Technical characteristics of diesel engines (Peugeot 405)

Engines

Cylinder head

The head is made of aluminum alloy and has inserted valve seats. The camshaft is installed in the upper part of the head.

Nominal height	157.40 – 157.75 mm (the measurement is made between the surface of the head joint and the surface on the cross-section of the camshaft sealing ring) (see picture Cylinder head height measurement location and reground head sign)
Maximum tolerance for non-flatness of the lower surface of the head	0.07 mm
Regrinding	maximum 0.4 mm relative to the measured nominal height
Warning! After regrinding the bottom surface of the head, the following steps must be taken: – grinding of valve seats; – replacement of vortex chambers with chambers of appropriate sizes and their correct installation; – installation of 0.4 mm thick compensation gaskets under the valve springs. The reground head is marked with the letter R stamped in the corresponding place on the head (see figure Cylinder head height measurement location and reground head sign).
Intake valve chamfer	0.9 – 1.45 mm
Exhaust valve chamfer	0.5 – 1.05 mm
Piston protrusion above the cylinder block	0 – 0.03 mm

Vortex chambers

The engines use pistons licensed from Ricardo Comet V.

Protrusion of vortex chambers	0 – 0.03 mm
Diameter of the mounting ball	3.0 mm
Vortex chamber size:
– flange diameter:
• nominal dimensions	32.05 – 32.25 mm
• 1st size repair	32.45 mm
• 2nd size repair	32.65 mm
• admission	+0.099 -0.060 mm
– flange thickness:
• nominal dimensions	4.0 – 4.1 mm
• 1st size repair	4.2 mm
• 2nd size repair	4.3 mm
• admission	+0.020 -0.025 mm
– head bore diameter:
• nominal dimensions	32.0 – 32.2 mm
• 1st size repair	32.4 mm
• 2nd size repair	32.6 mm
• admission	+0.039 0 mm
– head boring depth:
• nominal dimensions	3.9 – 4.0 mm
• 1st size repair	4.1 mm
• 2nd size repair	4.2 mm
• admission	+0.02 -0.04 mm

Valve guides

The valve guides are made of brass. As spare parts, the guides are supplied in repair sizes.

Dimensions of valve guides (see figure Valve guide bushing dimensions):
– diameter of the bore in the head (f):
• nominal dimensions	14.02 – 14.13 mm
• 1st size repair	14.29 mm
• 2nd size repair	14.59 mm
• admission	0 -0.011 mm
– outer diameter of the guide bushing (g):
• nominal dimensions	13.981 – 14.051 mm
• 1st size repair	14,211 mm
• 2nd size repair	14,511 mm
• admission	+0.032 0 mm
– length of guide bushing (h)	52 mm
• nominal dimensions	52 mm
• admission	±0.25 mm
– inner diameter of the guide bushing (k):
• nominal dimensions	8.02 mm
• admission	0 +0.2 mm
– distance between the cylinder head gasket surface and the guide (j):
• nominal dimensions	36.50 mm
• admission	±0.50 mm

Valve seats

Cast iron valve seats are inserted. The seating angle of the inlet and outlet valves is 90°.

Valves

The valves, fixed in the head, are actuated by the camshaft via pushrods. The intake valve stems are chromed.

The working clearance is adjusted by installing the appropriate adjusting plates on the pushers.

The thickness of the adjusting plates is given in the tappet characteristics.

Dimensions of inlet valve seats (see figure Valve seat dimensions):
– outer diameter of the seat (a):
• nominal dimensions	40.161 – 40.361 mm
• 1st size repair	40,461 mm
• 2nd size repair	40,661 mm
• admission	0 -0.025 mm
– diameter of the bore in the head (b):
• nominal dimensions	40.0 – 40.2 mm
• 1st size repair	40.3 mm
• 2nd size repair	40.5 mm
• admission	0 -0.025 mm
– saddle height (c):
• nominal dimensions	6.25 – 6.45 mm
• 1st size repair	6.45 mm
• 2nd size repair	6.45 mm
• admission	0 -0.1 mm
– depth of boring in the head (d):
• nominal dimensions	8.267 – 8.467 mm
• 1st size repair	8,467 mm
• 2nd size repair	8,467 mm
• admission	±0.015 mm
Dimensions of exhaust valve seats (see figure Valve seat dimensions):
– outer diameter of the seat (a):
• nominal dimensions	34.137 – 34.337 mm
• 1st size repair	34,467 mm
• 2nd size repair	34,637 mm
• admission	0 -0.025 mm
– diameter of the bore in the head (b):
• nominal dimensions	34.0 – 34.2 mm
• 1st size repair	34.3 mm
• 2nd size repair	34.5 mm
• admission	±0.025 mm
– saddle height (c):
• nominal dimensions	6.05 – 6.25 mm
• 1st size repair	6.25 mm
• 2nd size repair	6.45 mm
• admission	0 – 0.1 mm
– depth of boring in the head (d):
• nominal dimensions	8.15 – 8.35 mm
• 1st size repair	8.35 mm
• 2nd size repair	8.35 mm
• admission	±0.015 mm
Valve sizes:
– inlet valve:
• length	112.2 mm
• rod diameter	8,005 mm
• plate diameter	38.5 mm
• angle of contact	90°
• chamfer	0.5 – 1.05 mm
– exhaust valve:
• rod diameter	7.985 mm
• plate diameter	33.0 mm
• angle of contact	90°
• chamfer	0.9 – 1.45 mm
Valves on XUD 9TE engines (the valves are special, they have an additional stem seal):
– inlet valve:
• length	112.4 mm
• rod diameter	8.0 mm
• plate diameter	38.5 mm
• angle of contact	90°
• chamfer	0.5 – 1.05 mm
– exhaust valve:
• length	109.55 mm
• rod diameter	8.0 mm
• plate diameter	33.0 mm
• angle of contact	90°
• chamfer	0.9 – 1.45 mm
Valve clearance (when the engine is cold):
- inlet valve	0.15 mm
- exhaust valve	0.30 mm
- admission	±0.04 mm

Valve springs

Two springs are used per valve. The intake and exhaust valves have identical springs.

Inner spring:
- diameter	19.5 mm
– height/ under load	38.4 mm/ 85 N
– height/ under load	29.3 mm/ 237 N
External spring:
- diameter	29 mm
– height/ under load	42.4 mm/ 180 N
– height/ under load	33.3 mm/ 450 N

Pushers

The tappet sockets are made directly in the head. The valve working clearance is adjusted by placing an adjusting plate of the appropriate size on the tappet.

Diameter of plates	13.5 mm
Plate thickness (mm)	1.650, 1.725, 1.800, 1.900, 1.975, 2.050, 2.125, 2.225 to 3.025 every 0.025, 3.100, 3.175, 3.250, 3.325 to 4.000 every 0.025

Cylinder head gasket

Brand	Reinz
Designation	the gaskets have two types of signs indicating their purpose and thickness (see the drawing Cylinder Head Gasket Identification)
Designation identifying the engine (a,see picture Cylinder Head Gasket Identification):
– XUD 9	without cutout
– XUD 7TE	2 cutouts
Designation defining the thickness (b, see figure Cylinder Head Gasket Identification):
– XUD 9	2 notches 1.61 mm
– XUD 7TE	2 notches 1.65 mm
– XUD 7TE	3 notches 1.80 mm
XUD 9TE engines use a special cylinder head gasket. Identification - 3 cutouts made under the thickness designation cutouts.

Engine cylinder block

The engine block is made of cast iron. The cylinders are made directly in the block. In XUD 7TE engines, the coolant circulates between the cylinders, in XUD 9 engines, special channels are made between the cylinders.

Height of the cylinder block of the XUD 9TE engine	303 mm
Cylinder diameter:
– XUD 7TE engine:
• 1st size nominal	80,000 – 80,018 mm (no designation)
• 2nd size nominal	80.030 – 80.048 mm (designation A1)
• 1st size repair	80,200 – 80,218 mm (designation R1)
• 2nd size repair	80.500 – 80.518 mm (designation R2)
• 3rd size repair	80.800 – 80.818 mm (designation R3)
– XUD 9 engine:
• 1st size nominal	83,000 – 83,018 mm (no designation)
• 2nd size nominal	83.030 – 83.048 mm (designation A1)
• 1st size repair	83.200 – 83.218 mm (designation R1)
• 2nd size repair	83.500 – 83.518 mm (designation R2)
• 3rd size repair	83.800 – 83.818 mm (designation R3)

Crank mechanism

Crankshaft

The crankshaft is made of spheroidal cast iron, rests on five main bearings and has counterweights. The main and connecting rod journals are subjected to rolling and induction hardening.

Main journal diameter:
- nominal size	59,981 – 60,000 mm
– 1st size repair	59,681 – 59,700 mm
Connecting rod journal diameter:
- nominal size	49,984 to 50,000 mm
– 1st size repair	49.684 to 49.700 mm
Width of journal No.2 of the XUD 9 engine:
- nominal size	26.60 to 26.65 mm
– 1st size repair	26.80 to 26.85 mm
– 2nd size repair	26.90 to 26.95 mm
– 3rd size repair	27.00 to 27.05 mm
Width of journal No.2 of the XUD 7TE engine:
- nominal size	25.70 to 25.75 mm
– 1st size repair	25.90 to 25.95 mm
– 2nd size repair	26.00 to 26.05 mm
– 3rd size repair	27.00 to 27.05 mm
Thickness of thrust half rings of XUD 9 engines:
- nominal size	2.305±0.025 mm
– 1st size repair	2.405±0.025 mm
– 2nd size repair	2.455±0.025 mm
– 3rd size repair	2.505±0.025 mm
Thickness of thrust half rings of XUD 7TE engines:
- nominal size	1.855±0.025 mm
– 1st size repair	1.955±0.025 mm
– 2nd size repair	2.005±0.025 mm
– 3rd size repair	2.055±0.025 mm
Camshaft Drive Side Seal Ring	42 x 62 x 8 mm
Flywheel side sealing ring	90 x 110 x 10 mm
Crankshaft axial clearance	0.07 to 0.32 mm
The thrust half rings are located on main bearing No.2.
Main bearing shells:
– nominal thickness	1.842±0.003 mm
- repair size	1.992±0.003 mm

Flywheel

The flywheel is secured with eight bolts.

Information copied from the resource peugeotbook

Number of teeth on the ring gear: 136.

Connecting rods

The connecting rods are forged from steel.

Inner diameter of the upper connecting rod head (for boring after fixing):
– XUD 9 engine	25.007 to 25.020 mm
– XUD 7TE engine	28.007 to 28.020 mm
Distance between connecting rod axes	145±0.025 mm
Connecting rod bearings:
– nominal thickness	1.827±0.003 mm
- repair size	1.977±0.003 mm

Pistons

The pistons are made of an aluminum-silicon alloy and are connected to the connecting rods by means of pins secured by two spring rings.

Piston diameter:
– XUD 7TE engine:*
• 1st size nominal	79.93±0.009 mm (no designation)
• 2nd size nominal	79.96±0.009 mm (designation A1)
• 1st size repair	80.13±0.009 mm (designation R1)
• 2nd size repair	80.43±0.009 mm (designation R2)
• 3rd size repair	80.73±0.009 mm (designation R3)
– XUD 9 engine:*
• 1st size nominal	82.93±0.009 mm (no designation)
• 2nd size nominal	82.96±0.009 mm (designation A1)
• 1st size repair	83.13±0.009 mm (designation R1)
• 2nd size repair	83.43±0.009 mm (designation R2)
• 3rd size repair	83.73±0.009 mm (designation R3)

* Diameter is measured at a distance of 25 mm (for XUD 9 engines) and 2.5 mm (for XUD 7TE engines) from the piston bottom perpendicular to the axis of the pin.

Piston pins

The piston pin is secured in the connecting rod and piston. It is fixed with two spring rings.

Diameter:
– XUD 9 engine	25 mm
– XUD 7TE engine	28 mm
Piston pin clearance	0.003 mm to 0.014 mm

Piston rings

Each piston has three piston rings.

Gap in the lock:
- compression ring	0.20 to 0.40 mm
- sealing ring	0.15 to 0.35 mm
- oil scraper ring	0.10 to 0.35 mm
Thickness of compression ring in XUD 9TE engines	3.5 mm

Gas distribution system

The operation of the gas distribution system is controlled by a camshaft located in the head, which rotates in three bearings and is driven by a toothed belt. The valves are driven by the camshaft through tappets equipped with adjusting plates.

Camshaft

The cast iron camshaft is fixed in the head, rotates in three bearings and is driven by a toothed belt.

The camshaft of the XUD 7TE engine has a special convexity between the cams of the 1st cylinder.

Bearing diameter:
- bearing no. 1	27.5 mm (from the flywheel side)
- bearing no. 2	28.00 mm
- bearing no. 3	28.5 mm
Some camshafts have bearings with a diameter increased by 0.5 mm. Such camshafts are marked accordingly: a ring is drawn in yellow between the cams of the 1st cylinder. Heads in which the camshaft bearings have a diameter increased by 0.5 mm are marked with a stamped number 1.
Axial clearance	0.025 to 1.114 mm
On the part of the camshaft that should be on the drive side, there is an inscription "DIST".

Theoretical valve timing with zero valve clearance

Engine XUD 9, XUD 9TE:
- OZD lead	44°30'
- ZZD lag	83°30'
- OZW lead	89°30'
- ZZW delay	46°30'
XUD 7TE Engine:
- OZD lead	51°30'
- ZZD lag	76°30'
- OZW lead	89°30'
- ZZW delay	46°30'

OZD, ZZD – opening and closing of the intake valve, respectively.



OZW, ZZW – opening and closing of the exhaust valve, respectively.

Toothed belt

Brand: Uniroyal Powergrip or Pirelli Isoran.

The belt tension is provided by a roller tensioner.

Belt replacement frequency: every 75,000 km.

Lubrication system

Lubrication under pressure is provided by a gear oil pump, driven by a chain from the crankshaft.

The oil-coolant heat exchanger is present in all engine types. The piston bottom oil spray nozzles and turbocharger lubrication circuit are in the XUD 7TE engine.

Oil pump

Type	gear
Oil pressure:
- at idle	0.2 MPa
- at 2000 rpm	0.34 to 0.37 MPa
– at 4000 rpm	0.38 to 0.50 MPa
Opening pressure of the pressure reducing valve	0.40 MPa
Pressure sensor:
- turning off the control lamp	0.08 MPa
– the control lamp lights up	0.058 to 0.044 MPa

Oil filter

The oil filter with a replaceable element has a connected bypass valve (0.1 MPa).

Brand and type: Purflux LS 468 A or Mann 674 0258.035.

Motor oil

Recommended type	API SF/CD, MIL-L-2104 C or 46 152, CCMC PD1, SAE 10W/40, 15W/30 or 15W/40
Amount of oil	4.5 dm³ + 0.5 dm³ (oil filter)
Frequency of oil change together with filter	every 10,000 km

Cooling system

The engine is cooled under pressure (0.1 MPa) with a mixture of water and a special antifreeze liquid.

The cooling system consists of: a radiator, a coolant pump, an expansion tank connected to the radiator, two fans equipped with electric motors, a thermostat and a temperature sensor.

The cooling circuit provides fuel heating (in some versions).

Coolant pump

The centrifugal coolant pump is fixed in the housing and is driven by a toothed belt.

Radiator

The radiator has a horizontal flow core.

Brand: Chausson.

Thermostat

Brand: Calorstat.

Temperature of opening start	88°C
Full opening temperature	100°C

Fans

Brand: AOR.

Two fans equipped with electric motors are installed in front of the radiator.

Operation: simultaneous, with two speeds controlled by a two-level temperature sensor.

Switch-on and switch-off temperature:
– 1 speed:
• 93/ 88°C	in engines XUD 7TE and XUD 9 with chassis number up to 8 274 818
• 97/ 92°C	in XUD 9 engines with chassis number from 8 274 819
– 2 speed:
• 97/ 92°C	in engines XUD 7TE and XUD 9 with chassis number up to 8 274 818
• 101/ 96°C	in XUD 9 engines with chassis number from 8 274 819

Temperature sensor

This is a high coolant temperature sensor.

Temperature for switching on the control lamp: 105°C.

Coolant

Recommended type	a mixture of water and antifreeze in a 1:1 ratio (up to -17°C)
Quantity	7.8 l
Frequency of replacement of coolant and flushing of the cooling circuit	every 2 years

Power supply system

Fuel supply is provided by a high-pressure distribution pump and injectors, and in the XUD 7TE engines – additionally by a turbocharger.

Air filter

View	dry filter
Brand and type	Permabit FA 1526 or Mann

Fuel tank

Volume	70 l
Fuel	diesel

Bosch injection system

XUD 7TE Engine:
– fuel pump type	EP-VE 4/8F 2150 R 316
- nozzle	DNOSD 289
- type	KCA 17 S 42
- adjustment	13.0 to 13.5 MPa
- filter	Purflux
– initial warm-up:
• glow plugs	Bosch 0250 201 01, Beru 0100 22 133
• resistance at 20°C	0.3 to 0.4 Ohm
• heating time	8 sec
– adjustment:
• pump installation	Before TDC piston No.4 for piston distributor lift 0±0.03 mm
• dynamic installation	at 750 to 800 rpm 14°
• idle speed	750 to 800 rpm
• increased idle speed	950±50 rpm
XUD 9 Engine:
– fuel pump type	EP-VE 419F 2300 R
- nozzle	2722-2 DNOSD 287+
- type	KCA 17 S 42
- adjustment	13.0 to 13.5 MPa
- filter	Purflux
– initial warm-up:
• glow plugs	Bosch 0250 201 01, Beru 0100 22 133
• resistance at 20°C	0.3 to 0.4 Ohm
• heating time	8 sec
– adjustment:
• pump installation	Before TDC piston No.4 for piston distributor lift 0.9±0.03 mm
• dynamic installation	at 750 to 800 rpm 15° ±1°
• idle speed	750 to 800 rpm
• increased idle speed	950±50 rpm

Roto Diesel Injection System

XUD 7TE Engine:
– fuel pump type	DPCR 8443 B 451 C or 452 C
- nozzle	RDNOSD 6862C
- type	LCR 67307
- adjustment	13.0±0.5 MPa
- filter	Roto Diesel
- element	CAV
– initial warm-up:
• glow plugs	Bosch 0250 201 01900, Beru 0100 22 133
• resistance at 20°C	0.3 to 0.4 Ohm
• heating time	8 sec
– adjustment:
• pump installation	Before TDC piston No.4 for the piston lift of the pump measured by a dial indicator fixed in the pump is 0.01 mm
• dynamic installation*	9°
• dynamic setting at 750 – 800 rpm	15°
• idle speed	750 – 800 rpm
• increased idle speed	950±50 rpm
XUD 9 Engine:
– fuel pump type	DPCR 8443 B 380 A or 381 B
- nozzle	RDNOSD 6751C
- type	LCR 67307
- adjustment	11.5±0.5 MPa
- filter	Roto Diesel
- element	CAV
– initial warm-up:
• glow plugs	Bosch 0250 201 01900, Beru 0100 22 133
• resistance at 20°C	0.3 to 0.4 Ohm
• heating time	8 sec
– adjustment:
• pump installation	Before TDC piston No.4 for the piston lift of the pump measured by a dial indicator fixed in the pump is 0.01 mm
• dynamic installation*	15°
• dynamic setting at 750 – 800 rpm	15°
• idle speed	750 – 800 rpm
• increased idle speed	950±50 rpm

* Value for quick check using a special diagnostic device.

High pressure fuel pump on XUD 9TE engines

Brand and type	Bosch VER 445
The installation is static	distributor piston stroke 0.66 mm at TDC position of cylinder No.4
The installation is dynamic (the engine is warmed up)	11° ±1° at 800 rpm
Idle speed:
- without air conditioning	750±50 rpm
- with air conditioning	800±50 rpm
Maximum no-load speed	5100±80 rpm
Idle speed with increased speed limit (the engine is cold)	950±50 rpm

Set of injectors for XUD 9TE engines

Brand and type	Bosch KCA 17S42
Injector nozzles on XUD 9TE engines:
- brand and type	Bosch DNOSD 299
Injector opening pressure	17.5 MPa

Turbocharger

The turbocharger provides additional air supply to the engine. It has an air cooler that heats the air supplied to the engine.

Brand and type	Garrett T2 or KKK K 14
Compression pressure:
- at 2000 rpm	70±5 kPa
– at 4300 rpm	85±5 kPa
Turbocharger on XUD 9TE engines
Brand and type	Garrett T2 or KKK K14
Compression pressure:
- at 2000 rpm	70±5 kPa
– at 3000 rpm	100±5 kPa

Tightening moments

Cylinder head (new bolts and washers):
- stage 1	30 Nm
- stage 2	70 Nm
- stage 3	Turn to an angle of 120°
Sealing frame plate on the distributor drive side	15 Nm
Fastening the oil pan to the block	20 Nm
Camshaft Bearing Caps	15 – 17.5 Nm
Connecting rod caps:
- Stage 1	tightening torque 40 Nm
– Stage 2	loosening of nuts
– Stage 3	tightening torque 20 Nm
– Stage 4	turning to an angle of 70°
Fastening the main bearing caps to the cylinder block	70 Nm
Cylinder head cover	10 Nm
Fastening the injector to the cylinder head	90 Nm
Camshaft pulley	35 to 40 Nm
High pressure fuel pump pulley	50 Nm
Crankshaft pulley	40 Nm +60°
Pressure pump pulley	35 Nm
Timing Belt Tensioner	15 Nm
Oil heat exchanger	65 Nm
Flywheel	50 Nm
Coolant pump	15 Nm
Oil pump	20 Nm
Left engine bracket:
- side nuts	17.5 Nm
- central nut	35 Nm
Right engine bracket:
- nut near the body	27.5 Nm
Lower Engine Bracket:
- nut near the body	55 Nm
- nut near the engine	35 Nm

Changes in engines XUD 7TE, XUD 9 and XUD 9TE

Cylinder head gasket

Some engines have a cylinder block marked with the symbol "B", which is characterized by a piston protrusion above the cylinder rim equal to or greater than 0.84 mm. They must be fitted with a 1.83 mm thick head gasket, which is marked with four notches.

Valve springs

Since December 1988, the valves have been equipped with only one spring, which has replaced the two-spring assembly.

Diameter	29 mm
Height under load 320 N	42.4 mm
Height under load 550 N	33.0 mm
Wire diameter	3.8 mm
Color designation	blue, "sea wave" color

Seats and exhaust valves

For the purposes of unification, the XUD 7T and XUD 9 engines are equipped with the same exhaust valve seats as in the XUD 9TE engine.

The application of this modification resulted in the fact that the recess of the exhaust valve seat relative to the surface of the cylinder head connection became equal to 2.5 mm instead of the previous 2 mm, and the thickness of the valve plate also increased accordingly to maintain the previous compression ratio.

The new type of heads are identified by 9 mm diameter holes (instead of 7mm diameter holes) in the protrusions located above the glow plugs.

Since January 1992, the XUD 9 engine with a modified cylinder head has been designated XUD 9A/L.

The components of both types of cylinder heads are not interchangeable.

Gas distribution system

Engines were gradually equipped with toothed belts made of HSN materials (Hydrogene Sature Nitrile), which are characterized by increased resistance to the effects of oils and high temperatures.

These belts are designated HSN.

When replacing the belt, it is imperative to install the HSN belt.

Make and type: Pirelli 136 RPP 254 or Gates HTD 58136x1.

Since January 1990, in vehicles with a steering system without hydraulic power steering, the diaphragm vacuum pumps have been gradually replaced by rotary vane pumps driven directly by the camshaft. As a result of this modification, the camshaft was changed - its length was increased to ensure the drive of the low-pressure pump.

As of serial number 70 491 894, a vacuum pump at the end of the camshaft is also installed in vehicles with a power steering system.

In cars with air conditioning, the previous solution has been retained.

Beginning with the 1993 model, the 89° thermostat was replaced with an 83° thermostat.

Starting with the 1993 model, the old temperature sensors were replaced with new ones with the following characteristics:

1st stage:
- without air conditioning	92,5°C
- with air conditioning	90°C
2nd stage:
- without air conditioning	97,5°C
- with air conditioning	101°C

Turbocharger

Starting with engine numbers 1CV33-49714, 1CV35-67544, 1CV47-77513, 1CV48-20272, 1CV87-2457, the fastening of the return oil line on the turbocharger was changed to improve the tightness of the connection. The supply oil line was also changed.

Individual parts of both types of fastening are not interchangeable.