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PEUGEOT
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205
PEUGEOT 205 User Manual
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1•6
Maintenance - component location
Fr
ont underside view of a 1360 cc GT model
1
Bottom hose
2
Reverse lamp switch
3
Engine/transmission oil drain plug
4
Radiator
5
Gear linkage
6
Clutch housing and transfer gear
assembly
7
Washer reservoir
8
Disc caliper
9
Lower suspension arm
10
Anti-roll bar
11
Track rod
12
Guide bar
13
Exhaust front pipe
14
Fuel feed and return pipes
15
Hydraulic brake lines
16
Subframe
17
Driveshaft
18
Front towing eye
5
7
Table of Contents
Contents
1
Servicing Specifications
2
Maintenance Schedule
3
Every 250 Miles (400 Km) or Weekly
3
Every 6000 Miles (9000 Km)
3
6 Months - Whichever Comes Sooner
3
Maintenance - Component Location
4
Underbonnet View of a 1360 CC GT Model
4
Underbonnet View of a 1360 CC XS Model (TU Series Engine)
5
Front Underside View of a 1360 CC GT Model
6
Rear Underside View of a 1360 CC GT Model
7
Maintenance Procedures
8
Intensive Maintenance
8
Engine Oil and Filter Renewal
8
Primary Operations
8
Every 6000 Miles or 6 Months
9
Front Brake Pad Check
9
Automatic Transmission Fluid Level Check
9
Using an Oil Filter Removal Tool to Slacken the Filter
9
Every 12 000 Miles or 12 Months
10
Underbonnet Check for Fluid Leaks and Hose Condition
10
Spark Plug Renewal
10
Metal Lines
10
Throttle and Choke Cable Lubrication and Adjustment
11
Auxiliary Drivebelt Check and Renewal
11
Auxiliary Drivebelt - Removal, Refitting and Tensioning
11
Checking the Auxiliary Drivebelt Condition
11
Seat Belt Check
12
Lock and Hinge Check and Lubrication
12
Rear Brake Shoe Check
12
Underbody and Fuel/Brake Line Check
12
Every 24 000 Miles or 2 Years
13
Bodywork, Paint and Exterior Trim Check
13
Headlight Beam Alignment Check
13
Air Conditioning System Check
13
Manual Transmission Oil Renewal
14
Automatic Transmission Fluid Renewal
14
Driveshaft Bellows Check
14
Steering and Suspension Check
15
Air Cleaner Filter Element Renewal
15
Rear Suspension Check
15
Front Suspension and Steering Check
15
Ignition System Check
16
Idle Speed and Mixture Check and Adjustment
16
Carburettor Models
16
General Component Check
16
Idle Speed Adjustment - Single Carburettor Engines
17
Idle Speed Adjustment - Twin Carburettor Engines
17
Single-Point Fuel Injection Models
18
Idle Mixture CO Level Adjustment
18
Adjustment Points on the Weber Twin Carburettor Installation
18
Road Test
19
Multi-Point Fuel Injection Models
19
Idle Speed Adjustment
19
Instruments and Electrical Equipment
19
Every 36 000 Miles or 3 Years
20
Timing Belt Renewal
20
Every 48 000 Miles or 4 Years
20
Every 2 Years (Regardless of Mileage)
20
Cooling System Flushing
21
Cooling System Filling
21
Engine Flushing
21
Radiator Flushing
21
Antifreeze Mixture
22
Brake Fluid Renewal
22
XV, XW and XY Engines In-Car Repair Procedures
23
Degrees of Difficulty
23
Specifications
23
Auxiliary Drivebelt Check and Renewal
23
General Information
24
Valve Clearances - Checking and Adjustment
24
Torque Wrench Settings
24
Engine Description
24
Compression Test - Description and Interpretation
25
Timing Chain, Tensioner and Sprockets - Removal and Refitting
25
Adjusting the Valve Clearances
25
Removing Oil Pump Screw with allen Key
26
Removing the Oil Pump and Spacer Plate
26
Timing Chain Tensioner Lock (2)
26
Check that the Crankshaft Is Positioned
26
Oil Pump - Removal
27
Camshaft and Rocker Arms
27
Rocker Arm Assembly
27
Cylinder Head - Removal and Refitting
28
Right-Hand Rear Engine Mounting Bolts
29
Lever up the Engine and Support It on a Wooden Block
29
Removing the Fuel Pump Plunger
29
Sequence for Tightening or Loosening the Cylinder Head Bolts
29
Preparation for Refitting
30
Removing the Rocker Shaft Assembly
30
Loosening the Camshaft Thrust Plate Bolt
30
Crankshaft Oil Seals
31
Right-Hand (Front) Oil Seal
31
Flywheel
32
Engine/Transmission Mountings - Inspection and Renewal
32
Left-Hand Oil Seal
32
XU Series Engine In-Car Repair Procedures
33
TU Series Engine In-Car Repair Procedures
45
Engine Removal and Overhaul Procedures
59
Cylinder Block
60
Piston Rings
60
Engine/Transmission Removal - Preparation and Precautions
62
Engine/Manual Transmission
63
Typical Engine Wiring Harness Connections
63
XV, XW and XY Series Engines
64
XU and TU Series Engines
64
Reconnection
64
Removing the Engine and Manual Transmission
64
Engine/Automatic Transmission
65
Cylinder Head
66
Measuring the Valve Stem Diameter
67
Grinding-In a Valve
67
Valve Components
68
Piston/Connecting Rod Assembly
68
Crankshaft
69
Checking Crankshaft Endfloat Using Feeler Blades
70
Main Bearing Cap Identification Markings (Arrowed)
70
Removing the Main Bearing Cap and Thrustwashers (Arrowed)
70
Cylinder Block/Crankcase
71
Measuring a Crankshaft Big-End Journal Diameter
71
Cleaning a Cylinder Block Threaded Hole Using a Suitable Tap
71
Cylinder Liner with Paper Base Seal
72
Cylinder Liner Size Group Marking
72
Measuring Cylinder Liner Protrusion
72
Main and Big-End Bearings
73
Fitting a Liner to the Cylinder Block
73
Typical Bearing Failures
73
Piston Rings - Refitting
74
Engine Overhaul
74
Main Bearing Shell Selection
74
Measuring Piston Ring End Gap
74
Piston Ring Identification
75
Main Bearing Shell Selection Chart - Later XU Series Engines
75
Aluminium Block Engine
76
Cast-Iron Block Engine
76
Main Bearing Shell Selection Chart
76
Plastigage in Place on a Crankshaft Main Bearing Journal
77
Lowering the Crankshaft into Place
78
Crankcase Flange O-Ring Seal
78
Tightening the Main Bearing/Casing Bolts
78
Refit the Casing Flange Bolts and Washers
78
Cooling, Heating and Air Conditioning Systems
83
General Information and Precautions
84
Cooling System Hoses
84
Antifreeze
84
Thermostat
85
Radiator
85
Thermostat Temperature Rating (Arrowed) Stamped on Base
85
Radiator Cooling Fan
86
Cooling System Electrical Switches and Sensors
86
Coolant Level Sensor
86
Coolant Temperature Sensor
86
Coolant Pump
87
Heater Assembly
88
TU Series Cast-Iron Block Engines
88
TU Series Aluminium Block Engines
88
Air Conditioning System
89
Air Conditioning System Layout
89
Precautions
90
The Refrigeration Side of the Air Conditioning
90
Fuel System - Carburettor Engines
91
Recommended Fuel
92
Fuel System - Single-Point Fuel Injection Engines
101
Fuel System - Multi-Point Fuel Injection Engines
109
Air Cleaner Assembly
110
Throttle Cable
110
Fuel System
110
Fuel Gauge Sender Unit
110
Bosch Motronic M1.3 System
111
Fuel Injection System
111
Idle Speed and Mixture CO Content
111
Throttle Initial Position
111
Throttle Position Switch
112
Throttle Housing
112
Fuel Pressure Regulator
112
Supplementary Air (Cold Start) Device
112
Inlet Manifold
113
Exhaust and Emission Control Systems
115
Exhaust System
115
Emission Control Systems
115
Typical Air Intake Heating System
115
Crankcase Ventilation System
116
Electro-Pneumatic Ignition Timing Retarding System
116
Catalytic Converter
116
Typical Crankcase Ventilation System
116
Fuel Vapour Recirculation System
117
Exhaust Manifold
118
Typical Exhaust System Layout
118
Air Inlet Heating System Components
119
Electro-Pneumatic Ignition Retarding System Components
119
Crankcase Ventilation
119
Carbon Canister
119
Solenoid Valve
120
Starting and Charging Systems
121
Battery - Removal and Refitting
122
Electrical Fault Finding
122
Battery - Testing and Charging
122
Charging System - Testing
122
Alternator - Removal and Refitting
123
Alternator - Testing and Overhaul
123
Starting System - Testing
123
Starter Motor - Removal and Refitting
123
Starter Motor - Testing and Overhaul
124
Ignition Switch - Removal and Refitting
124
Oil Pressure Warning Light Switch - Removal and Refitting
124
Electronic Oil Level Sensor
124
Ignition System Check
125
Electronic Breakerless Ignition System
126
Static Distributorless Ignition System
126
Engine will Not Start
126
Engine Misfires
126
Ignition HT Coil
127
Distributor
127
Models with Static Distributorless Ignition Systems
127
Ignition Amplifier
128
Ignition Module
128
All Engines Except TU Series
128
TU Series Engines
128
Timing Plate
129
Ignition Timing
129
Initial Static Ignition Timing on XU Series Engines
130
Dynamic Ignition Timing on XU Series Engines
130
TDC Sensor
131
Braking System
133
Table of Contents
133
Hydraulic System - Bleeding
134
Bleeding Sequence
134
Bleeding - Basic (Two-Man) Method
135
Bleeding - Using a Pressure- Bleeding Kit
135
Bleeding - Using a One-Way Valve Kit
135
Hydraulic Pipes and Hoses
136
Front Brake Pads - Renewal
136
DBA Bendix Caliper
136
Removing the Outer Pad
136
Girling Caliper
137
Rear Brake Shoes - Renewal
138
Early Type Anti-Squeal Shim
138
Later Type Anti-Squeal Shim
138
Unscrewing the Lower Caliper Guide Pin Bolt
138
Rear Brake Pads
139
DBA Bendix Type Rear Brake Component Layout
139
Girling Type Rear Brake Component Layout
139
Automatic Adjuster Lever - Arrowed
139
Front Brake Caliper
140
Brake Pad Locking Key Spring Clip
140
Removing the Rear Brake Pads
140
Correct Final Position of Caliper Piston
140
DBA Bendix Type Brake Caliper Components
141
Girling Type Brake Caliper Components
141
Rear Brake Caliper
142
Brake Disc - Inspection, Removal and Refitting
142
And Refitting
142
Rear Wheel Cylinder - Removal, Overhaul and Refitting
142
Rear Brake Hub/Drum
143
Rear Wheel Cylinder Mounting Bolts
143
Exploded View of a Rear Wheel Cylinder
143
Master Cylinder
144
Rear Brake Compensator
144
Rear Brake Compensator Fitted to 1.6 GTI Models
144
Air Filter Renewal
145
Vacuum Servo Unit - Testing, Removal and Refitting
145
Brake Pedal - Removal and Refitting
146
Handbrake - Adjustment
146
Handbrake Cables - Renewal
146
Handbrake Lever - Removal and Refitting
147
Anti-Lock Braking System
147
Electronic Control Unit
147
Regulator Unit
147
Suspension and Steering
149
Easy, Suitable for Fairly Easy, Suitable Fairly Difficult
149
Front Suspension Hub Carrier
150
R-Clip and Locking Collar Fitted to Hub Nut on Later Models
150
Front Hub Bearings - Renewal
151
Front Suspension Strut
151
Front Hub Bearing Retaining Circlip
151
Front Lower Suspension Arm - Removal and Refitting
152
Front Suspension Strut - Overhaul
152
Front Suspension Top Mounting Nuts
152
Front Anti-Roll Bar
153
Anti-Roll Bar Guide Bar Bolt (Arrowed) on Non-GTI Models
153
Anti-Roll Bar Mounting Clamp Bolts (Arrowed)
153
Rear Hub/Drum and Bearings - General Information
154
Rear Shock Absorber - Removal and Refitting
154
Rear Suspension Assembly - Removal and Refitting
155
Steering Column and Lock - Removal and Refitting
155
Steering Gear - Removal and Refitting
156
Steering Column and Lock Assembly Components
156
Manual Steering Gear
156
Power-Assisted Steering Gear
156
Steering Gear Rubber Bellows - Renewal
157
Extract the Spring Clip (6) from the Gearchange Linkage
157
Front Subframe Attachments
157
Correct Refitting of Power Assisted Steering Gear
157
Track Rod End - Removal and Refitting
158
Power Steering Pump
158
Separating the Track Rod End from the Hub Carrier Steering Arm
158
Wheel Alignment and Steering Angles - General Information
159
Adjusting the Front Wheel Toe Setting
159
Front Wheel Toe Setting - Checking and Adjustment
159
Bodywork and Fittings
161
Maintenance - Bodywork and Underframe
161
Minor Body Damage - Repair
162
Repair of Minor Scratches in Bodywork
162
Repair of Dents in Bodywork
162
Repair of Rust Holes or Gashes in Bodywork
162
Bodywork Repairs - Filling and Re-Spraying
163
Plastic Components
163
Major Body Damage - Repair
163
Bonnet - Removal and Refitting
163
Bonnet Lock and Remote Control Cable - Removal
164
Front Grille
164
Bumpers
164
Front Bumper
164
Door - Removal and Refitting
165
Front Bumper Components
165
Rear Bumper Components
165
Door Trim Panel
166
Removing the Armrest
166
Removing the Side Pocket
166
Removing the Interior Door Handle Surround
166
Door
167
Exterior Mirror (Early Models)
167
Hood and Rear Window
168
Power-Operated Hood Components
169
Tailgate
169
Tailgate Lock
169
Windscreen and Tailgate Glass
169
Seats - Removal and Refitting
170
Sunroof - General Information
170
Grab Handles
170
Front Seat Rear Inner Mounting Bolts
170
Sunroof Glass
171
Glovebox
171
Facia Panel
171
Facia Front Mounting Nut
172
Removing a Right-Hand Lower Facia Panel Securing Screw
172
Body Electrical System
175
Finding an Open-Circuit
178
Finding an Earth Fault
178
Finding a Short-Circuit
178
Fuses and Relays
179
Switches
179
Removing a Fuse
179
Combination Switch Screws
179
Instrument Panel Rheostat
180
Reversing Light Switch
180
Courtesy Light Switch
180
Glovebox Illumination Switch
180
Instrument Panel
181
Removing the Instrument Panel
181
Exploded Diagram of Non-GTI Instrument Panel
182
Exploded Diagram of GTI Instrument Panel
182
Clock - Removal and Refitting
183
Speedometer Cable - Renewal
183
Bulbs (Exterior Lights)
183
Bulb Renewal
183
Front Parking Lights
184
Front Direction Indicator
184
Front Direction Indicator Side Repeater
184
Rear Light Cluster Bulbs
184
Bulbs (Interior Lights)
185
Number Plate Light
185
Reversing Light (1991 Models Onward)
185
Map Reading Light
185
Headlight Unit
186
Front Direction Indicator Light Unit
186
Headlight Beam Alignment
186
Wiper Arms
187
Windscreen Wiper Motor and Linkage
187
Tailgate Wiper Motor
187
Washer System
187
Tailgate Heated Window
188
Central Door Locking System
188
Horn - Removal and Refitting
188
Air Compressor and Horn
188
Key to Wiring Diagrams
189
Reference
202
Dimensions and Weights
202
Conversion Factors
203
Fuel Consumption
203
Buying Spare Parts
204
Vehicle Identification
204
Officially-Appointed Garages
204
Motor Factors
204
Joint Mating Faces and Gaskets
205
Screw Threads and Fastenings
205
Oil Seals
205
Locknuts, Locktabs and Washers
205
Jacking and Vehicle Support
206
Radio/Cassette Unit Anti-Theft System
206
Front Jacking Point
206
Tools and Working Facilities
207
Maintenance and Minor Repair Tool Kit
207
Repair and Overhaul Tool Kit
207
Valve Spring Compressor
207
Buying Tools
208
Care and Maintenance of Tools
208
Working Facilities
208
Micrometer Set
208
MOT Test Checks
209
Handbrake
209
Footbrake
209
Steering Wheel and Column
209
Seat Belts and Seats
210
Electrical Equipment
210
Steering and Suspension
210
Shock Absorbers
210
Steering Mechanism
211
Springs and Shock Absorbers
211
Front and Rear Suspension and Wheel Bearings
211
Fuel and Exhaust Systems
212
Wheels and Tyres
212
Body Corrosion
212
HC Emissions
212
Road Test
212
Fault Finding
213
Engine Fails to Rotate When Attempting to Start
214
Engine Rotates, but will Not Start
214
Engine Difficult to Start When Cold
214
Engine Idles Erratically
214
Engine Misfires Throughout the Driving Speed Range
215
Engine Hesitates on Acceleration
215
Engine Stalls
215
Engine Lacks Power
215
Overheating
216
Overcooling
216
Excessive Fuel Consumption
216
Fuel Leakage And/Or Fuel Odour
216
Cooling System
216
Noisy in Neutral with Engine Running
217
Noisy in One Particular Gear
217
Difficulty Engaging Gears
217
Jumps out of Gear
217
Manual Transmission
217
Automatic Transmission
217
Vehicle Pulls to One Side under Braking
218
Brake Pedal Feels Spongy When Depressed
218
Excessive Brake Pedal Travel
218
Brakes Binding
218
Braking System
218
Suspension and Steering
218
Excessive Play in Steering
219
Lack of Power Assistance
219
Tyre Wear Excessive
219
Instrument Readings Inaccurate or Erratic
219
Electrical System
219
Glossary of Technical Terms
221
Index
226
Spark Plug Renewal
229
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PEUGEOT 205 Specifications
General
Brand
PEUGEOT
Model
205
Category
Automobile
Language
English
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