2.5L diesel and turbodiesel engine — manual (Peugeot J5)

Cylinder head

Cylinder head height: 117.00 + 0.5 mm

Minimum permissible cylinder head height is 116.3 mm

The maximum permissible distortion of the cylinder head surface is 0.10 mm

Cylinder head surface milling - Maintain minimum permissible height - 116.3 mm

Cylinder head gasket marking: L25

The recess of the valve head under the surface of the cylinder head is 0.70–0.90 mm

Valve guide bushings

Nominal outside diameter:

• first design - 13.055-13.075 mm
• second design - 13.305-13.325 mm
• repair size - 13.555-13.575 mm

Guide bushing holes:

• intake valve guides - 7.990-8.015 mm
• exhaust valve guides - 8.980-9.005 mm

Installation height, from head surface to bushing:

• intake valve guides - 9.9-11.4 mm
• exhaust valve guides - 11.9-13.4 mm

Cylinder head bore size (nominal diameter):

• first design - 13.003-13.023 mm
• second design - 13.253-13.273 mm
• repair size - 13.503-13.523 mm

Valve guide length:

• Intake valves - 53.75-54.25 mm
• Exhaust valves - 56.75-57.25 mm

Valve seats

Valve seat angle - 90°

Inlet/outlet valve seat width: 2.50 mm

Replacement of valve seat rings is performed in the workshop

Valve Seat Diameter/Cylinder Head Bore:

Valve seat diameter - Cylinder head bore

Intake valves -

• 1st design - 45.154-45.179 mm 45.000-45.039 mm
• 2nd design - 45.454-45.479 mm 45.300-45.339 mm

Intake valves -

• repair size - 45.754-45.779 mm 45.600-45.639 mm

Exhaust valves -

• 1st design - 38.160-38.185 mm 38.000-38.039 mm
• 2nd design - 38.460-38.475 mm 38.300-38.339 mm

Exhaust valves -

• repair size - 38.760-38.775 mm 38.600-38.639 mm

Valves:

Valve seat angle: - 45° (full angle 90°)

Valve head diameter:

• Intake valves - 41.85-42.15 mm
• Exhaust valves - 34.85-35.15 mm

(Original is located at Peugeotbook.ru)

Valve stem diameter:

• Intake valves - 7.960-7.975 mm
• Exhaust valves - 8.940-8.955 mm

Maximum 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 the holes:

• Inlet valves - 0.015-0.045 mm
• Exhaust valves - 0.045-0.075 mm

Maximum valve clearance in the guide bushing is 0.10 mm

Valve springs:

Number of springs - one for each valve

Wire diameter: 4.5 mm

Length in free state - 49.40 mm

Spring markings - the intake and exhaust valve springs are identical

Inner diameter: 25.20±0.2 mm

Spring length under load:

• under load - 29±2.1 kg 40.90 mm
• under load - 71±4.2 kg 30.9 mm

Camshaft

Axial play of the camshaft is 0.05-0.36 mm (not regulated)

The thickness of the retaining plate is 5.41 mm

Length of push rods: 180±0.3 mm

Maximum runout of push rods is 1.0 mm

Pistons and connecting rods

Piston pins are installed floating in the connecting rod bore and in the piston, with pin retaining rings

Installing Pistons - See "Pistons and Connecting Rods" section in the main text

Piston rings:

Number of rings - 3

Ring design - 1 regular compression ring, 1 trapezoidal ring, 1 oil-deflecting ring

Piston ring joint clearances nominal dimensions:

• upper compression ring - 0.20-0.45 mm
• middle upper compression ring - 0.15-0.40 mm
• oil deflector ring - 0.10-0.30 mm

Cylinder Bore/Piston Diameter (Diesel) - in mm:

		Cylinder bore		Piston diameter
	Nominal diameter	Designations in the drawing 352	Cylinder diameter	AEF piston diameter.	Designations in the drawing 350	Piston protrusion
Standard	93,00	A	93,007-93,022	92,89-93,91	1n	0,50-0,55
Piston repair sizes	93,25	B1	93,25-93,26	93,14-93,15	B1 n	0,47-0,52
		B2	93,26-93,27	93,15-93,16	B2 n	0,47-0,52
	93,50	C1	93,50-93,51	93,39-93,40	C1 n	0,44-0,49
		C2	93,51-93,52	93,40-93,41	C2 n	0,44-0,49
	93,75	D1	93,75-93,76	93,64-93,65	D1 n	0,41-0,46
		D2	93,76-93,77	93,65-93,66	D2 n	0,41-0,46

Other information about diesel engine pistons - Pistons are manufactured exclusively by AEF, from aluminum alloy with a zinc coating, piston pins are not offset

Piston clearances:

• marked "N" in position (1) in Figure 350 - 0.10-0.12 mm
• marked "U" in position (1) in Figure 350 - 0.0975-0.1305 mm

The maximum permissible difference in piston weight on one engine is 15 g

Piston pin bore diameter: 30.004-30.014 mm

Piston ring markings:

• diameter 93.00 mm - yellow marking
• diameter 93.25 mm - green marking
• diameter 93.50 mm - white marking
• diameter 93.75 mm - purple marking

Piston ring thickness/

Piston Groove Width - Piston ring thickness and piston groove width have varied over the years. Pistons must be replaced together with piston rings.

Turbodiesel engine piston data

Manufacturer - AEF or PDC.

Designation - "U" in position (1) in Figure 350

Cylinder bore diameter: 93.01-93.02 mm

Piston diameter - nominal size:

• aEF pistons - 92.895-92.903 mm
• pDC pistons - 92.859-92.877 mm

Piston pin diameter:

• aEF pistons - 32.014-32.019 mm
• pDC pistons - 32.005-32.011 mm

Connecting rods and connecting rod bearings:

• design - conventional bearing shells
• material - aluminum-zinc
• diameter - crank journals See. "Crankshaft"

Connecting rod bearing bushing diameter: 30.014-30.020 mm

Connecting rod bearing bore diameter:

• class 1 - 57.765-57.685 mm
• class 2 - 57.685-57.695 mm

Distance between connecting rod centers: 145.0±0.05 mm

The maximum permissible difference in weight between any two connecting rods in an engine is 7 g

Lateral play of the connecting rod bearing is 0.037-0.247 mm (not regulated)

Crankshaft and flywheel

Number of bearings - 5

Main bearing shells:

design - conventional bearing shells, with or without lubrication grooves, mark before removal

material: aluminum - zinc

Crankshaft axial play: 0.045-0.16 mm

Thickness of expansion washers: 3.10, 3.14, 3.18 or 3.22 mm

Main journal diameter:

• class A - 67.035-67.05 mm
• class B - 66.785-66.800 mm

Bearing bore diameter (in crankcase) - 71.695-71.705 mm

Main bearing shells:

• class A - 2.306-2.312 mm
• class B - 2.431-2.437 mm

Crankpin diameter:

• nominal diameter - class A 53.99-54.005 mm
• repair size - 53.505-53.490 mm

Connecting rod bearing shells:

Crankshaft - Connecting Rods

Thickness

Class A - Class I 1.820-1.826 mm

Class II - 1.825-1.831 mm

Class B - Class I 1.945-1.951 mm

Class II - 1,950-1,956 mm

Repair size - Class I 2.070-2.076 mm

Class II - 2.075-2.081 mm

Connecting rods:

Connecting rod bearing bushing diameter: 30.014-30.020 mm

Connecting rod bearing bore diameter:

• class 1 - 57.675-57.685 mm
• class 2 - 57.685-57.695 mm

Distance between connecting rod centers: 154.0±0.05 mm

The maximum permissible difference in weight between any two connecting rods in an engine is 7 g

The maximum permissible flywheel runout is 0.06 mm