Gasoline engine specifications (Peugeot 305)

Table of contents: General information 🠇 Camshaft 🠇 Connecting rods 🠇 Crankshaft and main bearings 🠇 Cylinder block 🠇 Pistons 🠇 Cylinder head 🠇 Valves 🠇 Valve springs 🠇 Valve guide bushings 🠇 Valve clearances (cold engine) 🠇 Valve timing 🠇 Lubrication system 🠇 Tightening torque (Nm) 🠇 Data on modifications and latest…🠇 XR5A engine 🠇 XR5S engine 🠇 XL/XR engine (since 1984) 🠇 Tightening torque (Nm) 🠇 XU5S engine 🠇

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) — 78 mm

Piston stroke:

XL5 - 67.5 mm
XR5 — 77 mm

Working volume:

XL5 — 1290 cm³
XR5 — 1472 cm³

Compression ratio:

XL5 — 8,8:1
XR5 — 9,2:1

Compression pressure (when starting with the starter, the spark plugs are removed):

XL5 — 11 kg/cm²
XR5 — 11.5 kg/cm²

Maximum power (DIN):

XL5:

Fan off - 65 hp at 6000 rpm
Fan on - 59.5 hp at 5750 rpm

XR5:

Fan off - 74 hp at 6000 rpm
Fan on - 67 hp at 5700 rpm

Maximum torque (DIN):

XL5:

Fan off - 9.6 kg m at 3750 rpm
Fan on - 9.4 kg m at 3750 rpm

XR5:

Fan off - 11.8 kg m at 3000 rpm
Fan on - 11.5 kg m at 3000 rpm

Location of cylinder #1 - Clutch side

The firing order of the cylinders is 1-3-4-2

Direction of rotation - Clockwise (when viewed from the pulley side)

Camshaft

Camshaft drive - via chain and sprockets

Identification marks (see section 35):

XL5 - Early Models - Green Mark Near Center Camshaft Journal
XL5 - Late models - Blue mark near center camshaft journal
XR5 - Early Models - White Mark Near Center Camshaft Journal
XR5 - Late Models - Yellow Marking Near Center Camshaft Journal

Camshaft bearings - 5 regular bearings in the cylinder head

Camshaft journal diameter:

1 (clutch side) — 40.03 mm
2 - 40.43 mm
3 - 40.83 mm
4 - 41.23 mm
5 (from the sprocket side) — 41.63 mm

Maximum ovality of the outer necks is 0.02 mm

Working clearance - 0.05 mm

Axial displacement of the camshaft is 0.04 mm

Cam lift —??? mm

Connecting rods

Type - Forged steel with H-shaped

Length between centers:

XL5 —??? mm
XR5 —??? mm

Connecting rod bearings - With a steel base made of an alloy of aluminum and 20% steel

Connecting rod bearing thickness:

New —??? mm
Repair -??? mm

Connecting rod bearing diameter: 48.655 mm

The diameter of the upper connecting rod bearings is 20.465 mm

The maximum allowable weight difference between the 4 cranks included in the kit is??? mm

Crankshaft and main bearings

Number of bearings -??

Main journal diameter:

New - 53.027 mm
After regrinding by 0.30 mm - 52.727 mm

Crankpin diameter:

New - 44.991 mm
After regrinding by 0.30 mm - 4.691 mm

Crank radius:

XL5 - 67.5 mm
XR5 — 77.5 mm

Working clearance of main journals: 0.016-0.066 mm

Working clearance of connecting rod journals: 0.024-0.063 mm

The crankshaft diameter at the location of the gearbox input shaft bearing is??? mm

Axial displacement of the crankshaft is 0.17-0.27 mm

Thrust washers:

Material:

Series 1 engines - with a steel base and all-lead steel construction
Series 2 engines - steel base and all lead coated steel

Washer thickness: 2.35, 2.40, 2.45 and 2.50 mm

Note: Series 1 engine thrust washers can be installed on Series 2 engines.

Main bearing thickness:

New - 1.874-1.880 mm
Repair - 2.024-2.030 mm

The main bearing caps are standard

The cylinder block bearings have grooves

Cylinder block

Cylinder liners:

Overall length: 133 mm

Markings - 1 to 4 lines on the top edge

Inner diameter of sleeves:

1 — 78.0-78.01 mm
2 — 78.01-78.02 mm
3 — 78.02-78.03 mm
4 — 78.03-78.04 mm

External protrusions of installed sleeves:

Relative to the cylinder block surface - 0.11-0.21 mm (ideal size 0.14 mm)
Relative to the adjacent sleeve(s) - 0.04 mm
The maximum deviation of the base from the horizontal is 0.02 mm

Sleeve gasket thickness:

Blue - 0.087 mm
White - 0.102 mm
Red - 0.122 mm
Yellow - 0.147 mm

Pistons

Type - aluminum alloy with two compression and one oil scraper ring

Marking - Letter A, B, C or D and number 1, 2 or 3 on the piston crown

Diameter:

A — 77.920-77.931 mm
B — 77.931-77.942 mm
C — 77.942-77.953 mm
D — 77.953-77.964 mm

Note: Class "A" piston must be used with a liner marked with 1 line, class "E" piston must be used with a liner marked with 2 lines, etc.

Piston pin bore diameter: 20.506-20.515 mm

Piston ring thickness:

Upper compression - 1.73-1.72 mm
Lower compression - 1.98-1.99 mm
Oil scraper - 4.011 mm

Piston pin:

Length - 68 mm
Diameter by class:

Blue - 20.500-20.497 mm
White - 20.497-20.494 mm
Red - 20.494-20.491 mm

Note: The blue piston pin should be used with the piston marked "1", the white pin should be used with the piston marked "2", and the red pin should be used with the piston marked "3".

Cylinder head

Type - Made of die-cast aluminum alloy with hemispherical combustion chambers, conical spark plug holes and 5 camshaft bearings

Camshaft bearing diameter:

1 (clutch side) — 40.1–40.139 mm
2 — 40.5-40.539 mm
3 — 40.9–40.939 mm
4 — 41.3-41.339 mm
5 (from the camshaft drive side) — 41.7–41.739 mm

Maximum deformation or deviation of the sealing surface from straightness is 0.05 mm

Valves

Head diameter:

Intake valves - 39.5 mm
Exhaust valves - 32.5 mm

Valve seat angle:

Inlet valves - 120°-120°25'
Exhaust valves - 90°-90°25'

Valve stem diameter:

Intake valves:

Bottom - 7.97-7.98 mm
Top - 7.98-7.99 mm

Exhaust valves:

XL5 - bottom - 7.95-7.96 mm
XL5 - top - 7.97-7.98 mm
XR5 - bottom - 7.945-7.96 mm
XR5 - top - 7.956-7.966 mm

Valve seat width:

Intake valves - 2.3 mm
Exhaust valves - 2.8 mm

Valve springs

Type - Single coil springs
Length in free state (approximate) - 47.2 mm
Height:

Valve open - 32.2 mm at a load of 54.9-57.9 kg
Valve closed - 40.0 mm at a load of 23.8-27.4 kg

Installed spring position - Double spiral towards the valve head

Valve guide bushings

Length - 5.1 mm

The inner diameter of the sleeve is 8.02-8.04 mm

Valve clearances (cold engine)

Inlet valves - 0.10 mm
Exhaust valves - 0.25 mm

Valve timing

Inlet valve:	XL5	XR5
opens	6° before TDC	3° before TDC
is closing	38° after BDC	41° after BDC
Exhaust valve:
opens	45° before BDC	42° BDC
is closing	1° after TDC	2° before TDC

Lubrication system

Type - Wet pan - pressure-spray
Lubricant type/specification: Universal motor oil, viscosity SAE 10W/40, according to API SG/CC specifications (Duckhams QXR, QS, Hypergrade Plus or Hypergrade)

System capacity: 4 liters (approximately)

Oil pump type - Eccentric bi-rotor

Oil pressure - 4 bar

The pressure at which the warning light comes on is 0.6 bar

Oil filter — Champion C204 (1978-1983.)

Tightening torque (Nm)

Cylinder head bolts (10):

Stage 1 - 44.1
Stage 2, early engines - 58.9
Stage 2, last engines - 73.5

Camshaft Sprocket Bolts (3) - 19.7
Timing chain housing bolts (17) - 14.6
Engine mounts:
Bolts (4) in the timing belt cover - 17.2
Upper bolts (4) in the engine - 14.6
Upper nuts (3) in the right cushion - 17.2
Bottom bolts and nut (3) - 17.6
Main cap bolts (10) - 51.5
Connecting rod cap nuts (8) - 36.7
Oil pan mesh filter bolts (3) - 5.8
Oil pan cover bolts (13) - 9.8
Oil pan drain plug (1) - 27
Camshaft Sprocket and Gear Bolt (1) - 108
Timing chain tensioner tongue pivot bolt (1) — 12.7
Timing chain tensioner bolts (2) — 5.8
Lubrication line cover bolts (5) - 12.2
Exhaust manifold nuts (8) - 14.6
Front gear selector link bolt (1) - 17.6
Starter bolts (3) - 34.3
Crankshaft pulley bolt - 88.3
Spark plugs - 17.6

Data on modifications and latest models

(in addition to or as a change to the basic data for petrol models)

XR5A engine

General information

Same as for XR5 engine, with the following exception:

Maximum power (DIN) - 74 hp at 5500 rpm
Maximum torque (DIN) - 12.3 kg m at 2500 rpm

XR5S engine

General information

Same as for XR5 engine, with the following exception:

Maximum power (DIN):

Fan off - 89 hp at 6000 rpm
Fan on - 86 hp at 5800 rpm

Maximum torque (DIN):

Fan off - 12.7 kg m at 3000 rpm
Fan on - 12.4 kg m at 3000 rpm

Tightening torque (Nm)

Side main cover bolts - 23

XL/XR engine (since 1984)

Cylinder liners

Sleeve base seal thickness (new type):

Red (or one) mark - 0.116-0.134 mm
Gray mark or 2 marks - 0.136-0.154 mm
Blue mark or 3 marks - 0.166-0.194 mm

Oil filter — Champion C204 (1290 cm³ and 1472 cm³ engines)

Tightening torque (Nm)

Cylinder head bolts (with new sleeve seals):

Stage 1 - 48.8
Stage 2 - 73.2
Step 3 (see text) - Tighten another 35°

XU5S engine

General information

Number of cylinders - 4

Cylinder diameter x piston stroke: 83 x 73 mm

Working volume - 1580 mm

Compression ratio: 9.5:1

Maximum power (DIN) - 94 hp at 6000 rpm

Maximum torque (DIN) - 13.7 kg m at 3750 rpm

The firing order of the cylinders is 1-3-4-2

Location of cylinder No. 1 - Flywheel side

Camshaft

Camshaft drive - via toothed belt

Action Type - Direct to Pushers

Axial displacement of the camshaft (not regulated) — 0.07-0.16 mm

Cam lift

Early models - 10.4 mm

Latest models - 9.7 mm

Connecting rods

Type - Forged steel

The diameter of the hole in the lower head of the connecting rod is 48.655-48-671 mm

Connecting rod upper head bore diameter: 21.959-21.971 mm

Crankshaft and main bearings

Number of bearings: 5

The diameter of the main bearing seat in the crankcase is 63.708-63.727 mm

Main journal diameter:

New - 59,981-60,000 mm
After regrinding - 59.681-59.700 mm

Crankpin diameter:

New - 44.971-44.990 mm
After regrinding - 44.671-44.690 mm

Crankpin out-of-roundness: max. 0.007 mm

Axial displacement of the crankshaft: 0.07-0.27 mm

Thrust washers thickness: 2.30, 2.35, 2.40, 2.45 and 2.50 mm

Cylinder liners

Type - Wet, removable, matched to pistons

The amount of protrusion of the installed liners above the cylinder block:

Hexagon head bolts - 0.08-0.15 mm
Torx bolts - 0.03-0.10 mm

Pistons

Type - Made of aluminum alloy with two compression and one oil scraper ring, matched to the sleeves

Marking:

By the piston pin - Number 1 (blue mark), 2 (white mark) or 3 (red mark)
On the sleeve - One, two or three slashes

Piston pins

Nominal diameter - 20 mm

Coding - Color Mark (see piston markings)

Fit - Floating fit in the piston, fixed fit in the connecting rod

Cylinder head

Material - Aluminum alloy

Maximum deformation of the sealing surface is 0.05 mm

Valve guide inner diameter: 7.978-8.000 mm

Number of camshaft bearings: 5

Valves

Head diameter:

Inlet valves - 40 mm
Exhaust valves - 32 mm (early models), 32.95 mm (latest models)

Valve stem diameter:

Intake valves - 7.965-7.980 mm
Exhaust valves - 7.945-7.960 mm

Valve length:

Intake - 107.39-107.59 mm
Graduation - 106.82-107.02 mm

Valve clearances (cold engine)

Inlet valves - 0.20 + 0.05 mm
Exhaust valves - 0.40 + 0.05 mm
Adjustment method - Using special washers between the pusher and the valve stem

Valve springs

Marking:

Early type (high-lift camshaft) - Blue mark
The last type (camshaft with reduced cam lift) Black mark of valve timing

Theoretical valve clearance is 1 mm

The intake valve opens at TDC

The inlet valve closes at 37° before TDC

The exhaust valve opens at 35° BDC

The exhaust valve closes at 2° after TDC