Bodywork And Fittings; Maintenance - Bodywork And Underframe - PEUGEOT 205 Manual

Chapter 11

Bodywork and fittings

Contents
Bodywork, paint and exterior trim check . . . . . . . . . . . .See Chapter 1
Bonnet - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bonnet lock and remote control cable - removal, refitting and
adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Bumpers - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Door - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Door, boot, tailgate and bonnet check and lubrication . .See Chapter 1
Door (Cabriolet models) - dismantling and reassembly . . . . . . . . . . 13
Door (Hatchback and Van models) - dismantling and reassembly . . 12
Door trim panel - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . 11
Facia panel - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Front grille - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Glovebox - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Grab handles - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . 22
Hood and rear window (Cabriolet models) - removal and refitting . . 14
Degrees of difficulty
Easy, suitable for Fairly easy, suitable
1
novice with little for beginner with
experience some experience
1 General information
The body shell is of one-piece design and
safety cell construction, whereby the outer
members yield progressively and in a
controlled direction in the event of impact,
giving maximum protection to the passenger
compartment. The body panels are of
lightweight high strength steel.
The front wings are bolted to the main body
for ease of removal. The complete body is
given an extensive anti-corrosion treatment
during manufacture; including stone chip
protection and wax injection. Peugeot
guarantee the body against perforation as a
result of corrosion for a period of six years
provided the car is given periodic inspections
by a Peugeot garage.

Maintenance - bodywork and underframe . . . . . . . . . . . . . . . . . . . . 2

Maintenance - upholstery and carpets . . . . . . . . . . . . . . . . . . . . . . . 3
Major body damage - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Minor body damage - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Power-operated hood components (Cabriolet models) - general
information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Rear quarter glass and regulator (Cabriolet models) - removal and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Rear quarter glass (GTI models) - removal and refitting . . . . . . . . . . 19
Seat belt check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Seats - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Sunroof - general information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Sunroof glass - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 24
Tailgate - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Tailgate lock - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . 17
Windscreen and tailgate glass - general information . . . . . . . . . . . . 18
Fairly difficult,
2
suitable for competent
DIY mechanic
2 Maintenance - bodywork and
underframe
The general condition of a vehicle's
bodywork is the one thing that significantly
affects its value. Maintenance is easy but
needs to be regular. Neglect, particularly after
minor damage, can lead quickly to further
deterioration and costly repair bills. It is
important also to keep watch on those parts
of the vehicle not immediately visible, for
instance the underside, inside all the wheel
arches and the lower part of the engine
compartment.
The basic maintenance routine for the
bodywork is washing preferably with a lot of
water, from a hose. This will remove all the
loose solids which may have stuck to the
vehicle. It is important to flush these off in
such a way as to prevent grit from scratching
Difficult, suitable for
4
3
experienced DIY
mechanic
the finish. The wheel arches and underframe
1
need washing in the same way to remove any
accumulated mud which will retain moisture
and tend to encourage rust. Oddly enough,
the best time to clean the underframe and
wheel arches is in wet weather when the mud
is thoroughly wet and soft. In very wet
weather the underframe is usually cleaned of
large accumulations automatically and this is
a good time for inspection.
Periodically, except on vehicles with a wax-
based underbody protective coating, it is a
good idea to have the whole of the
underframe of the vehicle steam cleaned,
engine compartment included, so that a
thorough inspection can be carried out to see
what minor repairs and renovations are
necessary. Steam cleaning is available at
many garages and is necessary for removal of
the accumulation of oily grime which
sometimes is allowed to become thick in
certain areas. If steam cleaning facilities are
11•1
Very difficult,
5
suitable for expert DIY
or professional
11