Gasoline car engines Peugeot 305

Gasoline engine specifications
General information Engine type: 4-cylinder, transversely mounted, in-line engine with overhead camshaft and water cooling. Engine code: Models GL and GR - XL5 (118) Models SR - XR5 (142) Cylinder diameter (all models)...

General description of gasoline engines
The Peugeot 305 is equipped with a 4-cylinder in-line engine with an overhead camshaft. There are two versions of this engine: the XL5 (118) with a capacity of 1290 cc is used in the GL and GR models, and the XR5 (142)...

Liner Seal Modifications (XL/XR Series Engines)
1. In 1984, steel seals began to be used instead of paper ones at the base of the cartridge cases. Changes were also made to the liner design (see liner seal markings. v Specifications ). 2. New liners and seals can be...

Side main cover bolts (XR5S engine)
1. For greater reliability, the central main bearing cap on the XR5S engine is additionally secured with two side bolts. 2. When removing the crankshaft, first unscrew the side bolts and only then remove the central...

Timing Housing Seal (all models)
1. On some models, the timing case gasket is not initially installed. Instead, a special sealant is used. On these models, the O-ring between the cylinder block and the timing case is a different size. 2. When...

XU Series Engine — general description
1. The XU series engine found in the GT, GTX and later GR and SR models is similar to the XL and XR engines in that it also has 4 wet cylinders, a 5-bearing crankshaft and an overhead camshaft. 2. The camshaft is driven...

Basic operations that can be carried out without removing the engine from the vehicle
Without removing the engine from the car, you can perform the following operations: a.* Removing and installing the clutch. b.* Removing and installing the drive shaft gear and seals. in.* Removing and installing the...

Basic operations requiring removal of the engine from the vehicle
The engine must be removed to perform the following operations: a. Removal and installation of the gearbox. b. Removal and installation of the crankshaft and main bearings. c. Removal and installation of connecting rod...

Engine and gearbox — removal
1. The engine and gearbox can only be removed as a single unit and not separately. The overall weight of the engine and gearbox is not that great due to the extensive use of aluminum alloy, however, some operations are...

Engine disassembly — general part
1. It is best to disassemble the engine on a clean work bench. Before installing the engine and gearbox on the table, they should be cleaned from the outside from dirt, oil and grease. 2. Be careful not to bring dirt...

Engine Disassembly — auxiliary equipment
1. Whether you are planning a complete engine rebuild or simply want to exchange it for a new or rebuilt one, you will need to remove the accessories from the engine. 2. The only way to assess the engine's condition is...

Removal with gearbox (XU series engine)
1. The method described here is to remove the engine together with the gearbox from below. If desired, you can first remove the gearbox and then pull the engine out through the top, however, we do not recommend this...

Disconnecting the gearbox from the XU series engine
32. Remove the starter, which is secured with 3 Allen head bolts, and its support bracket (see photos). 33. Remove the remaining bolts securing the engine to the gearbox. 34. Support the engine and disconnect the...

Disassembling the XU series engine
35. Remove the following auxiliary equipment from the engine: a. Generator and its drive belt. b. Oil filler tube and crankcase ventilation tubes (having previously memorized their location). c. Intake manifold and...

Cylinder head — removal from the engine while it is on the vehicle
1. The cylinder head can be removed and refitted without removing the engine from the car, however you will need the special Peugeot tool (N 8.0140) to hold the camshaft sprocket in place and prevent the timing chain...

Cylinder liner protrusion value — checking and adjustment
1. The liners installed in the block must protrude outward by a specified amount after installing the cylinder head; there is a gas-tight connection between it and the block. If even one sleeve protrudes too much or,...

Disassembling the cylinder head (XU series engines)
62. If not already done, remove the distributor, fuel pump and spark plugs. Remove the manifolds with their gaskets. 63. Loosen the bolts and remove the cooling system outlet pipe housing. Don't forget to remove the...

Cylinder head resurfacing (XU series engines)
71. The manufacturer prohibits regrinding of the cylinder head, therefore a head with a deformed surface must be replaced. 72. Heads supplied for exchange may have a contact surface reground by 0.2 mm. Such heads are...

Cylinder head — installation on the engine standing on the car
1. Check that all contact surfaces are clean. Check that the cylinder liners are not slanted and protrude above the cylinder block by the required amount. Prepare new cylinder head gaskets, timing case, valve cover and...

Cylinder head assembly (XU series engines)
1. Install new valve stem seals and then valve springs and crackers. Lubricate the valve stems well with oil. To keep the crackers in place while the springs are compressed, secure them with grease. The springs can be...

Valve timing mechanism — removal
1. If not already done, remove the 2 bolts securing the fuel pump to the rear surface of the timing case. Remove the pump with the gasket and pull out the pump plunger. 2. Unscrew the distributor clamp bolt and remove...

Engine and gearbox — disconnection
1. After removing the valve timing and clutch mechanism from the crankcase, the engine and gearbox are held together only by bolts in the front and rear flanges. 2. Place the engine with the gearbox under the hoists and...

Cylinder head — removal from the engine on the work bench
1. Support the engine with wooden blocks and then gradually loosen the 10 cylinder head bolts in the reverse order of tightening ( see section 35 ). As the bolts are loosened, the rocker arm will gradually lift the head...

Pistons, connecting rods and crankshaft — removal
1. The pistons, connecting rods and crankshaft may only be removed from the engine, which has been transferred to the work bench and disconnected from the gearbox, and the timing case, clutch and cylinder head must...

Piston rings — removal
1. Carefully remove the piston rings through the piston crown, being careful not to scratch the aluminum alloy. Do not try to remove the rings through the piston skirt, as they are iron and break easily. To make it...

Camshaft — removal
1. If the engine is still in the car, the cylinder head must be removed before removing the camshaft. If the engine has already been removed and placed on the work bench, it is necessary to remove the timing cover and...

Lubrication system — description
The models in question use a forced lubrication system, with oil circulation achieved by an oil pump that pumps oil from a sump under the gearbox. The high-performance rotary pump is located in the lower part of the...

Oil filter — removal and installation
1. The full-flow oil filter is located in the front of the timing case, on the right side of the engine. 2. The filter is replaceable and screwed directly into the threaded bushing in the timing case. 3. Before removing...

Cylinder head — disassembly, inspection and installation
1. Remove the cylinder head and place it on a clean work bench for disassembly and inspection. Please remember that the head is made of light alloy and is easily damaged. 2. Install a valve spring compressor on the...

Connecting rod and main bearings — inspection and maintenance
1. New bearings have a highly polished surface that becomes matte gray over time. There should be no pits, ridges, grooves, or scratches on the bearings. Even if the bearing shells appear to be in good condition, we...

Cylinder liners — inspection and maintenance
1. Cylinder liners can be inspected for wear either by removing them from the cylinder block or by leaving them in place (the cylinder head, of course, must be removed in both cases). If the liners are located in the...

Connecting rods, pistons and piston rings — inspection and cleaning
1. Remove the pistons and connecting rods from the sleeves and clean them thoroughly with kerosene. Use a scraper to scrape off any carbon deposits from the piston crowns, being careful not to damage them. Carefully...

Timing chain and sprockets — inspection and maintenance
1. Inspect the teeth of both sprockets for wear. The tooth is shaped like an inverted "V" and as it wears, one side of the tooth becomes more concave than the other. Severely worn teeth take on a hook-shaped form, in...

Camshaft and rockers — inspection and maintenance
1. Inspect the camshaft lobes for wear and damage. At the same time, inspect the rockers for wear, especially in those places where they rest on the camshaft lobes. If there are obvious defects or dents on the thrust...

Oil pump — inspection and maintenance
1. The oil pump is located in the lower part of the timing case and is driven by a shaft from a helical gear located on the crankshaft. The pump is an eccentric rotary pump and to get to it you need to remove the cover...

Intake and exhaust manifolds — inspection
1. The intake manifold is connected to the cylinder head by 4 short hoses, which we recommend replacing when overhauling the engine. The clamps on these hoses must be in good condition. If there is the slightest doubt,...

Engine mounts — inspection
Engine mounts are often forgotten because they usually don't cause much trouble. If the rubber parts of the cushions are in poor condition due to exposure to heat or oil or simply due to long-term use and they should be...

Engine assembly — general part
1. In order to ensure the maximum service life of a rebuilt engine, several basic principles should be followed during its assembly. 2. Absolute cleanliness must be maintained. Assembly must be carried out in a clean...

Engine — preparation for assembly
1. If the engine has been completely disassembled so that the cylinder block is open, it should be thoroughly cleaned inside and out. If not already done, remove the 5 bolts securing the oil line cover to the side of...

Inspection and tidying up of XU engine parts (general part)
1. See Chapter 1A, Sections 20 , 22 , 23 , 24 and 30 . 2. The camshaft drive belt must be replaced in any case, unless it is in excellent condition. Replace sprockets if they are damaged or defective. 3. Inspect the...

Assembly of the XU series engine
1. See Chapter 1A, Sections 31 and 32 (skipping everything that relates to the O-ring seal located on the cylinder block on the clutch side). 2. Turn the cylinder block over and install the upper main bearing shells....

Connecting the XU engine to the gearbox
41. Check that the clutch release mechanism components are correctly installed in the clutch housing and that the driven disc and clutch basket are installed on the flywheel. (On models with an automatic transmission,...

Installing an XU engine with a gearbox on a car
45. Install the drive shaft seal protector on the right side of the final drive assembly (see photo). 46. Raise and support the front of the vehicle and place the engine and gearbox under the engine compartment. 47....

Crankshaft — installation
1. Thoroughly clean the crankcase and cylinder block and turn the block over so that the surface on which the cylinder head is installed is at the bottom. 2. Wipe clean the main bearing seats in the crankcase and...

Pistons, connecting rods and cylinder liners — installation
1. First of all, you need to install the liners in the cylinder block and check that they are in place and not warped, and also check the amount of protrusion of the liners above the cylinder block and the difference in...

Cylinder head — installation on an engine removed from a car
1. If the cylinder head has been rebuilt as described in Section 20 and the cylinder block has been assembled to the stage reached in the previous section, the key and sprocket should be temporarily installed on the...

Engine and gearbox — connection to each other
1. Connect the gearbox to the engine ( see Chapter 6, Section 6 ). 2. If the transmission has not been disassembled, it is advisable to remove the lower transmission cover and then the oil intake filter, which is...

Timing chain and sprocket assembly
1. Check that the keyways on the end of the crankshaft are clean and install the keys (see B/Figure 1.20 for the installation sequence of the various parts). 2. Install the sprocket on the crankshaft (teeth towards the...

Timing mechanism housing — assembly and installation
1. Install the combined helical gear and fuel pump cam into place in the timing case, insert the drive shaft and engage the drive dogs (see photos). Lubricate the drive mechanism with clean engine oil. 2. Assemble the...

Valve clearances — checking and adjustment
1. The procedure for adjusting valve clearances remains the same regardless of whether the engine is removed from the car or not. In the latter case, adjustment is performed only on a cold engine. The engine's...

Clutch — installation
1. For clutch installation procedure, see. v chapter 5, Section 7 , starting with paragraph 5 (taking into account that the engine is on the car).

Engine assembly — final operations
1. After the main engine components have been assembled, auxiliary equipment and minor parts can be installed. Try to fully assemble the engine before installing it and the gearbox on the car, if possible. If you are...

Engine and gearbox installation
1. In general, the installation of the engine with the gearbox is carried out in the reverse order of its removal. Check that the components are securely fastened to the engine lugs. 2. Before lowering the engine, check...

Checking valve clearances (XU series engines)
1. Remove the distributor cap with high voltage wires. Unscrew the bolts and remove the valve cover, being careful not to damage the gasket. 2. The engine can be turned either by jacking up one of the front wheels and...

Adjusting valve clearances (XU series engines)
9. Remove the camshaft (see below). 10. Remove one of the tappets with its adjusting washer (make sure that the washer does not fall out of the pusher). Clean the washer and measure its thickness with a micrometer (see...

Removal and installation the camshaft drive belt (engine is on the car)
18. Disconnect the ground cable from the battery. 19. Remove the generator drive belt. 20. Remove the inner shield from the right wheel arch and wedge the lower radiator hose under the pan. Move the expansion tank to...

Removal and installation the camshaft (engine is on the car)
40. Remove the camshaft drive belt as described above. 41. Remove the valve cover. For easier access, remove the distributor cap with high voltage wires. 42. Remove the distributor and fuel pump from the thermostat...

Removal and installation the cylinder head (engine is on the car)
53. Remove the camshaft drive belt ( see above ). 54. Drain the fluid from the cooling system. 55. Loosen, without removing, the central bolt and nut of the lower engine mount rubber. 56. Remove the air cleaner with...

Modification of the crankcase ventilation system
79. When starting the engine in cold weather, the oil filler plug may be knocked out, which is caused by the freezing of water vapor on the wire mesh of the breather and the subsequent increase in pressure when it turns...

Cylinder Head Bolt Modifications (XU Series Engines from December 1986)
82. Since December 1986, the cylinder head is secured with bolts with a hole in the head for a hexagon (55) (torx bolts). 83. In addition, thicker washers (8.0 mm) are used and the height of the cylinder liners is...

Engine — first start after overhaul
1. Check that the battery is well charged, there is fuel in the tank, and the coolant and oil levels in the crankcase are at the correct level. 2. When starting the engine for the first time, you will need to turn the...

XU Series Engines — first run after overhaul
1. See. chapter 1, Section 44, Paragraphs 1-7 . 2. Wait at least 2 hours for the engine to cool down. Loosen the bolt securing the right engine support bracket to the cylinder block, and then retighten the cylinder head...

Engine fault diagnostics
The engine does not turn over with the starter The battery is dead The battery terminal contacts are loose or corroded A break in the wiring to the starter or poor grounding of the engine or battery The starter or...

This section is available on russian, bulgarian, belarusian, ukrainian, serbian, croatian, romanian, polish, slovak, hungarian

Share information:

See similar information for other Peugeot models

➨ Power unit: Petrol engines Peugeot 106 (1991-2003)
➨ Power unit: Gasoline engines Peugeot 206 (1998-2012)
➨ Power unit: Petrol engines 1.6-2.0 l Peugeot 405 (1987-1997)
➨ Power unit: Petrol engines «ZPJ» Peugeot 605 (1989-2000)
➨ Power unit: Gasoline engines Peugeot 807 (2002-2014)

Link to this section in different formats

TEXTHTMLBB Code