Peugeot 405 Manual

Specifications
Engine removal and overhaul procedures / Specifications


Note: At the time of writing, many specifications for the 1761 cc and 1998 cc (16-valve) engines were not available. Where the relevant specifications are not given here, refer to your Peugeot dealer for further information.

Cylinder head
Maximum gasket face distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm
Cylinder head height:
Standard:
1360 cc engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111.2 ± 0.08 mm 1580 cc, 1761 cc, 1905 cc (8-valve) and 1998 cc (8-valve and 16-valve) engines . . . . . . . . . . . . . . . . . . . . . 158.93 ± 0.05 mm
1905 cc (16-valve) engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132.0 ± 0.15 mm
Minimum after refinishing: 1360 cc engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111.0 mm
1580 cc, 1761 cc, 1905 cc (8-valve) and 1998 cc (8-valve and 16-valve) engines . . . . . . . . . . . . . . . . . . . . . 158.73 mm
1905 cc (16-valve) engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131.8 mm
Valves
Valve head diameter:
Inlet:
1360 cc engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.8 mm
1580 cc engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.6 mm
1761 cc engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not available 1905 cc 8-valve engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.8 mm
1998 cc 8-valve engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.6 mm
1905 cc and 1998 cc 16-valve engines . . . . . . . . . . . . . . . . . . . . . 34.7 mm
Exhaust:
1360 cc engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.4 mm
1580 cc and 1905 cc (8-valve) engines . . . . . . . . . . . . . . . . . . . . . 34.7 mm
1761 cc engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not available 1998 cc 8-valve engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.5 mm
1905 cc and 1998 cc 16-valve engines . . . . . . . . . . . . . . . . . . . . . 29.7 mm
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 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


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