Peugeot 405. Manual - part 21

Valves (continued)

Valve stem diameter:

Inlet:

1360 cc engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.84 to 6.99 mm

1580 cc and 1905 cc (8-valve) engines  . . . . . . . . . . . . . . . . . . . . .

7.83 to 7.98 mm

1761 cc engine  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Not available

1998 cc (8-valve) engine  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.83 to 8.13 mm

1905 cc  and 1998 cc 16-valve engines  . . . . . . . . . . . . . . . . . . . . .

6.83 to 6.98 mm

Exhaust:

1360 cc engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.83 to 6.98 mm

1580 cc and 1905 cc (8-valve) engines  . . . . . . . . . . . . . . . . . . . . .

7.83 to 7.98 mm

1761 cc engine  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Not available

1998 cc (8-valve) engine  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.82 to 8.12 mm

1905 cc  and 1998 cc 16-valve engines  . . . . . . . . . . . . . . . . . . . . .

6.83 to 6.98 mm

Overall length:

Inlet:

1360 cc engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

112.76 ± 0.25 mm

1580 cc and 1905 cc (8-valve) and 1998 cc (8-valve) engines  . . . .

108.79 ± 0.1 mm

1761 cc engine  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Not available

1905 cc  and 1998 cc 16-valve engines  . . . . . . . . . . . . . . . . . . . . .

104.48 ± 0.1 mm

Exhaust:

1360 cc engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

112.56 ± 0.25 mm

1580 cc and 1905 cc (8-valve) and 1998 cc (8-valve) engines  . . . .

108.37 ± 0.1 mm

1761 cc engine  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Not available

1905 cc  and 1998 cc 16-valve engines  . . . . . . . . . . . . . . . . . . . . .

103.00 ± 0.1 mm

Cylinder block

Cylinder bore diameter:

1360 cc engine:

Size group A  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75.000 to 75.010 mm

Size group B  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75.010 to 75.020 mm

Size group C  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75.020 to 75.030 mm

1580 cc, 1761 cc and 1905 cc (8-valve) engines:

Size group A  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

83.000 to 83.010 mm

Size group B  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

83.010 to 83.020 mm

Size group C  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

83.020 to 83.030 mm

1998 cc (8-valve) engines:

Size group A  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

86.000 to 83.018 mm

Size group B  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

86.250 to 86.268 mm

Size group C  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

86.600 to 86.618 mm

1905 cc (16-valve) engine:

Size group A  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

83.000 to 83.010 mm

Size group B  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

83.010 to 83.020 mm

Size group C  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

83.020 to 83.030 mm

1998 cc (16-valve) engine  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Not available

Liner protrusion above block mating surface - 
aluminium-block engine only (ie all except 1998 cc):

Standard  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.03 to 0.10 mm

Maximum difference between any two liners:

8-valve engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.05 mm

16-valve engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.02 mm

Pistons

Piston diameter:

1360 cc engine:

Size group A  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

74.950 ± 0.010 mm

Size group B  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

74.960 ± 0.010 mm

Size group C  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

74.970 ± 0.010 mm

1580 cc, 1761 cc and 1905 cc (8-valve) engines:

Size group A  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82.960 ± 0.007 mm

Size group B  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82.970 ± 0.007 mm

Size group C  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82.980 ± 0.007 mm

1905 cc 16-valve engine:

Size group A  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82.963 to 82.977 mm

Size group B  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82.973 to 82.987 mm

Size group C  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82.983 to 82.997 mm

1998 cc 16-valve engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Not available

2C•2 Engine removal and overhaul

Connecting rods

Maximum weight difference between any 
two piston/connecting rod assemblies:

1360 cc engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.0 g

1580 cc, 1761 cc and 1905 cc engines  . . . . . . . . . . . . . . . . . . . . . . .

13.0 g

1998 cc engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.0 g

Crankshaft

Endfloat:

8-valve engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.07 to 0.32 mm

16-valve engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.07 to 0.27 mm

Main bearing journal diameter:

1360 cc engines:

Standard  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49.965 to 49.981 mm

Undersize  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49.665 to 49.681 mm

1580 cc, 1905 cc and 1998 cc engines:

Standard  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59.981 to 60.000 mm

Undersize  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59.681 to 59.700 mm

1761 cc engine  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Not available

Big-end bearing journal diameter:

1360 cc engines:

Standard  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44.975 to 45.000 mm

Undersize  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44.675 to 44.700 mm

1580 cc, 1905 cc and 1998 cc engines:

Standard  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49.984 to 50.000 mm

Undersize  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49.684 to 49.700 mm

1761 cc engine  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Not available

Maximum bearing journal out-of-round (all models)  . . . . . . . . . . . . . . .

0.007 mm

Main bearing running clearance:

1360 cc models*:

Pre-February 1992 models  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.023 to 0.083 mm

February 1992-on models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.023 to 0.048 mm

1580 cc, 1761 cc and 
1905 cc engines**  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.025 to 0.050 mm

1998 cc engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.038 to 0.069 mm

Big-end bearing running clearance - all models**  . . . . . . . . . . . . . . . . .

0.025 to 0.050 mm

*On 1360 cc models, the main bearing shells were modified in February 1992, resulting in a reduction in the specified running clearance - 
see text for further information.

**These are suggested figures, typical for this type of engine - no exact values are stated by Peugeot.

Piston rings

Note: The following are suggested figures - no exact values are stated by Peugeot.
End gaps:

Top compression ring:

1360 cc engine  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.3 to 0.5 mm

1580 cc engine  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.4 to 0.6 mm

1905 cc engine  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.2 to 0.4 mm

1761 cc and 1998 cc engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.3 to 0.5 mm

Second compression ring:

1360 cc engine  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.3 to 0.5 mm

1580 cc and 1905 cc engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.15 to 0.35 mm

1761 cc and 1998 cc engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.3 to 0.5 mm

Oil control ring:

All models  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.3 to 0.5 mm

Torque wrench settings

TU series engine

Refer to Chapter 2A Specifications

XU series engine

Refer to Chapter 2B Specifications

Engine removal and overhaul  2C•3

2C

1

General information

Included in this Part of Chapter 2 are details

of removing the engine/transmission from the
car and general overhaul procedures for the
cylinder head, cylinder block/crankcase and
all other engine internal components.

The information given ranges from advice

concerning preparation for an overhaul and
the purchase of replacement parts, to detailed
step-by-step procedures covering removal,
inspection, renovation and refitting of engine
internal components.

After Section 6, all instructions are based

on the assumption that the engine has been
removed from the car. For information
concerning in-car engine repair, as well as the
removal and refitting of those external
components necessary for full overhaul, refer
to Part A or B of this Chapter (as applicable)
and to Section 6. Ignore any preliminary
dismantling operations described in Part A or
B that are no longer relevant once the engine
has been removed from the car.

Apart from torque wrench settings, which

are given at the beginning of Part A or B (as
applicable), all specifications relating to
engine overhaul are at the beginning of this
Part of Chapter 2.

2

Engine overhaul - 
general information

1 It is not always easy to determine when, or
if, an engine should be completely
overhauled, as a number of factors must be
considered.
2 High mileage is not necessarily an
indication that an overhaul is needed, while
low mileage does not preclude the need for an
overhaul. Frequency of servicing is probably
the most important consideration. An engine
which has had regular and frequent oil and
filter changes, as well as other required
maintenance, should give many thousands of
miles of reliable service. Conversely, a
neglected engine may require an overhaul
very early in its life.
3 Excessive oil consumption is an indication
that piston rings, valve seals and/or valve
guides are in need of attention. Make sure
that oil leaks are not responsible before
deciding that the rings and/or guides are
worn. Perform a compression test, as
described in Part A of this Chapter, to
determine the likely cause of the problem.
4 Check the oil pressure with a gauge fitted in
place of the oil pressure switch, and compare
it with that specified. If it is extremely low, the
main and big-end bearings, and/or the oil
pump, are probably worn out.
5 Loss of power, rough running, knocking or
metallic engine noises, excessive valve gear

noise, and high fuel consumption may also
point to the need for an overhaul, especially if
they are all present at the same time. If a
complete service does not remedy the
situation, major mechanical work is the only
solution.
6 An engine overhaul involves restoring all
internal parts to the specification of a new
engine. During an overhaul, the cylinder liners
(where applicable), the pistons and the piston
rings are renewed. New main and big-end
bearings are generally fitted; if necessary, the
crankshaft may be renewed, to restore the
journals. The valves are also serviced as well,
since they are usually in less-than-perfect
condition at this point. While the engine is
being overhauled, other components, such as
the distributor, starter and alternator, can be
overhauled as well. The end result should be
an as-new engine that will give many trouble-
free miles.

Note: Critical cooling system components
such as the hoses, thermostat and water
pump should be renewed when an engine is
overhauled. The radiator should be checked
carefully, to ensure that it is not clogged or
leaking. Also, it is a good idea to renew the oil
pump whenever the engine is overhauled.

7 Before beginning the engine overhaul, read
through the entire procedure, to familiarise
yourself with the scope and requirements of
the job. Overhauling an engine is not difficult if
you follow all of the instructions carefully,
have the necessary tools and equipment, and
pay close attention to all specifications. It can,
however, be time-consuming. Plan on the car
being off the road for a minimum of two
weeks, especially if parts must be taken to an
engineering works for repair or reconditioning.
Check on the availability of parts and make
sure that any necessary special tools and
equipment are obtained in advance. Most
work can be done with typical hand tools,
although a number of precision measuring
tools are required for inspecting parts to
determine if they must be renewed. Often the
engineering works will handle the inspection
of parts and offer advice concerning recondi-
tioning and renewal.

Note: Always wait until the engine has been
completely dismantled, and until all
components (especially the cylinder
block/crankcase and the crankshaft) have
been inspected, before deciding what service
and repair operations must be performed by
an engineering works. The condition of these
components will be the major factor to
consider when determining whether to
overhaul the original engine, or to buy a
reconditioned unit. Do not, therefore,
purchase parts or have overhaul work done on
other components until they have been
thoroughly inspected. As a general rule, time
is the primary cost of an overhaul, so it does
not pay to fit worn or sub-standard parts.

8 As a final note, to ensure maximum life and
minimum trouble from a reconditioned engine,
everything must be assembled with care, in a
spotlessly-clean environment.

3

Engine/transmission
removal - methods and
precautions

1 If you have decided that the engine must be
removed for overhaul or major repair work,
several preliminary steps should be taken.
2 Locating a suitable place to work is
extremely important. Adequate work space,
along with storage space for the car, will be
needed. If a workshop or garage is not
available, at the very least, a flat, level, clean
work surface is required.
3 Cleaning the engine compartment and
engine/transmission before beginning the
removal procedure will help keep tools clean
and organised.
4 An engine hoist or A-frame will also be
necessary. Ensure the equipment is rated in
excess of the combined weight of the engine
and transmission. Safety is of primary
importance, considering the potential hazards
in lifting the engine/transmission out of the car.
5 If this is the first time you have removed an
engine, an assistant should ideally be
available. Advice and aid from someone more
experienced would also be helpful. There are
many instances when one person cannot
simultaneously perform all of the operations
required when lifting the engine out of the car.
6 Plan the operation ahead of time. Before
starting work, arrange for the hire of or obtain
all of the tools and equipment you will need.
Some of the equipment necessary to perform
engine/transmission removal and installation
safely and with relative ease (in addition to an
engine hoist) is as follows: a heavy duty trolley
jack, complete sets of spanners and sockets
as described in the front of this manual,
wooden blocks, and plenty of rags and
cleaning solvent for mopping up spilled oil,
coolant and fuel. If the hoist must be hired,
make sure that you arrange for it in advance,
and perform all of the operations possible
without it beforehand. This will save you
money and time.
7 Plan for the car to be out of use for quite a
while. An engineering works will be required
to perform some of the work which the do-it-
yourselfer cannot accomplish without special
equipment. These places often have a busy
schedule, so it would be a good idea to
consult them before removing the engine, in
order to accurately estimate the amount of
time required to rebuild or repair components
that may need work.
8 Always be extremely careful when removing
and refitting the engine/transmission. Serious
injury can result from careless actions. Plan
ahead and take your time, and a job of this
nature, although major, can be accomplished
successfully.

2C•4 Engine removal and overhaul

4

Engine and manual
transmission - removal,
separation and refitting

4

Note: Peugeot recommend that 8-valve XU
engines are removed by lowering from the
engine compartment, however in practise we
found that on models not fitted with air
conditioning, there is ample room to lift the
engine upwards. Lowering the engine would
involve raising the front of the vehicle onto
axle stands approximately 21 inches high and
also removing the engine subframe. On
models fitted with air conditioning the engine
may be lowered, or alternatively it can be lifted
after removing the condenser and front panel
(the refrigerant must first be evacuated by a
qualified engineer if this method is used).

Removal

Note: The engine can be removed from the
car only as a complete unit with the
transmission; the two are then separated for
overhaul.
1 Park the vehicle on firm, level ground.
Chock the rear wheels, then firmly apply the
handbrake. Jack up the front of the vehicle,
and securely support it on axle stands (see
“Jacking and Vehicle Support”). Remove both
front roadwheels.
2 Set the bonnet in the upright position, and
remove the battery and tray as described in
Chapter 5A.
3 On 8-valve XU engines remove the front
cross panel with reference to Chapter 11 (see
note at the beginning of this Section).
4 Remove the complete air cleaner housing
and duct assembly, as described in the
relevant Part of Chapter 4 (see illustration).
5 If the engine is to be dismantled, working as
described in Chapter 1, first drain the oil and
remove the oil filter. Clean and refit the drain
plug, tightening it securely.
6 Drain the transmission oil as described in
Chapter 7A. Refit the drain and filler plugs,
and tighten them to their specified torque
settings.
7 Remove the alternator as described in
Chapter 5A.
8 Where applicable, remove the power
steering pump as described in Chapter 10.

9 On models with air conditioning, unbolt the
compressor, and position it clear of the
engine. Support the weight of the compressor
by tying it to the vehicle body, to prevent any
excess strain being placed on the compressor
lines whilst the engine is removed. Do not
disconnect the refrigerant lines from the
compressor (refer to the warnings given in
Chapter 3).
10 Drain the cooling system as described in
Chapter 1. Where necessary on 8-valve XU
engines, remove the radiator (see Chapter 3).
11 On carburettor models, carry out the
following operations, using the information
given in Chapter 4A:

a) Disconnect the fuel feed hose from the

anti-percolation chamber.

b) Disconnect the accelerator and choke

cables from the carburettor.

c) Disconnect the braking system servo

vacuum hose from the inlet manifold.

d) Remove the exhaust system front pipe.

12 On fuel injection models, carry out the
following operations, using the information
given in Chapter 4B or 4C (as applicable):

a) Depressurise the fuel system, and

disconnect the fuel feed and return hoses.

b) Disconnect the accelerator cable.
c) Disconnect the fuel system wiring

connectors.

d) Disconnect the purge valve and/or

braking system servo vacuum hoses from
the inlet manifold (as applicable).

e) Remove the exhaust system front pipe.

13 Referring to Chapter 3, release the
retaining clip and disconnect the heater matrix
hoses from their connection on the engine
compartment bulkhead.
14 Working as described in Chapter 6,
disconnect the clutch cable from the
transmission, and position it clear of the
working area (see illustration).
15 Trace the wiring harness back from the
engine to the wiring connector(s) in the engine
compartment. Release the locking ring(s) by
twisting them anti-clockwise and disconnect
the connectors. Also trace the harness lead(s)
back to the relay box, situated beside the
battery. Unclip the wiring connector plate
from the front of the relay box cover then
undo the retaining nut and remove the cover.
Lift up the engine harness lead cover then

undo the nut(s) and release the lead(s) from
the relay box. Check that all the relevant
connectors have been disconnected, and that
the wiring is released from any relevant clips
or ties, so that it is free to be removed with the
engine/transmission.
16 From underneath the vehicle, slacken and
remove the nuts and bolts securing the rear
mounting link to the mounting assembly and
subframe, and remove the link.
17 Remove both driveshafts as described in
Chapter 8.
18 Carry out the following operations, using
the information given in Chapter 7A:

a) Disconnect the gearchange selector

rod/link rods (as applicable) from the
transmission.

b) Disconnect the speedometer cable from

the speedometer drive.

c) Disconnect the wiring connector(s) from

the reversing light switch and
speedometer drive (as applicable).

19 Manoeuvre the engine hoist into position,
and attach it to the lifting brackets bolted onto
the cylinder head. Raise the hoist until it is
supporting the weight of the engine.
20 Remove the right-hand engine mounting
with reference to Chapter 2A. 

Note: On certain models, if the right-hand
engine mounting hydro-elastic unit is to be
renewed because of wear/perishing, a special
tool is needed to unscrew it from the wing
panel, and for refitting and tightening to the
specified torque (see illustration).

21 Slacken and remove the centre nut and
washer from the engine/transmission left-
hand mounting. Undo the two nuts and
washers securing the mounting to its bracket
and remove the mounting from the engine
compartment and recover the spacer (where
fitted). To improve clearance, (where possible)
undo the two retaining bolts and remove the
bracket from the body.
22 Make a final check that any components
which would prevent the removal of the
engine/transmission from the car have been
removed or disconnected. Ensure that
components such as the gearchange selector
rod are secured so that they cannot be
damaged on removal.

Engine removal and overhaul  2C•5

4.20  Special tool for removing and refitting

right-hand engine mounting 

hydro-elastic unit

4.14  Disconnecting the clutch cable

4.4  Inlet air duct connection to the front

crossmember

2C