Gasoline engines — manual (Peugeot J5)

Cylinder head

Material - Aluminum

Cylinder head height: 92.5+0.15 mm

Cylinder head height after surface milling: 92.10 mm

The maximum permissible cylinder head tilt is 0.10 mm

Gasket markings - Order by engine number

Valve guides:

• Nominal outside diameter, size 1 - 14.02 mm
• Nominal outside diameter, size 2 - 14.13 mm
• 1st repair size - 14.29 mm
• 2nd repair size - 14.59 mm

Guide bushing bore - nominal size - 8.02 mm ±0.022 mm

Guide bushing bore - repair size - 7.4 mm, requires reaming to the required size

Length of guide bushings: 58.4+0.3 mm

Cylinder head bore diameter:

• Nominal diameter, size 1 - 13.965 mm + 0.032 mm
• Nominal diameter, size 2 - 14.035 mm + 0.032 mm
• 1st repair size - 14.195 mm + 0.032 mm
• 2nd repair size - 14.495 mm + 0.032 mm

Installation height of guide bushings between the bottom of the guide bushing and the valve seat (dimension "X" in the figure):



Inlet valves (A) - 31.50 mm

Exhaust valves (B) - 21.30 mm

Installation angle of guide bushings (see top picture):

• Inlet valves (A) - 19° ±5'
• Exhaust valves (B) - 6° ±5'

Valves:

Valve head diameter:

• Inlet valves - 42.50±0.2 mm
• Exhaust valves - 35.50±0.2 mm

Overall length:

• Intake valves - 118.25 mm
• Exhaust valves - 112.00 mm

Valve stem diameter:

• Intake valves - 8.02-0.047 mm
• Exhaust valves - 8.00-0.040 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 guide clearances:

• Inlet valves - 0.02-0.042 mm
• Exhaust valves - 0.04-0.060 mm

Maximum working clearance: 0.10 mm

Valve clearances (the engine is cold):

• Inlet valves - 0.10 mm
• Exhaust valves - 0.25 mm

Valve seats

Valve seat angle

Inlet valves - 120°

Exhaust valves - 90°

		Nominal dimensions		Repair dimensions		Installation tolerances
		1	2	1	2
	Diameter A	43,51	43,71	43,81	44,01	+ 0,161 + 0,136
	Cylinder diameter. heads	43,50	43,70	43,80	44,00	±0,0125
		169V engine			Engine 170
	Diameter B*	41,00			41,00
	e	7,33 +0,1 / 0			10,257±0,25
	Angle (Alpha)*	120° — 15'			120° — 15'
	Angle (Veta)*	17°			70°
170 issues until November 1983.	Diameter A	37,01	37,21	37,31	37,51	+ 0,137 + 0,112
169 B issues since April 1985.	Cylinder diameter. heads	37,00	37,20	37,30	37,50	±0,025
	Diameter B*	35,00
	e	6,462 + 0,10 / 0,0
	Angle (Alpha)*	90° — 15'
	Angle (Veta)*	15°
170 B issued from July 1983 to November 1983.	Diameter A	38,01	38,21	38,31		+0,137 +0,112
	Cylinder diameter. heads	38,00	38,20	38,30		°0,025
170 B issued since April 1985.	Diameter A	37,01	37,21	38,31		+0,137 +0,112
169 B issues since April 1985.	Cylinder diameter. heads	37,03	37,23	37,33		±0,025
170 C	Diameter B*	35,00
	e	6,462 + 0,10 / 0,0
	Angle (Alpha)*	90° — 15'
	Angle (Veta)*	15°

* Measurements are taken after pressing the valve seats into the cylinder head.

Valve springs:

Number of springs: two internal and two external springs

Spring wire diameter - 3 mm - internal springs; 4.3 mm - outer springs

Spring marking - White color mark

Installation position is arbitrary

Length in free state:

• inner springs - 39.60 mm
• outer springs - 44.00 mm

Direction of turns:

• inner springs - left
• outer springs - right

Length under load - Inner springs:

• at a load of 8.8 kg - 35.9 mm
• at a load of 30.0 kg - 26.80 mm

Load Length - Outer Springs:

• at a load of 17.0 kg - 39.80 mm
• at a load of 59.0 kg - 39.70 mm

Camshaft

Number of bearings - 3, with forced lubrication

Axial play of the camshaft is 0.05-0.14 mm

The maximum permissible runout of the camshaft is 0.02 mm

Camshaft markings (color):

• new shafts - pink
• repair size - brown

Timing drive

Drive chain - Double roller chain, 58 links

The number of teeth on the crankshaft toothed pulley is 19

Number of teeth on the camshaft toothed pulley: 38

Hydraulic tensioner - Renold or Sedis

Valve Control - See above

Pistons and connecting rods

Piston pin installation - Floating fit in the piston and connecting rod bore. Fastening with two retaining rings.



Direction of piston installation - The arrow on the bottom of the housing must point towards the timing drive.

Piston rings:

• Number of rings - 3
• Ring design - 1 regular compression ring, 1 trapezoidal ring, 1 oil-deflecting ring

Piston ring thickness:

• top ring - 1.50 mm
• middle ring - 2.00 mm
• oil deflector ring - 3.96 mm

Piston ring joint clearances: middle rings are supplied ready to install

Nominal dimensions:

• upper compression ring - 0.20-0.50 mm
• middle upper compression ring - 0.40-0.55 mm
• oil deflector ring - 0.25-0.40 mm

Piston pin hole:

• blue piston marking - 23.009-23.005 mm
• white piston marking - 23.005-23.000 mm
• red piston marking - 23.000-22.995 mm

Piston pin bore diameter:

• blue piston marking - 23.005-23.001 mm
• white piston marking - 23.005-22.996 mm
• red piston marking - 22.996-22.992 mm

Piston pin length: - 74.00 mm

Piston pin diameter: 23.00 mm

Piston diameter:	169V engine	Engine 170*
nominal size	84.00 mm	88.00 mm
class A	83.930 - 83.941 mm	87.925 - 87.936 mm
class B	83.942 - 83.952 mm	87.937 - 87.947 mm
class C	83.953 - 83.963 mm	87.948 - 87.958 mm
class D	83.964 - 83.974 mm	87.959 - 87.969 mm

Oversized pistons - As per parts lists

Diameter of working sleeves - See. "Cylinder block and cylinder liners"

Piston clearance: 0.06–0.08 mm

Piston crown protrusion (only engines with a displacement of 2.0 liters):

• 170V motor - 0.51 mm
• 170 C engine - 2.98 mm

Connecting rods and connecting rod bearings

Connecting rod material: forged steel

The material of the connecting rod bearing shells is steel with bearing alloys

The length of the connecting rod between the centers of the holes is 132±0.07 mm



Bearing bore diameter (without liners) — 53.665 + 0.019 mm

Diameter of connecting rod journals and bearing shells - See. "Crankshaft"

Connecting rod bushing bore - nominal size - 24.408 + 0.068 mm

repair size - 24.708 + 0.068 mm

Piston pin clearance in the bushing: 0.04-0.08 mm

Crankshaft and flywheel

Number of bearings - 5

Material - Forged steel

Main bearing shells:

• design - crankshaft with screw plugs - Conventional bearing shells, with lubrication grooves in bearings I, III and V, without lubrication grooves in bearings II and IV.
• design - crankshaft without screw plugs - conventional bearing shells, with lubrication grooves in the cylinder block (all bearings), without lubrication grooves in the main bearing caps. Crankshaft axial play 0.08-0.20 mm

Axial play adjustment: four spacer washers, clutch side bearing

Thickness of expansion washers:

• nominal size - 2.30 mm, from the inside of the engine
• increased sizes - 2.30, 2.35, 2.40, 2.45, 2.50

Main journal diameter - all engines:
Bearing	I	II	III	IV	V
Nominal size
Diameter	54.92 mm	56.165 mm	57.573 mm	58.573 mm	59.416 mm
Width	37.00 mm	30.00 mm	38.00 mm	30.00 mm	38.00 mm
Repair size
Diameter	54.62 mm	58.865 mm	56.889 mm	58.273 mm	59.116 mm
Crankshaft bearing shells
Width	29.35 mm	21.50 mm	29.5 mm	21.5 mm	29.5 mm
Thickness
Nov.	1,885 mm	1,885 mm	1,885 mm	1,885 mm	1,885 mm
Repair.	2.035 mm	2.035 mm	2.035 mm	2.035 mm	2.035 mm

Crankshaft journal dimensions

Bearing shell width: 30.05 mm

Diameter:

• new - 50.00 mm
• repair - 49.70 mm

Connecting rod bearing shells:

• Nominal thickness: 1.815 mm
• Oversized - 1.965mm

The maximum permissible difference in weight on one engine is 3 g



Maximum flywheel runout: 0.06 mm

Cylinder block and cylinder liners

Cylinder block height: 285.9+0.15 mm

The height between the cylinder head surface and the flange of the working liners is 90.00 mm

The material of the working sleeves is centrifugal cast iron

Design - "wet" working sleeves

Length of working sleeves: 136.20 mm

Bottom diameter: 93.00 mm

Protrusion of working sleeves:

• until April 1989 - 0.07-0.14 mm
• since May 1989 - 0.03-0.10 mm

Adjusting shims/washers:

• until July 1987, paper - 0.07, 0.085, 0.105 and 0.130 mm
• since August 1987, steel - 0.10, 0.12 and 0.15 mm

Modifications of working sleeves. The working cartridges were modified several times. When purchasing new bushings, be sure to indicate the year of manufacture and engine number.

Working Sleeve Diameter - 169V Engine

Engines 170
class A - 1 marking line	84,000–84,011 mm	88,000–88,011 mm
class B - 2 marking lines	84.012 - 84.022 mm	88.012 - 88.022 mm
class C - 3 marking lines	84.023 - 84.033 mm	88.023 - 88.033 mm
class D - 4 marking lines	84.034 - 84.044 mm	88.034 - 88.044 mm