Specification of gasoline engines Total information Engine type - 4-cylinder transversely mounted in-line engine with overhead camshaft and water cooling. Engine code: Models GL and GR - XL5 (118) Models SR-XR5 (142) Cylinder diameter (all models) - 78...
General description of gasoline engines The Peugeot 305 has a 4-cylinder in-line engine with an overhead camshaft. There are two versions of this engine: XL5 (118) volume: 1290 cm 3 used on GL and GR models, a XR5 (142) volume 1472 cm 3 - on SR models. An...
Sleeve Seal Modifications (XL/XR Series Engines) 1. In 1984 steel case base seals were replaced with paper seals. Changes were also made to the design of the sleeves (for sleeve seal markings, see Specifications ). 2. New liners and seals can be installed as a kit on...
Main cover side bolts (XR5S engine) 1. For greater reliability, the central main bearing cap on the XR5S engine is additionally fastened with two side bolts. 2. When removing the crankshaft, first remove the side bolts and only then remove the central...
Timing Housing Seal (All Models) 1. On some models, the timing cover gasket is not initially installed. Instead, a special sealant is used. On these models, the O-ring between the cylinder block and the timing case has a different size. 2. When...
XU Series Engine — General Description 1. The XU series engine found on the GT, GTX and later GR and SR models is similar to the XL and XR engines in that it also has 4 wet sleeve cylinders, a 5 bearing crankshaft and an overhead camshaft. 2. The camshaft is...
Basic operations possible without removing the engine from the machine Without removing the engine from the machine, you can perform the following operations: a. * Removing and installing the clutch. b. * Removal and installation of the drive shaft gear and oil seals. * Removal and...
Basic operations requiring removal of the engine from the machine The engine must be removed to perform the following operations: A. Removal and installation of the gearbox. b. Removal and installation of crankshaft and main bearings. V. Removal and installation of connecting rod and...
Engine and transmission — removal 1. The engine and gearbox can only be removed as a single unit and not separately. The total weight of the engine with the box is not that great due to the extensive use of aluminum alloy, however, some operations are...
Engine disassembly — general part 1. Engine disassembly is best done on a clean work bench. Before installing the engine with gearbox on the table, they should be cleaned from dirt, oil and grease from the outside. 2. Be careful not to bring dirt into...
Engine Disassembly — Accessories 1. Whether you are going to completely overhaul the engine or just want to trade it in for a new or rebuilt one, you need to remove the accessories from it. 2. The only way to assess the condition of an engine is to...
Removal with gearbox (XU series engine) 1. The method described here is to remove the engine along with the gearbox through the bottom. If desired, you can first remove the gearbox and then pull the engine through the top, however, we do not recommend this...
Disconnecting the gearbox from the XU series engine 32. Remove the starter, which is attached with 3 hex bolts, and its support bracket (see pictures). 33. To turn out the remained bolts of fastening of the engine to a transmission. 34. Support the engine and disconnect...
XU Series Engine Disassembly 35. Remove the following accessories from the engine: A. Generator and its drive belt. b. Oil filler tube and crankcase breather tube (memorizing their location). V. intake manifold and carburetor. g. Clutch. e. Oil...
Cylinder head — removal from the engine standing on the machine 1. The cylinder head can be removed and reinstalled without removing the engine from the machine, however you will need a special tool "Peugeot" (N 8.0140) to hold the camshaft sprocket in place and prevent the timing...
Cylinder liner protrusion — checking and adjusting 1. The liners installed in the block must protrude outward by a specified amount after the cylinder head is installed between it and the block gas-tight connection. If even one liner protrudes too much or, on the...
Cylinder Head Disassembly (XU Series Engines) 62. If not already done, remove the distributor, fuel pump and spark plugs. Remove manifolds with their gaskets. 63. To turn out bolts and to remove the case of an exhaust branch pipe of system of cooling. Don't forget...
Cylinder head resurfacing (XU series engines) 71. The manufacturer prohibits regrinding of the cylinder head, so a head with a deformed surface must be replaced. 72. Heads supplied for exchange may have a contact surface ground to 0.2 mm. Such heads are marked with...
Cylinder head — installation on the engine standing on the machine 1. Check that all contact surfaces are clean. Check that the cylinder liners are straight and protrude above the cylinder block by the required amount. Prepare new gaskets for the cylinder head, timing case, valve cover...
Cylinder Head Assembly (XU Series Engines) 1. Install new valve stem seals and then valves, springs and crackers. Lubricate the valve stems well with oil. In order for the crackers to stay in place while the springs are being compressed, fix them with grease....
Timing mechanism — removal 1. If not already done, remove the 2 bolts securing the fuel pump to the back of the timing case. Remove the pump with gasket and pull out the pump plunger. 2. Unscrew the clamping bolt of the distributor and remove the...
Engine and transmission — disconnection 1. After removing the timing mechanism and the crankcase clutch, the engine and gearbox are held together only by bolts in the front and rear flanges. 2. Position the motor with box under the hoists and gradually loosen...
Cylinder head — removal from the engine located on the desktop 1. Support the engine with wooden blocks and then gradually loosen the 10 cylinder head bolts in the reverse order of their tightening ( see section 35 ). As the bolts are loosened, the rocker mechanism will gradually...
Pistons, connecting rods and crankshaft — removal 1. Pistons, connecting rods and crankshaft can only be removed from the engine, transferred to the work table and disconnected from the gearbox, and the timing cover, clutch and cylinder head must already be removed. 2....
Piston rings — removal 1. Carefully remove the piston rings through the piston crown, being careful not to scratch the aluminum alloy. Do not try to remove the rings through the piston skirt, because. they are iron and break easily. To...
Camshaft — removal 1. If the engine is on the machine, then before removing the camshaft, it is necessary to remove the cylinder head. If the engine has already been removed and moved to the desktop, it is necessary to remove the timing...
Lubrication system — description The models in question use a forced lubrication system, with oil circulation achieved by an oil pump pumping oil from a sump under the gearbox. The high-performance rotary pump is located in the lower part of the timing...
Oil filter — removal and installation 1. The full flow oil filter is located at the front of the timing case, on the right side of the engine. 2. The filter is replaceable and is screwed directly into the threaded bushing in the timing case. 3. Before...
Cylinder head — disassembly, inspection and installation 1. Remove the cylinder head and place it on a clean work bench for disassembly and inspection. Remember that the head is made of light alloy and is easily damaged. 2. Install a valve cracking tool on the first valve and...
Connecting rod and main bearings — inspection and alignment 1. New bearings have a highly polished surface that becomes matte gray over time. Bearings must be free of pits, ridges, gouges or scratches. Even if the bearing shells look good, we recommend replacing them anyway,...
Cylinder Liners — Inspection and Tidying 1. Cylinder liners can be inspected for wear by either removing them from the cylinder block or leaving them in place (the cylinder head must of course be removed in both cases). If the liners are in the cylinder block,...
Connecting rods, pistons and piston rings — inspection and tidying 1. Remove the pistons with connecting rods from the sleeves and clean them thoroughly with kerosene. Use a scraper to scrape off carbon deposits from the piston bottoms, being careful not to damage them. Carefully...
Timing chain and sprockets — inspection and tidying 1. Inspect the teeth of both sprockets for wear. The tooth is shaped like an inverted letter "V" and when worn, one side of the tooth becomes more concave than the other. Heavily worn teeth take on a hook-like shape, in...
Camshaft and Rockers — Inspection and Tidying 1. Inspect the camshaft lobes for wear and damage. At the same time, inspect the rockers for wear, especially where they rest on the camshaft cams. With obvious defects and dents on the thrust surfaces of the rockers or...
Oil pump — inspection and tidying up 1. The oil pump is located at the bottom of the timing housing and is driven by a shaft from a helical gear mounted on the crankshaft. The pump is an eccentric rotary and in order to get to it, it is necessary to remove...
Intake and exhaust manifolds — inspection 1. The intake manifold is connected to the cylinder head by 4 short hoses, which we recommend replacing when overhauling the engine. These hose clamps must be in good condition. At the slightest doubt, they should be...
Engine Mounts — Inspection Engine mounts are often overlooked because they usually don't cause much of a problem. If the rubber parts of the pads are in poor condition due to exposure to heat or oil, or simply due to long use, they should be...
Engine assembly — general part 1. In order to maximize the life of a remanufactured engine, a few basic principles should be followed when assembling it. 2. Absolute cleanliness must be observed. Assembly must be done in a clean room, with clean...
Engine — preparation for assembly 1. If the engine has been completely disassembled so that the cylinder block is open, thoroughly clean it inside and out. If not already done, remove the 5 bolts securing the oil line cover to the side of the cylinder...
Inspection and alignment of XU engine parts (general) 1. See chapter 1A, sections 20 , 22 , 23 , 24 and 30 . 2. The camshaft drive belt must be replaced in any case, unless it is in excellent condition. Replace sprockets if they are damaged or defective. 3. Inspect the...
XU Series Engine Assembly 1. See chapter 1A, sections 31 and 32 (skipping anything related to the o-ring on the clutch side of the cylinder block). 2. Turn the cylinder block over and install the upper main bearing shells. Install the thrust...
Connecting the XU engine to the gearbox 41. Check that the parts of the clutch release mechanism are correctly installed in the clutch housing and that the clutch disc and clutch basket are installed on the flywheel. (On models with automatic transmission,...
Installing the XU engine with gearbox on the machine 45. Install the drive shaft oil seal protector on the right side of the final drive assembly (see photo). 46. Raise and support the front of the machine and place the engine with the gearbox under the engine...
Crankshaft — installation 1. Thoroughly clean the crankcase and cylinder block and turn the block over so that the surface on which the cylinder head is mounted is at the bottom. 2. Wipe clean the main bearing seats in the crankcase and...
Pistons, connecting rods and cylinder liners — installation 1. First of all, you need to install the liners in the cylinder block and check that they stand without distortions, as well as check the amount of protrusion of the liners above the cylinder block and the difference in...
Cylinder head — installation on the engine removed from the machine 1. If the cylinder head has been rebuilt as described in section 20 and the cylinder block has been assembled to the point reached in the previous section, temporarily install the key and sprocket on the crankshaft and...
Engine and gearbox — connecting to each other 1. Connect gearbox to engine ( see chapter 6, section 6 ). 2. If the gearbox has not been disassembled, it is advisable to remove the bottom cover of the box and then the oil intake strainer, which is attached with 3...
Sprocket and Timing Chain — Assembly 1. Check that the keyways at the end of the crankshaft are clean and install the keys (see b/fig. 1.20 for the installation sequence of the various parts). 2. Install an asterisk on the crankshaft (teeth towards the...
Timing cover — assembly and installation 1. Install the combined helical gear and fuel pump cam into place in the timing case, insert the drive shaft and engage the drive pawls (see pictures). Lubricate the drive mechanism with clean engine oil. 2. Assemble...
Valve clearances — checking and adjusting 1. The valve clearance adjustment procedure remains the same whether the engine is removed from the machine or not. In the latter case, the regulation is carried out only on a cold engine. The operation of the engine...
Clutch — Installation 1. For clutch installation procedure, see chapter 5, section 7 , starting from paragraph 5 (taking into account the fact that the engine is on the car).
Engine assembly — final operations 1. After assembling the main components of the engine, you can install auxiliary equipment and secondary parts. Try to fully assemble the engine as far as possible before installing it with the gearbox on the machine....
Engine and Transmission — Installation 1. In general, the installation of the engine with the gearbox is carried out in the reverse order of its removal. Check that the elements are securely fastened to the engine lugs. 2. Before lowering the engine, check...
Checking Valve Clearances (XU Series Engines) 1. Remove the distributor cover with high voltage wires. Loosen the bolts and remove the valve cover, being careful not to damage the gasket. 2. The engine can be turned by either jacking up one of the front wheels and...
Valve Clearance Adjustment (XU Series Engines) 9. Remove the camshaft (see below). 10. Pull out one of the pushers with its adjusting washer (make sure that the washer does not fall out of the pusher). Clean the washer and measure its thickness with a micrometer...
Removal and installation of the camshaft (the engine is on the machine) 40. Remove the camshaft drive belt as described above. 41. Remove the valve cover. To facilitate access, remove the distributor cover with high voltage wires. 42. Remove the distributor and fuel pump from the thermostat...
Modification of the crankcase ventilation system 79. When starting the engine in cold weather, it is possible to knock out the oil filler plug, which is caused by the freezing of water vapor on the breather wire mesh and the subsequent increase in pressure when they...
Cylinder head bolt modifications (XU-series engines from December 1986) 82. Since December 1986, the cylinder head is bolted with a polyhedral hole in the head (55) (Togh bolts). 83. In addition, thicker washers are used (8.0mm) and the height of the cylinder liners is reduced by 0.05 mm,...
Engine — first start after overhaul 1. Check that the battery is well charged, there is fuel in the tank, and the level of coolant and oil in the crankcase reaches the desired level. 2. When starting for the first time, it will be necessary to turn the...
XU series engines — first start after overhaul 1. See chapter 1, section 44, paragraph 1-7 . 2. Wait at least 2 hours for the engine to cool down. Loosen the bolt securing the right engine support bracket to the cylinder block, and then retighten the cylinder head...
Engine Troubleshooting Engine does not turn over with starter Low battery Loose or corroded battery terminals Open in wiring to starter or poor engine or battery ground Faulty starter or solenoid ( see chapter 10 ) Faulty ignition/starter...