PEUGEOT 205 Manual
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PEUGEOT 205 Manual

PEUGEOT 205 Manual

Routine maintenance and servicing
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Chapter 1
Routine maintenance and servicing

Contents

Air Cleaner Filter Element Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Air Conditioning System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Automatic Transmission Fluid Level Check . . . . . . . . . . . . . . . . . . . . . 5
Automatic Transmission Fluid Renewal . . . . . . . . . . . . . . . . . . . . . . . . 23
Auxiliary Drivebelt Check And Renewal . . . . . . . . . . . . . . . . . . . . . . . . 9
Bodywork, Paint And Exterior Trim Check . . . . . . . . . . . . . . . . . . . . . . 18
Brake Fluid Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Clutch pedal stroke adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Coolant renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Driveshaft Bellows Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Engine Oil And Filter Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Exhaust System check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Emissions control systems check . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Front Brake Pad Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel filter renewal - fuel injection models . . . . . . . . . . . . . . . . . . . . . 32
Handbrake check and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Headlight Beam Alignment Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Easy, suitable for
Fairly easy, suitable
1
novice with little
for beginner with
experience
some experience
Idle Speed And Mixture Check And Adjustment . . . . . . . . . . . . . . . . . 28
Ignition System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Intensive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Lock And Hinge Check And Lubrication . . . . . . . . . . . . . . . . . . . . . . . . 12
Manual Transmission oil level check . . . . . . . . . . . . . . . . . . . . . . . . . 21
Manual Transmission Oil Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Rear brake pad condition check - models with rear disc brakes . . . 14
Rear Brake Shoe Check - models with rear drum brakes . . . . . . . . . 13
Road Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Seat Belt Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Spark Plug Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Steering And Suspension Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Timing Belt Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Underbody And Fuel/Brake Line Check . . . . . . . . . . . . . . . . . . . . . . . . 16
Fairly difficult,
2
3
suitable for competent
DIY mechanic
Difficult, suitable for
Very difficult,
4
experienced DIY
suitable for expert DIY
mechanic
or professional
1•1
1
5

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Summary of Contents for PEUGEOT 205

  • Page 1 1•1 Chapter 1 Routine maintenance and servicing Contents Air cleaner filter element renewal ......26 Idle speed and mixture check and adjustment .

  • Page 2: Servicing Specifications

    Champion RC7YCC or C7YCX* *Peugeot recommendation Spark plug electrode gap** ........

  • Page 3: Maintenance Schedule

    Check the operation of the handbrake (Section 15). ˛ Note: This is the interval recommended by Peugeot, but we Inspect the underbody and the brake hydraulic pipes and hoses recommend that the belt is changed more frequently, at 36 000 miles ˛...
  • Page 4 Maintenance - component location 1•4 Underbonnet view of a 1360 cc GT model (XY8 series engine) 1 Right-hand front engine mounting 13 Heater hose 23 Clutch housing 2 Jack 14 Oil filler cap/crankcase ventilation filter 24 Washer reservoir 3 Drivebelt 15 Windscreen wiper arm 25 Battery 4 Oil filter...
  • Page 5 Maintenance - component location 1•5 Underbonnet view of a 1360 cc XS model (TU series engine) 1 Brake fluid reservoir filler cap 9 Fuel filter 16 Bonnet lock 2 Brake master cylinder 10 Washer fluid reservoir 17 Engine oil filler cap 3 Brake vacuum servo unit 11 Battery 18 Exhaust manifold hot air shroud...
  • Page 6 Maintenance - component location 1•6 Front underside view of a 1360 cc GT model 1 Bottom hose 7 Washer reservoir 13 Exhaust front pipe 2 Reverse lamp switch 8 Disc caliper 14 Fuel feed and return pipes 3 Engine/transmission oil drain plug 9 Lower suspension arm 15 Hydraulic brake lines 4 Radiator...
  • Page 7 Maintenance - component location 1•7 Rear underside view of a 1360 cc GT model 1 Exhaust front pipe 6 Rear shock absorber 11 Spare wheel 2 Handbrake cables 7 Trailing arm 12 Rear towing eye 3 Heatshield 8 Side-member 13 Torsion bars 4 Rear suspension cross-tube 9 Exhaust rubber mounting 14 Fuel tank...

  • Page 8: Maintenance Procedures

    These wrenches can be chosen, make sure that the vehicle remains obtained from most motor factors or your level, or if it is at an angle, that the drain point Peugeot dealer. is at the lowest point. 1 Frequent changes...
  • Page 9 Every 6000 miles or 6 months 1•9 3.7 Using an oil filter removal tool to slacken the filter 5.1 Withdrawing the automatic transmission fluid dipstick 4 Allow the oil to drain into the container, and 12 Start the engine and run it for a few 3 If any of the pads friction material is worn to check the condition of the plug’s sealing minutes;...
  • Page 10 Every 12 000 miles or 12 months 1•10 type clamps with screw clips whenever a hose 6 Underbonnet check for fluid is replaced. leaks and hose condition Metal lines 13 Sections of metal piping are often used for fuel line between the fuel filter and the Warning: Renewal of any air engine.
  • Page 11 Every 12 000 miles or 12 months 1•11 7.9 Measuring the spark plug gap with a 7.10 Measuring the spark plug gap with a It is very often difficult to insert spark feeler blade wire gauge plugs into their holes without cross- Keep the socket aligned with the spark plug - threading them.
  • Page 12 Every 12 000 miles or 12 months 1•12 by moving the alternator by hand, or 3 Subtract the first measurement from the measured through the top of the caliper body. tightening the adjuster bolt. second to obtain the clutch pedal travel. If this If any pad’s friction material is worn to the 11 Tension the drivebelt as described in the with...
  • Page 13 (water) dripping show up as a black sooty stain in the vicinity therefore be carried out by a Peugeot dealer from this while the system is in operation, of the leak.
  • Page 14 Every 24 000 miles or 2 years 1•14 4 The oil level should reach the lower edge of these should be renewed whenever they are disturbed. the filler/level hole. A certain amount of oil will 5 When the fluid has finished draining, clean have gathered behind the filler/level plug, and the drain plug threads and those of the will trickle out when it is removed;...

  • Page 15: Air Cleaner Filter Element Renewal

    Every 24 000 miles or 2 years 1•15 roadwheels. If this is not the case, closely the inner joint and attempting to rotate the observe the joints and mountings previously driveshaft. appreciable movement indicates wear in the joints, wear in the described, but in addition, check the steering driveshaft splines, or a loose driveshaft column universal joints for wear, and also...
  • Page 16 Every 24 000 miles or 2 years 1•16 that the arm is securely pressed onto the shaft, and tighten the cap retaining screws securely. 10 Even with the ignition system in first-class condition, some engines may still occasionally experience poor starting attributable to damp ignition components.
  • Page 17 Every 24 000 miles or 2 years 1•17 28.4a Typical idle speed adjusting screw 28.4b Idle speed adjusting screw (1) and 28.4c Idle speed adjusting screw location location (A) on the Solex PBISA mixture screw (2) location on the (1) on the Weber 32 IBSH carburettors carburettors Solex 32-34 Z2 carburettors Carburettor models...
  • Page 18 CO level. On twin carburettor installations turn idling speed by means of the idle speed screw available, the car must be taken to a Peugeot both mixture adjustment screws by equal to obtain the specified speed. Note that if one dealer for the work to be carried out.
  • Page 19 Instruments and electrical the LE2-Jetronic fuel injection system instructions. Note the idle speed, and equipment be taken to a Peugeot dealer for the work to compare it with that specified. 1 Check the operation of all instruments and be carried out.
  • Page 20 Every 24 000 miles or 2 years 1•20 9 Check that the clutch action is smooth and driveshaft joint, in which case, the complete 15 Test the operation of the brake servo unit driveshaft must be renewed (see Chapter 8). progressive, that the drive is taken up as follows.
  • Page 21 Although Peugeot dealers use a special 18 With bottom hoses unnecessary contamination. header tank, the same effect can be achieved disconnected from the radiator, insert a...
  • Page 22 Every 2 years 1•22 Slacken and retighten the bleed screws to allow any air that has risen to escape. Note: Take great care not to scald yourself with the hot coolant during this operation. 26 Stop the engine and allow it engine to cool, then remove the “header tank”...

  • Page 23: Auxiliary Drivebelt Check And Renewal

    2A•1 Chapter 2 Part A: XV, XW and XY engines in-car repair procedures Contents Auxiliary drivebelt check and renewal ....See Chapter 1 Engine oil level check ..... .See “Weekly checks” Camshaft and rocker arms - removal, inspection and refitting .
  • Page 24 2A•2 XV, XW and XY series engine in-car repair procedures Torque wrench settings lbf ft Engine mounting nuts ........Oil pump screws .
  • Page 25 Refer to a arm and steel pad, have different valve Peugeot dealer or other specialist if in doubt clearances than earlier engines. Ensure that as to whether a particular pressure reading is acceptable.
  • Page 26 2A•4 XV, XW and XY series engine in-car repair procedures 4.10b Removing the oil pump and spacer 4.12 Timing chain tensioner lock (2) plate Turn in direction of arrow to release slipper - turn in opposite direction to retract slipper gasket are removed from the timing cover, rocker cover and engine mating faces.
  • Page 27 XV, XW and XY series engine in-car repair procedures 2A•5 4.23 Tightening the camshaft sprocket 4.24 Releasing the timing chain tensioner 4.27 Timing cover bolt next to coolant retaining bolt pump pulley in place prior to fitting cover 24 Using a very thin screwdriver blade, turn 33 Lower engine, reconnect...
  • Page 28 Inspection pistons) it will be necessary to use the Slide the camshaft back into position in the Peugeot special tool to hold the camshaft cylinder head. Rocker arm assembly 9 Examine the rocker arm bearing surfaces which contact the camshaft lobes for wear ridges and scoring.
  • Page 29 XV, XW and XY series engine in-car repair procedures 2A•7 7.17 Right-hand rear engine mounting 7.18 Lever up the engine and support it on 7.21 Removing the fuel pump plunger bolts a wooden block sprocket, or fabricate a suitable alternative. If it engagement rods with reference to Chapter 7A.
  • Page 30 33 With the camshaft sprocket supported so In the absence of the Peugeot tool, a as to allow rotation, commence the cleaning using a drift (see illustration).
  • Page 31 2 Release the nuts on the right-hand flexible cover. amount). Although Peugeot do not actually engine mounting at the base of the timing 54 Adjust the valve clearances (Section 2). specify that the bolts must be renewed, it is chain cover.
  • Page 32 However, it may be possible to have it such damage or deterioration is evident. crankshaft pulley and nut. Tighten the surface-ground; seek the advice of a Peugeot 4 Check that all the mounting’s fasteners are crankshaft pulley nut to the specified torque, dealer or engine reconditioning specialist.
  • Page 33 2B•1 Chapter 2 Part B: XU series engine in-car repair procedures Contents Auxiliary drivebelt check and renewal ....See Chapter 1 Flywheel/driveplate - removal, inspection and refitting ... 13 Camshaft and followers - removal, inspection and refitting .
  • Page 34 2B•2 XU series engine in-car repair procedures Torque wrench settings lbf ft Camshaft cover bolts ........Camshaft bearing caps .
  • Page 35 XU series engine in-car repair procedures 2B•3 Adjustment 11 To adjust the clearances remove the camshaft as described in Section 7. 12 Lift off a cam follower and its shim. Be careful that the shim does not fall out of the follower.
  • Page 36 2B•4 XU series engine in-car repair procedures 4.9 Spring loaded timing belt tensioner (earlier assembly) and eccentric roller type tensioner (later assembly) 1 Right-hand engine mounting Timing belt Tensioner roller Tensioner roller nut wise precaution to check the condition of the 8 Remove the plastic covers from the front of 3 Compression test - coolant pump at the same time (check for...
  • Page 37 No 1 cylinder firing, then slacken and to 12, noting that the crankshaft pulley timing can be checked by a Peugeot dealer; if the belt dowel must be of 10 mm diameter, stepped retighten the tensioner nuts once more.
  • Page 38 2B•6 XU series engine in-car repair procedures is available, it should be refitted to the Crankshaft sprocket 14 Refit the sprocket retaining bolt and tensioned run of the belt. The reading should washer, and tighten it to the specified torque. 4 Remove the timing belt as described in now be between 42 and 46 units.
  • Page 39 XU series engine in-car repair procedures 2B•7 on which these conditions are apparent. If a follower bearing surface is badly scored, also examine the corresponding lobe on the camshaft for wear, as it is likely that both will be worn. Renew worn components as necessary.
  • Page 40 In the absence of the head. special Peugeot liner clamps, the liners can 10 Disconnect the exhaust downpipe(s) at be clamped in position as follows. Use large 7.21 Align the camshaft sprocket cover the manifold flange.
  • Page 41 Section 4 and retension it if necessary. spacer to the bolt at the timing belt end. When amount). Although Peugeot do not actually 36 Tighten the engine mounting bracket bolt. fitting the Torx type cylinder head bolts, apply...
  • Page 42 2B•10 XU series engine in-car repair procedures 39 Check the valve clearances and adjust, if gasket have been removed, and that the necessary (see Section 2). sump mating surfaces are clean and dry. 40 Refit the remaining components in the Position the new gasket on the top of the reverse order of removal and with reference to sump, using a dab of grease to hold it in...
  • Page 43 XU series engine in-car repair procedures 2B•11 measured by comparing it with a new one; if 4 Disconnect the coolant hoses from the filter. Be prepared for coolant spillage, and there is any doubt about its condition, it plug the open ends of the hoses to prevent should also be renewed.
  • Page 44 1.0 mm between the buffers and top plate. preferable. Seek the advice of a Peugeot On later models, the shims have been deleted dealer or engine reconditioning specialist to and the rubber buffers are increased in see if machining is possible.
  • Page 45 2C•1 Chapter 2 Part C: TU series engine in-car repair procedures Contents Auxiliary drivebelt check and renewal ....See Chapter 1 Engine/transmission mountings - inspection and renewal ..16 Camshaft and rocker arms - removal, inspection and refitting .
  • Page 46 6°. The clutch and transmission j) Cylinder head and pistons - screw-and-locknut arrangement. are attached to its left-hand end. The 205 decarbonising. camshaft rotates directly in the cylinder head. range is fitted with 954 cc (TU9), 1124 cc The timing belt also drives the coolant pump.
  • Page 47 (see illustration). in the engine compartment. This will reduce 4 With the camshaft sprocket hole correctly Where the original crimped-type Peugeot the possibility of the engine being accidentally positioned, insert a 6 mm diameter bolt or drill hose clip is still fitted, cut it off and discard it.
  • Page 48 2C•4 TU series engine in-car repair procedures 4.6a Lift off the spacers (second one 4.6b . . . and remove the oil baffle plate 4.8 Ensure the rubber seal is correctly arrowed) . . . located on the cover when refitting Valve fully open Adjust valves Examine the seal for signs of damage and 1 The importance of having the valve...
  • Page 49 6 Undo the three crankshaft pulley retaining 9 Check the timing belt carefully for any signs Note: Peugeot specify the use of a special bolts and remove the pulley, noting which way of uneven wear, splitting, or oil contamination.
  • Page 50 7.14 Using the Peugeot special tool to tension the timing belt of 80 mm from the centre of the square- section bar.
  • Page 51 TU series engine in-car repair procedures 2C•7 pin to the rear of the timing hole in the rear of Removal the flywheel. 1 Disconnect the battery negative lead. 12 If the Woodruff key is a loose fit in the 2 Position the engine assembly/valve timing crankshaft, remove it and store it with the holes as described in Section 3, and lock both sprocket for safe-keeping.
  • Page 52 2C•8 TU series engine in-car repair procedures 21 Loosen the tensioner pulley retaining nut. 1 Remove camshaft sprocket Rotate the pulley anti-clockwise to remove all described in Section 8. free play from the timing belt, then retighten 2 Punch or drill two small holes opposite the nut.
  • Page 53 TU series engine in-car repair procedures 2C•9 10.8 Undo the retaining bolt and remove 10.9a . . . prise out the oil seal . . . 10.9b . . . and slide out the camshaft the camshaft thrust fork (arrowed) . . . which contact the camshaft lobes for wear 16 Refit the cylinder head and rocker arm 5 Note that the following text assumes that...
  • Page 54 26 If warpage of the cylinder head gasket remove distributor lead absence of the special Peugeot liner surface is suspected, use a straight-edge to assembly. clamps, the liners can be clamped in check it for distortion. Refer to Part D of this...
  • Page 55 Molykote G Rapid Plus grease cut-out, or no cut-out at all, at the rear of the (available from your Peugeot dealer - a sachet left-hand side of the gasket identifying the is supplied with the top-end gasket set); in the engine type (ie.
  • Page 56 2C•12 TU series engine in-car repair procedures 49 Check and, if necessary, adjust the valve and dry, then apply a coating of suitable clearances as described in Section 5. sealant to the sump mating surface. 50 On completion, reconnect the battery, 9 Offer up the sump, locating it on its and refill the cooling system as described in retaining studs, and refit its retaining nuts and...
  • Page 57 However, it may be possible to have it complete pump assembly must be renewed. 4 Lubricate the lips of the new seal with clean surface-ground; seek the advice of a Peugeot 6 Examine the relief valve piston for signs of dealer or engine reconditioning specialist.
  • Page 58 2C•14 TU series engine in-car repair procedures Renewal 15 Place a jack beneath the transmission, Rear mounting with a block of wood on the jack head. Raise 22 If not already done, firmly apply the Right-hand mounting the jack until it is supporting the weight of the handbrake, then jack up the front of the 5 Disconnect the battery negative lead.
  • Page 59 Specifications Note: At the time of writing, many specifications for certain engines were not available. Where the relevant specifications are not given here, refer to your Peugeot dealer for further information. Cylinder head Maximum gasket face distortion ......

  • Page 60: Cylinder Block

    All other engines ......... 0.05 mm *These are suggested figures, typical for this type of engine - no exact values are stated by Peugeot. Pistons Piston to bore clearance: XV, XW, and XY series engines .
  • Page 61 0.025 to 0.050 mm *These are suggested figures, typical for this type of engine - no exact values are stated by Peugeot. **On XU series engines and TU series (aluminium block) engines the bearing clearance was modified on later models - see text for further information.
  • Page 62 Peugeot dealer or an inspection, renovation and refitting of engine help to keep tools clean. engineering works - these establishments internal components.
  • Page 63 Engine removal and overhaul procedures 2D•5 3 Engine/manual transmission - removal, separation, reconnection and refitting Removal Note: The engine can be removed from the car only as a complete unit with the transmission; the two are then separated for overhaul. 1 Park the vehicle on firm, level ground.
  • Page 64 2D•6 Engine removal and overhaul procedures XV, XW and XY series engines 23 Unscrew and remove the flywheel housing-to-engine connecting bolts and nuts. 24 There are thirteen bolts and two nuts altogether. Note that an engine lifting lug and earth strap are fitted under some of the bolts. 25 Refer to Chapter 6 and remove the clutch assembly, ignoring any procedures that have already been carried out as part of the...
  • Page 65 Molykote BR2 plus - available from your f) Refill the engine and transmission with the refitting. Peugeot dealer) to the splines of the correct quantity and type of lubricant, as 10 Carefully withdraw the transmission from transmission input shaft. Do not apply too described in Chapter 1 and 7A.
  • Page 66 Molykote G1 grease (available from your e) Flywheel/driveplate - XU and TU series when working without a stand. Peugeot dealer) to the torque converter If you intend to obtain a reconditioned engines. centring pin. Do not apply too much, engine, all ancillaries must be removed first, to f) Sump - XU and TU series engines.
  • Page 67 Seek the advice of a illustration). Any significant difference in the 8 Thoroughly clean all traces of old gasket Peugeot dealer or engine overhaul specialist if material and sealing compound from the readings obtained indicates wear of the valve distortion is suspected.
  • Page 68 No minimum free hold the collets in position on original sequence and the correct way round. length is specified by Peugeot, so the only the valve stem while the A centre punch or hacksaw blade is useful for way of judging valve spring wear is by spring compressor is released.
  • Page 69 Note that No 1 cylinder in the ring grooves are clear. carried out by a Peugeot dealer or engine liner is at the transmission (flywheel) end of 22 If the pistons and cylinder liners/bores are...
  • Page 70 2D•12 Engine removal and overhaul procedures 8.7 Checking crankshaft endfloat using 8.11 Removing the oil seal carrier from the 8.12a Slide off the oil pump drive feeler blades front of the block - XU series engines sprocket . . . and then zero the gauge.
  • Page 71 Consult your Peugeot dealer cracking. surfaces and the cylinder bores as described or engine specialist for further information on 36 Big-end bearing wear is accompanied by above, to prevent rusting.
  • Page 72 23 Fit the liners without the seals into their exceeds 0.05 mm, rotate the liners through bores, seek the advice of a Peugeot dealer or original locations. If new liners are being fitted, half a turn or interchange the liner position in engine reconditioning specialist.
  • Page 73 It may be left in the block then, using a hammer and a block of bores, seek the advice of a Peugeot dealer or the engine during assembly, or it may pass wood, tap each liner lightly but fully onto its suitable engine reconditioning specialist.
  • Page 74 Specifications. Where no figures are given, 13 Crankshaft - refitting and seek the advice of a Peugeot dealer or engine main bearing running 1 Before reassembly begins, ensure that all reconditioning specialist.
  • Page 75 Peugeot during production, lines cross. This crossover point will indicate thickness, as listed in the following table. The...
  • Page 76 10 Repeat this procedure so that the required bearing shell grade is obtained for each of the five main bearing journals. 11 Seek the advice of your Peugeot dealer on parts availability, and on the best course of action when ordering new bearing shells.
  • Page 77 18 Seek the advice of your Peugeot dealer 29 Compare the width of the crushed micrometers or internal/external expanding for the latest information on parts availability Plastigage on each journal to the scale printed when ordering new bearing shells.
  • Page 78 2D•20 Engine removal and overhaul procedures 13.38 Crankshaft thrustwashers - 13.39 Lowering the crankshaft into place 13.41 Crankcase flange O-ring seal XV, XW and XY series engines R Oil grooves fitted, ensure that all traces of protective grease are cleaned off using paraffin. Wipe be fitted, obtain a set of new Black (Class B) dry the shells with a lint-free cloth.
  • Page 79 Peugeot housing. grooves on each thrustwasher face outwards garages use a special tool, which acts as a...
  • Page 80 2D•22 Engine removal and overhaul procedures 13.72 Refitting the oil pump drive chain 13.73 Apply a thin film of sealant to the 13.74 . . . then lower the main bearing and sprocket cylinder block/crankcase mating face . . . ladder into position bearing ladder to the base of the cylinder 72 Refit the Woodruff key, then slide on the...
  • Page 81 Peugeot; a through the specified Stage 2 angle, using a 13 Note that Peugeot do not specify a standard size for use with the standard socket and extension bar. It is recommended...
  • Page 82 2D•24 Engine removal and overhaul procedures 14.19 Tap the piston into the bore using a 14.22 Tightening a big-end bearing cap 14.23 . . . and further, on XU series hammer handle nut using a torque wrench . . . engines, through the specified angle using an angle tightening gauge crankpin and both bearing shells.
  • Page 83 3•1 Chapter 3 Cooling, heating and air conditioning systems Contents Air conditioning system check ....See Chapter 1 Cooling system electrical switches and sensors - removal Air conditioning system - general information and precautions .
  • Page 84 Chapter 1. If antifreeze is used that is not to equipped with air conditioning. hose clips. Peugeot’s specification, old or contaminated...
  • Page 85 Cooling, heating and air conditioning systems 3•3 coolant mixtures are likely to cause damage, and encourage the formation of corrosion and scale in the system. 3 Before adding antifreeze, check all hoses and hose connections, because antifreeze tends to leak through very small openings. Engines don’t normally consume coolant, so if the level goes down, find the cause and correct it.
  • Page 86 3•4 Cooling, heating and air conditioning systems 5 Disconnect mountings, 6 Partially drain the cooling system (see applicable, then lift the radiator, complete with Chapter 1) to below the level of the sensor cooling fan, from the car - taking care not to unit.
  • Page 87 Cooling, heating and air conditioning systems 3•5 8 Coolant pump - removal and refitting Note: Refer to the warnings given in Section 1 of this Chapter before proceeding. XV, XW, and XY series engines Removal 1 Drain the cooling system and remove the auxiliary drivebelt as described in Chapter 1.
  • Page 88 3•6 Cooling, heating and air conditioning systems 8.17a On TU series aluminium block engines, disconnect the 8.17b . . . then undo the bolts (arrowed) and remove the housing hoses (arrowed) from the coolant pump housing from the block 10 If the coolant pump is worn, noisy or leaks Remove the O-ring seal (see illustrations).
  • Page 89 Cooling, heating and air conditioning systems 3•7 9.6a Remove the heater matrix mounting 9.6b . . . then withdraw the matrix from the 9.7 Removing the heater blower motor screws and pipe clip (arrowed) . . . heater casing 5 Unscrew the heater assembly mounting 8 If necessary remove the heater control 10 Air conditioning system - nuts and withdraw it from the car.
  • Page 90 6 Components of the air conditioning system entrust this task to your Peugeot dealer or air enters its liquid phase. After dehydration the may obstruct work being undertaken in other conditioning specialist.
  • Page 91 4A•1 Chapter 4 Part A: Fuel system - carburettor engines Contents Air cleaner assembly - removal and refitting ....2 General fuel system checks ..... .See Chapter 1 Air cleaner element renewal .

  • Page 92: Recommended Fuel

    4A•2 Fuel system - carburettor engines Carburettor data (continued) Calibrations and settings: XU51C Solex Weber Venturi diameter ......... 28 mm 26 mm 28 mm...
  • Page 93 Fuel system - carburettor engines 4A•3 2.2 On all engines except TU series, 2.4a Air cleaner mounting bracket bolt 2.4b . . . and cable retaining bracket release the air cleaner rubber straps from (arrowed) . . . the mounting brackets The air cleaner contains a disposable paper spillage.
  • Page 94 4A•4 Fuel system - carburettor engines 2.7a Release the spring clips . . . 2.7b . . . and remove the air cleaner 2.9 Disconnect the hose from the vacuum ducting and element from the body motor 7 Release the spring clips, and lift the accelerator pedal arm.
  • Page 95 13 If the valves are in good condition, locate system. information is thought to be required, check the diaphragm, push the operating arm into with a Peugeot dealer. If travelling abroad, Removal position so that its forked end engages with consult one of the motoring organisations (or a...
  • Page 96 Fit a new gasket, and securely tighten the are typical for the various carburettors carburettor body assembly mating surfaces carburettor retaining nuts. encountered on 205 models. Refer to the for distortion. b) Use the notes made on dismantling to accompanying illustrations for details of...
  • Page 97 Fuel system - carburettor engines 4A•7 Solex 32 and 34 PBISA Choke opening after starting adjustments 23 To adjust the choke opening after starting, first close the choke then pull the vacuum Idle speed and mixture opener rod and, using a suitable twist drill, 16 Refer to Chapter 1.
  • Page 98 4A•8 Fuel system - carburettor engines 10.44 Choke opening after starting adjustment on the Weber 36 TLC carburettor 1 Locknut 4 Adjusting screw 2 Hole 5 Can 3 Roller 6 Peg on special tool 10.39 Checking the choke opening setting on the Weber 35 IBSH carburettor 2 Adjustment screw on vacuum capsule 10.45 Choke opening after starting adjusting screw (1) on the...
  • Page 99 (see illustration). Weber 36 TLC adjustments 48 To adjust the choke cam, Peugeot tool No 0.145G must again be used. Fit the tool, Idle speed and mixture loosen the locknut, and adjust the screw until 41 Refer to Chapter 1.
  • Page 100 4A•10 Fuel system - carburettor engines 11.4 Disconnecting the brake servo vacuum hose at the inlet 11.6 Unscrewing the inlet manifold retaining nuts - manifold - TU series engine shown TU series engine shown Throttle damper 3 Remove the air cleaner assembly and use a new gasket or seals on models so carburettor(s) as described in Sections 2 and 9.
  • Page 101 4B•1 Chapter 4 Part B: Fuel system - single-point fuel injection engines Contents Air cleaner assembly - removal and refitting ....2 General information and precautions .
  • Page 102 4B•2 Fuel system - single-point fuel injection engines 6 Disconnect the wiring and release the fuel 2 Air cleaner assembly - pump from the upper collar. removal and refitting Refitting 7 Refitting is a reversal of removal, but fit new collars and make sure that the wiring Refer to the procedures in Chapter 4A, terminals are positioned away from the pump...
  • Page 103 G5 is possible, these being under the complete with a Peugeot dealer. If travelling abroad, system, and via a control motor on the G6 control of the ECU. Should the idle speed or consult one of the motoring organisations (or a system.
  • Page 104 4B•4 Fuel system - single-point fuel injection engines 11.6a Remove the Torx screw . . . 11.6b . . . and lift off the wiring connector 11.7 Withdrawing the fuel injector c) Before refitting the injector securing any signs of leakage are detected the injector wiring connector to the top of the screw, apply a few drops of a suitable problem must be rectified before the...
  • Page 105 Fuel system - single-point fuel injection engines 4B•5 11.23a Disconnecting the wiring plug from 11.23b . . . and the throttle switch 11.25 Vacuum hose connection to throttle the fuel injector . . . body (arrowed) 19 Do not attempt to adjust the throttle 27 If desired, the throttle body upper and 30 Disconnect the battery negative lead.
  • Page 106 It is advisable to throttle valve is fully closed. that at the time of writing, the injector does seek the advice of a Peugeot dealer before b) Ensure that the switch wiper engages not appear to be available separately from the deciding on the course of action to be correctly with the throttle shaft.
  • Page 107 Fuel system - single-point fuel injection engines 4B•7 body (upper and lower) can be separated by Inlet air temperature sensor the wiring plug from the idle speed control removing the securing screws. Note that in motor (MMFD G6 systems only). 22 The sensor is screwed into the top of the 38 Slacken the clamp (if fitted), and this case, a new gasket must be used on...
  • Page 108 4B•8 Notes...
  • Page 109 4C•1 Chapter 4 Part C: Fuel system - multi-point fuel injection engines Contents Air cleaner assembly - removal and refitting ....2 Fuel tank - removal and refitting .
  • Page 110 Peugeot dealer. If travelling abroad, LU2-Jetronic system incorporates an oxygen present in the system components, and consult one of the motoring organisations (or a sensor in the exhaust system.
  • Page 111 If problems still exist, the vehicle should be taken to a suitably-equipped Peugeot dealer for testing. A wiring block connector is incorporated in the engine management circuit, into which a special electronic diagnostic tester can be plugged.
  • Page 112 Peugeot dealer before dismantling. assembly, whilst counter holding the nuts. described in Section 10. Fuel injectors...
  • Page 113 Fuel system - multi-point fuel injection engines 4C•5 compartment. Recover the four manifold seals Coolant temperature sensor 3 Disconnect the throttle inner cable from the throttle cam, then withdraw the outer cable and discard them; new ones must be used on 31 Refer to Chapter 3, Section 7.
  • Page 114 4C•6 Notes...
  • Page 115 4D•1 Chapter 4 Part D: Exhaust and emission control systems Contents Air inlet heating system components - removal and refitting ..4 Exhaust system - removal and refitting ..... . . 2 Catalytic converter - general information and precautions .
  • Page 116 4D•2 Exhaust and emission control systems 1.7 Typical crankcase ventilation system 1 Oil filler cap with oil trap 2 Air filter 3 Throttle valve 4 Inlet manifold 5 Jet 6 Ventilation hose 7 Calibrated jet 8 Sump 9 Camshaft cover Crankcase ventilation system in the exhaust gases (see illustration).
  • Page 117 Exhaust and emission control systems 4D•3 1.9 Electro-pneumatic ignition timing retarding system 1 Coolant temperature sensor 2 Electronic control unit 3 Solenoid valve 4 Distributor vacuum capsule Fuel vapour recirculation system 14 This system been introduced progressively on all fuel injection models, and prevents fuel vapour from the fuel tank from being ejected into the atmosphere (see illustration).
  • Page 118 4D•4 Exhaust and emission control systems 2 In many cases it will be found easier to remove the complete system from the car and then to renew individual sections on the bench. 3 To remove the complete system, raise and support the vehicle at a convenient working height (see “Jacking and vehicle support”).
  • Page 119 Exhaust and emission control systems 4D•5 wire mesh filter in the engine oil filler cap on c) If the engine develops a misfire, do not 4 Air inlet heating system certain models. Removal and refitting is self- drive the vehicle at all (or at least as little components - removal and explanatory, but it may be necessary to as possible) until the fault is cured.
  • Page 120 4D•6 Exhaust and emission control systems 8.7a Unscrew the securing nut . . . 8.7b . . . and withdraw the solenoid bracket 3 Unscrew the clamp bolt, and lift the Solenoid valve 8 Disconnect the hoses from the valve, noting canister from its clamp on the body panel.
  • Page 121 5A•1 Chapter 5 Part A: Starting and charging systems Contents Alternator - removal and refitting ......6 Electronic oil level sensor - general information .
  • Page 122 (condition reading less than electrical system. possible. The condition of the battery can 12.2 volts), have it recharged by your Peugeot Before using electric-arc welding...
  • Page 123 Starting and charging systems 5A•3 3 If the alternator output is suspect even good condition, check the circuit by 7 Alternator - testing and though the warning light functions correctly, disconnecting the wire from the solenoid overhaul the regulated voltage may be checked as blade terminal.
  • Page 124 5A•4 Starting and charging systems 9.5 Starter motor brush end bracket retaining bolts on XV, XW 9.6 Removing the starter motor mounting bolts on XV, XW and XY series engines and XY series engines Refitting 12 Oil pressure warning light 13 Electronic oil level sensor - 8 Refitting is a reversal of removal, but first switch - removal and refitting...

  • Page 125: Ignition System Check

    5B•1 Chapter 5 Part B: Ignition system Contents Distributor (breakerless ignition systems) - removal and refitting . . . 4 Ignition system - testing ........2 General information .
  • Page 126 A number of different breakerless ignition amplifier unit, HT coil and distributor in a obtained while turning over the engine on the systems are used on 205 models according to conventional system. The ignition module starter for (no more than) ten seconds. If the engine type and fuel system fitted.
  • Page 127 14 If the coil is thought to be faulty, have your hand side of the engine compartment mounted findings confirmed by a Peugeot dealer before 4.5 Pull back the plastic cover then unclip on the side of the suspension strut tower.
  • Page 128 5.9 Removing the ignition amplifier on TU 6.5 HT lead connections on the static amplifier. If necessary, obtain new grease series engines distributorless ignition module from a Peugeot dealer.
  • Page 129 XV, XW and XY series Note: On engines equipped with MMFD two marks visible on the flywheel close to engines. Peugeot special tool 80133 or a Mono-point G5/6 or Motronic M1.3 engine each other. In this case the mid-point...
  • Page 130 5B•6 Ignition system 8.13 Initial static ignition timing on XU series engines 8.19 Dynamic ignition timing on XU series engines a Single flywheel mark b BTDC mark on timing plate a Double flywheel mark b TDC mark on timing plate 10 To check the vacuum advance unit, run light manufacturer’s instructions, and with the TU series engines...
  • Page 131 31 When the timing is correctly set, increase and therefore it will normally be used only by a the engine speed, and check that the flywheel Peugeot garage. mark advances to beyond the beginning of 2 To remove the sensor, unscrew the...
  • Page 132 5B•8 Notes...
  • Page 133 9•1 Chapter 9 Braking system Contents Anti-lock braking system (ABS) - general information ... . 19 Hydraulic system - bleeding ....... 2 Anti-lock braking system (ABS) components - removal and refitting 20 Master cylinder - removal, overhaul and refitting .
  • Page 134 RH rear wheel genuine Peugeot replacement parts, or at that the cause is traced and rectified before LH front wheel least those of known good quality. Note the proceeding further.
  • Page 135 Braking system 9•3 Bleeding - using a one-way valve kit 22 As their name implies, these kits consist of a length of tubing with a one-way valve fitted, to prevent expelled air and fluid being drawn back into the system; some kits include a translucent container, which can be positioned so that the air bubbles can be more easily seen flowing from the end of the tube.
  • Page 136 4 If a brake pipe is to be renewed, it can be obtained, cut to length and with the union nuts and end flares in place, from Peugeot dealers. All that is then necessary is to bend it to shape, following the line of the original, 4.5 Removing the outer pad...
  • Page 137 The the anti-squeal shims, the arrow cut-out must positions as shown (see illustration). The spring (obtainable from Peugeot dealers) may face downwards (ie in the forward rotational inner pads with pad wear wires must be be fitted to earlier models by tapping the inner direction of the disc).
  • Page 138 30 Note that genuine Peugeot brake cleaner or methylated spirit only. 19 Hold the lower guide stationary with one replacements have been fitted, these pads Note: The rear brake shoe assemblies may be...
  • Page 139 Braking system 9•7 5.3a DBA Bendix type rear brake component layout 5.3b Girling type rear brake component layout 7 Expand the shoes over the wheel cylinder 13 Engage the strut with the slots at the top 20 Adjust the handbrake, as described in then release them from the bottom anchor.
  • Page 140 9•8 Braking system 7 Front brake caliper - removal, overhaul and refitting Note: Before starting work, refer to the warning at the beginning of Section 2 concerning the dangers of hydraulic fluid, and to the warning at the beginning of Section 4 concerning the dangers of asbestos dust.
  • Page 141 Braking system 9•9 7.7a DBA Bendix type brake caliper components 1 Mounting bolt 5 Retaining plate 2 Caliper assembly 6 Sliding guide kit with grease 3 Sliding key kit 7 Repair kit with grease 4 Bleed screw 7.4 Brake caliper mounting bolts - arrowed (DBA Bendix type) 9 Prise the seal from inside the cylinder, taking care not to damage the cylinder wall.
  • Page 142 9•10 Braking system 12 Remove the brake hose clamp or clean and that the securing screws are tight- 8 Rear brake caliper (1.9 GTI polythene sheeting, and bleed the hydraulic ened fully. If the caliper has been removed, models) - removal, overhaul system as described in Section 2.
  • Page 143 Braking system 9•11 10.7 Rear wheel cylinder mounting bolts (arrowed) 10.9 Exploded view of a rear wheel cylinder 1 Cap 4 Piston 7 Spring 2 Bleed screw 5 Seal 8 Body 3 Dust excluder 6 Spring seat Overhaul Refitting rear of the car and support it on axle stands (see “Jacking and vehicle support”).
  • Page 144 9•12 Braking system 11.9 Lock the hub nut by staking the nut flange into the groove on 13.1 Rear brake compensator fitted to 1.6 GTI models the stub axle Inspection 2 Prise the reservoir from the master cylinder Refitting and remove the seals. 4 Brush the dust and dirt from the brake drum 12 Refitting is a reversal of removal, but fit a 3 Unscrew the union nuts securing the rigid...
  • Page 145 Braking system 9•13 Refitting Air filter renewal 6 Refitting is a reversal of removal, but note 10 Although not a specified operation, the air that the nose of the unit must face forwards filter through which the pushrod passes at the rear of the servo can become clogged after a and be inclined upwards at an angle of 22°...
  • Page 146 9•14 Braking system 16 Handbrake cables - renewal All models except 1.9 GTI 1 Remove the rear brake shoes, as described in Section 5. 2 Working inside the car, remove the screw and lift the cover from the handbrake lever. 3 Unhook the cable(s) from the compensator.
  • Page 147 Peugeot dealer to fluid and tighten the bolt securely. 18 Handbrake lever - removal determine the nature of the fault. and refitting The brake components used on models...
  • Page 148 9•16 Notes...
  • Page 149 10•1 Chapter 10 Suspension and steering Contents Auxiliary drivebelt check and renewal ....See Chapter 1 Rear suspension assembly - removal and refitting ....11 Front anti-roll bar - removal and refitting .
  • Page 150 10•2 Suspension and steering Torque wrench settings lbf ft Front suspension Driveshaft/hub nut: Non-GTI models ......... GTI models .
  • Page 151 3.3 Front hub bearing retaining circlip to Chapters 8 and 9 respectively when carrier. Peugeot garages use two special (arrowed) refitting the driveshaft and disc brake caliper. cables inserted through the holes at the top of...
  • Page 152 7 Refitting is a reversal of removal but ensure 3 Chock the rear wheels then jack up the applicable, remove the Peugeot cables. that the strut fully enters the hub carrier. If there front of the car and support it on axle stands...
  • Page 153 Suspension and steering 10•5 5 Lever down the anti-roll bar where necessary and withdraw the arm from the car. 6 Check the inner pivot bushes for wear and deterioration. Check the lower balljoint on the outer end of the arm for excessive wear indicated by up and down movement of the ball in the socket.
  • Page 154 DIY 9 Unscrew the self-locking nuts from the work, and should be entrusted to a Peugeot bottom of the link arms (see illustration) and dealer. if necessary use a separator tool to release...
  • Page 155 4 Disconnect the flexible brake hoses from The operation should be entrusted to a the rear suspension assembly, with reference Peugeot dealer, as it not possible to carry out to Chapter 9. Removal checking accurately without the use of the 5 Unscrew the left-hand rear mounting nut, appropriate tools.
  • Page 156 10•8 Suspension and steering 14.8 Steering column and lock assembly components 1 Bolt 2 Steering lock and ignition switch 3 Steering column 4 Mounting nut 5 Clamp bolt and nut 14.7 Steering column intermediate shaft (arrowed) 7 If necessary, the intermediate shaft can be removed after prising out the grommet and unscrewing the bottom clamp bolt (see illustration).
  • Page 157 Suspension and steering 10•9 15.13 Extract the spring clip (6) from the gearchange linkage 15.16 Front subframe attachments 9 Rear securing bolts 11 Lower engine mounting nut 10 Front securing bolts engagement rods, and support them in an to enable removal of the steering gear, d) When reconnecting the fluid pipes to the upright position out of the way, using wire or ensuring that the subframe is adequately...
  • Page 158 10•10 Suspension and steering Refitting 18 Power steering pump - 5 Screw on the locknut then screw the new removal and refitting track rod end the same number of turns onto the track rod. 6 Clean the taper surfaces then fit the balljoint shank to the hub carrier steering arm Removal and tighten the nut to the specified torque.
  • Page 159 Peugeot dealer or similar expert. Note the toe setting; re-adjust if necessary. When threads on the left-hand side. If there are the...
  • Page 160 10•12 Notes...
  • Page 161 The basic maintenance routine for the protection and wax injection. Peugeot bodywork is washing preferably with a lot of necessary. Steam cleaning is available at guarantee the body against perforation as a many garages and is necessary for removal of water, from a hose.
  • Page 162 11•2 Bodywork and fittings not available, there are one or two excellent Should the dent be in a section of the 4 Minor body damage - repair grease solvents available which can be brush bodywork which has a double skin or some applied;...
  • Page 163 Peugeot dealer. turn should be encircled by the finely body panels), rectification of more serious “feathered”...
  • Page 164 11•4 Bodywork and fittings 6.2 Bonnet hinge 6.3 Braided lead fitted to the bonnet 7.2 Bonnet lock retaining bolts 4 While an assistant supports the bonnet, Refitting 2 Working under the vehicle, unscrew the two unscrew the nut and remove the bottom of the front bumper mounting nuts at the brackets 6 Refitting is a reversal of removal, but check stay from the right-hand suspension tower.
  • Page 165 Bodywork and fittings 11•5 9.2 Front bumper components 1 Side mounting (non-GTI) 2 Side mounting (GTI) 3 Side bracket (non-GTI) 4 Bracket 5 Side bracket (GTI) 6 Seal clip 7 Seal 8 Bumper 9 Moulding 10 Mounting plate 11 Headlight washer bracket 10 Door - removal and refitting Removal 1 The door hinges are welded to the body...
  • Page 166 11•6 Bodywork and fittings 11.2 Removing the armrest 11.3 Removing the side pocket 11.4 Removing the window regulator handle 5 Prise out the interior door handle surround 11 Door trim panel - removal (see illustration). and refitting 6 Using a wide-bladed screwdriver, or similar tool, prise the trim panel from the door - working progressively from the bottom upwards and inserting the screwdriver...
  • Page 167 Bodywork and fittings 11•7 12.4 Pull out the retaining clip to remove 12.6a On early models, remove the inner 12.6b . . . and remove the exterior mirror the private lock cover . . . mounting screws Exterior mirror (early models) 6 To remove the early type mirror, prise off the inner cover and use an Allen key to remove...
  • Page 168 11•8 Bodywork and fittings 14.2 Prise off the trim caps (1) and unscrew the hinge cover 14.3 Hood bracket securing bolt (3) and lower hood securing securing screw (2) - Cabriolet models bolts (4 and 5) - Cabriolet models Velcro securing strips from the hood, then not aligned, move the hood support brackets 14 Hood and rear window withdraw the window from outside the...
  • Page 169 Peugeot dealer. home mechanic. 16 Tailgate - removal and Removal 19 Rear quarter glass (GTI...
  • Page 170 Fit them to the new glass using the special sleeves and screws obtainable from a 20.10 Removing the rear quarterlight glass regulator mechanism on Cabriolet models Peugeot dealer (see illustration). Apply a little locking fluid to the screw threads before inserting and tightening them. Unlike the door glass, there are no adjustment points.
  • Page 171 Bodywork and fittings 11•11 26.4 Removing the central air vents 26.5 Digital clock and retaining barbs 26.6 Removing the rear of the oddments (arrowed) tray be a problem when the sunroof is open, a 24 Sunroof glass - removal and 26 Facia panel - removal and modified rubber seal or a wind deflector is refitting...
  • Page 172 11•12 Bodywork and fittings 26.13 Facia front mounting nut 26.16 Removing a right-hand lower facia 26.19a Prise out the coin box . . . panel securing screw 13 With the bonnet open, remove the plastic 19 Prise out the coin box and the triangular 26 Unclip clock surround...
  • Page 173 Bodywork and fittings 11•13 26.27a Method of releasing the switch 26.27b Remove the lower screws and 26.29 Steering column mounting nuts surround upper clips withdraw the surround (arrowed) and choke cable, where applicable (Chap- 32 Prise the small tray from the centre Refitting console (see illustration).
  • Page 174 11•14 Notes...
  • Page 175 12•1 Chapter 12 Body electrical system Contents Air compressor and horn (1.9 GTI models) - removal and refitting . . 21 Horn - removal and refitting ....... . 20 Battery, bulbs and fuses .
  • Page 176 12•2 Body electrical system Fuses (1986 to 1988 GTI and CTI models) No Circuit protected Rating (amp) Reversing lights, tachometer ......Direction indicators, heater blower motor, oil pressure gauge, oil temperature gauge, heated seats, fuel gauge, coolant temperature gauge, low battery charge warning, oil pressure warning, brake...
  • Page 177 Body electrical system 12•3 Fuses (1989 to 1991 - all models) No Circuit protected Rating (amp) Reversing lights, tachometer, fuel gauge, warning lights (low battery charge, coolant temperature, oil pressure, low coolant level, brake system, choke)....... Direction indicators, gauges (fuel, oil temperature, .
  • Page 178 12•4 Body electrical system circuits fail at one time, the problem is likely to 11 Switch on the circuit, then connect the 1 General information and be related to a shared fuse or earth tester lead to the connector nearest the circuit precautions connection.
  • Page 179 Body electrical system 12•5 3.4 Removing a fuse 4.4 Combination switch screws (arrowed) 22 If an earth connection is thought to be 5 Always renew a fuse with one of an 12 Make sure that the ignition is switched off, faulty, dismantle the connection, and clean then pull the relay from its socket.
  • Page 180 12•6 Body electrical system 4.13a On later models, remove the switch 4.13b Insert lengths of rod into the special 4.13c . . . and withdraw the switch panel panel lower screws . . . holes . . . surround Facia switches (1988 models 21 The switch is secured to the door pillar by Ignition switch/steering column onward)
  • Page 181 Body electrical system 12•7 5 Withdraw the surround from the facia. 5 Instrument panel - removal 6 Pull out the instrument panel while and refitting depressing the lower spring supports, then disconnect the multi-plugs and speedometer cable (see illustrations). 7 If necessary, the individual components can Removal be removed for repair or renewal (see illustrations).
  • Page 182 12•8 Body electrical system 5.7a Exploded diagram of non-GTI instrument panel 5.7b Exploded diagram of GTI instrument panel...
  • Page 183 Body electrical system 12•9 Refitting 13 On all models, refitting is a reversal of removal. 7 Speedometer cable - renewal 1 Disconnect the speedometer cable from the transmission by removing the retaining bolt or rubber plug. 2 Remove the instrument panel, as described 5.16 Removing the instrument panel 5.17 .
  • Page 184 12•10 Body electrical system 8.7a . . . release the spring clips . . . 8.7b . . . and withdraw the headlight bulb 8.9 Removing the front parking light bulbholder 7 Release the spring clips and withdraw the Front parking lights light so that the location peg enters the hole in bulb (see illustrations).
  • Page 185 Body electrical system 12•11 8.19 Removing a rear light cluster bulb 8.20 Remove the rear foglight lens . . . 8.21 . . . and extract the bulb Bulb renewal Interior light 3 Prise the light from the console (see illustration).
  • Page 186 18 Pull the bulb from the control panel (see It is recommended that beam alignment is Heater control panel illumination illustration). be carried out by a Peugeot dealer or other bulbs (1988 models onward) specialist heaving the necessary optical 14 Disconnect the battery negative lead.
  • Page 187 Body electrical system 12•13 3 Open the bonnet then remove the air inlet grille by removing the screws and easing the grille from the windscreen weatherstrip (see illustration). 4 Unscrew the nuts from the wiper spindle bodies (see illustration). 5 Disconnect wiper motor wiring...
  • Page 188 19 Central door locking system be overlooked if the car cannot be started, - general information and other areas of investigation have failed to locate the cause. Refer to a Peugeot dealer for additional information. On models fitted with a central door locking Removal...
  • Page 189 Wiring diagrams 12•15 Key to wiring diagrams...
  • Page 190 12•16 Wiring diagrams Key to wiring diagrams (continued)
  • Page 191 Wiring diagrams 12•17...
  • Page 192 12•18 Wiring diagrams...
  • Page 193 Wiring diagrams 12•19...
  • Page 194 12•20 Wiring diagrams...
  • Page 195 Wiring diagrams 12•21...
  • Page 196 12•22 Wiring diagrams...
  • Page 197 Wiring diagrams 12•23...
  • Page 198 12•24 Wiring diagrams...
  • Page 199 Wiring diagrams 12•25...
  • Page 200 12•26 Wiring diagrams...
  • Page 201 Wiring diagrams 12•27...

  • Page 202: Dimensions And Weights

    Reference REF•1 Dimensions and weights ....REF•1 Radio/cassette unit anti-theft system ..REF•5 Conversion factors ....REF•2 Tools and working facilities .

  • Page 203: Fuel Consumption

    Mass (weight) Ounces (oz) x 28.35 = Grams (g) x 0.035 = Ounces (oz) Pounds (lb) x 0.454 = Kilograms (kg) x 2.205 = Pounds (lb) Force Ounces-force (ozf; oz) x 0.278 = Newtons (N) x 3.6 = Ounces-force (ozf; oz) Pounds-force (lbf;...

  • Page 204: Vehicle Identification

    Buying spare parts REF•3 Buying spare parts maintenance of your car (oil, air and fuel Tyre and exhaust specialists filters, spark plugs, light bulbs, drivebelts, oils These outlets may be independent, or Spare parts are available from many and greases, brake pads, touch-up paint, etc). members of a local or national chain.
  • Page 205 General repair procedures REF•4 Whenever servicing, repair or overhaul work unshouldered, the seal should be fitted with effectiveness after long periods of use, and is carried out on the car or its components, its face flush with the housing top face (unless should then be renewed as a matter of course.
  • Page 206 If this happens, or if the security code is lost immediately reconnected, vehicle. or forgotten, seek the advice of your Peugeot radio/cassette unit will not function until the To enter the correct security code, follow dealer.

  • Page 207: Tools And Working Facilities

    Tools and working facilities REF•6 Introduction Maintenance Repair and overhaul tool kit and minor repair tool kit A selection of good tools is a fundamental These tools are virtually essential for requirement for anyone contemplating the The tools given in this list should be anyone undertaking any major repairs to a maintenance and repair of a motor vehicle.
  • Page 208 Tools and working facilities REF•7 Special tools Buying tools Working facilities The tools in this list are those which are not Reputable motor accessory shops and Not to be forgotten when discussing tools used regularly, are expensive to buy, or which superstores often offer excellent quality tools is the workshop itself.
  • Page 209 MOT test checks REF•8 This is a guide to getting your vehicle through the MOT test. Obviously it will not be possible to examine the vehicle to the same standard as the professional MOT tester. However, working through the following checks will enable you to identify any problem areas before submitting the vehicle for the test.
  • Page 210 MOT test checks REF•9 Electrical equipment Inspect both front brake flexible hoses for cracks or deterioration of the rubber. Turn the Switch on the ignition and check the steering from lock to lock, and ensure that the operation of the horn. hoses do not contact the wheel, tyre, or any Check the windscreen washers and wipers, part of the steering or suspension mechanism.
  • Page 211 MOT test checks REF•10 Exhaust system Front and rear suspension and The same general checks apply to vehicles wheel bearings fitted with other suspension types, such as Start the engine. With your assistant torsion bars, hydraulic displacer units, etc. holding a rag over the tailpipe, check the Starting at the front right-hand side, grasp Ensure that all mountings and attachments are entire system for leaks.

  • Page 212: Road Test

    MOT test checks REF•11 the engine speed to return to idle, and watch for smoke emissions from the exhaust tailpipe. If the idle speed is obviously much too high, or if dense blue or clearly-visible black smoke comes from the tailpipe for more than 5 seconds, the vehicle will fail.
  • Page 213 Fault finding REF•12 Engine ....... .1 Automatic transmission ....6 Fluid leakage Engine fails to rotate when attempting to start Transmission fluid brown, or has burned smell...
  • Page 214 Fault finding REF•13 failure of components such as fuses or spark are before starting work. This is particularly changing oil-fouled spark plugs for a new set plugs may only be pointers to some important if you are investigating a fault for will get you moving again, but remember that underlying fault.
  • Page 215 Fault finding REF•14 Engine (continued) Engine misfires throughout the driving speed Engine backfires range Timing chain or belt incorrectly fitted or tensioned (Chapter 2A, 2B Fuel filter choked - fuel-injected models (Chapter 1). or 2C). Fuel pump faulty, or delivery pressure low (Chapter 4A, 4B or 4C). Vacuum leak at the carburettor/throttle body, inlet manifold or Fuel tank vent blocked, or fuel pipes restricted (Chapter 4A, 4B associated hoses (Chapter 4A, 4B or 4C).

  • Page 216: Cooling System

    Fault finding REF•15 2 Cooling system Overheating External coolant leakage Insufficient coolant in system (“Weekly checks” ). Deteriorated or damaged hoses or hose clips (Chapter 1). Thermostat faulty (Chapter 3). Radiator core or heater matrix leaking (Chapter 3). Radiator core blocked, or grille restricted (Chapter 3). Pressure cap faulty (Chapter 3).

  • Page 217: Manual Transmission

    Fault finding REF•16 5 Manual transmission Noisy in neutral with engine running Jumps out of gear Input shaft bearings worn (noise apparent with clutch pedal Worn or damaged gear linkage (Chapter 7A). released, but not when depressed) (Chapter 7A).* Incorrectly-adjusted gear linkage (Chapter 7A). Clutch release bearing worn (noise apparent with clutch pedal Worn synchroniser units (Chapter 7A).* depressed, possibly less when released) (Chapter 6).

  • Page 218: Braking System

    Master cylinder mounting nuts loose (Chapter 9). hose connections, any faults occurring on the anti-lock braking system Faulty master cylinder (Chapter 9). should be referred to a Peugeot dealer for diagnosis. Excessive brake pedal effort required to stop Vehicle pulls to one side under braking...

  • Page 219: Electrical System

    Fault finding REF•18 Suspension and steering (continued) Excessive play in steering Tyre wear excessive Worn steering column intermediate shaft universal joint Tyres worn on inside or outside edges (Chapter 10). Tyres under-inflated (wear on both edges) (“Weekly checks” ). Worn steering track rod end balljoints (Chapters 1 and 10). Incorrect camber or castor angles (wear on one edge only) Worn rack-and-pinion steering gear (Chapter 10).
  • Page 220 Fault finding REF•19 Windscreen/tailgate wipers inoperative, or Electric windows inoperative, or unsatisfactory in unsatisfactory in operation operation Wipers fail to operate, or operate very slowly Window glass will only move in one direction Wiper blades stuck to screen, or linkage seized or binding Faulty switch (Chapter 12).
  • Page 221 Glossary of technical terms REF•20 would tend to clog the radiator and coolant Bearing The curved surface on a shaft or in a passages and reduce cooling efficiency. bore, or the part assembled into either, that ABS (Anti-lock brake system) A system, Anti-seize compound A coating that...
  • Page 222 Glossary of technical terms REF•21 Camshaft A rotating shaft on which a series Catalytic converter A silencer-like device in Crocodile clip See Alligator clip the exhaust system which converts certain of cam lobes operate the valve mechanisms. pollutants in the exhaust gases into less The camshaft may be driven by gears, by harmful substances.
  • Page 223 Glossary of technical terms REF•22 Feeler blade A thin strip or blade of hardened electrode in a spark plug. Also refers to the steel, ground to an exact thickness, used to spacing between the points in a contact EGR valve A valve used to introduce exhaust check or measure clearances between parts.
  • Page 224 Glossary of technical terms REF•23 Overhead cam (ohc) engine An engine with the ozone in the upper atmosphere. the camshaft(s) located on top of the cylinder Rocker arm A lever arm that rocks on a shaft Jump start Starting the engine of a vehicle head(s).
  • Page 225 Glossary of technical terms REF•24 automatic transmission, switch that front wheel drive vehicles, a slight amount of obstructs one or more ports or passageways. prevents starting if the vehicle is not in Neutral toe-out is usually specified. A valve is also the movable part of such a or Park.
  • Page 226 Index REF•25 Note: References throughout this index are in the form - “Chapter number” • “page number” Bulbs and fuses - 0•15, 12•1 Bulbs exterior lights - 12•9 Bulbs interior lights - 12•11 Accelerator cable - 1•11, 4A•4, 4B•2, 4C•2 Bumpers - 11•4 Acknowledgements - 0•4 Air cleaner - 1•15, 4A•3, 4B•2, 4C•2...
  • Page 227 Index REF•26 Engine/transmission removal - 2D•4 et seq Exhaust and emission control systems - 4D•1 et seq air inlet heating system components - 4D•5 Dents - 11•2 catalytic converter - 4D•5 Dim-dip lighting system - 12•12 crankcase ventilation system components - 4D•5 Dimensions and weights - REF•1 emission check - 1•19 Distributor - 5B•3...
  • Page 228 Index REF•27 Gearbox oil (manual) - 0•16, 1•13, 7A•2 Leaks and hose condition - 0•9, 1•10 Gearbox oil (automatic) - 0•16, 1•9, 1•14 Lubricants and fluids - 0•16 Gearchange linkage manual transmission - 7A•4 Glass - 11•9 Glossary of technical terms - REF•20 Main and big-end bearings - 2D•15 Glovebox - 11•11 Maintenance schedule - 1•3...

  • Page 229: Spark Plug Renewal

    Index REF•28 cooling system electrical - 3•4 facia - 12•5 glovebox - 12•6 Radiator - 3•3 handbrake warning - 12•6 Radiator cooling fan - 3•4 Radio - 12•14 instrument panel - 12•6 Radio/cassette anti-theft system - REF•5 oil pressure warning light - 5A•4 Relays - 12•5 reversing light - 12•6 Repair procedures - REF•4...
  • Page 230 Notes REF•29...
  • Page 231 Left blank for manual listing pages...
  • Page 232 Left blank for manual listing pages...
  • Page 233 Preserving Our Motoring Heritage < The Model J Duesenberg Derham Tourster. Only eight of these magnificent cars were ever built – this is the only example to be found outside the United States of America Almost every car you’ve ever loved, loathed or desired is gathered under one roof at the Haynes Motor Museum.

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