Professional Documents
Culture Documents
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)
1/151
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
2/151
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
L4
W4
L5
W5
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 .
3/151
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)
01/01/2000
all models
01/01/2001
all models
petrol *
01/01/2000
01/01/2001
Diesel *
01/01/2003
01/01/2004
2 - 1 - CONFORMITY IN PRODUCTION
Conformity in production aims to check that the vehicles produced conform to the approved type .
The tests concern :
4/151
sulphur
500 ppm*
from 01/01/2000
sulphur
150 ppm*
petrol benzene
4%
benzene
1%
diesel sulphur
500 ppm*
sulphur
350 ppm*
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 :
5/151
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 :
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 .
6/151
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
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
7/151
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
8/151
3 - DATA
engine type
engine code
RHZ
unit reference
RHY
vehicle specific
number of cylinders
85 x 88
capacity (cm3)
1996
compression ratio
18/1
80
66
110
90
25
20.5
vehicle specific
yes
no
BOSCH
type
EDC 15C2
opacity of smoke (m - 1)
9/151
COMMON RAIL
specific to : vehicles
4 - CYLINDER BLOCK
Cylinder block :
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 .
10/151
DW10 TD engine :
5 - 3 - CONNECTING RODS
New connecting rods (145 mm between centres) (Identical to DW8 engine) :
5 - 4 - PISTONS
11/151
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) :
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) .
12/151
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
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
14/151
6 - 7 - TAPPETS (OPERATION)
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
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 :
16/151
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
-
160 000
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
17/151
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
4.5
4.2
tilted engine
engine code
RHY - RHZ
special features
air conditioning
RHY - RHZ
without air
conditioning
4.25
4
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
minimum pressure (bar(s))
2000 rpm
2.8
2000 rpm
2.8
check 3
minimum pressure (bar(s))
3000 rpm
3.8
3000 rpm
3.8
check 4
minimum pressure (bar(s))
4000 rpm
4
4000 rpm
4
19/151
The EGR valve (42) is secured by 2 bolts on the exhaust manifold (40) .
9 - 2 - EXHAUST GAS RECIRCULATION
20/151
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)
21/151
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 :
22/151
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 :
11 - FUEL SYSTEM
11 - 1 - PRESENTATION
This engine is fitted with a new COMMON RAIL direct injection system from BOSCH .
24/151
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
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
the bimetallic strip (63) closes the direct passage to the heating circuit: all the fuel is directed
to the filtering element
25/151
26/151
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 .
28/151
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
engine type
engine code
DW10ATED
RHZ
DW10TD
RHY
10DYAF - 10DYAG 10DYAH
10DYAJ - 10DYAK 10DYAL
10DTAR - 10DYAS 10DYAT
10DYAU - 10DYBA -
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
description
reference reference
[1]
kit
[1a]
(-).0188 - A
[1b]
(-).0188 - A
30/151
(-).0188-ZX (-).0188
fitting drift
(cone)
A2
[1c]
(-).0188 B1
(-).0188 - B
[1d]
(-).0188 B1
(-).0188 - B
[1e]
(-).0188 C1
(-).0188 - C
[1f]
(-).0188
-C1
(-).0188 - C
[1g]
(-).0188 - D (-).0188 - D
[1h]
[1i]
flywheel stop
(-).0188 - F (-).0188 - F
[1j]
(-).0188 - G -
[1k]
(-).0188 - H -
[1l]
tension lever
square 8 mm
square 7 mm
(-).0188 J1
(-).0188 J2
[1m]
(-).0188 - K -
[1n]
(-).0188 - L (-).0188 - L
[1p]
(-).0188 - M -
(-).0188 - J
description
reference reference
kit
(-).0188 ZX
[1q]
(-).0188 - N (-).0188 - N
[1r]
[1s]
(-).0188 - Q (-).0188 - Q
[1t]
(-).0188 - R (-).0188 - R
[1u]
set of plugs
(-).0188 - T (-).0188 - T
[1v]
(-).0188 - U (-).0188 - U
[1w]
(-).0188 - V (-).0188 - V
[1x]
[1y]
(-).0188 - X (-).0188 - X
[1z]
(-).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]
FACOM D360
4069-T
type
[4]
(-).0185
32/151
(-).0192
FACOM STX
14
reference
description
reference
reference
[5]
5602 - T
[6]
7004-T.F
[7]
2437-T
[8]
[9]
reference
description
(-).0113 - EZ +
1132-T
FZ
reference
reference
[10]
pipe spanner
(-).1603 -
4220-T.D
[11]
pipe spanner
(-).1603 - G
4220-T.C
33/151
reference description
[12]
reference
[13]
34/151
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
reference
description
reference
reference
[14]
crankshaft spanner
(-).0117-EZ
XXX
[15]
(-).0110-H
1754 - T bis
reference
reference
reference
[16]
35/151
description
stand
DESVIL
2509 - T
reference description
[17]
adaptor
reference
[18]
reference
reference
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
36/151
[1] - [2] - [3] Engine and/or gearbox oil leak checking kit (-).1523 (Part No. 9780.43) .
[1] Pressure release valve assembly, consisting of :
[3] Set of plugs for the engine oil vapours recirculation circuit, for the gearbox breather, consisting of
the following plugs :
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 .
38/151
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 .
39/151
Fit :
40/151
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 .
APPLY (E10) SEALING COMPOUND TO THE CORNERS AND ENDS (A) OF MAIN BEARING NO.
1.
41/151
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) .
42/151
Engage the cap/side seal assembly in the cylinder block, by tilting the assembly .
Position the main bearing on the centralising bushes .
43/151
Position :
the side stop thrust washers grooved surface in contact with the crankshaft
the bearing caps (15)
44/151
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 .
45/151
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) .
46/151
Stage 2 :
(X) = 10 mm .
Clean the checking surfaces .
FIT THE DIAL GAUGE [7] ON THE BRACKET [15] .
47/151
Fit :
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 .
49/151
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
3 - REMOVAL
Remove the front right-hand wheel .
Move aside the right-hand front mud shield .
Remove the shield under the power train .
52/151
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
53/151
54/151
55/151
Drain :
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 :
57/151
58/151
Disconnect, unclamp and remove the harnesses from the fuse box .
Move aside The clutch control .
Move aside :
59/151
Without disconnecting the hoses, move aside and clamp the power steering pump .
Remove the alternator (19) .
ALL MODELS
Remove the assembly (22) .
61/151
Remove :
62/151
Use the drifts [2] to fit the final drive oil seals, having greased the space between the seal lips .
Position the power train .
Fit :
63/151
Fit :
WARNING : centralise the power train before tightening the flexible mounting securing bolts .
Tighten :
Fit :
64/151
AIR CONDITIONING
65/151
66/151
the gearbox
the engine (if necessary)
67/151
68/151
69/151
Drain :
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 :
71/151
72/151
Disconnect, unclamp and remove the harnesses from the fuse box .
Move aside The clutch control .
Move aside :
73/151
Without disconnecting the hoses, move aside and clamp the power steering pump .
Remove the alternator (19) .
ALL MODELS
Remove the assembly (22) .
75/151
Remove :
76/151
Use the drifts [2] to fit the final drive oil seals, having greased the space between the seal lips .
Position the power train .
Fit :
77/151
Fit :
WARNING : centralise the power train before tightening the flexible mounting securing bolts .
Tighten :
Fit :
78/151
AIR CONDITIONING
79/151
80/151
3,20
3,25
2,90
3,20
3,10
3,40
capacities in litres
with filter
3,50
TUD5
4,50
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
4,25
1,70
engines
capacities in
litres
DW10TD
capacities in litres
between min and
max
dipstick
4,75
1,60
4,50
1,40
without
filter
with
filter
3,95
4,25
4,45
4,75
3,95
4,25
4,20
4,50
3,95
4,25
4,45
4,75
3,95
4,25
82/151
4,20
4,50
3,95
4,25
4,50
4,75
5,00
XU10J4RS
4,25
TU gravity draining
2,90
3,20
TU suction draining
3,25
capacities in litres
engine type
with filter
4,00
4,50
4,00
4,50
4,00
4,50
4,50
4,75
4,25
4,50
capacities in
litres
with filter
4,25
4,75
4,75
5,00
83/151
4,25
4,75
4,50
4,75
5,25
4,75
4,50
5,00
EW7J4
4,25
EW10J4
4,25
EW12J4
4,25
capacities in litres
engine type
XUD9BTF/XUD9TF air con.
with filter
4,00
4,75
5,25
4,25
4,00
DW10ATED
4,50
DW10TD
4,50
DW12TED4
4,75
capacities in litres
with filter
4,50
4,75
4,50
4,75
4,25
4,75
XU10J4R
4,25
EW10J4
4,25
84/151
806 - Diesel
engine type
capacities in litres
with filter
4,00
4,25
4,00
4,25
4,25
4,75
DW10ATED
4,50
DW10ATED4
4,75
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 :
The grade (viscosity index) must be selected in accordance with the climate of the country of use .
85/151
ESSO
ESSOLUBE
X101 10W
Part No.
9730.GA (1)
API
ACEA
standards standards
SC/CC
A2
power steering
pump
ESSO ATF D
(1)
Part No.
9730.94
units
TOTAL
CCMC/
API
standards
standards
ACEA
CD/SF
CC/SF
D2
D1
A3/B3
TOTAL
TRANSMISSION TM
vacuum pump
MULTIGRADE
(with separate
80W90
GL5
lubrication)
TOTAL
SAGINAW
TRANSMISSION TM
80W90
API
standards
units
power
steering
pump
PENTOSIN CHF
11 S
Part No. 9979.64
(1) (2)
ACEA
standards
-
ESSO
BC3
GX 80W90
ACEA
standards
SJ
A2
ATF 4HP20/AL4
Part No.
9736.22 (1) (3)
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
TM 80W90
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
ESSO
API/PEUGEOT
standards
conventional
rear axle
TOTAL
API/PEUGEOT
standards
TOTAL
TRANSMISSION TM
MULTIGRADE 80W90
(4)
GL5
TOTAL
TRANSMISSION TM
80W90
conventional
TOTAL
hypoid rear axle
TRANSMISSION X4
with limited slip
80W90
and 405 x 4
GL5
(4) if another oil has been used, drain and rinse but Never
Mix the oils
2 - 4 - SUSPENSION
units
88/151
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
API
standards
GL5
TOTAL
TOTAL TRANSMISSION TM
rear
MULTIGRADE 80W90
suspension J7
TOTAL TRANSMISSION TM
- J9
80W90
API
standards
GL5
2 - 6 - STEERING
units
ESSO
API
standards
GL5
TOTAL
API
standards
TOTAL TRANSMISSION TM
J7 - J9 steering
MULTIGRADE 80W90
systems except J9
GL5
TOTAL TRANSMISSION TM
power steering
80W90
2 - 7 - SHOCK ABSORBERS
89/151
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
TOTAL
NLGI2
NLGI standards
NLGI2
products
packagin
Part No.
g
LUNARIA-S
125 ml
(*)
9735.H8
40 ml
250 ml
9735.C8
9735.C6
40 ml
250 ml
9735.C5
9735.C4
40 ml
250 ml
9979.41
9979.40
UCON 488
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
90/151
ESSO
ESSO
UNIFLO
ESSO
ULTRA
grade
15W40
10W40
5W40
0W30
API
standards
ACEA
standards
SJ
SJ/SH EC-I A2
SJ/SH EC-I A3
SJ/SH EC-II A3
FRANCE
Great Britain
Greece
Hungary
Italy
Ireland
Luxemburg
Netherlands
Poland
Portugal
Czech
Republic
Slovakia
Switzerland
Rumania
Russia
Denmark
Finland
Norway
Sweden
ESSO
ULTRON
ESSO
5W30 ULTRON (6)
ESSO
ULTRA (6)
ESSO
UNIFLO
ESSO
ULTRA
ESSO
ULTRON
ESSO
ULTRON (6)
ESSO
ULTRA (6)
10W40
10W40
5W40
0W30
5W30
A3
specific to
Peugeot
A2
SJ
A3
SJ/SH EC-I
A3
SJ/SH EC-I
A3
SJ/SH EC-II
specific to
Peugeot
(6) this energy saving oil can only be used with engines
designed to receive it (from my 2000)
Country
FRANCE
TOTAL
API
ACEA
standards standards
TOTAL ACTIVA
5000
TOTAL ACTIVA 15W40 SJ
7000
10W40 SJ
TOTAL ACTIVA 5W40 SJ
9000
0W40
5W30 SJ EC
TOTAL ACTIVA
9000 (6)
Germany TOTAL
Austria
QUARTZ 5000
Belgium TOTAL
Belorussia QUARTZ 7000
Bosnia
TOTAL
Croatia
QUARTZ 9000
Denmark TOTAL
Estonia QUARTZ 9000
Finland
Great Britain TOTAL
Hungary QUARTZ 9000
Ireland
(6)
Italy
Latvia
91/151
grade
A2
A3
A3
specific to
Peugeot
15W40 SJ
10W40 SJ
5W40 SJ
0W40 SJ
A2
A3
A3
A3
5W30 SJ EC
specific to
Peugeot
Lithuania
Luxemburg
Macedonia
Norway
Netherlands
Poland
Czech
Republic
Russia
Slovenia
Sweden
Switzerland
Bulgaria
Cyprus
Spain
Greece
Malta
Portugal
Rumania
TOTAL
QUARTZ 5000
TOTAL
QUARTZ 7000
TOTAL
QUARTZ 7000
TOTAL
QUARTZ 9000
TOTAL
QUARTZ 9000
A2
A3
A3
A3
A3
15W40 SJ
15W50 SJ
10W40 SJ
5W40 SJ
0W40 SJ
specific to
Peugeot
5W30 SJ EC
TOTAL
QUARTZ 9000
(6)
(6) this energy saving oil can only be used with engines
designed to receive it (from my 2000)
3 - 2 - AFRICA
Country
ESSO
grade
API
standards
ACEA
standards
ESSO SUPER
20W50 SJ
A2
OIL (7)
Tunisia
15W50 SJ
A3
ESSO ULTRA
5W40 SJ/SH EC-I A3
ESSO ULTRON
(7) mineral oil(s)
Country
TOTAL
grade
API
standards
TOTAL QUARTZ
5000
20W50 SJ
all
TOTAL QUARTZ
15W50 SJ
countries 7000
5W40 SJ
TOTAL QUARTZ
9000
ACEA
standards
A2
A3
A3
3 - 3 - SOUTHERN EUROPE
Country
92/151
TOTAL
grade
API
CCMC/ACEA
standards
TOTAL
QUARTZ 5000
SJ
TOTAL
20W50
SJ
QUARTZ 7000 15W50
Turkey
SJ
TOTAL
5W40
SJ/SH ECQUARTZ 9000 0W40
II
TOTAL
QUARTZ 9000
standards
A2
A3
A3
A3
ESSO
API
standards
grade
ACEA
standards
ESSO
UNIFLO
French West
ESSO
Indies
ULTRA
Reunion
ESSO
ULTRON
15W40 SJ
A2
10W40 SJ/SH EC-I A3
5W40 SH/SH EC-I A3
Country
grade
TOTAL
TOTAL ACTIVA
5000
TOTAL ACTIVA
Caribbea
5000
n
TOTAL ACTIVA
Pacific
7000
Polynesia
TOTAL ACTIVA
Reunion
7000
TOTAL ACTIVA
9000
API
standards
20W50 SJ
15W40 SJ
15W50 SJ
10W40 SJ
5W40 SJ
ACEA
standards
A2
A2
A3
A3
A3
3 - 5 - MIDDLE EAST
Country
ESSO
grade
API
ACEA
standards standards
Bahrain
United Arab
Emirates
ESSO
Kuwait
RACING OIL 10W40 SJ/SH EC-I A3
Lebanon
(8)
Oman
Qatar
Yemen
(8) semi-synthetic oil(s)
Country
93/151
TOTAL
grade
API
ACEA
standards standards
Bahrain
United Arab
Emirates
Kuwait
Lebanon
Oman
Qatar
Yemen
Country
Iran
TOTAL
QUARTZ 5000
20W50 SJ
TOTAL
15W50 SJ
QUARTZ 7000
5W40 SJ
TOTAL
QUARTZ 9000
TOTAL
grade
API
standards
TOTAL QUARTZ
20W50 SJ
5000
A2
A3
A3
ACEA
standards
A2
3 - 6 - SOUTH-EAST ASIA
Country
ESSO
grade
API
standards
ACEA
standards
Australia
China
Korea
Hong
Kong
ESSO
India
10W40 SJ/SH EC-I A3
ULTRAFLO
Indonesia
5W40 SJ/SH EC-I A3
ESSO ULTRON
Malaysia
Singapore
Taiwan
Thailand
Vietnam
Australia ESSO
Thailand SUPERFLO
JAPAN
Hong
Kong
Country
ESSO
10W40 SJ/SH EC-I
ULTRAFLO
5W40 SJ/SH EC-I
ESSO ULTRON
5W40 SI/S4 EC-I
UNOIL GX-7
10W40 SJ/S4 EC-I
UNOIL GX-6
A2
A3
A3
A3
A2
TOTAL
20W50 SJ
grade
API
standards
20W50 SJ
15W40 SJ
15W50 SJ
10W40 SJ
5W40 SJ
ACEA
standards
A2
A2
A3
A3
A3
Thailand
9000
Vietnam
3 - 7 - SOUTH AMERICA
Country
ESSO
grade
API
standards
ACEA
standards
ESSO ULTRA
15W50 SJ
ESSO
5W40 SJ/SH EC-I
ULTRON
A3
A3
Argentin ESSO
a
UNIFLO
15W40 SJ
Bolivia ESSO ULTRA 10W40 SJ/SH EC-I
Paraguay ESSO
5W40 SJ/SH EC-I
Uruguay ULTRON
A2
A3
A3
Chile
Columbia ESSO
Ecuador ULTRON
Surinam
A3
Brazil
Country
TOTAL
grade
API
standards
TOTAL QUARTZ
5000
Argentin
TOTAL QUARTZ
a
5000
Chile
TOTAL QUARTZ
Bolivia
7000
Brazil
TOTAL QUARTZ
Paraguay
7000
Uruguay
TOTAL QUARTZ
9000
20W50 SJ
15W40 SJ
15W50 SJ
10W40 SJ
5W40 SJ
Country
grade
TOTAL
API
standards
TOTAL QUARTZ
5000
20W50 SJ
TOTAL QUARTZ
Cuba
15W50 SJ
7000
5W40 SJ
TOTAL QUARTZ
9000
ACEA
standards
A2
A2
A3
A3
A3
ACEA
standards
A2
A3
A3
ESSO
ESSO
ULTRON
grad
API
e
standards
ACEA
standards
Haiti
Honduras
Jamaica
Mexico
Panama
Puerto Rico
Dominican
Republic
Salvador
Trinidad and
Tobago
ESSO
grade
API
ACEA
standards standards
Germany
Austria
Belgium
ESSO UNIFLO
Spain
DIESEL
FRANCE
ESSO ULTRA
Great Britain
15W40 CF
DIESEL
Greece
10W40 CF
ESSO
Ireland
5W40 CF
ULTRON
Italy
5W30 DIESEL
Luxemburg
ESSO ULTRA
Netherlands
(6)
Portugal
Russia
Switzerland
B2
B3
B3
specific to
Peugeot
Hungary
Norway
Poland
Czech
Republic
Rumania
Slovakia
ESSO UNIFLO
DIESEL
15W40 CF
ESSO ULTRA
10W40 CF
DIESEL
5W30 ESSO ULTRA
(6)
B2
B3
specific to
Peugeot
Finland
ESSO ULTRA
DIESEL
10W40 CF
ESSO ULTRA 5W30 (6)
B3
specific to
Peugeot
Denmark
Sweden
(6) this energy saving oil can only be used with engines
designed to receive it (from my 2000)
Country
FRANCE
96/151
TOTAL
grade
API
ACEA
standards standards
B2
B3
TOTAL ACTIVA
DIESEL 7000
TOTAL ACTIVA 5W40 CF
DIESEL 9000
5W30 CF
TOTAL ACTIVA
9000 (6)
Germany
Austria
Belgium
Belorussia
Bosnia
Bulgaria
Cyprus
Croatia
Denmark
Spain
Estonia
Finland
TOTAL
Great
QUARTZ
Britain
DIESEL 5000
Greece
TOTAL
Hungary
QUARTZ
Ireland
DIESEL 7000
Italy
TOTAL
Latvia
QUARTZ 9000
Lithuania
TOTAL
Luxemburg
QUARTZ 9000
Macedonia
(6)
Malta
Norway
Netherlands
Poland
Portugal
Czech
Republic
Rumania
Russia
Slovenia
Sweden
Switzerland
15W40 CF
10W40 CF
5W40 CF
5W30 CF
B3
specific to
Peugeot
B2
B3
B3
specific to
Peugeot
(6) this energy saving oil can only be used with engines
designed to receive it (from my 2000)
4 - 2 - AFRICA
Country
Tunisia
ESSO
ESSO ULTRON
DIESEL
Country
97/151
TOTAL
grad
API
e
standards
ACEA
standards
5W40 CF
B3
grade
API
ACEA
standards standards
TOTAL QUARTZ
DIESEL 5000
15W40 CF
all
TOTAL QUARTZ
15W50 CF
countries DIESEL 7000
5W40 CF
TOTAL QUARTZ
9000
B2
B3
B3
4 - 3 - SOUTHERN EUROPE
Country
TOTAL
TOTAL QUARTZ
DIESEL 5000
TOTAL QUARTZ
Turkey
DIESEL 7000
TOTAL QUARTZ
9000
grade
API
standards
15W40 CF
15W50 CF
5W40 CF
ACEA
standards
B2
B3
B3
ESSO
grade
API
ACEA
standards standards
ESSO UNIFLO
DIESEL
French West
15W40 CF
ESSO ULTRA
Indies
10W40 CF
DIESEL
Reunion
5W40 CF
ESSO ULTRON
DIESEL
Country
TOTAL
TOTAL ACTIVA
DIESEL 5000
Caribbea
TOTAL ACTIVA
n
DIESEL 7000
Pacific
TOTAL ACTIVA
Polynesia
DIESEL 7000
Reunion
TOTAL ACTIVA
DIESEL 9000
grade
B2
B3
B3
API
ACEA
standards standards
15W40 CF
15W50 CF
10W40 CF
5W40 CF
B2
B3
B3
B3
4 - 5 - MIDDLE EAST
Country
Bahrain
United Arab
Emirates
Kuwait
Lebanon
98/151
TOTAL
grade
API
ACEA
standards standards
B2
B3
B3
Oman
Qatar
Yemen
9000
4 - 6 - SOUTH-EAST ASIA
Country
TOTAL
China
India
TOTAL QUARTZ
Indonesi
DIESEL 5000
a
TOTAL QUARTZ
JAPAN
DIESEL 7000
Malaysia
TOTAL QUARTZ
Singapor
DIESEL 7000
e
TOTAL QUARTZ
Taiwan
9000
Thailand
Vietnam
grade
API
ACEA
standards standards
15W40 CF
15W50 CF
10W40 CF
5W40 CF
B2
B3
B3
B3
4 - 7 - SOUTH AMERICA
Country
ESSO
Argentin
ESSO UNIFLO
a
DIESEL
Bolivia
ESSO ULTRA
Paraguay
DIESEL
Uruguay
Country
TOTAL
TOTAL QUARTZ
Argentin
DIESEL 5000
a
TOTAL QUARTZ
Bolivia
DIESEL 7000
Brazil
TOTAL QUARTZ
Chile
DIESEL 7000
Paraguay
TOTAL QUARTZ
Uruguay
9000
grade
API
standards
15W40 CF
10W40 CF
grade
ACEA
standards
B2
B3
API
ACEA
standards standards
15W40 CF
15W50 CF
10W40 CF
5W40 CF
B2
B3
B3
B3
Remove :
Remove :
the nipple (16)
101/151
the alternator
the diesel filter support (17)
the accessory bracket (18)
the oil vapours breather tube (19)
103/151
104/151
105/151
Remove :
106/151
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 :
Remove :
108/151
IMPERATIVE : mark the location of the big end caps and main bearings .
Remove :
Recover the end float adjusting shims on the main bearing (no. 2) .
109/151
Remove :
Fit :
Remove :
NOTE : the gudgeon pins are paired with the pistons, do not mix the components .
110/151
Remove :
111/151
the seal
the collar (3) (specific to Service)
112/151
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
113/151
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
114/151
front wings
driver's seat
mat (on the driver's side)
steering wheel
2 - REMOVAL
Disconnect the battery .
Remove :
115/151
116/151
Remove :
IMPERATIVE : open the sachet containing the new filter element just before refitting .
Fit :
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) .
118/151
Apply pressure to the cover (4) and simultaneously slacken a quarter turn .
Remove :
C5BG00F1 - 206
REMOVAL - REFITTING FUEL CAP COVER
1 - REMOVAL
Remove the fuel cap .
Remove the key .
119/151
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
120/151
Brush [3] .
Cleaning tray [4] .
2 - REMOVAL
Disconnect the battery .
Remove the shield under the power train .
121/151
122/151
Remove :
123/151
Fit :
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 .
124/151
front wings
driver's seat
mat (on the driver's side)
steering wheel
2 - REMOVAL
Remove the style cover .
Disconnect the battery .
125/151
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) .
126/151
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] .
127/151
128/151
distance
nominal (mm)
53,7
+ 0,008
- 0,005
28
+ 0,02
- 0,007
30,2
+ 0,021
0
145
0,025
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
129/151
piston rings
(1) upper
(2) lower
(3) scraper
sealing ring compression ring
ring
clearance at the
0,2 to 0,35
gap (mm)
0,8 to 1
0,25 to 0,5
yellow
mauve
colour
mauve
130/151
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
131/151
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
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
nominal
distance (mm)
20,8
37 / 26
27,7 / 45,5
132/151
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
133/151
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
nominal (mm)
B
0
- 0,013
27
repair 1 (mm)
26,8
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
144
1,100
89
0,320
76
0,150
vehicles
end-piece diameter
(mm)
14
106
14
306 - 406
14
TUD5
106
16
XU7JB
406
14
XU7JP4
306 - 406
14
14
XU10J4RS
306 S16
14
DJ
BOXER
16
DK
605
16
ES9J4
406 - 605
14
ES9J4S
406 - 607
14
EW7
406
14
EW10
14
EW12
406 - 607
14
DW8
206 - 306
PARTNER - EXPERT
14
DW10
14
DW12
406 - 607
14
TU5J4
TU5JP4
XU10J4R
2 - APPROVED EQUIPMENT
135/151
B1FB0IK1 - 206
RECOMMENDATIONS LUBRICANTS
1 - OIL QUALITIES
The engine lubrication oils are categorised in accordance with 3 quality levels :
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 :
The grade (viscosity index) must be selected in accordance with the climate of the country of use .
136/151
ESSO
ESSOLUBE
KF - KF1 - KF2 - KF6 X101 10W
KF5 - XN2 petrol
Part No.
injection pump
9730.GA (1)
API
ACEA
standards standards
SC/CC
A2
ESSO ATF D
(1)
power steering pump
Part No.
9730.94
units
TOTAL
API
CCMC/
standard standards
s
ACEA
GL5
D2
D1
A3/B3
-
TRANSMISSION TM
MULTIGRADE
(with separate
80W90
lubrication)
TOTAL
SAGINAW
TRANSMISSION TM
80W90
power steering
TOTAL FLUIDE AT42 pump
API
standards
units
power
steering
pump
PENTOSIN CHF
11 S
Part No. 9979.64
(1) (2)
ACEA
standards
-
ESSO
BC3
GX 80W90
API
ACEA
standards standards
SJ
A2
ATF 4HP20/AL4
4HP20/AL4
Part No. 9736.22 automatic gearbox
(1) (3)
TOTAL
TM 80W90
API
ACEA
standards standards
SJ/CF
A3/B3
TOTAL
manual gearbox
TRANSMISSION BV specific to
MA-BE-ME-ML75W80
Peugeot
BA7-BA10
(4) new formula
TOTAL
405 x 4 transfer
TRANSMISSION X4 GL5
box
80W90
(4) if another oil has been used, drain and rinse but Never
Mix the oils
API/PEUGEOT
standards
ESSO
conventional
rear axle
API/PEUGEOT
standards
TOTAL
TOTAL
TRANSMISSION TM
MULTIGRADE 80W90
(4)
GL5
TOTAL
TRANSMISSION TM
80W90
conventional
TOTAL
hypoid rear axle
TRANSMISSION X4
with limited slip
80W90
and 405 x 4
GL5
(4) if another oil has been used, drain and rinse but Never
Mix the oils
2 - 4 - SUSPENSION
units
hydraulic
suspension
units
139/151
ESSO
ESSO LHM
EXTRA
TOTAL
API/PEUGEOT
standards
specific to Peugeot
API/PEUGEOT
standards
hydraulic
suspension
TOTAL LHM
PLUS
specific to Peugeot
2 - 5 - REAR SUSPENSION
units
API
standards
ESSO
GL5
API
standards
TOTAL
TOTAL TRANSMISSION TM
rear
MULTIGRADE 80W90
suspension J7
TOTAL TRANSMISSION TM
- J9
80W90
GL5
2 - 6 - STEERING
units
API
standards
ESSO
GL5
TOTAL
API
standards
TOTAL TRANSMISSION TM
J7 - J9 steering
MULTIGRADE 80W90
systems except J9
GL5
TOTAL TRANSMISSION TM
power steering
80W90
2 - 7 - SHOCK ABSORBERS
units
front shock
absorbers
ESSO
API standards
ESSO OLEOFLUID PA
specific to
(1)
Peugeot
Part No. 9730.27
2 - 8 - MECHANICAL UNITS
units
NLGI
standards
ESSO
TOTAL
NLGI2
NLGI standards
NLGI2
products
packagin
Part No.
g
LUNARIA-S
125 ml
(*)
9735.H8
40 ml
250 ml
9735.C8
9735.C6
40 ml
250 ml
9735.C5
9735.C4
40 ml
250 ml
9979.41
9979.40
UCON 488
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
Great Britain
Greece
Hungary
Italy
Ireland
Luxemburg
141/151
ESSO
ESSO
UNIFLO
ESSO
ULTRA
ESSO
ULTRON
ESSO
ULTRON (6)
ESSO
ULTRA (6)
grade
15W40
10W40
5W40
0W30
5W30
API
standards
ACEA
standards
SJ
SJ/SH EC-I A2
SJ/SH EC-I A3
SJ/SH EC-II A3
A3
specific to
Peugeot
Netherlands
Poland
Portugal
Czech
Republic
Slovakia
Switzerland
Rumania
Russia
Denmark
Finland
Norway
Sweden
ESSO
UNIFLO
ESSO
ULTRA
ESSO
ULTRON
ESSO
ULTRON (6)
ESSO
ULTRA (6)
10W40
10W40
5W40
0W30
5W30
A2
SJ
A3
SJ/SH EC-I
A3
SJ/SH EC-I
A3
SJ/SH EC-II
specific to
Peugeot
(6) this energy saving oil can only be used with engines
designed to receive it (from my 2000)
Country
FRANCE
TOTAL
API
ACEA
standards standards
TOTAL ACTIVA
5000
TOTAL ACTIVA 15W40 SJ
7000
10W40 SJ
TOTAL ACTIVA 5W40 SJ
9000
0W40
5W30 SJ EC
TOTAL ACTIVA
9000 (6)
Germany TOTAL
Austria
QUARTZ 5000
Belgium TOTAL
Belorussia QUARTZ 7000
Bosnia
TOTAL
Croatia
QUARTZ 9000
Denmark TOTAL
Estonia QUARTZ 9000
Finland
Great Britain TOTAL
Hungary QUARTZ 9000
Ireland
(6)
Italy
Latvia
Lithuania
Luxemburg
Macedonia
Norway
Netherlands
Poland
Czech
142/151
grade
A2
A3
A3
specific to
Peugeot
15W40 SJ
10W40 SJ
5W40 SJ
0W40 SJ
A2
A3
A3
A3
5W30 SJ EC
specific to
Peugeot
Republic
Russia
Slovenia
Sweden
Switzerland
Bulgaria
Cyprus
Spain
Greece
Malta
Portugal
Rumania
TOTAL
QUARTZ 5000
TOTAL
QUARTZ 7000
TOTAL
QUARTZ 7000
TOTAL
QUARTZ 9000
TOTAL
QUARTZ 9000
A2
A3
A3
A3
A3
15W40 SJ
15W50 SJ
10W40 SJ
5W40 SJ
0W40 SJ
specific to
Peugeot
5W30 SJ EC
TOTAL
QUARTZ 9000
(6)
(6) this energy saving oil can only be used with engines
designed to receive it (from my 2000)
3 - 2 - AFRICA
Country
ESSO
grade
API
standards
ACEA
standards
ESSO SUPER
20W50 SJ
A2
OIL (7)
Tunisia
15W50 SJ
A3
ESSO ULTRA
5W40 SJ/SH EC-I A3
ESSO ULTRON
(7) mineral oil(s)
Country
TOTAL
grade
API
standards
TOTAL QUARTZ
5000
20W50 SJ
all
TOTAL QUARTZ
15W50 SJ
countries 7000
5W40 SJ
TOTAL QUARTZ
9000
ACEA
standards
A2
A3
A3
3 - 3 - SOUTHERN EUROPE
Country
TOTAL
grade
API
standards
Turkey TOTAL
20W50 SJ
QUARTZ 5000 15W50 SJ
TOTAL
5W40 SJ
QUARTZ 7000 0W40 SJ/SH ECTOTAL
II
143/151
CCMC/ACEA
standards
A2
A3
A3
A3
QUARTZ 9000
TOTAL
QUARTZ 9000
ESSO
API
standards
grade
ACEA
standards
ESSO
UNIFLO
French West
ESSO
Indies
ULTRA
Reunion
ESSO
ULTRON
15W40 SJ
A2
10W40 SJ/SH EC-I A3
5W40 SH/SH EC-I A3
Country
grade
TOTAL
TOTAL ACTIVA
5000
TOTAL ACTIVA
Caribbea
5000
n
TOTAL ACTIVA
Pacific
7000
Polynesia
TOTAL ACTIVA
Reunion
7000
TOTAL ACTIVA
9000
API
standards
20W50 SJ
15W40 SJ
15W50 SJ
10W40 SJ
5W40 SJ
ACEA
standards
A2
A2
A3
A3
A3
3 - 5 - MIDDLE EAST
Country
ESSO
grade
API
ACEA
standards standards
Bahrain
United Arab
Emirates
ESSO
Kuwait
RACING OIL 10W40 SJ/SH EC-I A3
Lebanon
(8)
Oman
Qatar
Yemen
(8) semi-synthetic oil(s)
Country
Bahrain
United Arab
Emirates
Kuwait
Lebanon
Oman
144/151
TOTAL
grade
API
ACEA
standards standards
TOTAL
20W50 SJ
QUARTZ 5000 15W50 SJ
TOTAL
5W40 SJ
QUARTZ 7000
TOTAL
QUARTZ 9000
A2
A3
A3
Qatar
Yemen
Country
Iran
TOTAL
grade
API
standards
TOTAL QUARTZ
20W50 SJ
5000
ACEA
standards
A2
3 - 6 - SOUTH-EAST ASIA
Country
ESSO
grade
API
standards
ACEA
standards
Australia
China
Korea
Hong
Kong
ESSO
India
10W40 SJ/SH EC-I A3
ULTRAFLO
Indonesia
5W40 SJ/SH EC-I A3
ESSO ULTRON
Malaysia
Singapore
Taiwan
Thailand
Vietnam
Australia ESSO
Thailand SUPERFLO
JAPAN
Hong
Kong
Country
ESSO
10W40 SJ/SH EC-I
ULTRAFLO
5W40 SJ/SH EC-I
ESSO ULTRON
5W40 SI/S4 EC-I
UNOIL GX-7
10W40 SJ/S4 EC-I
UNOIL GX-6
A2
A3
A3
A3
A2
TOTAL
China
TOTAL QUARTZ
India
5000
Indonesi
TOTAL QUARTZ
a
5000
JAPAN
TOTAL QUARTZ
Malaysia
7000
Singapor
TOTAL QUARTZ
e
7000
Taiwan
TOTAL QUARTZ
Thailand
9000
Vietnam
3 - 7 - SOUTH AMERICA
145/151
20W50 SJ
grade
API
standards
20W50 SJ
15W40 SJ
15W50 SJ
10W40 SJ
5W40 SJ
ACEA
standards
A2
A2
A3
A3
A3
Country
ESSO
grade
API
standards
ACEA
standards
ESSO ULTRA
15W50 SJ
ESSO
5W40 SJ/SH EC-I
ULTRON
A3
A3
Argentin ESSO
a
UNIFLO
15W40 SJ
Bolivia ESSO ULTRA 10W40 SJ/SH EC-I
Paraguay ESSO
5W40 SJ/SH EC-I
Uruguay ULTRON
A2
A3
A3
Chile
Columbia ESSO
Ecuador ULTRON
Surinam
A3
Brazil
Country
TOTAL
grade
API
standards
TOTAL QUARTZ
5000
Argentin
TOTAL QUARTZ
a
5000
Chile
TOTAL QUARTZ
Bolivia
7000
Brazil
TOTAL QUARTZ
Paraguay
7000
Uruguay
TOTAL QUARTZ
9000
20W50 SJ
15W40 SJ
15W50 SJ
10W40 SJ
5W40 SJ
Country
grade
TOTAL
API
standards
TOTAL QUARTZ
5000
20W50 SJ
TOTAL QUARTZ
Cuba
15W50 SJ
7000
5W40 SJ
TOTAL QUARTZ
9000
ACEA
standards
A2
A2
A3
A3
A3
ACEA
standards
A2
A3
A3
ESSO
ESSO
ULTRON
grad
API
e
standards
ACEA
standards
Dominican
Republic
Salvador
Trinidad and
Tobago
ESSO
grade
API
ACEA
standards standards
Germany
Austria
Belgium
ESSO UNIFLO
Spain
DIESEL
FRANCE
ESSO ULTRA
Great Britain
15W40 CF
DIESEL
Greece
10W40 CF
ESSO
Ireland
5W40 CF
ULTRON
Italy
5W30 DIESEL
Luxemburg
ESSO ULTRA
Netherlands
(6)
Portugal
Russia
Switzerland
B2
B3
B3
specific to
Peugeot
Hungary
Norway
Poland
Czech
Republic
Rumania
Slovakia
ESSO UNIFLO
DIESEL
15W40 CF
ESSO ULTRA
10W40 CF
DIESEL
5W30 ESSO ULTRA
(6)
B2
B3
specific to
Peugeot
Finland
ESSO ULTRA
DIESEL
10W40 CF
ESSO ULTRA 5W30 (6)
B3
specific to
Peugeot
Denmark
Sweden
(6) this energy saving oil can only be used with engines
designed to receive it (from my 2000)
Country
TOTAL
FRANCE
TOTAL ACTIVA
DIESEL 5000
TOTAL ACTIVA
DIESEL 7000
TOTAL ACTIVA
DIESEL 9000
TOTAL ACTIVA
9000 (6)
147/151
grade
API
ACEA
standards standards
15W40 CF
10W40 CF
5W40 CF
5W30 CF
B2
B3
B3
specific to
Peugeot
Germany
Austria
Belgium
Belorussia
Bosnia
Bulgaria
Cyprus
Croatia
Denmark
Spain
Estonia
Finland
TOTAL
Great
QUARTZ
Britain
DIESEL 5000
Greece
TOTAL
Hungary
QUARTZ
Ireland
DIESEL 7000
Italy
TOTAL
Latvia
QUARTZ 9000
Lithuania
TOTAL
Luxemburg
QUARTZ 9000
Macedonia
(6)
Malta
Norway
Netherlands
Poland
Portugal
Czech
Republic
Rumania
Russia
Slovenia
Sweden
Switzerland
15W40 CF
10W40 CF
5W40 CF
5W30 CF
B2
B3
B3
specific to
Peugeot
(6) this energy saving oil can only be used with engines
designed to receive it (from my 2000)
4 - 2 - AFRICA
Country
Tunisia
ESSO
ESSO ULTRON
DIESEL
Country
TOTAL
grad
API
e
standards
5W40 CF
B3
grade
API
ACEA
standards standards
TOTAL QUARTZ
DIESEL 5000
15W40 CF
all
TOTAL QUARTZ
15W50 CF
countries DIESEL 7000
5W40 CF
TOTAL QUARTZ
9000
148/151
ACEA
standards
B2
B3
B3
4 - 3 - SOUTHERN EUROPE
Country
TOTAL
TOTAL QUARTZ
DIESEL 5000
TOTAL QUARTZ
Turkey
DIESEL 7000
TOTAL QUARTZ
9000
grade
API
standards
15W40 CF
15W50 CF
5W40 CF
ACEA
standards
B2
B3
B3
ESSO
grade
API
ACEA
standards standards
ESSO UNIFLO
DIESEL
French West
15W40 CF
ESSO ULTRA
Indies
10W40 CF
DIESEL
Reunion
5W40 CF
ESSO ULTRON
DIESEL
Country
TOTAL
TOTAL ACTIVA
DIESEL 5000
Caribbea
TOTAL ACTIVA
n
DIESEL 7000
Pacific
TOTAL ACTIVA
Polynesia
DIESEL 7000
Reunion
TOTAL ACTIVA
DIESEL 9000
grade
B2
B3
B3
API
ACEA
standards standards
15W40 CF
15W50 CF
10W40 CF
5W40 CF
B2
B3
B3
B3
4 - 5 - MIDDLE EAST
Country
Bahrain
United Arab
Emirates
Kuwait
Lebanon
Oman
Qatar
Yemen
TOTAL
grade
API
ACEA
standards standards
TOTAL QUARTZ
DIESEL 5000
15W40 CF
TOTAL QUARTZ
15W50 CF
DIESEL 7000
5W40 CF
TOTAL QUARTZ
9000
B2
B3
B3
4 - 6 - SOUTH-EAST ASIA
Country
149/151
TOTAL
grade
API
ACEA
standards standards
China
India
TOTAL QUARTZ
Indonesi
DIESEL 5000
a
TOTAL QUARTZ
JAPAN
DIESEL 7000
Malaysia
TOTAL QUARTZ
Singapor
DIESEL 7000
e
TOTAL QUARTZ
Taiwan
9000
Thailand
Vietnam
15W40 CF
15W50 CF
10W40 CF
5W40 CF
B2
B3
B3
B3
4 - 7 - SOUTH AMERICA
Country
ESSO
Argentin
ESSO UNIFLO
a
DIESEL
Bolivia
ESSO ULTRA
Paraguay
DIESEL
Uruguay
Country
TOTAL
TOTAL QUARTZ
Argentin
DIESEL 5000
a
TOTAL QUARTZ
Bolivia
DIESEL 7000
Brazil
TOTAL QUARTZ
Chile
DIESEL 7000
Paraguay
TOTAL QUARTZ
Uruguay
9000
grade
API
standards
15W40 CF
10W40 CF
grade
B1GG0XK1 - 206
REMOVAL - REFITTING COOLANT PUMP
150/151
B2
B3
API
ACEA
standards standards
15W40 CF
15W50 CF
10W40 CF
5W40 CF
1 - REMOVAL
ACEA
standards
B2
B3
B3
B3
151/151