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B1BBM7K1406D9EW10J4ENGINEENGINEINTRODUCTION1DESCRIPTIONNEWENGINEEW10J4ENGINEEWENGINESAREPROGRESSIVELYREPLACINGXUENGINESSPECIALFEATURES4CYLINDERSINLINE16VALVES2OVERHEADCAMSHAFTSDRIVENBYTOOTHEDTIMINGBELTMULTIPOINTINJECTIONSYSTEMENGINEWITHREDUCEDFUELCONSUMPTIONRAISEDOUTPUTNOTETHEENGINEISPREPAREDFORFUTUREEMISSIONCONTROLSTANDARDSTHEENGINEOUTPUTISIMPROVEDDUETOTHEFOLLOWINGFACTORSREDUCTIONOFMECHANICALLOSSESREDUCTIONOFWEIGHTOPTIMISATIONOFINDUCTIONANDEXHAUSTDUCTSCONTROLLEDEXHAUSTGASRECIRCULATIONVALVEREDUCTIONINFUELCONSUMPTION11POWERTRAININSTALLATIONTHENEWCRASHPROTECTIONSTANDARDSIMPOSEACORRECTIONTOTHEINCLINATIONOFTHEPOWERTRAININTHEFRONTSECTIONFORNEWVEHICLESHOMOLOGATEDFROM199812DATAENGINETYPEPLATEALEGISLATIONTYPEBUNITREFERENCECBUILDORDERNUMBER2DATAENGINETYPEEW10J4LEGISLATIONTYPERFRUNITREFERENCEVEHICLESPECIFICNUMBEROFCYLINDERS4BOREXSTROKEMM85X88CAPACITYCM31997COMPRESSIONRATIO10,8MAXIMUMPOWEREC99KWMAXIMUMPOWERHPDIN138ENGINESPEEDATMAXPOWERRPM6000RPMMAXIMUMTORQUEEC19DANMENGINESPEEDATMAXIMUMTORQUERPM4100RPMINJECTIONSYSTEMMULTIPOINTMAKEMAGNETIMARELLITYPEMMDCM48P3CYLINDERBLOCKASSEMBLY1CYLINDERBLOCK2CRANKSHAFTBEARINGCAPCASING3SUMP4OILPUMP5CASTIRONCYLINDERLINERSTHELIGHTALLOYCYLINDERBLOCKHASCASTIRONLINERSFITTEDONASSEMBLYFOUNDRYTHELINERSAREOFTHEDRYTYPELIGHTALLOYCRANKCASEINCORPORATING5CASTIRONMAINBEARINGCAPSSPECIALFEATURESBORE85MMNUMBEROFMAINBEARINGS5THECOOLANTDRAINPLUGISINTHEREARFACETHESUMPISNEW,WITHSTIFFENINGRIBSTOIMPROVETHERIGIDITYOFTHECONNECTIONTOTHEGEARBOXNOTENO1CYLINDERFLYWHEELENDTHESEALINGBETWEENTHEFOLLOWINGCOMPONENTSISENSUREDBYSEALINGCOMPOUNDCYLINDERBLOCKBEARINGCAPCOVERSUMP4CRANKSHAFTANDCONNECTINGRODS6CRANKSHAFT7COMPRESSIONRING8LOWERSEALINGRING9SCRAPERRING10PISTON11GUDGEONPIN12CONNECTINGROD13BIGENDBEARINGSHELL14CRANKSHAFTENDFLOATWASHERS15TOPHALFSHELLS16LOWERHALFSHELLDLUBRICATIONHOLE41CRANKSHAFTNEWCRANKSHAFTMATERIALCASTIRONLIGHTERCOUNTERWEIGHTSNUMBEROFMAINBEARINGS5NUMBEROFCOUNTERWEIGHTS8CRANKSHAFTSEALEDBYALIPSEALCRANKSHAFTENDFLOATTHEENDFLOATSHOULDBE0,06TO0,15MMTHEENDFLOATISDETERMINEDBY2HALFWASHERSONMAINBEARINGNO22CYLINDERBLOCKSIDE42CRANKSHAFTHALFSHELLS6CRANKSHAFT1CYLINDERBLOCKEMARKINGOFCATEGORYOFMAINBEARINGSTOCRANKSHAFTPAINTBARCODEUSEDINPLANTMARKINGOFDIAMETERCATEGORYMAINBEARING1TOMAINBEARING5FMARKINGOFCATEGORYOFMAINBEARINGSTOCYLINDERBLOCKCOLDSTAMPEDINSCRIPTIONMARKINGOFDIAMETERCATEGORYMAINBEARING1TOMAINBEARING5FACTORYMARKINGSTHECRANKSHAFTBEARINGSCYLINDERBLOCKMAINBEARINGCAPSANDTHECRANKSHAFTJOURNALSAREMATCHEDBYREFERENCESONTHECYLINDERBLOCKANDTHECRANKSHAFTMATCHINGISBYMEANSOF4CLASSESOFSMOOTHHALFSHELLSSELECTIONOFTHEAPPROPRIATEHALFSHELLISBYMEANSOFAMATCHINGTABLESEECORRESPONDINGOPERATIONWITHTHEMARKINGSEANDFSMOOTHHALFSHELLSONTHEMAINBEARINGCAPSIDEGROOVEDHALFSHELLSCYLINDERBLOCKSIDENOTETHEREISONLYONECATEGORYOFUPPERHALFSHELL43CONNECTINGRODSCONNECTINGRODSMATERIALFORGEDSTEELDISTANCEBETWEENCENTRES139MMTHEBIGENDHALFSHELLSARESMOOTHTHEHALFSHELLSHAVEALOCATINGLUGNUMBEROFWEIGHTCATEGORIES4THEGUDGEONPINSAREFITTEDTIGHTINTHECONNECTINGRODS,ANDFREEINTHEPISTONSTHEHALFSHELLSAREIDENTIFIEDBYADABOFPAINTONTHEEDGETHECONNECTINGRODSAREDRILLEDTOLUBRICATETHEBASEOFTHELINERNOTETHEBIGENDHALFSHELLSTOPANDBOTTOMAREDRILLED44CONNECTINGRODHALFSHELLS6CRANKSHAFT12CONNECTINGRODGCRANKSHAFTMARKINGABCDBARCODEUSEDINPLANTDIAMETERCATEGORYMARKINGCRANKPIN1TOCRANKPIN5HMARKINGONTHECONNECTINGRODCOLDSTAMPEDINSCRIPTIONWEIGHTCATEGORYMARKINGXXDIAMETERCATEGORYMARKINGAFACTORYMARKINGSXTHEBIGENDSANDCRANKPINSAREMATCHEDBYREFERENCESMATCHINGISBYUSING3CATEGORIESOFLOWERHALFSHELLSNOTETHEREISONLYONECATEGORYOFUPPERHALFSHELLTHEHALFSHELLSAREIDENTIFIEDBYADABOFPAINTONTHEEDGESELECTIONOFTHEAPPROPRIATEHALFSHELLISBYMEANSOFAMATCHINGTABLESEECORRESPONDINGOPERATIONWITHTHEMARKINGSGANDH45PISTONSMATERIALLIGHTALLOYTHEREISONLYONEPISTONDIAMETERCATEGORYPRODUCTIONSIZETHEREISONLYONEPISTONDIAMETERCATEGORYREPAIRSIZE46PISTONRINGSTHEPISTONHAS3RINGSUPPERSEALINGRINGTHICKNESS1,2MMLOWERSEALINGRINGTHICKNESS1,5MMSCRAPERRINGTHICKNESS2,5MM47FLYWHEELFLYWHEELVEHICLESPECIFICMATERIALCASTIRONFRICTIONPLATEDIAMETER230MMTHEEDGEOFTHEFLYWHEELHAS60TEETHOFWHICH2HAVEBEENOMITTEDTODETERMINETOPDEADCENTREASPECIALTOOL0189CENABLESIMMOBILISATIONOFTHECRANKSHAFTBYAHOLEDRILLEDINTHECYLINDERBLOCKANDFLYWHEEL48THEANCILLARYDRIVEPULLEYSPECIALFEATURESSECUREDTOTHECRANKSHAFTBY4BOLTSDAMPEDHUBWITHDECLUTCHINGINTORSIONSTAGE5CYLINDERHEADASSEMBLY17CYLINDERHEADCOVERCOMPOSITEMATERIALS18CAMSHAFTBEARINGCAPCOVER19CYLINDERHEADIEXHAUSTGASRECIRCULATIONCHANNELSCASTINTOTHECYLINDERHEADFOUNDRYJCYLINDERHEADIDENTIFICATIONBOSS51CYLINDERHEADCOVERTWOCYLINDERHEADCOVERSTOPCYLINDERHEADCOVERWITHANOILDRAINANDOILFILLEROPENINGMATERIALCOMPOSITEMATERIALSTHEOILFILLERHOLEISINCORPORATEDINTHECYLINDERHEADCOVERTHESEALISPREFORMEDANDREMOVABLENOTETIGHTENINGISINASPIRALSEQUENCE52CAMSHAFTBEARINGCASTINGMATERIALALUMINIUMALLOYSEALINGBETWEENCAMSHAFTBEARINGCAPCASINGANDCYLINDERHEADSEALINGCOMPOUNDINSERVICEUSEAUTOJOINTORSEALINGCOMPOUNDTHECAMSHAFTENDFLOATISCONTROLLEDATNO5CYLINDERHEADBEARINGBEARINGNO1,FLYWHEELENDNOTETIGHTENINGISINASPIRALSEQUENCE53CYLINDERHEAD4VALVESPERCYLINDER2INLET,2EXHAUSTWITHCLEARANCEADJUSTMENTBYHYDRAULICTAPPETSHEIGHTOFNEWCYLINDERHEAD137MMEXHAUSTVALVEGUIDESSINTEREDSTEEL0,2MMMAXIMUMPERMISSIBLEBOW0,03MMTHEVALVESEATSANDGUIDESARENEWANDMADEFROMSINTEREDSTEELMAXIMUMALLOWABLEMACHININGINLETVALVEGUIDEBRASSNOTETIGHTENINGISINASPIRALSEQUENCEPARTOFTHEEXHAUSTGASRECIRCULATIONCHANNELSISINCORPORATEDINTHECYLINDERHEAD54CAMSHAFT20CAMSHAFT21ROTORDRIVENBYTHECAMSHAFTNEWCASTIRONCAMSHAFTSWITH8CAMSAND5BEARINGSTHECAMSHAFTREFERENCECYLINDERSENSORROTORISFITTEDTOTHEEXHAUSTCAMSHAFTTHECAMSHAFTBEARINGSAREPRESSURELUBRICATEDANDTHECAMSBYOILBATHNOTETHEROTOR21ISNOTREMOVABLE55CYLINDERHEADGASKET22CYLINDERHEADGASKETKENGINEIDENTIFICATIONHOLELMACHINEDCYLINDERHEADGASKETIDENTIFICATIONSPECIALFEATURESNUMBEROFCATEGORIES1THICKNESS0,8MMTYPELAMINATEDMETALGASKET3LAYERS56HYDRAULICTAPPETTHEHYDRAULICTAPPETSAUTOMATICALLYADJUSTVALVECLEARANCEDESIGNIDENTICALTOTHETAPPETSUSEDINTHEXUENGINESDIAMETER28,4MM57VALVESINLETVALVE33,3MMEXHAUSTVALVE29MMVALVESTEMSEAL6MMVALVESTEMSEALWITHINTEGRALCUP58VALVESPRINGSSPECIALFEATURESCONICALSHAPEMARKPAINTMARKSEXTERNALDIAMETER126,7MMEXTERNALDIAMETER215,1MM6TIMING23SECURINGBOLTS25CAMSHAFTGEAREXHAUST26CAMSHAFTGEARINLET27DYNAMICTENSIONERROLLER28ROLLERTENSIONER29CRANKSHAFTGEAR30COOLANTPUMPGEARTHETIMINGCOVERISCOMPOSEDOFTHEFOLLOWING2COMPONENTS24THETOPTIMINGCOVER5FASTENINGPOINTS31THEBOTTOMTIMINGCOVER5FASTENINGPOINTS61TIMINGBELTLEGISLATIONTYPERFRENGINETYPEEW10J4WIDTHMM25,4MMNUMBEROFTEETH153MATERIALHSNMANUFACTURERGATESIDENTIFICATIONMARKINGSREPLACEMENTINTERVALWITHNORMALUSEREFERTOTHEMAINTENANCESCHEDULE62CAMSHAFTGEAR25CAMSHAFTGEAR32CAMSHAFTHUB33SETTINGHOLE34OBLONGHOLETHECAMSHAFTISSETTHROUGHTHEHUBS32KEYEDTOTHECAMSHAFTSTHEGEARSAREATTACHEDTOTHEIRHUBSBY3BOLTSWHENTHE3FASTENINGBOLTSARESLACKENED,THEGEARSAREFREETOROTATEWITHINTHELIMITSOFTHEOBLONGHOLESTHISTYPEOFASSEMBLYMAKESPOSSIBLEIMPROVEDACCURACYOFTIMINGBETTERDISTRIBUTIONOFBELTTENSIONBETWEENTHEDIFFERENTRUNSCAMSHAFTHUBIDENTIFICATIONSTAMPINGONTHECAMSHAFTHUBREFERENCENUMBER7LUBRICATIONPRESSURELUBRICATIONBYANINTERNALLYDRIVENDUALECCENTRICROTORPUMPTHEOILFILTERCARTRIDGEISSEPARATEFROMTHECYLINDERBLOCK71OILPUMP4OILPUMP35OILPUMPEXTERNALROTOR36OILPUMPINTERNALROTOR6CRANKSHAFTMFLATSTHEOILPUMPISDRIVENFROMTHEENDOFTHECRANKSHAFTBYMEANSOFTWOFLATSMRELIEFVALVESETTING7BARS72OILCAPACITYENGINEEW10J4SPECIALFEATURESWITHOUTOILCAPACITYWITHREPLACEMENTOFTHEOILFILTER425LITRESOILCAPACITY,DRAINAGEBYSUCTIONWITHREPLACEMENTOFFILTERCARTRIDGEOILCAPACITYWITHOUTREPLACEMENTOFTHEOILFILTER40LITRESCAPACITYBETWEENMINANDMAXONTHEDIPSTICKALWAYSCHECKTHEOILLEVELUSINGTHEDIPSTICKCAPACITYBETWEENMINANDMAXONTHEDIPSTICK1,7LITRESIMPERATIVEALWAYSCHECKTHEOILLEVELUSINGTHEDIPSTICKOILCHANGEINTERVALREFERTOTHEMAINTENANCESCHEDULE73OILFILTEROILFILTER1STFITTING2NDFITTINGMAKEPURFLUXPURFLUXTYPELS867ALS867BOILCAPACITY032LITRESSAFETYVALVE15BARSREPLACEMENTINTERVALWITHNORMALUSEREFERTOTHEMAINTENANCESCHEDULEOILPRESSUREENGINEEW10J4CHECK1AT1000RPMMINIMUMPRESSUREBARS34CHECK2AT2000RPMMINIMUMPRESSUREBARS63CHECK3AT3000RPMMINIMUMPRESSUREBARS69CHECK4AT4000RPMMINIMUMPRESSUREBARSTHEVALUESGIVENAREINBARSFORANENGINEWHICHISRUNIN,ATANOILTEMPERATUREOF80C74ENGINEOILCHANGETHEENGINECANBEDRAINEDBYSUCTIONTHEENGINEOILMUSTBECHANGEDWITHTHEENGINEHOTJUSTAFTERSWITCHINGOFFTHEENGINETHEENDOFTHEDIPSTICKTUBEISFLARED,WHICHMAKESITPOSSIBLETOCONNECTASUCTIONDRAINAGENOZZLEDIAMETER14MMNOTEITISSTILLPOSSIBLETODRAINTHEENGINEBYREMOVINGTHEDRAINPLUGFROMTHESUMP8AIRSUPPLYCIRCUIT81AIRSYSTEM37THEAIRINLETHOSE38INJECTORSSUPPLYRAIL39EXHAUSTGASRECIRCULATIONTUBE40INLETMANIFOLD41THROTTLEHOUSINGALUMINIUMALLOY42JUBILEECLIPNACCESSTOTHESCREWSPECIALFEATURESINLETMANIFOLDMATERIALCOMPOSITEMATERIALSRESONATORINTEGRALWITHTHEAIRINLETMANIFOLDEXHAUSTGASRECIRCULATIONTUBETAKEOFFTHESEALISPREFORMEDANDREMOVABLESPECIALFEATURES,THROTTLEHOUSINGMATERIALLIGHTALLOYIDLEREGULATIONBYSTEPPERMOTORREMOVALOFTHEAIRINLETCONNECTORFROMTHETHROTTLEHOUSINGREQUIRESSLACKENINGOFITSATTACHMENTCOLLAR42VIAACCESSN82ADJUSTMENTOFEXHAUSTGASESARROWSDIRECTIONOFEXHAUSTGASCIRCULATION19CYLINDERHEAD39EXHAUSTGASRECIRCULATIONTUBE40INLETMANIFOLD41THROTTLEHOUSING43EXHAUSTMANIFOLD44EXHAUSTGASRECIRCULATIONEGRVALVE45WATEROUTLETHOUSINGEXHAUSTGASRECIRCULATIONISUSEDTOREDUCETHEPUMPINGEFFECTREDUCTIONINFUELCONSUMPTIONTHERECIRCULATIONISOFTHEPROGRESSIVETYPEMANAGEDBYMAPPINGTHEOPENINGOFTHEEGRVALVEISCONTROLLEDBYTHEEGRSOLENOIDVALVEWHICHISMANAGEDBYTHEENGINEMANAGEMENTCONTROLUNITWHICHRECEIVESTHEFOLLOWINGDATACOOLANTTEMPERATUREENGINESPEEDRPMENGINELOAD83EXHAUSTGASRECIRCULATIONEGRVALVESPECIALFEATURESPROPORTIONALSOLENOIDVALVECONTROLLEDBYTHEINJECTIONECU84EXHAUSTMANIFOLD43EXHAUSTMANIFOLD46INTERNALDUCTS1PERCYLINDER47EXTERNALENVELOPEMATERIALSTEELTHEEXHAUSTMANIFOLDISMADEUPOFTHEFOLLOWINGCOMPONENTS4DUCTS1PRESSEDSTEELENVELOPEASPACEBETWEENTHEEXHAUSTDUCTSANDTHEHALFSHELLSPROVIDESGOODHEATINSULATIONTHISEXHAUSTMANIFOLDMAKESPOSSIBLERAPIDWARMINGUPOFTHECATALYTICCONVERTERONCOLDSTARTS9FUELSUPPLYSYSTEMPDIRECTIONOFFUELCIRCULATIONQDIRECTIONOFPETROLVAPOURCIRCULATIONRTOPETROLVAPOURRECYCLINGPIPESSTOFUELSUPPLYPIPES38INJECTORSSUPPLYRAIL48CANISTERACTIVATEDCARBONFILTER49FUELFILTER50SCHRADERVALVE51FUELRETURNPIPES52CLICKONCONNECTOR53PETROLINJECT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