Technical characteristics of 1.4 liter engines (Peugeot 405)

Engine

The engine is four-stroke, four-cylinder, in-line, carburetor, water-cooled, the camshaft is in the cylinder head, mounted transversely at the front of the car with an inclination of 6° to the rear, front-wheel drive.

Type	TU 3.2 K
Working volume	1360 cm³
Cylinder diameter	75 mm
Piston stroke	77 mm
Compression ratio	9,3
Compression pressure	1.1 MPa
Maximum power	56 kW (76 hp)
Maximum moment	114 Nm at 3800 rpm

Gas distribution system

Valve timing:
– valve clearance for valve timing control	0.7 mm
– opening of the intake valve	7° 05' before TDC
- closing the intake valve	41° 27' after BDC
– opening of the exhaust valve	52° 42' before BDC
- closing the exhaust valve	1° 14' before TDC

Camshaft

The camshaft is installed in the cylinder head and secured on five bearings, driven by a toothed belt, the belt tensioner is mechanical.

Camshaft designation	letter B (from the ignition system side)
Longitudinal play of the camshaft	0.07 – 0.16 mm (adjustable with washer on ignition system side)

Toothed belt

The timing belt drives the camshaft and the coolant pump.

Type	Pirelli Isoran 108 RPP 170 HSL
Number of teeth	108
Width	15 mm
Number of pulley teeth:
- crankshaft	21
- camshaft	42

Valves

The valves in the V system are set at an angle of 33°, and are actuated by the camshaft via two-way levers. The number of valves per cylinder is 2.

Inlet valve:
- length	110.76±0.15 mm
– angle of contact	120°
– width of fit	1.9 mm
– rod diameter	6.90 – 0.015 mm
– plate diameter	36.8 mm
– minimum thickness of the plate chamfer	1.0 mm
Exhaust valve:
- length	110.6 mm
– angle of contact	90°
– width of fit	2.2 mm
– rod diameter	6.980 – 0.015 mm
– plate diameter	29.4 mm
– minimum thickness of the plate chamfer	1.5 mm
Valve clearance (on a cold engine):
- inlet valve	0.20 mm
- exhaust valve	0.40 mm

Valve seats

Inlet valve:
– angle of contact	90°
– outer 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
– inner diameter	29.5 mm
– nominal height	6.648 + 0.1 mm
– repair height	7,000 + 0.1 mm
Exhaust valve:
– angle of contact	90°
– outer 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
– inner diameter	24.3 mm
– nominal height	6.648 + 0.1 mm
– repair height	7,000 + 0.1 mm

Valve guides

Inner diameter	7+ 0,022 mm
O.D:
- nominal 1	13,02+ 0,039 or 13.02+ 0,028 mm
- nominal 2	13,13-0,011 mm
– repair size 1	13,29-0,011 mm
– repair size 2	13,59-0,011 mm

Valve springs

One spring is used per valve. Inlet and outlet valves have identical springs.

Inner diameter of the coil	21,4+0,4 mm
Spring wire diameter	3.6 mm
Height:
– under a load of 280 N	40 mm
– under a load of 500 N	32 mm

Cylinder head

The head is made of light alloy and has inserted steel valve seats.

Height:
- nominal	111.2±0.08 mm
- minimum	111 mm

Caution! Cylinder heads ground to minimum height are marked with the letter R on the head below the exhaust port of the third cylinder.

Such cylinder heads can no longer be ground during repairs. In addition, they require the use of a gasket, also marked with the letter R, during installation (with thickness increased by 0.2 mm).

Maximum tolerance for non-flatness of the lower surface of the head

0.05 mm

Cylinder head gasket

The cylinder head gasket has a metal ring around the cylinders.

Brand	Payen Curty
Gasket thickness:
- nominal	1.3 mm
- for reground head	1.5 mm

Engine cylinder block

The engine cylinder block is made of light alloy, consists of two parts, is divided along the crankshaft axis and has inserted wet cylinder liners.

Height of the top of the cylinder block

206.98 mm

Cylinder liners

The cylinder liners made of cast iron are divided into three groups, designated by the corresponding number of dashes.

Cylinder liner diameter:
- group 1 (1 dash)	75.00 – 75.01 mm
- group 2 (2 dashes)	75.01 – 75.02 mm
- group 3 (3 dashes)	75.02 – 75.03 mm
Sleeve protrusion	0.03 – 0.10 mm
Maximum difference between four points on one sleeve	0.02 mm
Maximum difference between cylinders	0.05 mm
Cross-section diameter of the sleeve sealing ring	1.15 – 1.35 mm

Crank mechanism

Pistons

The pistons are made of light alloy and have three rings.

Piston diameter (mm):
- Group A	74,960 – 74,970
- Group B	74,970 – 74,980
- Group C	74,980 – 74,990
Piston mounting clearance in the cylinder	0.03 – 0.05 mm
Installation	the arrow on the piston bottom should point towards the valve timing drive
Gaps on the ring lock:
- first (upper)	0.30 – 0.50 mm
- second (middle)	0.30 – 0.50 mm
- third (lower)	0.25 – 0.50 mm

Piston pins

The steel pins are divided into 3 groups corresponding to the piston groups and are marked with dashes.

Finger diameter:
- group 1 (on piston 1, on pin I)	19.495 – 19.498 mm
- group 2 (on piston 2, on finger II)	19.492 – 19.495 mm
- group 3 (on piston 3, on finger III)	19,489 – 19,492 mm
Mounting clearance of the pin in the piston	0.01 – 0.016 mm
Finger length	62±0.25 mm

Connecting rods

The connecting rods are forged from steel.

Maximum difference in mass between connecting rods of the same engine	3 g
Center distance	126±0.07 mm
Connecting rod upper head diameter	19,463+0,013 mm
Connecting rod lower head bore diameter	48,655+0,016 mm

Crankshaft

The crankshaft is made of cast iron and rests on five main bearings.

Crankshaft axial play	0.1 – 0.3 mm
Crankshaft dimensions:
– nominal:
• diameter of main journals	49,981-0,016 mm
• width 2 main journal	23,6+0,052 mm
• diameter of connecting rod journals	45,0-0,009 or 45.0-0,025 mm
• diameter of the seal neck on the flywheel	85,0-0,065 mm
– repair:
• diameter of main journals	49,681-0,016 mm
• width 2 main journal	23,8+0,052, 23,9+0,052, 24,0+0,052 mm
• diameter of connecting rod journals	47,7-0,025 mm
• diameter of the seal neck on the flywheel	84,8-0,065 mm

Main bearing shells

Thickness:
- nominal	1.829±0.003 mm
- repair size	1.979±0.003 mm

Connecting rod bearing shells

Thickness:
- nominal	1.817±0.003 mm
- repair size	1.967±0.003 mm

Thrust rings

Thickness:
- nominal	2.4 mm
– repair size 1	2.50 mm
– repair size 2	2.55 mm
– repair size 3	2.60 mm

Flywheel

Maximum beats	0.05 mm
Maximum thinning after processing	1.0 mm

Lubrication system

Pressure lubrication is provided by an externally toothed gear oil pump, attached to the bottom of the cylinder block and driven by a single-row chain from the crankshaft.

Oil pressure (at 90°C)

Depending on engine speed, the oil pressure is:
– at 750 rpm	0.15 MPa
– at 1000 rpm	0.20 MPa
- at 2000 rpm	0.30 MPa
– at 4000 rpm	0.40 MPa

Oil filter

The oil filter has a replaceable paper element.

Brand and type

Purflux LS 468 A or Mann 6740 258 035

Cooling system

The cooling system has a closed circuit of forced circulation, which is carried out by a centrifugal pump (driven by a toothed belt). The cooling system consists of a radiator, a coolant pump, an expansion tank and a fan with an electric motor controlled by a thermal switch.

Thermostat

Type	Calorstat
Temperature of opening start	88°C
Full opening temperature	102°C
Valve stroke	minimum 7.5 mm

Fan

Eight-blade fan, 120 W power, diameter 285 mm.

Switch-on temperature	98°C
Shutdown temperature	92°C

Temperature sensor

A sensor installed in the cylinder head causes a warning light on the instrument cluster to come on when the coolant temperature reaches 118°C.

Fuel system

Fuel pump

The diaphragm fuel pump is driven mechanically by the camshaft.

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

Pressure	25 kPa
Pump feed pressure:
– Fenix IB, MM G5 and MM G6	0.7 – 0.8 bar
– Bosch MA3. 0	1.0±0.1 bar.
Pump performance:
– Fenix IB and Bosch MA3.0	370 cm³ in 15 seconds
– MM G5 and G6 systems	360 cm³ in 15 seconds

Air filter

The dry air filter has a replaceable paper element.

Type	Purflux F 973

Carburetor

The two-chamber carburetor has a manually controlled starting device.

Type	Solex Z2/528 or Weber 34 TLP
Carburetor Solex Z2/528:
– diffuser diameter:
• 1 camera	24
• 2 camera	25
- main fuel jet:
• 1 camera	115
• 2 camera	120
- main air jet:
• 1 camera	155
• 2 camera	160
- idle fuel jet	40
- transition system jet (bypass)	50
- enrichment jet	45
– accelerator pump jet:
• 1 camera	35
• 2 camera	35
- fuel jet economizer	80
– diameter of the needle valve seat	1,6
- opening of the throttle valve	0.5 mm
- opening the air damper	3.0±0.5 mm
- float position (measured from the bottom surface of the float to the plane of the cover with a gasket in a horizontal position using a special template)	33.5 mm
– idle speed	750 rpm
– CO content	1,5%
– minimum CO ₂ content	10%
Weber Carburetor:
– float installation height	32.0 mm
- opening the damper after start	5.0 mm

Fuel injection system

System type:
– TU3 engine (K12X)	Solex Fenix IB single point
– TU3 engine (K12X)	Bosch Monotronic MA3.0 single point

Ignition system

The transistor ignition system has an ignition distributor with a contactless pulse generator, with a centrifugal and vacuum ignition advance regulator installed at the rear end of the camshaft.

Distributor

Type	Bosch 0237 009 604 or Ducellier 2 525 275
Firing order	1–3–4–2 (No. 1 from the flywheel side)
Initial ignition timing angle (at 750 rpm engine and vacuum regulator line disconnected)	8° before TDC

Ignition coil

Brand	Ducellier BTR 05
Winding resistance (at 20°C):
- primary	0.7 Ohm
- secondary	6.6 kOhm
Amplification module	Bosch 0227 100 140

Spark plugs

Type	Champion C9YCX or Eyquem FC 52 LS
Gap between electrodes	0.8 mm

Clutch

Clutch friction, single-disc, dry, with central spring, mechanically controlled, with automatic adjustment.

Type	Valeo 180 CP 3300
Outer diameter of the disc	180 mm
Full pedal travel	140±5 mm

Transmission

The gearbox is mechanical, five speeds plus reverse gear, the forward gears are synchronized.

Type	MA 5
Gear ratios:
- 1st gear	3,41
- 2nd gear	1,80
- 3rd gear	1,27
- 4th gear	0,97
- 5th gear	0,77
Reverse gear	3,58
Final drive ratio	4,08

Drive shafts

Drive shafts connected on both sides by parallel three-arm joints on the gearbox side and ball joints (Rzeppa) on the wheel side.

Steering system

Mechanical (without power steering) or mechanical with hydraulic booster (additional equipment), with adjustable steering column angle.

Steering gear

Steering gear – rack and pinion in a mechanical system and rack and pinion with a distribution valve and servomotor in a system with a hydraulic booster.

Steering without power steering

Gear ratio	23,8
Number of teeth of drive gear	6
Number of steering wheel turns from lock to lock	4,1
Turning radius:
- between the walls	5.5 m
- between the sidewalks	5,275 m

Power steering

Gear ratio	17,9
Number of teeth of drive gear	8
Number of steering wheel turns from lock to lock	3,1
Turning radius:
- between the walls	5.5 m
- between the sidewalks	5,275 m

Power steering pump

The vane pump is driven by a V-belt from the crankshaft. The pump brand is Saginaw.

V-belt

Type	Kleber Venuflex 10 x 650 Le
Tension:
- new belt	500 – 550 N
- used belt	400 – 500 N

Front suspension

Independent, Mac Pherson type, with lower arms and transverse stabilizer.

The front wheel hub is mounted on a double-row ball bearing.

Stabilizer diameter	20 mm
Suspension spring:
– diameter of turns	157 mm
– rod diameter	12 mm
– compression under load of 1000 N	63 mm
- full compression	195.2 mm

Installing the front wheels (equipped car)

Convergence (regulated)	3.5±1 mm (0° 35' ±10')
Wheel tilt (not regulated)	0° 13' ±30'
Steering knuckle lead (not regulated)	1° 10' ±30'
Steering knuckle tilt (not regulated)	10° 40' ±30'

Rear suspension

Independent, on separate levers connected by a torsion bar (mounted behind the axle) and stabilizer (installed in front of the axle), with longitudinal hydraulic telescopic shock absorbers of double action, mounted horizontally.

The rear wheel hub is on a double-row ball bearing.

Stabilizer diameter	18 mm
Torsion:
- diameter	18.6 mm
– wheel elasticity under a load of 1000 N	63 mm
- full wheel bend	257.6 mm

Installing the rear wheels (car without load)

Control height of suspension (not regulated)	205±7 mm
Discrepancy (not regulated)	0.5±1 mm (0° 05' ±10')
Wheel tilt (not regulated)	1° 20' ±30'

Brake system

The working brake system is hydraulic, dual-circuit (diagonal split), with vacuum brake booster.

The handbrake acts mechanically on the rear wheel brakes.

Front wheel brakes

Disc, with floating caliper, Bendix IV.

Outer diameter of the disc	266 mm
Disc thickness:
- nominal	10 mm
- minimum (after renovation)	9 mm
Permissible disc runout	0.07 mm
Brake pads	Abex 903 or Valeo F 599
Minimum permissible thickness of pads	is determined by the wear of the middle groove in the material of the shoe, signaled by the lighting of the corresponding control lamp (electrical wear signaling using a wire pressed into the brake pad)
Caliper cylinder diameter	48 mm

Rear wheel brakes

Drum brakes, with automatic adjustment of the shoe gap, with pressure limiters built into the brake cylinders.

Working diameter of the cylinder:
- nominal	228.6 mm
- maximum (after renovation)	229.6 mm
Brake pads	Valeo F 154
Nominal thickness of linings	5 mm
Width of pads	40 mm
Cylinder diameter	20.6 mm
Master brake cylinder	in tandem, Bendix or ATE system
Piston diameter	20.6 mm
Vacuum booster	type Isovac, Bendix or ATE
Piston diameter	203.2 mm

Wheels and tires

Disks	5.00 J x 14 FH 4.25
Tires	165/ 70 R 14 T
Tire pressure:
- front wheels	0.21 MPa
- rear wheels	0.21 MPa

Electrical equipment

Battery	12V 175A or 12V 200A, minus (-) on ground
Generator	55 A, Bosch or Valeo
V-belt	Hutchinson AV 10
Belt deflection	5 – 10 mm under finger pressure at half the distance between the pulleys
Starter	Bosch 0001 112 019 or Valeo 126 RA 37
Power	1256 W
Idling:
- voltage	11.4 V
- current	maximum 60 A
Braking:
- voltage	11.4 V
- current	maximum 500 A
Fuses	7 x (12V, 5A); 3 x (12V, 10A); 5 x (12V, 15A); 2 x (12V, 20 A); 2 x (12V, 25A)
Light bulbs:
- headlights	H4 55/60 W
- fog lights	55 W
- front and rear side lights	5 W
- direction indicators	21 W
- brake lights	21 W
- reversing lights	21 W
- rear fog lights	21 W

Masses

Own weight	1030 kg
Gross weight	1470 kg
Maximum trailer weight without brakes	435 kg
Maximum trailer weight with brakes	900 kg

Fuel consumption

At a speed of 90 km/h	5.5 dm³/ 100 km
At a speed of 120 km/h	7.5 dm³/ 100 km
Urban cycle	8.3 dm³/ 100 km

Maximum speed – 169 km/h.

Tightening moments

Engine

Cylinder head bolts:
- Stage 1	20 Nm
– Stage 2	tighten to 240°
Valve cover	16 Nm
Camshaft pulley	80 Nm
Timing Belt Tensioner Roller	23 Nm
Ignition distributor housing	16 Nm
Connecting rod bearing caps	40 Nm
Main bearing caps:
- Stage 1	20 Nm
– Stage 2	tighten by 45°
Bottom of cylinder block to top of cylinder block	8 Nm
Flywheel	65 Nm
Pulley to the crankshaft	110 Nm
Oil pump to cylinder block	8 Nm
Drain plug to the oil pan	30 Nm
Spark plugs	17.5 Nm
Clutch drive part to flywheel	10 Nm
Engine to gearbox	45 Nm

Transmission

Gearbox housing to clutch housing	18 Nm
Back cover	18 Nm
Primary shaft nut	140 Nm
Intermediate plate to clutch housing	50 Nm
Gearbox oil drain plug	25 Nm

Steering system

Steering gear to cross beam	40 Nm
Clamping collar to steering shaft	20 Nm
Tie rod end to shoulder	35 Nm
Distributor valve to steering gear	12.5 Nm
Wheel disc bolt	85 Nm

Front suspension

Cross beam to chassis	90 Nm
Rear mount of the lever to the beam	45 Nm
Front arm mount to beam	45 Nm
Steering knuckle cage	55 Nm
Pivot knuckle pin to lever	30 Nm
Steering knuckle pin to steering knuckle	260 Nm
The rod connecting the stabilizer to the lever	65 Nm
Tie rod end to shoulder	35 Nm
Suspension column to the body	25 Nm
Hub axle nut	265 Nm

Rear suspension

Shock absorber to the lever	110 Nm
Shock absorber to bracket	110 Nm
Front beam shoulders to chassis	60 Nm
Front rubber bushing to chassis	55 Nm
Rear rubber bushing to chassis	55 Nm
Torsion and stabilizer clip	55 Nm
Torsion bar side bolts	17.5 Nm
Hub axle nut	275 Nm

Brake system

Caliper to steering knuckle

120 Nm