Table of contents: Cylinder head 🠇 Valve seats 🠇 Valves: 🠇 Camshaft 🠇 Pistons and connecting rods 🠇 Piston rings: 🠇 Connecting rods and connecting rod…🠇 Crankshaft and flywheel 🠇
Cylinder head
- Cylinder head height (to the centerline of the camshaft) — 140.00±0.05 mm
- Minimum permissible cylinder head height is 139.55 mm
Maximum permissible cylinder head tilt
- diesel engine - 0.03 mm
- turbodiesel engine 0.03 - 0.07 mm
Permissible thickness of material removal during processing - not permitted
Cylinder Head Gasket Thickness - Diesel Engine - Depending on Piston Protrusion Height
- nominal size - 1.61 mm
- extra large size - 1.73
Cylinder Head Gasket Thickness - Turbo Diesel Engine - Depending on Piston Protrusion Height
Information copied from the resource PEUGEOTBOOK
- nominal size - 1.50 mm
- increased size - 1.60 or 1.70 mm
Size of valve heads below cylinder head surface:
- intake valves - 0.5-1.05 mm
- exhaust valves - 0.9-1.45 mm
Valve guides:
- Nominal outside diameter: 14.02 mm
- 1st repair size, 1 groove - 14.29 mm
- 2nd repair size, 2 grooves - 14.59 mm
- Guide bushing hole: 8.0 mm
Mounting height, head surface to guide bushing
- inlet/outlet valve guide bushings — 36.5±0.55 mm
- exhaust valve guide bushings - 36.5±0.55 mm
Cylinder head bore diameter:
- Nominal diameter: 13.981 mm
- 1st repair size - 14.195 mm
- 2nd repair size - 14.495 mm
- diameter tolerance - +0.032 mm
Valve seats
Valve seat angle: - 90°
Valve seat width:
- Intake valves - 1.45 mm
- Exhaust valves - 1.80 mm
Replacing valve seat rings - Performed in a specialized workshop
Valves:
Valve seat angle: - see above
Valve head diameter:
- Inlet valves - 38.60±0.2 mm
- Exhaust valves - 33.00±0.2 mm
Overall length:
- Inlet valves - 112.40±0.3 mm
- Exhaust valves - 111.85±0.3 mm
Valve stem diameter:
- Inlet valves - 7.99±0.03 mm
- Exhaust valves - 7.97±0.1 mm
The maximum permissible grinding of the valve stem end is 0.20 mm
The minimum permissible thickness of the valve edge is 0.50 mm
Valve stem clearances in valve guide bushings:
- Inlet valves - 0.015-0.045 mm
- Exhaust valves - 0.045-0.075 mm
Maximum working clearance of valve stems in guide bushings is 0.10 mm
Valve springs:
- The spring wire diameter is 3.8 mm
- Length in free state - 51.00 mm
- Spring markings - Intake and exhaust valve springs are identical
Camshaft
Number of bearings - 3
Axial clearance of the camshaft is 0.07-0.17 mm
Shaft journal diameter:
- Bearing No. 1 - 27.50 mm
- Bearing No. 2 - 28.00 mm
- Bearing No. 3 - 28.50 mm
Bearing bores in the cylinder head are 0.033 mm larger
Camshaft marking - Colored ring on cam of cylinder 1
Pistons and connecting rods
- Installing piston pins - Floating fit in the piston and in the connecting rod bore.
- Piston installation direction - See "Pistons and connecting rods" section.
Piston rings:
Number of rings - 3
Ring design - 1 regular compression ring, 1 trapezoidal ring, 1 oil-deflecting ring
Piston ring thickness:
- top ring - 2.00 mm
- middle ring - 2.00 mm
- oil deflector ring - 3.00 mm
Piston ring joint clearances:
- nominal dimensions - upper compression rings - 0.20 - 0.40 mm
- medium compression ring - 0.20 - 0.40 mm
- oil deflector ring - 0.25 - 0.40 mm
Piston diameter:
- nominal size - 82.930±0.009 mm
- increased size 1 - 83.130±0.009 mm
- increased size 2 - 83.430±0.009 mm
- increased size 3 - 83.730±0.009 mm
Cylinder bore diameter:
- nominal size - 83.00±0.018 mm
- increased size 1 - 83.20±0.018 mm
- increased size 2 - 83.50+0.018 mm
- increased size 3 - 83.80±0.018 mm
Piston clearance: 0.062-0.078 mm
Piston Protrusion Height/Cylinder Head Gasket:
| Ledge | Diesel engine | Turbodiesel engine |
| 0.54 - 0.65 mm | 1.49 mm | 1.50 mm |
| 0.65 - 0.77 mm | 1.61 mm | 1.60 mm |
| 0.77 mm - 0.82 mm | 1.73 mm | 1.70 mm |
Cylinder head gasket markings:
- 1 notch on the gasket for the protrusion - 0.54-0.65 mm
- 2 notches on the gasket for the protrusion - 0.65-0.77 mm
- 3 notches on the gasket for the protrusion - 0.77 mm - 0.82 mm
The maximum difference in the protrusions of the highest and lowest pistons is 0.12 mm
- Piston pin diameter: 25.0-0.006 mm
- Piston pin length: 72.00 mm
- Piston pin hole diameter: 25.00±0.020 mm
- Piston pin hole diameter: 25.00±0.008 mm
Connecting rods and connecting rod bearings
- Design - Conventional bearing shells
- Material - Aluminum-zinc alloy
- Connecting Rod Bearing Journal Diameter - See "Crankshaft"
- Pin hole diameter - see above
- Bearing bore diameter: 53.695 mm
- The length of the connecting rod between the centers of the holes is 145.0 +0.025 mm
Crankshaft and flywheel
Number of bearings - 5
Main bearing shells:
design - Conventional bearing shells, with or without lubrication grooves, to be marked before removal
Material - Aluminum-zinc alloy
Crankshaft axial play: 0.07-0.32 mm
Thickness of expansion washers:
- nominal size - 2.30 mm
- increased sizes - 2.40, 2.45 and 2.50
Main journal diameter - all engines:
- nominal size: 60,000 mm - 0.019 mm
- repair size - 59.700-0.019 mm
Bearing holes in the engine crankcase (the lids are installed): nominal diameter - 63.750 mm
The maximum permissible ovality of bearing journals is 0.007 mm
Main bearing shells:
- nominal thickness - 1.842 mm
- repair size - with white marking on the edge 1.992 mm
- black - 2.008 mm
- green - 2.019 mm
Crankpin diameter:
- nominal size 50.0 mm - 0.016 mm
- repair size 49.70 mm - 0.016 mm
- connecting rod bearing shells - nominal thickness - 1.827 mm
- connecting rod bearing shells - repair thickness - 1.977 mm
Connecting rods:
- Connecting rod bushing bore diameter: 25.000 mm
- Connecting rod bearing bore diameter: 53.965 mm
- Length between centers: 145.0 mm
- The maximum permissible difference in weight on one engine is 4 g
- Maximum flywheel runout: 0.06