THE FRUITS OF EXPERIENCE AND INNOVATION The latest generation of | Producing diesels for more PSA diesel engines, the acquired “an unmatched naturally aspirated DJS and expertise in their tech. turbocharged DIST models nelogs, design, and manu are manufactured at an" entirely new production Experience accumulated over many years center at the Francaise de jas allowed Méconique (Douvrin). These our engineers new engines hove fully te ssPlere benefited from she wealth —hologies of experience and innovative ae capabilfes ofthe corpora: Peve=t tion, the world leader in under diesels. standing of fuel injection, combustion phenomena, and multivalve engine architecture. To attain this cutting edge expertise, PSA ha always backed its ambitions with -esources: its engine research and develepment depariments employ a chou sand "people. invest more than 60 million francs cach year, and have the use of a Cray super computer's formidable capabili ties Conceived entirely using CAD, the DI Is the application of man: avant garde technologies: computer simulation of ‘constraints imposed on each 4 ‘component par heads and lasers to measure water parent circu lation, ultra-fast cameras to Film passages measured by ultrasound, TIG-treated camshafts, 16st foam casting used to create the bearing cap case, jon nitrided crank: shafts, and infrared testing of belt tension, among others An exceptional engine in every way, the DIS. is manufactured in the newest production center at the Douvrin planOUTSTANDING PERFORMANCE The DJS is a 2.5-litre engine, available in naturally aspirated and turbocharged versions. Its performance is excep: tional, putting out 26 kW/I and 63 Nm/I naturally aspirated and 31 kW/I ond 94 Nm/I turbocharged. 15% More Power These output figures mean that the DJ5 engines achieve 15% more power and torque than the previou: generation of 2.5-litre diesels. But improving power and torque was only one of the objectives set before the DJp's designers. Reliability and clean emis- sions were two critically important goals for all of the research and develop- ment put into this new generation of engines. Consistent Performance Over Time And so was the stability of engine performance over time, thanks to the adoption of hydraulic valve clearance ‘Tonaut Dis (ISO 1585) self-adjustment, which guar- antees permanent contact between cams and valves, requiring no outside inter- vention. g 3 OS ‘The engine timing system, too, is innovative, using a two-part ptlley that allows for easy, optimum adjust- ment. 17 MAY'S 1995 4 TITAN ENGINE THAT IS COMPAC The DJ engine hos @ cast iron cylinder block made of two sections Seated in a groove that is machined into the block's mating surface, a silicone bead provides perfect sealing, Integral Passages Even though this thin-walled cylinder block is exception- ally compact, expert foundry techniques permitted the creation of wafer-thin water passages between the cylin- ders, greatly improving engine cooling Also integrated into the DIS cylinder block are pressure equalizing pas pump by-pass, snd posi tive crankease ventilation pass ges, water The resulting reduction in that has more than proven its outside hoses greatly reduces benefits to engine perfor the risk of feaks, mance and its ability to The lower section of the improve emissions since block, cust by lost foam PSA introduced it on the process, houses the erank- XUDIIA diesel, shaft end caps and reinforces. The upper cylinder head the rigidity of the entire jon houses thy assembly carnshat Drilled oil holes in each eam svame lobe and journal ensure meee optimum lubrication. Hydraulic cam followers assure perm: ‘The aluminium eylinder hes sea the ad between the cams and the is alo split in oy valseit nl al ating peed yalvetrain, combustion chambers, injectors and pre ‘post-heat glow plugs Particular attention was The Right Treatment The drop-fonged steel crank: water within the cylinder head and to cooling the uri, eights. turns on five main ical thermal stress areas beatings: The crankshaft is heut treated The integral water galleries in the ejlinder head bring coolant preferentially to the valve seats, where steel appropriately for its expected operating constraints: for the naturally aspirat i induction hardened; it is won nitrided for the turbo: engine, it inserts reinforce the bridge area in between The DIS is equipped diesel with three A torsion valves dampe pulley at the end per of eylinder the erank- (including shall absorbs vibra two intake), fons and helps the engine to a technol run quietly 4 1V . geRIGID AND LIGHTWEIGHT Where Size on specially engineered steel hamars insert for reinforce. Timing is The drop-forged steel connecting rods have small tends shaped like « viper's head, This tapered design helps reduce weight while allowing an wrist pin deren 8 cogged belt weer than is sricl by uae of 8 tworpart pale. Mechanical Bosch VE (D9) or Leas DPC (DIST) injection pumps deliver the fuel. Integral fus! injector holders gusrante faultless sealing. i Inaudition wo the rapid pre. Lurbe prevsireol GS kat boss size, which improves eat system "for cold All of the DI's architecture Koad it reduces pressure improves cold running and passages. inthe block, to the piston and the ist emissions. Ie slope automati- cylinder head deign te) t0 pin by 25% ily thee minutes after the allow tts Installation The patons are cooled by oil engine is stared, or as soon anywhere from 17" on the jet Tall models): turbo ss the water temperature exhaust side t0 17° on the pistons are also cooled by reaches 60° C. injection side, oil gallons A pulley at the end of the The major’ component ‘A number of different camshalt drives the water requiring modification piston size classes ensures pump by means ofa belt. between these two exiremes perfect compression for A simple change in pulley is the oil pan, in order to each engine, providing diameter adapts the flow ensure proper engine lubrica: ‘maximam performance rates between tion. and minimum emis the nat sions, rally aspira and Precision from turbo ‘all Angles charged The The turbo pistons DPT is ‘ are anodized on equipped skirt and crown, with a and the lop KKK low . ‘combustion ring sits iTOTAL QUALITY: A PLANT MADE TO MEASURE An entirely new 36,000 mi production plant was built for the DJ at Dowwrin (FM). A total of nearly 2 billion Francs have been invested in the production of this engine. Select Application of Robotics The use of robots was limited to exiremely difficult tasks, quality checks and as im aid to diagnostics, Found to be irreplaceable hecauise of thetr flexibility men and women were placed where they are most valuable The procluction line, which is only 30% automated offers increased reliability, Innovative Techniques Because the engine block is designed with water circu: lating around the cylinders, special tools were 12: To bore the cylinders, the osition of the water galleries is determined by ultra-sound. tn this way, the bore is optimised while a minimum wall thickness is maintained between cylinders Cylinder walls ate finished with @ new technology, plateau honing. High spots In the crisscrossed grooves of the cylinder walls are honed off. This extremely precise procedure helps to reduce oil consumption and amissions levels Great atiention is alse given to cylinder head production, Both sections of the head ure deburred by # robo! that projects resin micro. spheres and cleaned by a high turbulence washing machine To ensure maximum preci sion, both sections of the cylinder head are paired from the start of machining. Because the naturally aspi rated and turbocharged engine crankshaft do not receive the same surface Ueaiment, “the super finishing tools are self-cali brating to allow for very subtle differences in the amount of material The precision of the timing belt tension is checked by an infrared system that measures belt vibrations when it is struck hy a small haminer The camshaft is drilled through and through, to provide pexfect lubrication two each and every cam and cam journal. The camshaft is TIG-treated forincreased strengthContinuous Quality Control A computer chip travels with each engine along the entire production line, inputting all pertinent data for each component, each assembly phase, and each quality check, In this way, quality is constantly under surveil Tance, The system will nat allow igine te leave the plant unless it is irreproachable, Furthermore, at the end of the line, cach engine under goes a final dyna west, belore ic is directed to final dress QUIET & CLEAN For PSA, designing © new diesel engine mecns above all, taking into consideration operator comfort and respect for the environment, Three foes ure primary ‘argels: noise, vibration, and pelltion The DI> was conceived during a time of rapid changes in emissions stan dards. It was designed therefore, to, satisly not only currently’ existing standards but also the far more strin {gent norms yet 10 come. Thanks to its rigid cast iron block, with its wafer-thin water gelleries between the cylinders, the DIS offers noteworthy reductions in both noise and vibrations. The choice of indirect Fuel injection also contribvites to reduced nolse and sions. The three-valv per: cylinder technology aysures better combustion of the fuel/air mixture, better engine performance, and less pollucon Built-in systems 10 maintain engine settings over time (hydraulic self-adjustment of cam clearance, precision tensioning: of the timing belt etc.) all contribuie to rigorous emissions contro, In concept and reality, the DIS is a naturally clean engine 4 Vil gg In anticipation of future changes in emissions stan- dards, nevertheless, the DJ was designed to allow easy use of an EGR system or a ‘catalytic converter lev. without er ECE wi Peugeot vile, acces EEC/95/59 standard (< 1700 hg) OHNO Pes SS Dpeyie EEL SideDKSATE: MORE RELIABLE, COMFORTAB MORE RELIABILITY/ LESS VIBRATION Particular attention was given to cooling the DR5ATE engine: in production, razor thin water passages between the cylinder are checked by ultra-sound water is brought preferentially to cool the hot spots between the valves: cil sprays and cooling galleries alleviaie heat siress Ench DKSATE component ic treated in the best vay appropriat for the mechanical and thermal it will encounter the crankshaft i fon nitrided, the camshaft is hard ened by tungsten inert gas (TIG) raiment, andthe piston heads are anodized. to name a feu. ast iron cylinder black is designedl in The lower section cradles the crankshaft and ene caps, enhancing the rigiay of the entire low increased durabi lity, and a solid base on which this develop ‘The camshaft is pierced through and through. 16 bring ol to the bearings and to each cam, ensuring proper lubrication of the tappets at any family ean The DKSATE is equipped with This reliable technology ensures ‘excellent cocting of ing the turbcharge, resulting in a remarkable savings in power. The pre h which the Liming, belt is mounted and ke under tension was 4 particular gn goal; the pulley has 1 tions, fer greater precision in justment; and in production the belt tension is checked by infrared vibration measure The timing belt desiga offers particularly low noise operation, A computer chip accompanies he engine along the entire assembly line, record component, cach phase of assembly and each 4 ‘mel check along the way: In this way, quality control is constant: the system will not allow an engine to leave the production line unless it is lreproschable. I; is these int gtaled assembly procedures , which ensure the quality and * reliability of the DKSATE At the end of the production h engine undergoes a itis run on the bench goes to final dress In addition to rapid preheat slow plugs, a post-heat device improves cold engine combu: tion It stops automatically three minutes alter the engine as started, or as soon as the water tem c C140" Ph Hydraulic lifters ensure permanent contact betweenSLE... CLEANER FOR THE ENVIRONMENT cams and valves, thus requiring ‘ng adjustments and reducing valve chatter, The DK3ATE is equipped with three valves per ejlinder, two exhaust. This technology has proven itself in both engine per- formance and emissions reduction ince PSA Peugeot Citron introduced: it on the XUDIT engine. An EGR valve is mounted on the DK3ATE iniake manifold, I. introe duces, into the air hes in. a portion the engine by grammed t0 open and close the EGR for ‘optimal results The RICARDO COMET V precombustion chamber con. tributes to the DKSATE's very low neise end emistions levels The engine's eylinder walls ar finished by plateau honing, which provides a surface con dition that reduces both oi consumpifon and oll seepage into the atmosphow. ELECTRONIC INJECTION PUMP ‘The DKSATE's eleetranie fuel injection is controled by the Iatest generation BOSCH pump, model VP36, governed by an MSA 11 ECU The ECU dk according te engine speed. information provided by strate gically placed nes pump flow ter Lemperature, af temperature, fuel tempera: ture}, and by the position of the potentiomoter/throttle/acceler ator, Injection advance ix controled ina closed loop. by the ECU, A sensor monitors needle lift fon ene of the injector ming, and informs the ECU The ECU also controls the pre snd post-heat relay bos, This sophisticated, reliable equipment allows the DK3ATE to meet, with the addition of only an oxydizing catahtic converter, the automobile missions standards thai will he pplied in Europe in 1995, ENGINE aALANEING. The DK5ATE engine has wo balancing shafts Each shaft is located in a special housing, son; the side of the engine block and carefily positioned with respect 4o the crankshaft centerfine The shafts rotate in opposite engine speed This offsets the second order ribrations created by the deicont of each piston and the ‘umming of the crankshal For ultimate vibration damp. ing, the DKSATE engine, as in PSA vehicles, Also has an inovaiive mounting ible rounts, centered on the engine roll axis, complemented by anii-torgue levers, consisting of hydro-fDKSATE: MORE RELIABLE, COMFORTAB MORE RELIABILITY/ LESS VIBRATION Particular attention was given to cooling the DR5ATE engine: in production, razor thin water passages between the cylinder are checked by ultra-sound water is brought preferentially to cool the hot spots between the valves: cil sprays and cooling galleries alleviaie heat siress Ench DKSATE component ic treated in the best vay appropriat for the mechanical and thermal it will encounter the crankshaft i fon nitrided, the camshaft is hard ened by tungsten inert gas (TIG) raiment, andthe piston heads are anodized. to name a feu. ast iron cylinder black is designedl in The lower section cradles the crankshaft and ene caps, enhancing the rigiay of the entire low increased durabi lity, and a solid base on which this develop ‘The camshaft is pierced through and through. 16 bring ol to the bearings and to each cam, ensuring proper lubrication of the tappets at any family ean The DKSATE is equipped with This reliable technology ensures ‘excellent cocting of ing the turbcharge, resulting in a remarkable savings in power. The pre h which the Liming, belt is mounted and ke under tension was 4 particular gn goal; the pulley has 1 tions, fer greater precision in justment; and in production the belt tension is checked by infrared vibration measure The timing belt desiga offers particularly low noise operation, A computer chip accompanies he engine along the entire assembly line, record component, cach phase of assembly and each 4 ‘mel check along the way: In this way, quality control is constant: the system will not allow an engine to leave the production line unless it is lreproschable. I; is these int gtaled assembly procedures , which ensure the quality and * reliability of the DKSATE At the end of the production h engine undergoes a itis run on the bench goes to final dress In addition to rapid preheat slow plugs, a post-heat device improves cold engine combu: tion It stops automatically three minutes alter the engine as started, or as soon as the water tem c C140" Ph Hydraulic lifters ensure permanent contact betweenSwen Penn ten ss PEUGEOT CITROEN 1 MOTEURS 49, nue Nost-Pors + E.P 420 + 92004 Nertorie cedex = France * Telephone: (1) 46 49-49 00 » Teecopie (1) 42-42 96 07