Peugeot405
1. The maintenance instruction
2. Maintenance service
3. Engines
    3.1. Petrol engines
    3.2. Diesel engines
    3.3. The petrol engine 1,4 дм3
      3.3.1. A technical characteristics
      3.3.2. Check and adjustment of a backlash of valves
      3.3.3. Check and adjustment of a corner of an advancing of ignition
      3.3.4. Carburettor adjustment
      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 from the petrol engine 1,4 дм3
      3.3.9. Features of dismantling of the petrol engine 1,4 дм3
      3.3.10. Engine TU3 dismantling
      3.3.11. Dismantling of a head of the block of cylinders
      3.3.12. Assemblage of a head of the block of cylinders
      3.3.13. Definition of the size of loose leaves
      3.3.14. Engine TU3 assemblage
      3.3.15. Removal of the oil pump
      3.3.16. Dismantling of the oil pump
      3.3.17. Removal of the pump of a cooling liquid
      3.3.18. Service and repair of a transmission of type МА
      3.3.19. Removal and installation of a transmission of type МА
      3.3.20. Transmission dismantling
      3.3.21. Dismantling of a secondary shaft
      3.3.22. Dismantling of a primary shaft
      3.3.23. Differential dismantling
      3.3.24. Dismantling of knot of plugs with their axes
      3.3.25. Dismantling of the plug of synchronizers
      3.3.26. Verification of parts of a transmission
      3.3.27. Assemblage of the plug of synchronizers
      3.3.28. Assemblage of knot of plugs with their axes
      3.3.29. Differential assemblage
      3.3.30. Assemblage of a primary shaft
      3.3.31. Assemblage of a secondary shaft
      3.3.32. Transmission assemblage
    3.4. Ignition system
4. Fuel system
5. Systems of greasing, cooling
6. Release system
7. Coupling
8. Transmissions
9. Power shafts
10. A steering
11. Suspension brackets
12. Brake system
13. A body
14. An electric equipment



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3.3.1. A technical characteristics
THE GENERAL DATA

THE ENGINE

The engine four-cycle, four-cylinder, рядный, carburettor, water cooling, a camshaft in a head of the block of cylinders, is established cross-section in front of the car with an inclination on 6 back, a drive on forward wheels.

Type
TU 3.2 TO
Working volume
1360 sm3
Diameter of the cylinder
75 mm
Piston stroke
77 mm
Compression degree
9,3
Pressure of compression
1,1 МПа
The maximum capacity
56 kw (76 h.p.)
The maximum moment
114 Nanometers at 3800 rpm

SYSTEM GAZORASPREDELENIJA

Phases timing:
  – A backlash of valves for the control of phases timing
0,7 mm
  – Opening of the inlet valve
7 05 ' before ВМТ
  – Closing of the inlet valve
41 27 ' after НМТ
  – Opening of the final valve
52 42 ' before НМТ
  – Closing of the final valve
1 14 ' before ВМТ

Camshaft

The camshaft is established 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.

Camshaft designation
The letter In (from outside ignition systems)
Longitudinal backlash a camshaft
0,07 – 0,16 mm (it is regulated by a washer from outside ignition systems)

Gear belt

The gear belt puts in action a camshaft and the pump of a cooling liquid.

Type
Pirelli Isoran 108 RPP 170 HSL
Number of teeths
108
Width
15 mm
Number of teeths of a pulley:
  – A cranked shaft
21
  – A camshaft
42

Valves

Valves in system V are established at an angle 33 , put in action from a camshaft through bilaterial levers. Number of valves on the cylinder – 2.

The inlet valve:
  – Length
110,76 0,15 mm
  – A corner прилегания
120
  – Width прилегания
1,9 mm
  – Diameter of a core
6,90 – 0,015 mm
  – Diameter of a plate
36,8 mm
  – The minimum thickness of a facet of a plate
1,0 mm
The final valve:
  – Length
110,6 mm
  – A corner прилегания
90
  – Width прилегания
2,2 mm
  – Diameter of a core
6,980 – 0,015 mm
  – Diameter of a plate
29,4 mm
  – The minimum thickness of a facet of a plate
1,5 mm
Working backlash of valves (on the cold engine):
  – The inlet valve
0,20 mm
  – The final valve
0,40 mm

Saddles of valves

The inlet valve:
  – A corner прилегания
90
  – External 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 nominal
6,648 0,1 mm
  – Height repair
7,000 0,1 mm
The final valve:
  – A corner прилегания
90
  – External 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 nominal
6,648 0,1 mm
  – Height repair
7,000 0,1 mm

Directing valves

Internal diameter
7 0,022 mm
External diameter:
  – Nominal 1
13,02 0,039 or 13,02 0,028 mm
  – Nominal 2
13,13-0,011 mm
  – The repair size 1
13,29-0,011 mm
  – The repair size 2
13,59-0,011 mm

Springs of valves

It is used on one spring on the valve. Inlet and final valves have identical springs.

Internal diameter of a coil
21,40,4 mm
Diameter of a wire of a spring
3,6 mm
Height:
  – At loading 280 Н
40 mm
  – At loading 500 Н
32 mm

Head of the block of cylinders

The head is executed from an easy alloy and has the inserted steel saddles of valves.

Height:
  – The nominal
111,2 0,08 mm
  – The minimum
111 mm

The prevention

Heads of the block of cylinders, сошлифованные to the minimum height, are designated by letter R on a head below a final aperture of the third cylinder.


Such heads of the block of cylinders during repair cannot be exposed more to grinding any more. Besides, they it is obligatory at installation use of the lining also designated by letter R (with the thickness increased by 0,2 mm) demand.

The maximum admission неплоскостности the bottom surface of a head
0,05 mm

Lining of a head of the block of cylinders

The lining of a head of the block of cylinders has a metal fringing round cylinders.

Mark
Payen Curty
Thickness of a lining:
  – The nominal
1,3 mm
  – For перешлифованной heads
1,5 mm

The block of cylinders of the engine

The block of cylinders of the engine is made of an easy alloy, consists of two parts, is divided on an axis of a cranked 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 pig-iron are divided into three groups designated by 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
Vystupanie 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-SHATUNNYJ THE MECHANISM

Pistons

Pistons are made of an easy alloy and have three rings.

Diameter of pistons (mm):
  – Group And
74,960 – 74,970
  – Group In
74,970 – 74,980
  – Group With
74,980 – 74,990
Assembly backlash of the piston in the cylinder
0,03 – 0,05 mm
Installation
The arrow on the piston bottom should be directed towards a drive timing
Backlashes on the ring lock:
  – First (top)
0,30 – 0,50 mm
  – The second (average)
0,30 – 0,50 mm
  – Third (bottom)
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 I)
19,495 – 19,498 mm
  – Group 2 (on the piston 2, on a finger II)
19,492 – 19,495 mm
  – Group 3 (on the piston 3, on a finger III)
19,489 – 19,492 mm
Assembly backlash of a finger in the piston
0,01 – 0,016 mm
Length of a finger
62 0,25 mm

Rods

Rods are shaped from a steel.

The maximum difference of weights between rods of the same engine
3 г
Interaxal distance
126 0,07 mm
Diameter of the top head of a rod
19,4630,013 mm
Diameter of an aperture of the bottom head of a rod
48,6550,016 mm

Cranked shaft

The cranked shaft is made of pig-iron and leans against five radical bearings.

Axial backlash a cranked shaft
0,1 – 0,3 mm
The sizes of a cranked shaft:
  – The nominal:
     • diameter of radical necks
49,981-0,016 mm
     • width 2 radical necks
23,60,052 mm
     • diameter шатунных 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
  – The repair:
     • diameter of radical necks
49,681-0,016 mm
     • width 2 radical necks
23,80,052, 23,90,052, 24,00,052 mm
     • diameter шатунных necks
47,7-0,025 mm
     • diameter of a neck of consolidation on a flywheel
84,8-0,065 mm

Loose leaves of radical bearings

Thickness:
  – The nominal
1,829 0,003 mm
  – The repair size
1,979 0,003 mm

Loose leaves шатунных bearings

Thickness:
  – The nominal
1,817 0,003 mm
  – The repair size
1,967 0,003 mm

Persistent rings

Thickness:
  – The nominal
2,4 mm
  – The repair size 1
2,50 mm
  – The repair size 2
2,55 mm
  – The repair size 3
2,60 mm

Flywheel

Maximum palpation
0,05 mm
Maximum утоньшение after processing
1,0 mm

GREASING SYSTEM

Greasing under pressure provides шестеренчатый the oil pump with an external arrangement of the teeths, attached from below to the block of cylinders and put in action a single-row chain from a cranked shaft.

Pressure of oil (at temperature 90 )

Depending on turns of the engine pressure of oil makes:
  – At 750 rpm
0,15 МПа
  – At 1000 rpm
0,20 МПа
  – At 2000 rpm
0,30 МПа
  – At 4000 rpm
0,40 МПа

The oil filter

The oil filter has a paper replaced element.

Mark 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 (a gear belt put in action). Into structure of system of cooling enter: a radiator, the pump of a cooling liquid, a broad tank and the fan with the electric motor, operated a thermoswitch.

The thermostat

Type
Calorstat
Temperature of the beginning of opening
88 WITH
Temperature of full opening
102 WITH
Valve stroke
The minimum 7,5 mm

The fan

The fan восьмилопастной, capacity of 120 Vt, diameter of 285 mm.

Inclusion temperature
98 WITH
Deenergizing temperature
92 WITH

The temperature gauge

Established in a head of the block of cylinders the gauge causes fire of a control bulb on a combination of devices at achievement by a cooling liquid of temperature 118 With.

FUEL SYSTEM

The fuel pump

Диафрагменный the fuel pump is put in action mechanically from a camshaft.

Electric type – external (early models) or internal (later models).

Pressure
25 кПа
Pressure of giving of the pump:
  – Fenix IB, MM G5 and MM G6
0,7 – 0,8 bar
  – Bosch MA3. 0
1,0 0,1 bar.
Productivity of the pump:
  – Fenix IB and Bosch MA3. 0
370 sm3 for 15секунд
  – MM G5 and G6 systems
360 sm3 for 15секунд

The air filter

The dry air filter has a replaced paper element.

Type
Purflux F 973

The carburettor

The two-chamber carburettor has the starting arrangement operated manually.

Type
Solex Z2/528 or Weber 34 TLP
Carburettor Solex Z2/528:
  – Diameter диффузора:
     • 1 chamber
24
     • 2 chamber
25
  – The main fuel jet:
     • 1 chamber
115
     • 2 chamber
120
  – The main air jet:
     • 1 chamber
155
     • 2 chamber
160
  – A fuel jet of idling
40
  – A jet of transitive system (bypass)
50
  – An enrichment jet
45
  – A jet of the accelerating pump:
     • 1 chamber
35
     • 2 chamber
35
  – A fuel jet эконостата
80
  – Diameter of a saddle needle valves
1,6
  – Opening throttle заслонки
0,5 mm
  – Opening air заслонки
3,0 0,5 mm
  – Float position (measured from the lowest surface of a float to a plane of a cover with a lining in horizontal position by means of a special template)
33,5 mm
  – Idling turns
750 rpm
  – The maintenance WITH
1,5 %
  – The minimum maintenance СО2
10 %
Carburettor Weber:
  – Height of installation of a float
32,0 mm
  – Opening заслонки after start
5,0 mm

Cистема fuel injection

System type:
  – Engine TU3 (K12X)
Solex Fenix IB the one-dot
  – Engine TU3 (K12X)
Bosch Monotronic MA3. 0 one-dot

IGNITION SYSTEM

The transistor system of ignition has the distributor of ignition with the contactless generator of impulses, with a regulator of an advancing of ignition centrifugal and vacuum, established on the back end of a camshaft.

The ignition distributor

Type
Bosch 0237 009 604 or Ducellier 2 525 275
Ignition order
1–3–4–2 (№1 from outside a flywheel)
Initial corner of an advancing of ignition (at 750 rpm of the engine and the disconnected pipeline of a vacuum regulator)
8 before ВМТ

The ignition coil

Mark
Ducellier BTR 05
Resistance of a winding (at temperature 20С):
  – The primary
0,7 Ohm
  – The secondary
6,6 clod
The strengthening module
Bosch 0227 100 140

Spark plugs

Type
Champion C9YCX or Eyquem FC 52 LS
Backlash between electrodes
0,8 mm

COUPLING

Coupling frictional, one-disk, dry, with the central spring, operated mechanically, with automatic adjustment.

Type
Valeo 180 СР 3300
External diameter of a disk
180 mm
Pedal full speed
140 5 mm

TRANSMISSION

Transmission mechanical, five speeds plus transfer of a backing, transfer for advance are synchronised.

Type
МА 5
Transfer numbers:
  – 1st transfer
3,41
  – 2nd transfer
1,80
  – 3rd transfer
1,27
  – 4th transfer
0,97
  – 5th transfer
0,77
Backing transfer
3,58
Transfer number of the main transfer
4,08

Power shafts

The power shafts connected from both parties by means of parallel three-humeral hinges from outside of a transmission and spherical hinges (Rzeppa) cо of the party of wheels.

STEERING SYSTEM

Mechanical (without the hydraulic booster) or mechanical with the hydraulic booster (additional equipment), with an adjustable angle of slope of a steering column.

Steering transfer

Steering transfer – реечная in mechanical system and реечная with the distributing valve and the servomotor in system with the hydraulic booster.

Steering without the hydraulic booster

The transfer relation
23,8
Number of teeths driving gear wheels
6
Number of turns of a steering wheel from an emphasis against the stop
4,1
Turn radius:
  – Between walls
5,5 m
  – Between sidewalks
5,275 m

Steering with the hydraulic booster

The transfer relation
17,9
Number of teeths driving gear wheels
8
Number of turns of a steering wheel from an emphasis against the stop
3,1
Turn radius:
  – Between walls
5,5 m
  – Between sidewalks
5,275 m

The hydraulic booster pump

The lopastnoj pump is put in action from a cranked shaft клиновым by a belt. Mark of the pump – Saginaw.

Klinovoj belt

Type
Kleber Venuflex 10 х 650 Le
Tension:
  – A new belt
500 – 550 Н
  – A belt which was in the use
400 – 500 Н

FORWARD SUSPENSION BRACKET

Independent, type Mac Pherson, with the bottom levers and the cross-section stabilizer.

Nave of a forward wheel – on двухрядном the ball bearing.

Diameter of the stabilizer
20 mm
Suspension bracket spring:
  – Diameter of coils
157 mm
  – Diameter of a core
12 mm
  – Compression under loading 1000 Н
63 mm
  – Full compression
195,2 mm

Installation of forward wheels (the equipped car)

The convergence (is regulated)
3,5 1 mm (0 35 ' 10 ')
The wheel inclination (is not regulated)
0 13 ' 30'
The advancing of a finger of a rotary fist (is not regulated)
1 10 ' 30'
The inclination of a finger of a rotary fist (is not regulated)
10 40 ' 30'

BACK SUSPENSION BRACKET

Independent, on the separate levers connected torsionом (established behind an axis) and the stabilizer (established before an axis), with the longitudinal hydraulic telescopic shock-absorbers of double action established horizontally.

Nave of a back wheel – on двухрядном the ball bearing.

Diameter of the stabilizer
18 mm
Торсион:
  – Diameter
18,6 mm
  – Elasticity of a wheel at loading 1000 Н
63 mm
  – A full bend of a wheel
257,6 mm

Installation of back wheels (the car without loading)

The control height of a suspension bracket (is not regulated)
205 7 mm
The divergence (is not regulated)
0,5 1 mm (0 05 ' 10 ')
The wheel inclination (is not regulated)
1 20 ' 30'

BRAKE SYSTEM

Working brake system hydraulic, two-planimetric (division on a diagonal), with the vacuum amplifier of brakes.

The manual brake operates mechanically on brakes of back wheels.

Brakes of forward wheels

Disk, with a floating support, Bendix IV.

External diameter of a disk
266 mm
Thickness of a disk:
  – The nominal
10 mm
  – Minimum (after repair)
9 mm
Admissible disk palpation
0,07 mm
Brake pads
Abex 903 or Valeo F 599
The minimum admissible thickness pads
It is defined by deleting of an average flute in a material pads, it is signalled by fire of a corresponding control bulb (the electric alarm system of deterioration by means of a wire, впрессованного in brake pads)
Diameter of the cylinder of a support
48 mm

Brakes of back wheels

Drum-type, with automatic adjustment of a backlash pads, with the terminators of the pressure which have been built in brake cylinders.

Working diameter of the cylinder:
  – The nominal
228,6 mm
  – Maximum (after repair)
229,6 mm
Brake pads
Valeo F 154
Nominal thickness of overlays
5 mm
Width of overlays
40 mm
Diameter of cylinders
20,6 mm
The main brake cylinder
In system a tandem, Bendix or АТЕ
Diameter of pistons
20,6 mm
The vacuum amplifier
Type Isovac, Bendix or АТЕ
Diameter of the piston
203,2 mm

WHEELS AND TYRES

Disks
5.00 J х 14 FH 4.25
Tyres
165/70 R 14 Т
Pressure in wheels:
  – Forward wheels
0,21 МПа
  – Back wheels
0,21 МПа

THE ELECTRIC EQUIPMENT

The accumulator
12 In 175 And or 12 In 200 And, a minus (-) on weight
The generator
55 And, Bosch or Valeo
Klinovyj belt
Hutchinson AV 10
Belt deflection
5 – 10 mm under finger pressing half of distance between pulleys
Starter
Bosch 0001 112 019 or Valeo 126 RA 37
Capacity
1256 Vt
Idling:
  – Pressure
11,4 IN
  – A current
Maximum 60 And
Braking:
  – Pressure
11,4 IN
  – A current
Maximum 500 And
Safety locks
7 х (12 In, 5); 3 х (12 In, 10); 5 х (12 In, 15); 2 х (12 In,
20; 2 х (12 In, 25)
Bulbs:
  – Headlights
H4 55/60 Vt
  – Antifog headlights
55 Vt
  – Dimensional fires forward and back
5 Vt
  – Indexes of turns
21 Vt
  – Braking fires
21 Vt
  – Backing lanterns
21 Vt
  – Antifog back lanterns
21 Vt

WEIGHTS

Body weight
1030 kg
Full weight
1470 kg
The maximum weight of the trailer without brakes
435 kg
The maximum weight of the trailer with brakes
900 kg

FUEL CONSUMPTION

At speed of 90 km/h
5,5 dm3/100 km
At speed of 120 km/h
7,5 dm3/100 km
City cycle
8,3 dm3/100 km

The maximum speed – 169 km/h.

THE TIGHTENING MOMENTS

The engine

Bolts of a head of the block of cylinders:
  – 1 stage
20 Nanometers
  – 2 stage
To tighten on 240
Cover of valves
16 Nanometers
Camshaft pulley
80 Nanometers
Roller of the tension device of a gear belt
23 Nanometers
The case of the distributor of ignition
16 Nanometers
Covers шатунных bearings
40 Nanometers
Covers of radical bearings:
  – 1 stage
20 Nanometers
  – 2 stage
To tighten on 45
The bottom part of the block of cylinders to the top part of the block of cylinders
8 Nanometers
Flywheel
65 Nanometers
Pulley to a cranked shaft
110 Nanometers
The oil pump to the block of cylinders
8 Nanometers
Drain stopper to the oil pallet
30 Nanometers
Spark plugs
17,5 Nanometers
Leading part of coupling to a flywheel
10 Nanometers
The engine to a transmission
45 Nanometers

Transmission

Carter of a box to картеру couplings
18 Nanometers
Back cover
18 Nanometers
Nut of a primary shaft
140 Nanometers
Intermediate plate to картеру couplings
50 Nanometers
Drain stopper of oil from a transmission
25 Nanometers

Steering system

Steering transfer to a cross-section beam
40 Nanometers
Tightening holder to a steering shaft
20 Nanometers
Tip of steering bent for to a shoulder
35 Nanometers
The distributing valve to steering transfer
12,5 Nanometers
Bolt of a disk of a wheel
85 Nanometers

Forward suspension bracket

Cross-section beam to the chassis
90 Nanometers
Back fastening of the lever to a beam
45 Nanometers
Forward fastening of the lever to a beam
45 Nanometers
Holder of a rotary fist
55 Nanometers
Finger of a rotary fist to the lever
30 Nanometers
Finger of a rotary fist to a rotary fist
260 Nanometers
The draught connecting the stabilizer with the lever
65 Nanometers
Tip of steering bent for to a shoulder
35 Nanometers
Suspension bracket column to a body
25 Nanometers
Nut of an axis of a nave
265 Nanometers

Back suspension bracket

The shock-absorber to the lever
110 Nanometers
The shock-absorber to an arm
110 Nanometers
Shoulders of a forward beam to the chassis
60 Nanometers
The forward rubber plug to the chassis
55 Nanometers
The back rubber plug to the chassis
55 Nanometers
Holder torsionа and the stabilizer
55 Nanometers
Lateral bolts torsionа
17,5 Nanometers
Nut of an axis of a nave
275 Nanometers

Brake system

Support to a rotary fist
120 Nanometers