Table Of Contents - PEUGEOT 205 Manual

Table of Contents

Contents1
Servicing Specifications2
Maintenance Schedule3
Every 250 Miles (400 Km) Or Weekly3
Every 6000 Miles (9000 Km)3
6 Months - Whichever Comes Sooner3
Maintenance - Component Location4
Underbonnet View Of A 1360 Cc Gt Model4
Underbonnet View Of A 1360 Cc Xs Model (Tu Series Engine)5
Front Underside View Of A 1360 Cc Gt Model6
Rear Underside View Of A 1360 Cc Gt Model7
Maintenance Procedures8
Intensive Maintenance8
Engine Oil And Filter Renewal8
Primary Operations8
Every 6000 Miles Or 6 Months9
Front Brake Pad Check9
Automatic Transmission Fluid Level Check9
Using An Oil Filter Removal Tool To Slacken The Filter9
Every 12 000 Miles Or 12 Months10
Underbonnet Check For Fluid Leaks And Hose Condition10
Spark Plug Renewal10
Metal Lines10
Throttle And Choke Cable Lubrication And Adjustment11
Auxiliary Drivebelt Check And Renewal11
Auxiliary Drivebelt - Removal, Refitting And Tensioning11
Checking The Auxiliary Drivebelt Condition11
Seat Belt Check12
Lock And Hinge Check And Lubrication12
Rear Brake Shoe Check12
Underbody And Fuel/Brake Line Check12
Every 24 000 Miles Or 2 Years13
Bodywork, Paint And Exterior Trim Check13
Headlight Beam Alignment Check13
Air Conditioning System Check13
Manual Transmission Oil Renewal14
Automatic Transmission Fluid Renewal14
Driveshaft Bellows Check14
Steering And Suspension Check15
Air Cleaner Filter Element Renewal15
Rear Suspension Check15
Front Suspension And Steering Check15
Ignition System Check16
Idle Speed And Mixture Check And Adjustment16
Carburettor Models16
General Component Check16
Idle Speed Adjustment - Single Carburettor Engines17
Idle Speed Adjustment - Twin Carburettor Engines17
Single-Point Fuel Injection Models18
Idle Mixture Co Level Adjustment18
Adjustment Points On The Weber Twin Carburettor Installation18
Road Test19
Multi-Point Fuel Injection Models19
Idle Speed Adjustment19
Instruments And Electrical Equipment19
Every 36 000 Miles Or 3 Years20
Timing Belt Renewal20
Every 48 000 Miles Or 4 Years20
Every 2 Years (Regardless Of Mileage)20
Cooling System Flushing21
Cooling System Filling21
Engine Flushing21
Radiator Flushing21
Antifreeze Mixture22
Brake Fluid Renewal22
Xv, Xw And Xy Engines In-Car Repair Procedures23
Degrees Of Difficulty23
Specifications23
General Information24
Valve Clearances - Checking And Adjustment24
Torque Wrench Settings24
Engine Description24
Compression Test - Description And Interpretation25
Timing Chain, Tensioner And Sprockets - Removal And Refitting25
Adjusting The Valve Clearances25
Removing Oil Pump Screw With Allen Key26
Removing The Oil Pump And Spacer Plate26
Timing Chain Tensioner Lock (2)26
Check That The Crankshaft Is Positioned26
Oil Pump - Removal27
Camshaft And Rocker Arms27
Rocker Arm Assembly27
Cylinder Head - Removal And Refitting28
Right-Hand Rear Engine Mounting Bolts29
Lever Up The Engine And Support It On A Wooden Block29
Removing The Fuel Pump Plunger29
Sequence For Tightening Or Loosening The Cylinder Head Bolts29
Preparation For Refitting30
Removing The Rocker Shaft Assembly30
Loosening The Camshaft Thrust Plate Bolt30
Crankshaft Oil Seals31
Right-Hand (Front) Oil Seal31
Flywheel32
Engine/Transmission Mountings - Inspection And Renewal32
Left-Hand Oil Seal32
Xu Series Engine In-Car Repair Procedures33
Tu Series Engine In-Car Repair Procedures45
Engine Removal And Overhaul Procedures59
Cylinder Block60
Piston Rings60
Engine/Transmission Removal - Preparation And Precautions62
Engine/Manual Transmission63
Typical Engine Wiring Harness Connections63
Xv, Xw And Xy Series Engines64
Xu And Tu Series Engines64
Reconnection64
Removing The Engine And Manual Transmission64
Engine/Automatic Transmission65
Cylinder Head66
Measuring The Valve Stem Diameter67
Grinding-In A Valve67
Valve Components68
Piston/Connecting Rod Assembly68
Crankshaft69
Checking Crankshaft Endfloat Using Feeler Blades70
Main Bearing Cap Identification Markings (Arrowed)70
Removing The Main Bearing Cap And Thrustwashers (Arrowed)70
Cylinder Block/Crankcase71
Measuring A Crankshaft Big-End Journal Diameter71
Cleaning A Cylinder Block Threaded Hole Using A Suitable Tap71
Cylinder Liner With Paper Base Seal72
Cylinder Liner Size Group Marking72
Measuring Cylinder Liner Protrusion72
Main And Big-End Bearings73
Fitting A Liner To The Cylinder Block73
Typical Bearing Failures73
Piston Rings - Refitting74
Engine Overhaul74
Main Bearing Shell Selection74
Measuring Piston Ring End Gap74
Piston Ring Identification75
Main Bearing Shell Selection Chart - Later Xu Series Engines75
Aluminium Block Engine76
Cast-Iron Block Engine76
Main Bearing Shell Selection Chart76
Plastigage In Place On A Crankshaft Main Bearing Journal77
Lowering The Crankshaft Into Place78
Crankcase Flange O-Ring Seal78
Tightening The Main Bearing/Casing Bolts78
Refit The Casing Flange Bolts And Washers78
Cooling, Heating And Air Conditioning Systems83
General Information And Precautions84
Cooling System Hoses84
Antifreeze84
Thermostat85
Radiator85
Thermostat Temperature Rating (Arrowed) Stamped On Base85
Radiator Cooling Fan86
Cooling System Electrical Switches And Sensors86
Coolant Level Sensor86
Coolant Temperature Sensor86
Coolant Pump87
Heater Assembly88
Tu Series Cast-Iron Block Engines88
Tu Series Aluminium Block Engines88
Air Conditioning System89
Air Conditioning System Layout89
Precautions90
The Refrigeration Side Of The Air Conditioning90
Fuel System - Carburettor Engines91
Recommended Fuel92
Fuel System - Single-Point Fuel Injection Engines101
Fuel System - Multi-Point Fuel Injection Engines109
Air Cleaner Assembly110
Throttle Cable110
Fuel System110
Fuel Gauge Sender Unit110
Bosch Motronic M1.3 System111
Fuel Injection System111
Idle Speed And Mixture Co Content111
Throttle Initial Position111
Throttle Position Switch112
Throttle Housing112
Fuel Pressure Regulator112
Supplementary Air (Cold Start) Device112
Inlet Manifold113
Exhaust And Emission Control Systems115
Exhaust System115
Emission Control Systems115
Typical Air Intake Heating System115
Crankcase Ventilation System116
Electro-Pneumatic Ignition Timing Retarding System116
Catalytic Converter116
Typical Crankcase Ventilation System116
Fuel Vapour Recirculation System117
Exhaust Manifold118
Typical Exhaust System Layout118
Air Inlet Heating System Components119
Electro-Pneumatic Ignition Retarding System Components119
Crankcase Ventilation119
Carbon Canister119
Solenoid Valve120
Starting And Charging Systems121
Battery - Removal And Refitting122
Electrical Fault Finding122
Battery - Testing And Charging122
Charging System - Testing122
Alternator - Removal And Refitting123
Alternator - Testing And Overhaul123
Starting System - Testing123
Starter Motor - Removal And Refitting123
Starter Motor - Testing And Overhaul124
Ignition Switch - Removal And Refitting124
Oil Pressure Warning Light Switch - Removal And Refitting124
Electronic Oil Level Sensor124
Electronic Breakerless Ignition System126
Static Distributorless Ignition System126
Engine Will Not Start126
Engine Misfires126
Ignition Ht Coil127
Distributor127
Models With Static Distributorless Ignition Systems127
Ignition Amplifier128
Ignition Module128
All Engines Except Tu Series128
Tu Series Engines128
Timing Plate129
Ignition Timing129
Initial Static Ignition Timing On Xu Series Engines130
Dynamic Ignition Timing On Xu Series Engines130
Tdc Sensor131
Braking System133
Table Of Contents133
Hydraulic System - Bleeding134
Bleeding Sequence134
Bleeding - Basic (Two-Man) Method135
Bleeding - Using A Pressure- Bleeding Kit135
Bleeding - Using A One-Way Valve Kit135
Hydraulic Pipes And Hoses136
Front Brake Pads - Renewal136
Dba Bendix Caliper136
Removing The Outer Pad136
Girling Caliper137
Rear Brake Shoes - Renewal138
Early Type Anti-Squeal Shim138
Later Type Anti-Squeal Shim138
Unscrewing The Lower Caliper Guide Pin Bolt138
Rear Brake Pads139
Dba Bendix Type Rear Brake Component Layout139
Girling Type Rear Brake Component Layout139
Automatic Adjuster Lever - Arrowed139
Front Brake Caliper140
Brake Pad Locking Key Spring Clip140
Removing The Rear Brake Pads140
Correct Final Position Of Caliper Piston140
Dba Bendix Type Brake Caliper Components141
Girling Type Brake Caliper Components141
Rear Brake Caliper142
Brake Disc - Inspection, Removal And Refitting142
And Refitting142
Rear Wheel Cylinder - Removal, Overhaul And Refitting142
Rear Brake Hub/Drum143
Rear Wheel Cylinder Mounting Bolts143
Exploded View Of A Rear Wheel Cylinder143
Master Cylinder144
Rear Brake Compensator144
Rear Brake Compensator Fitted To 1.6 Gti Models144
Air Filter Renewal145
Vacuum Servo Unit - Testing, Removal And Refitting145
Brake Pedal - Removal And Refitting146
Handbrake - Adjustment146
Handbrake Cables - Renewal146
Handbrake Lever - Removal And Refitting147
Anti-Lock Braking System147
Electronic Control Unit147
Regulator Unit147
Suspension And Steering149
Easy, Suitable For Fairly Easy, Suitable Fairly Difficult149
Front Suspension Hub Carrier150
R-Clip And Locking Collar Fitted To Hub Nut On Later Models150
Front Hub Bearings - Renewal151
Front Suspension Strut151
Front Hub Bearing Retaining Circlip151
Front Lower Suspension Arm - Removal And Refitting152
Front Suspension Strut - Overhaul152
Front Suspension Top Mounting Nuts152
Front Anti-Roll Bar153
Anti-Roll Bar Guide Bar Bolt (Arrowed) On Non-Gti Models153
Anti-Roll Bar Mounting Clamp Bolts (Arrowed)153
Rear Hub/Drum And Bearings - General Information154
Rear Shock Absorber - Removal And Refitting154
Rear Suspension Assembly - Removal And Refitting155
Steering Column And Lock - Removal And Refitting155
Steering Gear - Removal And Refitting156
Steering Column And Lock Assembly Components156
Manual Steering Gear156
Power-Assisted Steering Gear156
Steering Gear Rubber Bellows - Renewal157
Extract The Spring Clip (6) From The Gearchange Linkage157
Front Subframe Attachments157
Correct Refitting Of Power Assisted Steering Gear157
Track Rod End - Removal And Refitting158
Power Steering Pump158
Separating The Track Rod End From The Hub Carrier Steering Arm158
Wheel Alignment And Steering Angles - General Information159
Adjusting The Front Wheel Toe Setting159
Front Wheel Toe Setting - Checking And Adjustment159
Bodywork And Fittings161
Maintenance - Bodywork And Underframe161
Minor Body Damage - Repair162
Repair Of Minor Scratches In Bodywork162
Repair Of Dents In Bodywork162
Repair Of Rust Holes Or Gashes In Bodywork162
Bodywork Repairs - Filling And Re-Spraying163
Plastic Components163
Major Body Damage - Repair163
Bonnet - Removal And Refitting163
Bonnet Lock And Remote Control Cable - Removal164
Front Grille164
Bumpers164
Front Bumper164
Door - Removal And Refitting165
Front Bumper Components165
Rear Bumper Components165
Door Trim Panel166
Removing The Armrest166
Removing The Side Pocket166
Removing The Interior Door Handle Surround166
Door167
Exterior Mirror (Early Models)167
Hood And Rear Window168
Power-Operated Hood Components169
Tailgate169
Tailgate Lock169
Windscreen And Tailgate Glass169
Seats - Removal And Refitting170
Sunroof - General Information170
Grab Handles170
Front Seat Rear Inner Mounting Bolts170
Sunroof Glass171
Glovebox171
Facia Panel171
Facia Front Mounting Nut172
Removing A Right-Hand Lower Facia Panel Securing Screw172
Body Electrical System175
Finding An Open-Circuit178
Finding An Earth Fault178
Finding A Short-Circuit178
Fuses And Relays179
Switches179
Removing A Fuse179
Combination Switch Screws179
Instrument Panel Rheostat180
Reversing Light Switch180
Courtesy Light Switch180
Glovebox Illumination Switch180
Instrument Panel181
Removing The Instrument Panel181
Exploded Diagram Of Non-Gti Instrument Panel182
Exploded Diagram Of Gti Instrument Panel182
Clock - Removal And Refitting183
Speedometer Cable - Renewal183
Bulbs (Exterior Lights)183
Bulb Renewal183
Front Parking Lights184
Front Direction Indicator184
Front Direction Indicator Side Repeater184
Rear Light Cluster Bulbs184
Bulbs (Interior Lights)185
Number Plate Light185
Reversing Light (1991 Models Onward)185
Map Reading Light185
Headlight Unit186
Front Direction Indicator Light Unit186
Headlight Beam Alignment186
Wiper Arms187
Windscreen Wiper Motor And Linkage187
Tailgate Wiper Motor187
Washer System187
Tailgate Heated Window188
Central Door Locking System188
Horn - Removal And Refitting188
Air Compressor And Horn188
Key To Wiring Diagrams189
Reference202
Dimensions And Weights202
Conversion Factors203
Fuel Consumption203
Buying Spare Parts204
Vehicle Identification204
Officially-Appointed Garages204
Motor Factors204
Joint Mating Faces And Gaskets205
Screw Threads And Fastenings205
Oil Seals205
Locknuts, Locktabs And Washers205
Jacking And Vehicle Support206
Radio/Cassette Unit Anti-Theft System206
Front Jacking Point206
Tools And Working Facilities207
Maintenance And Minor Repair Tool Kit207
Repair And Overhaul Tool Kit207
Valve Spring Compressor207
Buying Tools208
Care And Maintenance Of Tools208
Working Facilities208
Micrometer Set208
Mot Test Checks209
Handbrake209
Footbrake209
Steering Wheel And Column209
Seat Belts And Seats210
Electrical Equipment210
Steering And Suspension210
Shock Absorbers210
Steering Mechanism211
Springs And Shock Absorbers211
Front And Rear Suspension And Wheel Bearings211
Fuel And Exhaust Systems212
Wheels And Tyres212
Body Corrosion212
Hc Emissions212
Fault Finding213
Engine Fails To Rotate When Attempting To Start214
Engine Rotates, But Will Not Start214
Engine Difficult To Start When Cold214
Engine Idles Erratically214
Engine Misfires Throughout The Driving Speed Range215
Engine Hesitates On Acceleration215
Engine Stalls215
Engine Lacks Power215
Overheating216
Overcooling216
Excessive Fuel Consumption216
Fuel Leakage And/Or Fuel Odour216
Cooling System216
Noisy In Neutral With Engine Running217
Noisy In One Particular Gear217
Difficulty Engaging Gears217
Jumps Out Of Gear217
Manual Transmission217
Automatic Transmission217
Vehicle Pulls To One Side Under Braking218
Brake Pedal Feels Spongy When Depressed218
Excessive Brake Pedal Travel218
Brakes Binding218
Excessive Play In Steering219
Lack Of Power Assistance219
Tyre Wear Excessive219
Instrument Readings Inaccurate Or Erratic219
Electrical System219
Glossary Of Technical Terms221
Index226