Emirates
Kuwait
Lebanon
Oman
Qatar
Yemen
grade
API
standards
TOTAL
QUARTZ
DIESEL 5000
15W40 CF
TOTAL
15W50 CF
QUARTZ
5W40 CF
DIESEL 7000
TOTAL
QUARTZ 9000
ACEA
standards
B2
B3
B3
Country
TOTAL
TOTAL
China QUARTZ
India
DIESEL 5000
Indonesia TOTAL
JAPAN QUARTZ
Malaysia DIESEL 7000
Singapore TOTAL
Taiwan QUARTZ
Thailand DIESEL 7000
Vietnam TOTAL
QUARTZ 9000
grade
API
standards
15W40
15W50
10W40
5W40
CF
CF
CF
CF
grade
API
standards
ACEA
standards
B2
B3
B3
B3
Country
Argentina
Bolivia
Paraguay
Uruguay
99/152
ESSO
ESSO UNIFLO
DIESEL
15W40 CF
ESSO ULTRA 10W40 CF
DIESEL
ACEA
standards
B2
B3
Country
Argentina
Bolivia
Brazil
Chile
Paraguay
Uruguay
TOTAL
TOTAL
QUARTZ
DIESEL 5000
TOTAL
QUARTZ
DIESEL 7000
TOTAL
QUARTZ
DIESEL 7000
TOTAL
QUARTZ 9000
API
standards
grade
15W40
15W50
10W40
5W40
CF
CF
CF
CF
ACEA
standards
B2
B3
B3
B3
B1BS00K1 - 206 DW10TD ENGINE

DISMANTLING - DISMANTLING ENGINE
1 - DISMANTLING - DISMANTLING
Unclip the engine harness, then disconnect it from the various sensors .
Remove :
the engine harness assembly

the egr valve assembly
Remove :
the exhaust manifold (1) and its gasket

the inlet manifold assembly and its gasket (2)
the securing clip 3
100/152
Disconnect the connectors (4) .

Remove :
the bracket (5)

the dipstick guide fasteners (6)
the nuts (7)
the pins (8) (use a lock nut)
the bolts (9)
Secure the engine on a stand .

Remove : The thermostat (10) .
Place a draining tray under the engine .

Open the bleed screw (11) .
IMPERATIVE : WHEN WORKING ON THE DIESEL CIRCUIT, FOLLOW THE ADVICE ON
CLEANLINESS .
Move aside the connections (12) .
101/152
IMPERATIVE : PLUG THE HOLES USING TOOL [1U] .

Remove :
the assembly (13)

the oil filter (14)
the heat exchanger (15)
Remove :
the nipple (16)

the alternator
the diesel filter support (17)
the accessory bracket (18)
the oil vapours breather tube (19)
LOCK THE FLYWHEEL WITH THE STOP [1I] .

Remove :
the ancillary drive pulley (20) (USING THE TOOL [1R])
102/152
the timing gear top covers (21)

the bottom timing cover (22)
the engine mounting (23)
REMOVE THE STOP [1I] .

Remove the starter .
1 - 1 - 1ST FITTING : WITH SINGLE ENGINE FLYWHEEL
PEG THE FLYWHEEL USING THE ROD [1G] .

1 - 2 - 2ND FITTING : WITH DOUBLE ENGINE FLYWHEEL
peg the flywheel using the rod [1y] .

Peg :
the camshaft (USING THE TOOL [1P])
Slacken the bolt (24) .

103/152
Remove the timing belt .

Slacken the bolts (25) .
Remove :
the camshaft pulley (26)

the tensioning roller (27)
the tensioner roller (28)
the crankshaft gear (29) (retrieve the cotter)
Pin the pulley (31) USING THE TOOL [1W] .

Slacken the nut (30) .
Remove the high pressure pump drive pulley (31) (USING THE TOOL [1T]) .
IMPERATIVE : CLEAN THE FUEL UNIONS BEFORE SLACKENING .

IMPERATIVE : apply a counter-torque at (A) .
Remove :
high pressure pipes (32)

the bolts (33)
Disconnect the connectors (34), (35) .

Move aside : The hoses (36) and (37) .
PLUG THE HOLES USING TOOL [1U] .
Remove the fastenings (38) .
Remove the high pressure fuel pump .
NOTE : if necessary : entrust the checking of the high pressure injection pump to a dealer .
Remove :
104/152
the bolts (39)

the injection pump bracket (40)
IMPERATIVE : WHEN WORKING ON THE DIESEL CIRCUIT, FOLLOW THE ADVICE ON

CLEANLINESS .
WARNING : if any work is carried out on the high pressure pipes they must always be replaced .
Apply a counter-torque at (b) .

Slacken the unions .
Apply a counter-torque at (c) .

Slacken the unions on the high pressure fuel direct injection rail .
Remove : The 4 high pressure pipes .
IMPERATIVE : plug the openings, USING THE TOOL [1U] .
105/152
Remove :
the injector return rail (42)

the supply rail (43)
the glow plugs
Plug the openings, USING THE TOOL [1U] .

Remove :
the lifting plates (45)

the vacuum pump (46)
IMPERATIVE : do not turn the nut (d) .

Remove :
the nuts (47)

the cups (48)
the injector clamps (49)
the injectors (50)
106/152
the sealing rings (51)

the O-rings (52)
the thrust buttons (53)
NOTE : if the injector cannot be removed, remove the stud (54) by using a lock-nut, then, using an
open ended spanner, turn the injector at (e) .
IMPERATIVE : close the injector holes, plug the openings (USING THE TOOL [1U]) .
Remove :
the cylinder head cover (55) (in the order shown)
ROD(S) [1P] IN POSITION .

SLACKEN THE CYLINDER HEAD BOLTS IN THE ORDER INDICATED, USING THE TOOL [4] .
Remove the cylinder head bolts .
ROCK AND FREE THE CYLINDER HEAD USING LEVERS [1N] .
Remove the cylinder head and gasket .
107/152
Clean the threads and taps .

REMOVE THE TOOL [1G] OR [1Y] .
INSERT THE FLYWHEEL STOP [1I] .

Remove :
the clutch mechanism

the flywheel (56)
the sump (57)
WARNING : take care not to distort the mating surface .

Remove :
the coolant pump (58)

the seal carrier plate (59)
the oil gallery plug (60)
Remove :
108/152
the dipstick tube (61)

the oil pump (62)
the oil pump chain and drive pinion
IMPERATIVE : mark the location of the big end caps and main bearings .
Remove :
the big end caps (63)

the bearing caps (64)
the oil seal (65)
Recover the end float adjusting shims on the main bearing (no. 2) .
IMPERATIVE : mark the location of the main bearing half shells .

Remove :
the crankshaft (66)

the bearing half-shells
the end float adjustment shims (67)
109/152
Remove :
the piston/connecting rod assemblies
Fit :
the big end caps (68)
Remove :
the lock washers (75)

gudgeon pin (69)
the piston (70)
NOTE : the gudgeon pins are paired with the pistons, do not mix the components .
110/152
Remove the piston head jets (71) .
Remove :
the oil gallery plug (72)

the oil level sensor (73)
the oil pressure sensor (74)
B1KG04K1 - 206 DW10TD ENGINE

REMOVAL - REFITTING EGR VALVE
1 - REMOVAL
111/152
Remove the style cover .

Remove the hose (1) .
Disconnect the pipe (2) .
Remove the bolts (3) .
Move aside the clip (4) .
Remove :
the pipe (5)

the nuts (6)
EGR valve (7)
Retrieve the joint .

2 - REFITTING
Always renew :
the seal
the collar (3) (specific to Service)
Proceed in the reverse order to removal .

Tighten :
the nuts (5) to 1 da.Nm

B1BB1VK1 - 206 DW10TD ENGINE

DATA INJECTOR CARRIER SEALS
112/152
dimensions (mm)
A 0.05
nominal
1,5
repair 1
1,9
IMPERATIVE : on grinding the cylinder head joint face : the injector carrier seals are replaced with
repair dimension injector carrier seals .
B1BB1VK1 - 206 DW10TD ENGINE
DATA INJECTOR CARRIER SEALS
dimensions (mm)
A 0.05
nominal
1,5
repair 1
1,9
IMPERATIVE : on grinding the cylinder head joint face : the injector carrier seals are replaced with
repair dimension injector carrier seals .
B1DF01K1 - 206 DW10TD ENGINE
CYLINDER REFERENCE SENSOR AIR GAP ADJUSTMENT
113/152
1 - NEW CYLINDER REFERENCE SENSOR
Peg the crankshaft .

Position the cylinder reference sensor on the cylinder head cover .
Position the sensor at the stop on the camshaft ring .
Tighten the bolt (2) to 0.2 da.Nm .
Connect the harness .
2 - RE-USED CYLINDER REFERENCE SENSOR
Remove the adjusting stud (1) .
Peg the crankshaft .
Remove :
the top timing cover
Using a set of shims [1], create a 1,2 mm pile which is as flexible as possible .
Position the cylinder reference sensor on the cylinder head cover .
Move the pile of shims between the sensor and the camshaft ring .
Move the sensor until it stops against the shims .
Tighten the bolt (2) to : 0.2 da.Nm .
Connect the harness .
B1BT06K1 - 206 DW10TD ENGINE
REMOVAL - REFITTING DIESEL FILTER ASSEMBLY
1 - PROTECTION
114/152
IMPERATIVE : observe the safety and cleanliness instructions .
Place a protector on the following elements :
front wings
driver's seat
mat (on the driver's side)
steering wheel
2 - REMOVAL
Remove :
the sound insulation under the engine (according to specification)

the style cover
115/152

Clean the connectors on the fuel filter assembly at (A) : USING THE TOOLS [2] - [3] - [4] .
Disconnect the pipes (2) - (3) .

Wait for the diesel to drain off completely .
When uncoupling the pipes, block the holes : USING THE TOOLS [6] .
Block the unions on the fuel filter assembly at (B) : USING THE TOOLS [1] .
116/152
Fit a 22 mm socket : At (C) .

Apply pressure to the cover (4) and simultaneously slacken a quarter turn .
Remove :
the cover (4)

the corrugated washer (5)
the filter element (6)
the fuel filter assembly seal (7)
3 - CLEANING THE CHAMBER OF THE FILTER ELEMENT

IMPERATIVE : do not clean the chamber of the filter element with a rag; do not use compressed air .
Allow the fuel contained in the filter element chamber (8) to drain .
Disconnect the pipes under the filter element chamber .
IMPERATIVE : when uncoupling the pipes, block the holes : USING THE TOOLS [1] - [6] .
Unclip and raise the filter element chamber (8) .
POUR THE PRODUCT [13] INTO THE TRAY [4] .
Clean and drain the filter element chamber : USING THE TOOL [3] .
Drain the fuel filter .
Dry and wipe the chamber of the filter element chamber with a high precision wiper, available from
parts .
Replace the filter element chamber (8) .
4 - REFITTING
117/152
IMPERATIVE : open the sachet containing the new filter element just before refitting .
Fit :
the new filter element (6) and position it correctly

THE NEW, LUBRICATED SEAL (7) WITH SOME [13] PRODUCT (DIESEL SUBSTITUTE)
the cover (4)
WARNING : position the cover (4) and the pipes (B) at right angles to the engine (mark (D) located
on the air filter side) .
Fit a 22 mm socket : At (C) .
118/152
Remove :
THE TOOL [6] FROM THE PIPE (2)

THE EQUIPMENT [1] FROM THE UNIONS (B)
Connect the pipe (2) .

Connect the battery .
BLEED THE FUEL SUPPLY CIRCUIT .
Fit :
the style cover

the sound insulation under the engine (according to specification)
C5BG00F1 - 206
REMOVAL - REFITTING FUEL CAP COVER
1 - REMOVAL
Remove the fuel cap .
Remove the key .
Fit a protector under the cover (1) .

Press and turn (opposite direction to the arrow) the cap (2) to detach it from the lugs (A) of the cover .
Remove the cover (1) .
2 - REFITTING
119/152
Fit opposite the arrow, the lug cut at right angles (B) .
Engage all three lugs by turning (in the direction of the arrow) and press .
Refit the fuel cap .
B1HG1VK1 - 206 DW10TD ENGINE
REMOVAL - REFITTING FUEL FILTER
1 - SPECIAL TOOLS
[1] Set of plugs (-).0188-T .
120/152
[2] Degreaser : SODIMAC No.35 (Available from Parts Division) .
Brush [3] .
Cleaning tray [4] .
2 - REMOVAL
Remove the shield under the power train .
121/152

Move aside the connections (2), (3) .
IMPERATIVE : plug the holes using tool [1] .
Fit a 22 mm socket (At (a)) .

122/152
Remove :
the cover (4)

the filter element (6)
3 - CLEANING THE FUEL FILTER

Allow the fuel contained in the fuel filter (5) to flow out .
Move aside the connections (Under the fuel filter) .
IMPERATIVE : plug the holes using tool [1] .
Unclip and lift the fuel filter .
Remove the fuel filter (5) .
Pour the product [2] into the tray [4] .
Clean the fuel filter (Using the tool [3]) .
Before refitting : Allow the fuel filter to drip .
IMPERATIVE : only use RESISTEL cloths (available from Parts Division) ; do not use compressed air
.
4 - REFITTING
IMPERATIVE : open the sachet containing the new filter element just before refitting .
Fit : The fuel filter (5) .
123/152
Fit :
the new filter element (6) and position it correctly

the cover (4)
WARNING : position the cover (4) and the pipes (b) at right angles to the engine (mark (c) located on
the air filter side) .
Fit a 22 mm socket (At (a)) .
Apply pressure to the cover (4) and at the same time tighten by a quarter turn .
124/152
Remove the tools [1] .

Couple up the unions (2) .
5 - BLEEDING THE SUPPLY CIRCUIT
To fill the fuel filter, switch the ignition on and off several times (6 times) .
6 - LEAKAGE CHECK
Start the engine .
Check that there are no fuel leaks .
B1BT07K1 - 206 DW10TD ENGINE
REMOVAL - REFITTING FUEL HIGH PRESSURE REGULATOR ON FUEL HIGH PRESSURE
PUMP
1 - PROTECTION
IMPERATIVE : observe the safety and cleanliness instructions .
Place a protector on the following elements :
front wings
driver's seat
mat (on the driver's side)
steering wheel
2 - REMOVAL
Remove the style cover .
125/152
Disconnect, block and move aside the pipe(s) (4) - (5) : USING THE TOOLS [1] - [6] .
Raise and move aside the diesel filter (6) .
Unclip and move aside the lower pipes (2) - (3) .
Remove the diesel filter bracket (1) .
Disconnect the connector (9) .

IMPERATIVE : clean and suck up the dirt around the pressure regulator (8) : USING THE TOOLS [2]
- [3] - [4] - [11] - [12] .
IMPERATIVE : do not use a tool to remove the pressure regulator (e.g. a screwdriver) .
Remove the 2 bolts (7) .
Remove the pressure regulator (8) by hand by rotating half way from right to left, at the same time as
pulling .
126/152
IMPERATIVE : FIT THE CLOSER [1] .

3 - REFITTING
REMOVE THE BLANK [1] .
IMPERATIVE : using a mirror, check that there is no dirt in the pressure housing; clean if necessary .
IMPERATIVE : fit the pressure regulator with a ring and new seals; lubricate the ring and the seals
with vaseline (or similar) .
PLACE THE FUEL PRESSURE REGULATOR ON THE STAND [5]; TIGHTEN THE BOLTS (A) OF
THE EQUIPMENT [5] ALONG THE WHOLE THREAD .
INSERT THE TEFLON DISC (B) BETWEEN THE FUEL PRESSURE REGULATOR AND THE
STAND [5] .
Tighten the centre bolt (C) in such a way that the pressure regulator is held at the inlet of its housing,
without damaging the high pressure seal .
PUSH THE PRESSURE REGULATOR UNTIL IT IS IN CONTACT WITH THE HIGH PRESSURE
PUMP BODY, USING THE CENTRE BOLT (C) OF THE EQUIPMENT [5] .
127/152
REMOVE THE TOOL [5] .

Refit the bolts (7) .
Pre-tighten the bolts (7) to 0.25 0.02 m.daN : TOOLS [7] - [8] - [9] - [10] .
Tighten the bolts (7) to 0.9 0.1 daN.m : TOOLS [7] - [8] - [9] - [10] .
Re-connect the connector (9) .
Position the diesel filter support (1) .
Position :
the pipes (2) - (3)

the fuel filter (6)
Reconnect the pipes (4) - (5) .

Switch off the ignition and switch it on again : 3 times .
Start the engine .
Take the engine speed up to 4000 rpm .
Check that there are no leaks and fault code(s) .
Carry out a road test : 30 km minimum .
During the road test make several stops and starts with the engine and acceleration manoeuvres with
a full load .
Replace the style cover .
B1BB1XK1 - 206 DW10TD ENGINE
DATA CONNECTING RODS
128/152
distance
nominal (mm)
53,7
+ 0,008
- 0,005
28
+ 0,02
- 0,007
30,2
+ 0,021
0
145
0,025
(1) Connecting rod .

(2) Little end socket .
When assembling the little end socket with the connecting rod, align the socket lubrication hole with
the little end socket lubrication hole .
B1BB1ZK1 - 206 DW10TD ENGINE
DATA PISTONS PISTON RINGS
1 - PISTONS
distance (mm)
nominal (mm)
repair (mm)
A
+ 0,018
0
85
85,6
B
+ 0,01
+ 0,005
28
28
46,75
46,75
C
- 0,02
- 0,07
129/152
(D) Flywheel end .

(E) Timing gear end .
The direction is given by the valve stamp (stamp on the side opposite the oil filter) .
WARNING : the pistons are fitted with their pin and rings, do not mix them up .
2 - PISTON RINGS
The piston has 3 rings :
upper sealing ring (1): double trapezoid compression ring

lower sealing ring (2): curved
scraper ring (3): with spiral spring
piston rings
(1) upper
(2) lower
(3) scraper
sealing ring compression ring
ring
thickness (mm) 3,5
clearance at the
0,2 to 0,35
gap (mm)
0,8 to 1
0,25 to 0,5
yellow
mauve
colour
mauve
B1DB3EK1 - 206 DW10TD ENGINE

DATA THRUST WASHER - VALVE SPRING
130/152
A
tolerance
nominal
0,07
0,8
repair
1,2
IMPERATIVE : on grinding the cylinder head joint face : the valve spring thrust washers are replaced
with repair dimension washers .
B1DB3AK1 - 206 DW10TD ENGINE
DATA VALVES
nominal dimensions
dimensions
inlet
exhaust
A 0,007 mm
5,978
5,973
B 0,1 mm
35,6
33,8
C (mm)
107,13
107,13
+07'30"
0
9015
9015
131/152
repair dimensions
dimensions
inlet
exhaust
A 0,007 mm
5,978
5,973
B 0,1 mm
35,6
33,8
C (mm)
106,73
106,73
+07'30"
0
9015
9015
B1DB3CK1 - 206 DW10TD ENGINE

DATA VALVE SPRINGS
nominal
distance (mm)
20,8
H1 (mm) for F1 (daN) 5 %
37 / 26
H2 (mm) for F2 (daN) 5 %
27,7 / 45,5
B1DB3FK1 - 206 DW10TD ENGINE

IDENTIFICATION - DATA CYLINDER HEAD GASKET
1 - IDENTIFICATION
1 - 1 - 1ST FITTING : CYLINDER HEAD GASKET ELRING
132/152
(A) : Thickness identification .

1 - 2 - 2ND FITTING : CYLINDER HEAD GASKET REINZ
(B) : thickness identification .

2 - DATA
There are 5 categories of laminated metal cylinder gaskets .
piston protrusion
measurements
(mm)
thickness
(mm)
notch(es) : at (A)
or (B)
0.47 to 0.605
1.30 0.06
0.605 to 0.655
1.35 0.06
0.655 to 0.705
1.40 0.06
0.705 to 0.755
1.45 0.06
0.755 to 0.83
1.50 0.06
133/152
IMPERATIVE : if the value measured does not correspond to the values indicated, investigate the
origin of the fault (measurement error, handling error etc.) .
B1EB0JK1 - 206 DW10TD ENGINE
DATA CAMSHAFTS
(A) : Camshaft joint face .

distance
tolerance (mm)
nominal (mm)
B
0
- 0,013
27
repair 1 (mm)
26,8
Grinding of camshaft seal bearings to 0.2 mm (production seals fitted) .

B1KB05V1 - 206 TU ENGINE EW/DW ENGINE
IDENTIFICATION - ENGINE OIL FILTER CARTRIDGE
identification - oil filter
diameter
(mm)
reference
height
(mm)
capacities in
litres
LS 520C
86
140
0,615
A 596
79
100
0,500
LS 867B
76
89
0,320
LS 880
86
97
0,405
SAVARA
S0416
116
144
1,100
134/152
LS 304
76
89
0,320
622 084 727 filtering element ( only)
0,150
B1FI01V1 - 206 TU ENGINE EW/DW ENGINE

SUCTION DRAINING ENGINE
Following a recent modification to petrol and diesel engines, it is now possible to carry out an oil
change by suction (without a nozzle) .
The oil draining occurs via the oil dipstick tube, which reaches to the bottom of the oil sump .
The end of the dipstick tube is widened to allow connection of the suction draining equipment (2
diameters: 14 and 16 mm according to engine) .
WARNING : it is not possible to carry out this type of draining on engines which are not designed for
it; in some cases, because of the shape of the bottom of the sump, the amount of oil remaining is too
great (approx. 1 litre) .
1 - LIST OF ENGINES WHICH CAN BE SUCTION DRAINED
engine type
TU9 - TU1 TU3
vehicles
end-piece diameter
(mm)
106 - 206 - 306

PARTNER
14
106
14
306 - 406
14
TUD5
106
16
XU7JB
406
14
XU7JP4
306 - 406
14
306 - 406 - 605 - 806
14
XU10J4RS
306 S16
14
DJ
BOXER
16
DK
605
16
ES9J4
406 - 605
14
ES9J4S
406 - 607
14
EW7
406
14
EW10
206 - 406 - 607

806 - EXPERT
14
EW12
406 - 607
14
DW8
206 - 306
PARTNER - EXPERT
14
DW10
206 - 306 - 406 - 607

806 - PARTNER EXPERT
14
DW12
406 - 607
14
TU5J4
TU5JP4
XU10J4R
2 - APPROVED EQUIPMENT
135/152
Currently, 2 types of equipment have been given part numbers :
Z INTERNATIONAL : approval number(s) 9914.53 (ordered directly from the supplier)

FOG : approval number(s) 9914.65 (ordered directly from the supplier)
B1FB0IK1 - 206
RECOMMENDATIONS LUBRICANTS
1 - OIL QUALITIES
The engine lubrication oils are categorised in accordance with 3 quality levels :
mineral oil(s) (ESSO UNIFLO, TOTAL ACTIVA/QUARTZ 5000)

semi-synthetic oil(s) (ESSO ULTRA, TOTAL ACTIVA/QUARTZ 7000)
synthetic oil(s) (ESSO ULTRON, TOTAL ACTIVA/QUARTZ 9000)
In addition to the existing range of oils, for vehicles from model year 2000, an "energy saving" oil is
available; This oil contributes to the objective of resolving the problem of fuel consumption, which is
Peugeot's aim .
IMPERATIVE : the energy saving oil must not be used in engines prior to 2000 Model Year, nor in
engines XU10J4RS, DW12TED4, EW12J4, 1580 SPI or SOFIM engines ; likewise, 0W30 oil must
not be used in the above mentioned engines .
Automobiles PEUGEOT recommends the quality of lubricants to use in the owner's documentation :
handbook
warranty and maintenance record
WARNING : for vehicles sold from model year 1999, in accordance with the normal maintenance
plan, the use of an approved semi-synthetic oil is imperative .
Organisations categorise the oils in accordance with their performance and give them a quality label
which is visible on the packaging :
API : American Petroleum Institute

ACEA : European Automobile Manufacturers' Association
NLGI : National Lubrication Grease Institute
The grade (viscosity index) must be selected in accordance with the climate of the country of use .
136/152
2 - RECOMMENDED LUBRICANTS AND PERFORMANCE SPECIFICATIONS FOR INDIVIDUAL

UNITS
2 - 1 - PUMPS
units
ESSO
KF - KF1 - KF2 KF6 - KF5 - XN2

petrol injection
pump
ESSOLUBE
X101 10W
Part No.
9730.GA (1)
API
ACEA
standards standards
SC/CC
vacuum pump (with

separate
ESSO UNIFLO
SJ
lubrication)
10W40
PIERBURG
A2
vacuum pump (with

separate
ESSO GEAR
GL5
lubrication)
OIL GX 80W90
SAGINAW
power steering
pump
ESSO ATF D
(1)
Part No.
9730.94
units
TOTAL
KF - KF1 - KF2 - TOTAL RUBIA S

KF5 - KF6 - XN2 10W
petrol injection TOTAL RUBIA H
pump
10W
vacuum pump
(with separate
lubrication)
PIERBURG
137/152
CCMC/
API
standards
standards
ACEA
CD/SF
CC/SF
TOTAL ACTIVA 7000

10W40
SJ/CF
TOTAL QUARTZ
7000 10W40
D2
D1
A3/B3
TOTAL
TRANSMISSION TM
vacuum pump
MULTIGRADE
(with separate
80W90
GL5
lubrication)
TOTAL
SAGINAW
TRANSMISSION TM
80W90
power steering TOTAL FLUIDE

pump
AT42
API
standards
units
power
steering
pump
PENTOSIN CHF
11 S
Part No. 9979.64
(1) (2)
ACEA
standards
-

(2) for cold climates only, this oil cannot be mixed with
other oils; it is therefore necessary to completely drain the
system and to rinse it before filling with this oil
2 - 2 - GEARBOX FINAL DRIVE - TRANSFER BOX

units
ESSO
BC3
GX 80W90
ACEA
standards
SJ
A2
ATF 4HP20/AL4
Part No.
9736.22 (1) (3)
4HP14 - 4HP18 - ESSO ATF D

MB3 automatic Part No.
gearbox
9730.94 (1) (3)
4HP20/AL4
automatic
gearbox
API
standards
ESSO GEAR
manual gearbox OIL BV 75W80
MA-BE-ME-ML- (1) (3)
BA7-BA10
Part No.
9736.41
specific to
Peugeot
ESSO GEAR
OIL BT 80W90
405 x 4 transfer
(1)
box
Part No.
9736.19
GL5

(3) never use any other grade of oil
units
BC3
TM 80W90
4HP14 - 4HP18 TOTAL FLUIDE

- MB3
AT42
138/152
API
ACEA
standards standards
TOTAL
SJ/CF
A3/B3
automatic
gearbox
4HP20 - AL4
automatic gearbox
manual
gearbox MABE-ME-MLBA7-BA10
specific to
Peugeot
TOTAL
TRANSMISSION
BV 75W80
(4) new formula
TOTAL
405 x 4
TRANSMISSION X4 GL5
transfer box
80W90
Mix the oils
2 - 3 - REAR FINAL DRIVE

units
ESSO
API/PEUGEOT
standards
conventional rear ESSO GEAR OIL

specific to Peugeot
axle
VT (5)
conventional hypoid
ESSO GEAR OIL
rear axle
BT 80W90 (1)
GL5
with limited slip and
Part No. 9736.19
405 x 4
(5) if there is no ESSO GEAR OIL VT oil available, use
ESSO GEAR OIL GP90 or GX-80W90 after emptying and
rinsing the final drive, but never mix the two oils
units
TOTAL
API/PEUGEOT
standards
TOTAL
TRANSMISSION TM
MULTIGRADE 80W90
conventional rear
(4)
GL5
axle
TOTAL
TRANSMISSION TM
80W90
conventional
TOTAL
hypoid rear axle
TRANSMISSION X4
with limited slip
80W90
and 405 x 4
GL5
Mix the oils
2 - 4 - SUSPENSION
units
139/152
ESSO
API/PEUGEOT
standards
hydraulic
suspension
units
hydraulic
suspension
ESSO LHM
EXTRA
specific to Peugeot
API/PEUGEOT
standards
TOTAL
TOTAL LHM
PLUS
specific to Peugeot
2 - 5 - REAR SUSPENSION
units
ESSO
ESSO GEAR OIL BT

80W90 (1)
rear suspension J7 Part No. 9736.19
J9
ESSO GEAR OIL GX
80W90
API
standards
GL5

units
TOTAL
rear suspension MULTIGRADE 80W90
J7 - J9
80W90
API
standards
GL5
2 - 6 - STEERING
units
ESSO
API
standards
ESSO GEAR OIL

BT 80W90 (1)
J7 - J9 steering systems
Part No. 9736.19 GL5
except J9 power steering
ESSO GEAR OIL
GX 80W90
units
TOTAL
API
standards
TOTAL TRANSMISSION
J7 - J9 steering
TM MULTIGRADE 80W90
systems except J9
GL5
TOTAL TRANSMISSION
power steering
TM 80W90
2 - 7 - SHOCK ABSORBERS
140/152
units
ESSO
front shock
absorbers
API standards
ESSO OLEOFLUID PA
specific to
(1)
Peugeot
Part No. 9730.27
2 - 8 - MECHANICAL UNITS
units
NLGI
standards
ESSO
mechanical
units
ESSO MULTIPURPOSE
GREASE 4746
units
TOTAL
NLGI2
NLGI standards
mechanical units TOTAL MULTIS 2
NLGI2
2 - 9 - AIR CONDITIONING COMPRESSORS

units
products packaging Part No.
compressors for R12

refrigerant
LUNARIA-S
125 ml
(*)
9735.H8
compressors SANDEN
SANDEN
with fixed displacement for
SP20
R134a refrigerant
40 ml
250 ml
9735.C8
9735.C6
compressors SANDEN
SANDEN
with variable displacement
SP10
for R134a refrigerant
40 ml
250 ml
9735.C5
9735.C4
40 ml
250 ml
9979.41
9979.40
compressors DELPHIHARRISON for V5

refrigerant
UCON 488
(*) do not use LUNARIA-S in compressors made by

SANDEN or DELPHI
NOTE : for vehicles manufactured and sold in countries where ESSO and TOTAL products are not
available, use PEUGEOT locally recommended lubricants .
3 - OILS FOR PETROL ENGINES
3 - 1 - EUROPE
Country
Germany
Austria
Belgium
Spain
FRANCE
141/152
ESSO
ESSO
UNIFLO
ESSO
ULTRA
ESSO
grade
API
standards
15W40
10W40
5W40
0W30
5W30
SJ
SJ/SH EC-I
SJ/SH EC-I
SJ/SH EC-II
-
ACEA
standards
A2
A3
A3
A3
Great Britain
Greece
Hungary
Italy
Ireland
Luxemburg
Netherlands
Poland
Portugal
Czech
Republic
Slovakia
Switzerland
Rumania
Russia
Denmark
Finland
Norway
Sweden
ULTRON
ESSO
ULTRON (6)
ESSO
ULTRA (6)
specific to
Peugeot
ESSO
UNIFLO
ESSO
10W40
ULTRA
10W40
ESSO
5W40
ULTRON
0W30
ESSO
5W30
ULTRON (6)
ESSO
ULTRA (6)
SJ
SJ/SH EC-I
SJ/SH EC-I
SJ/SH EC-II
-
A2
A3
A3
A3
specific to
Peugeot
Country
FRANCE
Germany
Austria
Belgium
Belorussia
Bosnia
Croatia
Denmark
Estonia
Finland
Great Britain
Hungary
Ireland
Italy
Latvia
142/152
TOTAL
grade
TOTAL
ACTIVA 5000
TOTAL
15W40
ACTIVA 7000
10W40
TOTAL
5W40
ACTIVA 9000
0W40
5W30
TOTAL
ACTIVA 9000
(6)
TOTAL
QUARTZ
5000
TOTAL
QUARTZ
7000
TOTAL
QUARTZ
9000
TOTAL
QUARTZ
9000
TOTAL
API
standards
SJ
SJ
SJ
ACEA
standards
A2
A3
A3
SJ EC
specific to
Peugeot
15W40
10W40
5W40
0W40
SJ
SJ
SJ
SJ
A2
A3
A3
A3
5W30
SJ EC
specific to
Peugeot
Lithuania
Luxemburg
Macedonia
Norway
Netherlands
Poland
QUARTZ
Czech
9000 (6)
Republic
Russia
Slovenia
Sweden
Switzerland
TOTAL
QUARTZ
5000
TOTAL
QUARTZ
7000
TOTAL
QUARTZ
7000
TOTAL
QUARTZ
9000
TOTAL
QUARTZ
9000
Bulgaria
Cyprus
Spain
Greece
Malta
Portugal
Rumania
15W40
15W50
10W40
5W40
0W40
SJ
SJ
SJ
SJ
SJ
5W30
SJ EC
A2
A3
A3
A3
A3
specific to
Peugeot
TOTAL
QUARTZ
9000 (6)
3 - 2 - AFRICA
Country
ESSO
grade
API
standards
ESSO SUPER
20W50 SJ
OIL (7)
Tunisia
15W50 SJ
ESSO ULTRA
5W40 SJ/SH EC-I
ESSO ULTRON
ACEA
standards
A2
A3
A3
(7) mineral oil(s)

Country
TOTAL
grade
API
standards
TOTAL
QUARTZ 5000
20W50 SJ
all
TOTAL
15W50 SJ
countries QUARTZ 7000
5W40 SJ
TOTAL
QUARTZ 9000
143/152
ACEA
standards
A2
A3
A3
Country
grade
API
standards
20W50
15W50
5W40
0W40
SJ
SJ
SJ
SJ/SH EC-II
TOTAL
TOTAL
QUARTZ
5000
TOTAL
QUARTZ
7000
Turkey
TOTAL
QUARTZ
9000
TOTAL
QUARTZ
9000
CCMC/ACEA
standards
A2
A3
A3
A3

Country
ESSO
ESSO
UNIFLO
French West
ESSO
Indies
ULTRA
Reunion
ESSO
ULTRON
Country
TOTAL
TOTAL
ACTIVA 5000
TOTAL
Caribbean ACTIVA 5000
Pacific TOTAL
Polynesia ACTIVA 7000
Reunion TOTAL
ACTIVA 7000
TOTAL
ACTIVA 9000
API
standards
grade
ACEA
standards
15W40 SJ
A2
10W40 SJ/SH EC-I A3
5W40 SH/SH EC-I A3
API
standards
grade
20W50
15W40
15W50
10W40
5W40
SJ
SJ
SJ
SJ
SJ
ACEA
standards
A2
A2
A3
A3
A3
3 - 5 - MIDDLE EAST
Country
ESSO
grade
API
standards
ACEA
standards
Bahrain ESSO
10W40 SJ/SH EC-I A3
United Arab RACING OIL
Emirates (8)
Kuwait
144/152
Lebanon
Oman
Qatar
Yemen
(8) semi-synthetic oil(s)
Country
TOTAL
Bahrain
United Arab
Emirates
Kuwait
Lebanon
Oman
Qatar
Yemen
TOTAL
QUARTZ
5000
TOTAL
QUARTZ
7000
TOTAL
QUARTZ
9000
Country
TOTAL
Iran
API
standards
grade
20W50 SJ
15W50 SJ
5W40 SJ
grade
API
standards
TOTAL
20W50 SJ
QUARTZ 5000
ACEA
standards
A2
A3
A3
ACEA
standards
A2
Country
Australia
China
Korea
Hong
Kong
India
Indonesia
Malaysia
Singapore
Taiwan
Thailand
Vietnam
ESSO
ESSO
ULTRAFLO
ESSO
ULTRON
Australia ESSO
Thailand SUPERFLO
JAPAN
Hong
Kong
145/152
grade
API
standards
ACEA
standards
10W40 SJ/SH EC-I A3

5W40 SJ/SH EC-I A3
20W50 SJ
A2
ESSO
ULTRAFLO
ESSO
ULTRON
UNOIL GX-7
UNOIL GX-6
10W40
5W40
5W40
10W40
A3
A3
A3
A2
ESSO
ULTRON
0W30 SJ/SH EC-II A3
SJ/SH EC-I
SJ/SH EC-I
SI/S4 EC-I
SJ/S4 EC-I
Country
TOTAL
grade
TOTAL
China
QUARTZ 5000
India
TOTAL
Indonesia
20W50
QUARTZ 5000
JAPAN
15W40
TOTAL
Malaysia
15W50
QUARTZ 7000
Singapore
10W40
TOTAL
Taiwan
5W40
QUARTZ 7000
Thailand
TOTAL
Vietnam
QUARTZ 9000
API
standards
SJ
SJ
SJ
SJ
SJ
ACEA
standards
A2
A2
A3
A3
A3
Country
ESSO
grade
API
standards
ACEA
standards
Brazil
ESSO
ULTRA
ESSO
ULTRON
15W50 SJ
5W40 SJ/SH EC-I
A3
A3
Argentina
Bolivia
Paraguay
Uruguay
ESSO
UNIFLO
ESSO
ULTRA
ESSO
ULTRON
15W40 SJ
10W40 SJ/SH EC-I
5W40 SJ/SH EC-I
A2
A3
A3
Chile
Columbia ESSO
Ecuador ULTRON
Surinam
5W40 SJ/SH EC-I
A3
API
standards
Country
TOTAL
grade
Argentina
Chile
Bolivia
Brazil
Paraguay
Uruguay
TOTAL
QUARTZ 5000
TOTAL
QUARTZ 5000
TOTAL
QUARTZ 7000
TOTAL
QUARTZ 7000
TOTAL
QUARTZ 9000
20W50
15W40
15W50
10W40
5W40
SJ
SJ
SJ
SJ
SJ
grade
API
standards
Country
TOTAL
Cuba TOTAL
20W50 SJ
QUARTZ 5000 15W50 SJ
TOTAL
5W40 SJ
QUARTZ 7000
146/152
ACEA
standards
A2
A2
A3
A3
A3
ACEA
standards
A2
A3
A3
TOTAL
QUARTZ 9000
3 - 8 - CENTRAL AMERICA AND THE CARIBBEAN

Country
ESSO
Bahamas
Barbados
Belize
Guatemala
Haiti
Honduras
Jamaica
ESSO
Mexico
ULTRON
Panama
Puerto Rico
Dominican
Republic
Salvador
Trinidad and
Tobago
grade
API
standards
ACEA
standards
5W40 SJ/SH EC-I A3
4 - OILS FOR DIESEL ENGINES

4 - 1 - EUROPE
Country
ESSO
grade
API
standards
ACEA
standards
Germany
Austria
Belgium
Spain
FRANCE
Great Britain
Greece
Ireland
Italy
Luxemburg
Netherlands
Portugal
Russia
Switzerland
ESSO
UNIFLO
DIESEL
ESSO
ULTRA
DIESEL
ESSO
ULTRON
DIESEL
ESSO
ULTRA (6)
15W40
10W40
5W40
5W30
CF
CF
CF
-
B2
B3
B3
specific to
Peugeot
Hungary
Norway
Poland
Czech
Republic
Rumania
Slovakia
ESSO
UNIFLO
DIESEL
ESSO
ULTRA
DIESEL
ESSO
ULTRA (6)
15W40 CF
10W40 CF
5W30 -
B2
B3
specific to
Peugeot
147/152
Finland
Denmark
Sweden
ESSO
ULTRA
DIESEL
ESSO
ULTRA (6)
10W40 CF
5W30 -
B3
specific to
Peugeot
API
standards
Country
TOTAL
grade
FRANCE
TOTAL
ACTIVA
DIESEL 5000
TOTAL
ACTIVA
DIESEL 7000
TOTAL
ACTIVA
DIESEL 9000
TOTAL
ACTIVA 9000
(6)
15W40
10W40
5W40
5W30
CF
CF
CF
CF
15W40
10W40
5W40
5W30
CF
CF
CF
CF
Germany
Austria
Belgium
Belorussia
Bosnia
Bulgaria
Cyprus
Croatia
Denmark
Spain
Estonia
Finland
Great Britain
Greece
Hungary
Ireland
Italy
Latvia
Lithuania
Luxemburg
Macedonia
Malta
Norway
Netherlands
Poland
Portugal
Czech
Republic
Rumania
Russia
148/152
TOTAL
QUARTZ
DIESEL 5000
TOTAL
QUARTZ
DIESEL 7000
TOTAL
QUARTZ
9000
TOTAL
QUARTZ
9000 (6)
ACEA
standards
B2
B3
B3
specific to
Peugeot
B2
B3
B3
specific to
Peugeot
Slovenia
Sweden
Switzerland
4 - 2 - AFRICA
Country
Tunisia
ESSO
grade
API
standards
ESSO ULTRON
5W40 CF
DIESEL
Country
TOTAL
grade
ACEA
standards
B3
API
standards
TOTAL
QUARTZ
DIESEL 5000
15W40 CF
all
TOTAL
15W50 CF
countries QUARTZ
5W40 CF
DIESEL 7000
TOTAL
QUARTZ 9000
ACEA
standards
B2
B3
B3
Country
TOTAL
grade
API
standards
TOTAL QUARTZ
DIESEL 5000
15W40 CF
TOTAL QUARTZ
Turkey
15W50 CF
DIESEL 7000
5W40 CF
TOTAL QUARTZ
9000
ACEA
standards
B2
B3
B3

Country
ESSO
grade
API
standards
ESSO
UNIFLO
DIESEL
French
15W40 CF
ESSO ULTRA
West Indies
10W40 CF
DIESEL
Reunion
5W40 CF
ESSO
ULTRON
DIESEL
149/152
ACEA
standards
B2
B3
B3
Country
TOTAL
TOTAL ACTIVA
DIESEL 5000
Caribbean TOTAL ACTIVA
Pacific DIESEL 7000
Polynesia TOTAL ACTIVA
Reunion DIESEL 7000
TOTAL ACTIVA
DIESEL 9000
grade
15W40
15W50
10W40
5W40
API
standards
ACEA
standards
CF
CF
CF
CF
B2
B3
B3
B3
4 - 5 - MIDDLE EAST
Country
TOTAL
Bahrain
United Arab
Emirates
Kuwait
Lebanon
Oman
Qatar
Yemen
grade
API
standards
TOTAL
QUARTZ
DIESEL 5000
15W40 CF
TOTAL
15W50 CF
QUARTZ
5W40 CF
DIESEL 7000
TOTAL
QUARTZ 9000
ACEA
standards
B2
B3
B3
Country
TOTAL
TOTAL
China QUARTZ
India
DIESEL 5000
Indonesia TOTAL
JAPAN QUARTZ
Malaysia DIESEL 7000
Singapore TOTAL
Taiwan QUARTZ
Thailand DIESEL 7000
Vietnam TOTAL
QUARTZ 9000
grade
API
standards
15W40
15W50
10W40
5W40
CF
CF
CF
CF
grade
API
standards
ACEA
standards
B2
B3
B3
B3
Country
Argentina
Bolivia
Paraguay
Uruguay
150/152
ESSO
ESSO UNIFLO
DIESEL
15W40 CF
ESSO ULTRA 10W40 CF
DIESEL
ACEA
standards
B2
B3
Country
Argentina
Bolivia
Brazil
Chile
Paraguay
Uruguay
TOTAL
TOTAL
QUARTZ
DIESEL 5000
TOTAL
QUARTZ
DIESEL 7000
TOTAL
QUARTZ
DIESEL 7000
TOTAL
QUARTZ 9000
grade
15W40
15W50
10W40
5W40
API
standards
CF
CF
CF
CF
ACEA
standards
B2
B3
B3
B3
B1GG0XK1 - 206
REMOVAL - REFITTING COOLANT PUMP
1 - REMOVAL
DRAIN THE COOLING SYSTEM .
REMOVE THE TIMING BELT .
Remove the 4 bolts (1) .

IMPERATIVE : do not slacken the securing bolts (2) .
Remove the coolant pump .
2 - REFITTING
IMPERATIVE : check that the centralising dowels are present on the cylinder block .
Refit the coolant pump after first coating the pipe seal (3) with grease .
Replace the 4 bolts (1) .
151/152
Tightening torque(s) :
pre-tightening : 0.4 da.Nm

tightening : 1.4 da.Nm
REFIT THE TIMING BELT .

FILL AND BLEED THE COOLING SYSTEM .
152/152

DW 10 TD

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B1BB1YK1 - 206 DW10TD ENGINE

Grinding of the joint face to - 0,2 mm (fitting of standard seal) .

Crankshaft stop thrust washers .

EURO 2000 EURO 3

EURO 2005 EURO 4

This directive specifies :

stricter limits for emission values according to homologation of exhaust pollutants

1 - 4 - APPLICATION DATES FOR PRIVATE VEHICLES

(*) except vehicles whose weight exceeds 2500 kg

(*) except vehicles whose weight exceeds 2500 kg

2 - CONFORMITY IN PRODUCTION AND WITHIN THE NETWORK

checks carried out according to the statistical rules of the directive

average exhaust emissions after a cold start

2 - 2 - CONFORMITY WITHIN THE NETWORK

(*) Parts per million .

unleaded 98 : 45 % of the market

to detect the faults of the vehicle emission control equipment

the efficiency of the catalytic converter

4 - 6 - CLEARING OF THE MANUFACTURING AND EOBD FAULT CODES

total number of operations counter

Main structure of the DW10 engine :

diesel engine with direct injection

There are 2 versions of this engine :

DW10 ATED : with air/air exchanger

(A) Identification marking comprising :

DW10 ATED DW10 TD

bore x stroke (mm)

maximum power (KW - EC)

maximum power (HP DIN)

engine speed at max. power (r.p.m.) 4000

engine speed at max. torque (r.p.m.) 2000

turbocharger pressure (2000 rpm) 1 bar(s)

in cast iron (not lined)

(5) Top half shells .

crankshaft (identical to XUD9TE engine)

crankshaft (identical to XUD7TE engine)

Front and rear sealing is by lip seals .

identical to XUD9TE engine

forged steel connecting rods

(E) : Flywheel end .

in cast iron with lamellar graphite

These pulleys are secured to the crankshaft by 1 bolt (Identical to XUD) .

6 - 1 - CYLINDER-HEAD COVER (16)

(G) : Thickness identification .

(19) Roller cam follower .

Compression phase (valve lift) (J) :

inlet (diameter 35.6 mm)

Valve stem (Diameter 5.978 mm) .

(29) crankshaft gear (21) teeth .

Timing cover in 3 sections secured by 9 bolt(s) :

(37) upper cover (4 fastening points)

replacement interval (km)

replacement interval (km)

(K) : Low pressure oil descent circuit .

(N) : Low pressure oil descent circuit .

oil capacity (with filter) 4.5

oil capacity (without

oil capacity (with filter) 4.25