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Peugeot 205
Service and Repair Manual
A K Legg LAE MIMI and John S Mead
Models covered
All Peugeot 205 models with petrol engines (inc. GTi, Cabriolet, Automatic & special/limited editions)
954 cc, 1124 cc, 1360 cc, 1580 cc & 1905 cc
Covers mechanical features of Vans
Does not cover diesel engine or T16 Turbo models (932 - 272 - 10Y12)
Printed by J. H. Haynes & Co. Ltd, Sparkford, Nr Yeovil,
Somerset BA22 7JJ, England
© Haynes Publishing 1996
Haynes Publishing
A book in the Haynes Service and R
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Contents LIVING WITH YOUR PEUGEOT 205 Introduction Page 0•4 Safety First! Page 0•5 ROADSIDE REPAIRS Introduction Page 0•6 If your car won’t start Page 0•6 Jump starting Page 0•7 Wheel changing Page 0•8 Identifying leaks Page 0•9 Towing Page 0•9 WEEKLY CHECKS Introduction Page 0•10 Underbonnet check points Page 0•10 Engine oil level Page 0•11 Coolant level Page 0•11 Brake fluid level Page 0•12 Power steering fluid level Page 0•12 Screen washer fluid level Page 0•13 Battery Page 0•13 Tyre condit
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Contents REPAIRS & OVERHAUL Engine and Associated Systems XV, XW and XY engines in-car repair procedures Page 2A•1 XU series engine in-car repair procedures Page 2B•1 TU series engine in-car repair procedures Page 2C•1 Engine removal and overhaul procedures Page 2D•1 Cooling, heating and air conditioning systems Page 3•1 Fuel system - carburettor engines Page 4A•1 Fuel system - single-point fuel injection engines Page 4B•1 Fuel system - multi-point fuel injection engines Page 4C•1 Exhaust and em
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0•4 Introduction The Peugeot 205 was introduced in the UK in September 1983 as a based on the GT version. In September 1985 the XT was introduced, five-door Hatchback with a transversely-mounted engine and trans- being a three-door version of the GT, and at the same time the 954 cc mission assembly driving the front wheels. The suspension is of front XL three-door was introduced, having a higher specification than the coil springs and rear transverse torsion bars. XE. The 1580 cc Automatic was i
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Safety first! 0•5 Working on your car can be dangerous. • Mains voltage is also dangerous. Make Special hazards This page shows just some of the potential sure that any mains-operated equipment is risks and hazards, with the aim of creating a correctly earthed. Mains power points should Hydrofluoric acid safety-conscious attitude. be protected by a residual current device • This extremely corrosive acid is formed (RCD) circuit breaker. when certain types of synthetic rubber, found General hazar
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0•6 Roadside repairs The following pages are intended to help in dealing with common roadside emergencies and breakdowns. You will find more detailed fault finding information at the back of the manual, and repair information in the main chapters. If your car won’t start If your car won’t start and the starter motor even though the starter doesn’t turn motor turns as normal M If it’s a model with automatic transmission, make sure the M Is there fuel in the tank? selector is in ‘P’ or ‘N’. M Is
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Roadside repairs 0•7 Jump starting will get you out Jump starting of trouble, but you must correct whatever made the battery go When jump-starting a car using a 4 Make sure that the booster battery is flat in the first place. There are booster battery, observe the following the same voltage as the discharged three possibilities: precautions: one in the vehicle. The battery has been drained by 4 If the battery is being jump-started 1 repeated attempts to start, or by 4 Before connecting the boo
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0•8 Roadside repairs Wheel changing Some of the details shown here will vary Warning: Do not change a wheel in a situation where you risk being hit by according to model. For instance, the location other traffic. On busy roads, try to stop in a lay-by or a gateway. Be wary of of the spare wheel and jack is not the same passing traffic while changing the wheel – it is easy to become distracted by on all cars. However, the basic principles the job in hand. apply to all vehicles. Preparation M When
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Roadside repairs 0•9 Identifying leaks Puddles on the garage floor or drive, or Warning: Most automotive oils The smell of a fluid leaking obvious wetness under the bonnet or and fluids are poisonous. Wash from the car may provide a underneath the car, suggest a leak that needs them off skin, and change out of clue to what’s leaking. Some investigating. It can sometimes be difficult to contaminated clothing, without fluids are distinctively decide where the leak is coming from, delay. coloured.
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0•10 Weekly checks Introduction There are some very simple checks which M Keeping an eye on tyre condition and M If your car develops a brake fluid leak, the need only take a few minutes to carry out, but pressures, will not only help to stop them first time you might know about it is when which could save you a lot of inconvenience wearing out prematurely, but could also save your brakes don't work properly. Checking and expense. your life. the level regularly will give advance warning of this
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Weekly checks 0•11 Engine oil level Before you start 4 Make sure that your car is on level ground. 4 Check the oil level before the car is driven, or at least 5 minutes after the engine has been switched off. If the oil is checked immediately after driving the vehicle, some of the oil will remain in the upper engine The dipstick top is often brightly coloured Using a clean rag or paper towel remove components, resulting in an inaccurate 1 2 for easy identification (see “Underbonnet all oil fro
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0•12 Weekly checks Brake fluid level Warning: l Brake fluid can harm your eyes and damage painted surfaces, so use extreme caution when handling and pouring it. l Do not use fluid that has been standing open for some time, as it absorbs moisture from the air, which can cause a The “MAX” and “MIN” marks are If topping-up is necessary, first wipe dangerous loss of braking 1 2 indicated on the front of the reservoir. clean the area around the filler cap to effectiveness. The fluid level must
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Weekly checks 0•13 Screen washer fluid level Screenwash additives not only keep the The washer fluid reservoir filler is located at winscreen clean during foul weather, they also the front left-hand side of the engine prevent the washer system freezing in cold compartment (or right-hand side on models weather - which is when you are likely to need it with headlight wash). most. Don’t top up using plain water as the The washer reservoir itself is actually located screenwash will become too dilut
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0•14 Weekly checks Tyre condition and pressure It is very important that tyres are in good the tyre has been punctured, refit the nail so New tyres should be balanced when they are condition, and at the correct pressure - having that its point of penetration is marked. Then fitted, but it may become necessary to re- a tyre failure at any speed is highly dangerous. immediately change the wheel, and have the balance them as they wear, or if the balance Tyre wear is influenced by driving style - ha
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Weekly checks 0•15 Wiper blades Check the condition of the wiper blades; To remove a windscreen wiper blade, pull 4 Don’t forget to check the tailgate wiper 1 2 if they are cracked or show any signs of the arm fully away from the screen until it blade as well. To remove the blade, depress deterioration, or if the glass swept area is locks. Swivel the blade through 90°, the retaining tab and slide the blade out of the smeared, renew them. Wiper blades should press the locking tab with your finge
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0•16 Lubricants, fluids and tyre pressures Lubricants and fluids Engine . . . . . . . . . . . . . . . . . . . . . . . Multigrade engine oil, viscosity SAE 10W/40, or 15W/40, to API SG/CD (Duckhams QXR, QS or Hypergrade Plus) Cooling system . . . . . . . . . . . . . . . . Ethylene glycol-based antifreeze (Duckhams Antifreeze and Summer Coolant) Manual transmission: BH3 transmission . . . . . . . . . . . . Multigrade engine oil, viscosity SAE 10W/40 or 15W/40, to API SG/CD (Duckhams QXR or Hypergr
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1•1 Chapter 1 Routine maintenance and servicing 1 Contents Air cleaner filter element renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Idle speed and mixture check and adjustment . . . . . . . . . . . . . . . . . 28 Air conditioning system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Ignition system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Automatic transmission fluid level check . . . . . . . . . . . . . . . . . .
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1•2 Servicing Specifications Lubricants and fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to end of “Weekly checks” Capacities Engine oil XV and XW series engines (including filter) . . . . . . . . . . . . . . . . . . . . 4.5 litres XY and XU series engines (including filter) . . . . . . . . . . . . . . . . . . . . 5.0 litres TU series engines (including filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 litres Cooling system XV8, XW7, TU9 an
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Maintenance schedule 1•3 The maintenance intervals in this manual on territory of use, and conditions If the vehicle is driven in dusty areas, used are provided with the assumption that you, encountered. If you wish to keep your vehicle to tow a trailer, driven frequently at slow not the dealer, will be carrying out the work. in peak condition at all times, you may wish to speeds (idling in traffic) or on short journeys, These are the average maintenance intervals perform some of these procedur
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1•4 Maintenance - component location 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 16 Hydraulic brake lines 26 Ignition timing aperture 5 Bottom hose 17 Cooling fan motor resistor 27 Diagnostic socket 6 Water pump 18 Front suspension shock absorber top 28 Radiator filler cap 7 Throt
