EP6 1.6 Engine Repair for Peugeot 308, 408 and 3008

Everything for Peugeot Engine Repair

The second EP6 1.6 l engine is developed jointly by Peugeot and BMW. The volume of its predecessor, the combustion EP6DT engine, is 1 598 cm³
Over time, this engine will replace TU5JP4.

The peculiarity of the EP6 engine for Peugeot 308, 408 and 3008 is a possibility to use the inlet valve control system and to achieve the power of 88 kW, which is 120 hp at 6 000 rpm according to the Euro 4 exhaust emission standard.

Cylinder Head of EP6

It is made of aluminum alloy in a disposable mold. The model of the cylinder head is made of polystyrene and then injected with resin. When being molded the alloy is replaced by the polystyrene model.

The cylinder head cover is made of composite materials and has an oil separator. Its tightness is ensured by 7 rubber gaskets.

Such molding technology provides a high precision and accuracy of different channels and molds in the cylinder head.

On each countershaft, there are:

• valve phase shifters,
• hydraulic pressure control valve for phase shifters;
• countershaft sensor targets;
• vacuum pump drive.

Inlet valves are controlled by the additional intermediate shaft and electric motor.

The inlet valve control system includes the following components:

• Electric motor
• Intermediate shaft
• Intermediate shaft gears
• Intermediate shaft position sensor
• Inlet countershaft
• Pull-back springs

1.  Intermediate shaft
2. Adjusting drive
3. Intermediate shaft gears
4. Gear
5. Hydraulic adjuster
6. Inlet valve
7. Increasing valve stroke

The vacuum pump drive installed on the outlet countershaft provides the easy braking.

Phase shifters work within specified limits: the angle of shift at the inlet shaft is 35° and at the outlet shaft is 30°, as there is the IN 35 (inlet) and EX 30 (outlet) marks on them.

Also, there are solenoid valves installed on both sides of the cylinder head. They are controlled by the engine computer and regulate phase shifters.

EP6 engine (indirect fuel injection)

Mark	Description	Torque
(1)	bolt (cylinder head cover) (*)	Preliminary tightening to a torque of 0.2 dNm
		Tightening to a torque of 1 dNm
(2)	bolt (cylinder head) (*)	Preliminary tightening to the torque of 3 dNm
		Angle tightening 90
		Angle tightening 90
(3)	bolt (cooling liquid outlet unit)	1 dNm
(4)	bolt (vacuum pump)	0.9 dNm
(5)	Pins (exhaust manifold)	1.5 dNm
(6)	bolt (cylinder head / cylinder block) (*)	Preliminary tightening to the torque of 1.5 dNm
		Angle tightening 90
		Angle tightening 90
(7)	Plugs	2.3 dNm
(8)	bolt (cylinder head / cylinder block) (*)	2.5 dNm
		Angle tightening 30
(*) Follow the correct order of tightening screw connections

Cylinder Block of 1.6 l Engine for Peugeot

Pistons are made of alloy materials and have holes for valves with marks on the gas distribution system. A complete lack of the central hole is conditioned by the fact that it does not imply the direct injection to the combustion chamber. The EP6 engine flywheel has a hole for marking when the circuit is changed or regulates the gas distribution system.

EP6 engine (indirect fuel injection)

Rod assembly

 

 

Mark	Description	Torque
(1)	bolt (cylinder head cover) (*)	Preliminary tightening to a torque of 0.2 dNm
		Tightening to a torque of 1 dNm
(2)	bolt (cylinder head) (*)	Preliminary tightening to the torque of 3 dNm
		Angle tightening 90
		Angle tightening 90
(3)	bolt (cooling liquid outlet unit)	1 dNm
(4)	bolt (vacuum pump)	0.9 dNm
(5)	Pins (exhaust manifold)	1.5 dNm
(6)	bolt (cylinder head / cylinder block) (*)	Preliminary tightening to the torque of 1.5 dNm
		Angle tightening 90
		Angle tightening 90
(7)	Plugs	2.3 dNm
(8)	bolt (cylinder head / cylinder block) (*)	2.5 dNm
		Angle tightening 30
(*) Follow the correct order of tightening screw connections

Oil system of Peugeot 308, 408, 3008 for EP6 engine

The complete filling of oil is 4 l, without the oil filter is 3.7 l.

Each oil supply channel of phase shifters is equipped with a non-return valve installed directly in front of the solenoid valve.

EP6 Engine Air System

It includes the following components:

1. Air inlet resonator
2. Inlet connection
3. Air filter
4. Throttle blade manifold
5. Intake manifold

Air inlet resonator is located behind the head light and ensures the reduction of noise of an inlet air flow.

The air filter is installed on the intake manifold and ensures the inlet air purification. At normal operation, it should be replaced after achieving 60 000 km.

The throttle blade with electric drive is used only in emergency mode if there is an error in the inlet valve control system.

The intake manifold of the EP6 engine is made of composite materials. Its tightness is ensured by 4 removable gaskets.

Outlet system of Peugeot engine

The exhaust manifold is made of stainless steel and has two tap holes for the upper and lower lambda sensors.

Fuel supply system of Peugeot engine

The EP6 engine of Peugeot does not have a direct injection system. The fuel rail is located behind the cylinder head. It is also made of composite materials and includes fuel injection nozzles.

The pressure of the fuel pump and the fuel supply system is 3.5 bar. The fuel pump is located in the tank and is equipped with the pressure controller.

Fuel injection nozzles of solenoid type have 8 holes for fuel injected.

The absorber is installed under the tank. The absorber valve ensures fuel vapor recovery and is installed under the intake manifold.

EP6 engines are also installed in Citroën cars