Peugeot 405
+ 1. Maintenance instruction
+ 2. Maintenance
- 3. Engines
+ 3.1. Petrol engines
+ 3.2. Diesel engines
- 3.3. Petrol engine 1,4 of dm3
3.3.1. Technical characteristic
3.3.2. Check and adjustment of a gap of valves
3.3.3. Check and adjustment of a corner of an advancing of ignition
3.3.4. Adjustment of the carburetor
3.3.5. Removal of the air filter
3.3.6. Removal of a head of the block of cylinders
3.3.7. Installation of a head of the block of cylinders
3.3.8. Removal and installation of the power unit with the petrol engine 1,4 of dm3
3.3.9. Features of dismantling of the petrol engine 1,4 of dm3
3.3.10. Dismantling of the TU3 engine
3.3.11. Dismantling of a head of the block of cylinders
3.3.12. Assembly of a head of the block of cylinders
3.3.13. Determination of the size of inserts
3.3.14. Assembly of the TU3 engine
3.3.15. Removal of the oil pump
3.3.16. Dismantling of the oil pump
3.3.17. Removal of the pump of cooling liquid
3.3.18. Service and repair of the MA transmission
3.3.19. Removal and installation of the MA transmission
3.3.20. Dismantling of the transmission
3.3.21. Dismantling of a secondary shaft
3.3.22. Dismantling of a main shaft
3.3.23. Dismantling of differential
3.3.24. Dismantling of knot of forks with their axes
3.3.25. Dismantling of the plug of synchronizers
3.3.26. Verification of parts of the transmission
3.3.27. Assembly of the plug of synchronizers
3.3.28. Assembly of knot of forks with their axes
3.3.29. Assembly of differential
3.3.30. Assembly of a main shaft
3.3.31. Assembly of a secondary shaft
3.3.32. Assembly of the transmission
+ 3.4. System of ignition
+ 4. Fuel system
+ 5. Lubrication systems, coolings
+ 6. System of release
+ 7. Coupling
+ 8. Transmissions
+ 9. Power shafts
+ 10. Steering
+ 11. Suspension brackets
+ 12. Brake system
+ 13. Body
+ 14. Electric equipment
|
ENGINE
The engine is four-cycle, four-cylinder, line, carburetor, water cooling, the camshaft in a head of the block of cylinders, is installed cross in front of the car with an inclination on 6 ° back, the drive on forward wheels.
| Type |
TU 3.2 K
|
| Working volume |
1360 cm3
|
| Diameter of the cylinder |
75 mm
|
| Piston stroke |
77 mm
|
| Extent of compression |
9,3
|
| Compression pressure |
1,1 MPas
|
| Maximum power |
56 kW (76 h.p.)
|
| Maximum moment |
114 Nanometer at 3800 rpm
|
SYSTEM OF GAS DISTRIBUTION
| Gas distribution phases: |
| – a gap of valves for control of phases of gas distribution |
0,7 mm
|
| – opening of the inlet valve |
7 ° 05' before VMT
|
| – closing of the inlet valve |
41 ° 27' after NMT
|
| – opening of the final valve |
52 ° 42' before NMT
|
| – closing of the final valve |
1 ° 14' before VMT
|
Camshaft
The camshaft is installed in a head of the block of cylinders and fixed on five bearings, the tension device of a belt – mechanical is put in action by a gear belt.
| Designation of the camshaft |
letter B (from system of ignition)
|
| Longitudinal side play of the camshaft |
0,07 – 0,16 mm (it is regulated by a washer from system of ignition)
|
Gear belt
The gear belt puts the camshaft and the pump of cooling liquid in action.
| Type |
Pirelli Isoran 108 RPP 170 HSL
|
| Number of teeths |
108
|
| Width |
15 mm
|
| Number of teeths of a pulley: |
| – bent shaft |
21
|
| – camshaft |
42
|
Valves
Valves in system V are installed at an angle 33 °, are put in action from the camshaft via bilateral levers. Number of valves on the cylinder – 2.
| Inlet valve: |
| – length |
110,76 ± 0,15 mm
|
| – prileganiye corner |
120 °
|
| – prileganiye width |
1,9 mm
|
| – diameter of a core |
6,90 – 0,015 mm
|
| – diameter of a plate |
36,8 mm
|
| – minimum thickness of a facet of a plate |
1,0 mm
|
| Final valve: |
| – length |
110,6 mm
|
| – prileganiye corner |
90 °
|
| – prileganiye width |
2,2 mm
|
| – diameter of a core |
6,980 – 0,015 mm
|
| – diameter of a plate |
29,4 mm
|
| – minimum thickness of a facet of a plate |
1,5 mm
|
| Working gap of valves (on the cold engine): |
| – inlet valve |
0,20 mm
|
| – final valve |
0,40 mm
|
Saddles of valves
| Inlet valve: |
| – prileganiye corner |
90 °
|
| – outer diameter: |
| • nominal 1 |
38,122 – 38,147 mm
|
| • nominal 2 |
38,422 – 38,447 mm
|
| • repair 1 |
38,322 – 38,347 mm
|
| • repair 2 |
38,622 – 38,647 mm
|
| – internal diameter |
29,5 mm
|
| – height is nominal |
6,648 + 0,1 mm
|
| – height is repair |
7,000 + 0,1 mm
|
| Final valve: |
| – prileganiye corner |
90 °
|
| – outer diameter: |
| • nominal 1 |
31,122 – 31,147 mm
|
| • nominal 2 |
31,422 – 31,447 mm
|
| • repair 1 |
31,322 – 31,347 mm
|
| • repair 2 |
31,622 – 31,647 mm
|
| – internal diameter |
24,3 mm
|
| – height is nominal |
6,648 + 0,1 mm
|
| – height is repair |
7,000 + 0,1 mm
|
Guides of valves
| Internal diameter |
7+ 0,022 mm
|
| Outer diameter: |
| – nominal 1 |
13,02+ 0,039 or 13,02 + 0,028 mm
|
| – nominal 2 |
13,13-0,011 mm
|
| – repair size 1 |
13,29-0,011 mm
|
| – repair size 2 |
13,59-0,011 mm
|
Springs of valves
About one spring on the valve is used. Inlet and final valves have identical springs.
| Internal diameter of a round |
21,4+0,4 mm
|
| Diameter of a wire of a spring |
3,6 mm
|
| Height: |
| – at load of 280 N |
40 mm
|
| – at load of 500 N |
32 mm
|
Head of the block of cylinders
The head is made of light alloy and has the inserted steel saddles of valves.
| Height: |
| – nominal |
111,2 ± 0,08 mm
|
| – minimum |
111 mm
|
Prevention
Heads of the block of cylinders, soshlifovanny up to the minimum height, are designated by a letter R on a head below the outlet of the third cylinder.
Such heads of the block of cylinders during repair cannot be exposed to grinding more any more. Besides, they surely at installation demand use of the laying which is also designated by a letter R (with thickness increased by 0,2 mm).
| Maximum admission of not planeness of the lower surface of a head |
0,05 mm
|
Laying of a head of the block of cylinders
Laying of a head of the block of cylinders has a metal fringing around cylinders.
| Brand |
Payen Curty
|
| Laying thickness: |
| – nominal |
1,3 mm
|
| – for a repolished head |
1,5 mm
|
Block of cylinders of the engine
The block of cylinders of the engine is manufactured of light alloy, consists of two parts, is divided on an axis of a bent shaft and has plug-in wet sleeves of cylinders.
| Height of the top part of the block of cylinders |
206,98 mm
|
Sleeves of cylinders
The sleeves of cylinders made of cast iron are divided into three groups designated by the corresponding number of hyphens.
| Diameter of a sleeve of the cylinder: |
| – group 1 (1 hyphen) |
75,00 – 75,01 mm
|
| – group 2 (2 hyphens) |
75,01 – 75,02 mm
|
| – group 3 (3 hyphens) |
75,02 – 75,03 mm
|
| Vystupany sleeves |
0,03 – 0,10 mm
|
| The maximum difference between four points on one sleeve |
0,02 mm
|
| The maximum difference between cylinders |
0,05 mm
|
| Diameter of section of a sealing ring of a sleeve |
1,15 – 1,35 mm
|
KRIVOSHIPNO-SHATUNNYY MECHANISM
Pistons
Pistons are manufactured of light alloy and have three rings.
| Diameter of pistons (mm): |
| – group A |
74,960 – 74,970
|
| – group B |
74,970 – 74,980
|
| – group C |
74,980 – 74,990
|
| Assembly gap of the piston in the cylinder |
0,03 – 0,05 mm
|
| Installation |
the arrow has to be directed to the bottom of the piston towards the gas distribution drive
|
| Gaps on the ring lock: |
| – first (top) |
0,30 – 0,50 mm
|
| – second (average) |
0,30 – 0,50 mm
|
| – third (lower) |
0,25 – 0,50 mm
|
Piston fingers
Steel fingers are divided into 3 groups corresponding to piston groups and designated by hyphens.
| Diameter of a finger: |
| – group 1 (on the piston 1, on a finger of I) |
19,495 – 19,498 mm
|
| – group 2 (on the piston 2, on a finger of II) |
19,492 – 19,495 mm
|
| – group 3 (on the piston 3, on a finger of III) |
19,489 – 19,492 mm
|
| Assembly gap of a finger in the piston |
0,01 – 0,016 mm
|
| Finger length |
62 ± 0,25 mm
|
Rods
Rods are shaped from steel.
| The maximum difference of masses between rods of the same engine |
3 g
|
| Interaxal distance |
126 ± 0,07 mm
|
| Diameter of the top head of a rod |
19,463+0,013 mm
|
| Diameter of an opening of the lower head of a rod |
48,655+0,016 mm
|
Bent shaft
The bent shaft is made of cast iron and leans on five radical bearings.
| Axial side play of a bent shaft |
0,1 – 0,3 mm
|
| Sizes of a bent shaft: |
| – nominal: |
| • diameter of radical necks |
49,981-0,016 mm
|
| • width 2 radical necks |
23,6+0,052 mm
|
| • diameter of conrod necks |
45,0-0,009 or 45,0-0,025 mm
|
| • diameter of a neck of consolidation on a flywheel |
85,0-0,065 mm
|
| – repair: |
| • diameter of radical necks |
49,681-0,016 mm
|
| • width 2 radical necks |
23,8+0,052, 23,9+0,052, 24,0+0,052 mm
|
| • diameter of conrod necks |
47,7-0,025 mm
|
| • diameter of a neck of consolidation on a flywheel |
84,8-0,065 mm
|
Inserts of radical bearings
| Thickness: |
| – nominal |
1,829 ± 0,003 mm
|
| – repair size |
1,979 ± 0,003 mm
|
Inserts of conrod bearings
| Thickness: |
| – nominal |
1,817 ± 0,003 mm
|
| – repair size |
1,967 ± 0,003 mm
|
Persistent rings
| Thickness: |
| – nominal |
2,4 mm
|
| – repair size 1 |
2,50 mm
|
| – repair size 2 |
2,55 mm
|
| – repair size 3 |
2,60 mm
|
Flywheel
| Maximum beats |
0,05 mm
|
| The maximum thinning after processing |
1,0 mm
|
LUBRICATION SYSTEM
Lubricant under pressure is provided by the gear oil pump with an external arrangement of teeths attached from below to the block of cylinders and put in action by a single-row chain from a bent shaft.
Oil pressure (at a temperature of 90 °C)
| Depending on engine turns pressure of oil makes: |
| – at 750 rpm |
0,15 MPas
|
| – at 1000 rpm |
0,20 MPas
|
| – at 2000 rpm |
0,30 MPas
|
| – at 4000 rpm |
0,40 MPas
|
Oil filter
The oil filter has the paper replaced element.
| Brand and type |
Purflux LS 468 A or Mann 6740 258 035
|
COOLING SYSTEM
The cooling system has the closed contour of compulsory circulation which is carried out by the centrifugal pump (put in action by a gear belt). Are a part of the cooling system: the radiator, the pump of cooling liquid, a broad tank and the fan with the electric motor operated by a thermoswitch.
Thermostat
| Type |
Calorstat
|
| Temperature began opening |
88 °C
|
| Temperature of full opening |
102 °C
|
| Valve stroke |
minimum 7,5 mm
|
Fan
The fan eight-bladed, 120 W, diameter is 285 mm.
| Inclusion temperature |
98 °C
|
| Switching off temperature |
92 °C
|
Temperature sensor
The sensor installed in a head of the block of cylinders causes fire of a control bulb on a combination of devices at achievement by cooling liquid of temperature of 118 °C.
FUEL SYSTEM
Fuel pump
The diaphragm fuel pump is put in action mechanically from the camshaft.
Electric type – external (early models) or internal (later models).
| Pressure |
25 kPa
|
| Pressure of giving of the pump: |
| – Fenix IB, MM G5 and MM G6 |
0,7 – 0,8 bars
|
| – Bosch MA3. 0 |
1,0 ± 0,1 bars.
|
| Pump productivity: |
| – Fenix IB and Bosch MA3. 0 |
370 cm3 in 15 seconds
|
| – MM G5 and G6 of system |
360 cm3 in 15 seconds
|
Air filter
The dry air filter has the replaced paper element.
Carburetor
The two-chamber carburetor has the starting arrangement operated manually.
| Type |
Solex Z2/528 or Weber 34 TLP
|
| Solex Z2/528 carburetor: |
| – diameter of the diffuser: |
| • 1 camera |
24
|
| • 2nd camera |
25
|
| – main fuel jet: |
| • 1 camera |
115
|
| • 2nd camera |
120
|
| – main air jet: |
| • 1 camera |
155
|
| • 2nd camera |
160
|
| – fuel jet of idling |
40
|
| – jet of transitional system (bypass) |
50
|
| – enrichment jet |
45
|
| – jet of the accelerating pump: |
| • 1 camera |
35
|
| • 2nd camera |
35
|
| – fuel jet of an ekonostat |
80
|
| – diameter of a saddle needle valves |
1,6
|
| – opening of a butterfly valve |
0,5 mm
|
| – opening of the air gate |
3,0 ± 0,5 mm
|
| – the provision of a float (measured from the lowest surface of a float to the cover plane with laying in horizontal position by means of a special template) |
33,5 mm
|
| – idling turns |
750 rpm
|
| – contents WITH |
1,5%
|
| – minimum content of CO2
|
10%
|
| Weber carburetor: |
| – height of installation of a float |
32,0 mm
|
| – opening of the gate after start |
5,0 mm
|
System of injection of fuel
| System type: |
| – TU3 (K12X) engine |
Solex Fenix IB is single-point
|
| – TU3 (K12X) engine |
Bosch Monotronic MA3. 0 single-point
|
SYSTEM OF IGNITION
The transistor system of ignition has the ignition distributor with the contactless generator of impulses, with the ignition advancing regulator centrifugal and vacuum, established on the back end of the camshaft.
Ignition distributor
| Type |
Bosch 0237 009 604 or Ducellier 2 525 275
|
| Ignition order |
1–3–4–2 (No. 1 from a flywheel)
|
| Initial corner of an advancing of ignition (at 750 rpm of the engine and the switched-off pipeline of the vacuum regulator) |
8 ° before VMT
|
Ignition coil
| Brand |
Ducellier BTR 05
|
| Winding resistance (at a temperature of 20 °C): |
| – primary |
0,7 Ohm
|
| – secondary |
6,6 kOhm
|
| Strengthening module |
Bosch 0227 100 140
|
Spark plugs
| Type |
Champion C9YCX or Eyquem FC 52 LS
|
| Gap between electrodes |
0,8 mm
|
COUPLING
Coupling is frictional, one-disk, dry, with the central spring, operated mechanically, with automatic adjustment.
| Type |
Valeo 180 CP 3300
|
| Outer diameter of a disk |
180 mm
|
| Full speed of a peda | |
