Peugeot 205 Service and Repair Manual

A K Legg LAE MIMI and John S Mead

Models covered All 205 models with petrol (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 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 Repair Manual Series Sparkford Nr Yeovil Somerset BA22 7JJ England All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or Haynes North America, Inc mechanical, including photocopying, recording or by any 861 Lawrence Drive, Newbury Park information storage or retrieval system, without permission in California 91320 USA writing from the copyright holder. Editions Haynes S.A ISBN 1 85960 189 8 147/149, rue Saint Honoré, 75001 PARIS, France

British Library Cataloguing in Publication Data Haynes Publishing Nordiska AB A catalogue record for this book is available from the British Library. Fyrisborgsgatan 5, 754 50 Uppsala, Sverige Contents

LIVING WITH YOUR 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 condition and pressure Page 0•14 Wiper blades Page 0•15 Bulbs and fuses Page 0•15 Lubricants and fluids Page 0•16 Tyre pressures Page 0•16

MAINTENANCE Routine Maintenance and Servicing Servicing Specifications Page 1•2 Maintenance schedule Page 1•3 Maintenance procedures Page 1•8 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 engines Page 4B•1 Fuel system - multi-point fuel injection engines Page 4C•1 Exhaust and emission control and exhaust systems Page 4D•1 Starting and charging systems Page 5A•1 Ignition system Page 5B•1

Transmission Clutch Page 6•1 Manual Page 7A•1 Page 7B•1 Driveshafts Page 8•1

Brakes and Suspension Braking system Page 9•1 Suspension and steering Page 10•1

Body Equipment Bodywork and fittings Page 11•1 Body electrical system Page 12•1

Wiring Diagrams Page 12•15 REFERENCE Dimensions and weights Page REF•1 Conversion factors Page REF•2 Buying spare parts Page REF•3 Vehicle identification Page REF•3 General repair procedures Page REF•4 Jacking and vehicle support Page REF•5 Radio/cassette anti-theft system Page REF•5 Tools and working facilities Page REF•6 MOT test checks Page REF•8 Fault finding Page REF•12 Glossary of technical terms Page REF•20

Index Page REF•25 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 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 introduced in April 1986 at the same Three engine sizes were originally available, featuring a chain driven time as the Cabriolet CTI. The XS replaced the XT in July 1986, at overhead camshaft design mounted directly over the transmission. The which time the limited edition Junior, based on the XE, became GTi was introduced in the Spring of 1984 and was fitted with a available. The 1.9 GTI was introduced in August 1986, and at the same belt-driven overhead camshaft engine with a side-mounted time dim-dip headlights and rear seat belts were fitted as standard. In transmission. The GTI engine is equipped with an electronically December 1987 the new TU engines and MA transmissions were fitted controlled fuel injection system. to all except fuel injection, diesel and automatic models. In October 1984 three-door versions became available, with an X Latest models feature single- and multi-point fuel injection, with full series designation, in addition to the three-door GTI. Van versions were emission control equipment and a sophisticated engine management introduced in June 1985, together with the limited edition Lacoste, system.

Peugeot 205 GTi Peugeot 205 van

Your Peugeot 205 Manual The aim of this manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work The Peugeot 205 Team must be done (even should you choose to get it done by a garage), provide information on routine maintenance and servicing, and give a logical course of action and diagnosis when random faults occur. Haynes manuals are produced by dedicated and However, it is hoped that you will use the manual by tackling the work enthusiastic people working in close co-operation. The yourself. On simpler jobs it may even be quicker than booking the car team responsible for the creation of this book included: into a garage and going there twice, to leave and collect it. Perhaps most important, a lot of money can be saved by avoiding the costs a Authors Andy Legg garage must charge to cover its labour and overheads. John Mead The manual has drawings and descriptions to show the function of Sub-editors Carole Turk the various components so that their layout can be understood. Then the tasks are described and photographed in a clear step-by-step Editor & Page Make-up Steve Churchill sequence. Workshop manager Paul Buckland Acknowledgements Photo Scans John Martin Thanks are due to Champion Spark Plug, who supplied the illustrations Paul Tanswell showing spark plug condition. Certain illustrations are the copyright of Cover illustration & Line Art Roger Healing Peugeot Motor Company Limited, and are used with their permission. Thanks are also due to Sykes-Pickavant Limited, who Wiring diagrams Matthew Marke provided some of the workshop tools, and to Duckhams Oils who provided lubrication data, also to all those people at Sparkford who We hope the book will help you to get the maximum helped in the production of this manual. enjoyment from your car. By carrying out routine We take great pride in the accuracy of information given in this maintenance as described you will ensure your car’s manual, but vehicle manufacturers make alterations and design reliability and preserve its resale value. changes during the production run of a particular vehicle of which they do not inform us. No liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from the information given. Safety first! 0•5

Working on your car can be dangerous. • Mains voltage is also dangerous. Make This page shows just some of the potential sure that any mains-operated equipment is Special hazards 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 (RCD) circuit breaker. • This extremely corrosive acid is formed General hazards when certain types of synthetic rubber, found Fume or gas intoxication in some O-rings, oil seals, fuel hoses etc, are 0 Scalding • Exhaust fumes are exposed to temperatures above 400 C. The • Don’t remove the radiator or expansion poisonous; they often rubber changes into a charred or sticky tank cap while the engine is hot. contain carbon substance containing the acid. Once formed, • Engine oil, automatic transmission fluid or monoxide, which is the acid remains dangerous for years. If it power steering fluid may also be dangerously rapidly fatal if inhaled. gets onto the skin, it may be necessary to hot if the engine has recently been running. Never run the amputate the limb concerned. engine in a • When dealing with a vehicle which has Burning confined space suffered a fire, or with components salvaged • Beware of burns from the exhaust system such as a garage from such a vehicle, wear protective gloves and from any part of the engine. Brake discs with the doors shut. and discard them after use. and drums can also be extremely hot • Fuel vapour is also The battery immediately after use. poisonous, as are the vapours from some cleaning solvents and paint thinners. • Batteries contain sulphuric acid, which Crushing attacks clothing, eyes and skin. Take care • When working under or near Poisonous or irritant substances when topping-up or carrying the battery. a raised vehicle, • Avoid skin contact with battery acid and • The hydrogen gas given off by the battery always with any fuel, fluid or lubricant, especially is highly explosive. Never cause a spark or supplement the antifreeze, brake hydraulic fluid and Diesel allow a naked light nearby. Be careful when jack with axle fuel. Don’t syphon them by mouth. If such a connecting and disconnecting battery stands, or use substance is swallowed or gets into the eyes, chargers or jump leads. drive-on seek medical advice. Air bags ramps. • Prolonged contact with used engine oil can Never cause skin cancer. Wear gloves or use a • Air bags can cause injury if they go off venture barrier cream if necessary. Change out of oil- accidentally. Take care when removing the under a car which soaked clothes and do not keep oily rags in steering wheel and/or facia. Special storage is only supported by a jack. your pocket. instructions may apply. • Take care if loosening or tightening high- • Air conditioning refrigerant forms a Diesel injection equipment torque nuts when the vehicle is on stands. poisonous gas if exposed to a naked flame • Diesel injection pumps supply fuel at very Initial loosening and final tightening should (including a cigarette). It can also cause skin high pressure. Take care when working on be done with the wheels on the ground. burns on contact. the fuel injectors and fuel pipes. Fire Asbestos • Fuel is highly flammable; fuel vapour is • Asbestos dust can cause cancer if inhaled Warning: Never expose the hands, explosive. or swallowed. Asbestos may be found in face or any other part of the body • Don’t let fuel spill onto a hot engine. gaskets and in brake and clutch linings. to injector spray; the fuel can • Do not smoke or allow naked lights When dealing with such components it is penetrate the skin with potentially fatal (including pilot lights) anywhere near a safest to assume that they contain asbestos. results. vehicle being worked on. Also beware of creating sparks (electrically or by use of tools). • Fuel vapour is heavier than air, so don’t Remember... A few tips work on the fuel system with the vehicle over an inspection pit. DO DON’T • Another cause of fire is an electrical • Do use eye protection when using power • Don’t attempt to lift a heavy component overload or short-circuit. Take care when tools, and when working under the vehicle. which may be beyond your capability – get repairing or modifying the vehicle wiring. assistance. • Do wear gloves or use barrier cream to • Keep a fire extinguisher handy, of a type • Don’t rush to finish a job, or take suitable for use on fuel and electrical fires. protect your hands when necessary. unverified short cuts. Electric shock • Do get someone to check periodically that all is well when working alone on the • Don’t use ill-fitting tools which may slip • Ignition HT vehicle. and cause injury. voltage can be • Do keep loose clothing and long hair well • Don’t leave tools or parts lying around dangerous, out of the way of moving mechanical parts. where someone can trip over them. Mop especially to up oil and fuel spills at once. people with heart • Do remove rings, wristwatch etc, before problems or a working on the vehicle – especially the • Don’t allow children or pets to play in or pacemaker. Don’t electrical system. near a vehicle being worked on. work on or near the • Do ensure that any lifting or jacking ignition system with equipment has a safe working load rating the engine running or adequate for the job. the ignition switched on. 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 Ⅺ If it’s a model with automatic transmission, make sure the Ⅺ Is there fuel in the tank? selector is in ‘P’ or ‘N’. Ⅺ Is there moisture on electrical components under the Ⅺ Open the bonnet and make sure that the battery terminals bonnet? Switch off the ignition, then wipe off any obvious are clean and tight. dampness with a dry cloth. Spray a water-repellent aerosol Ⅺ Switch on the headlights and try to start the engine. If the product (WD-40 or equivalent) on ignition and fuel system headlights go very dim when you’re trying to start, the electrical connectors like those shown in the photos. battery is probably flat. Get out of trouble by jump starting Pay special attention to the ignition coil wiring connector (see next page) using a friend’s car. and HT leads. (Note that Diesel engines don’t normally suffer from damp.)

Check that the spark plug HT leads are securely connected by Check that all ignition wiring connectors such as this at the A pushing them home B distributor are secure and spray with water dispersant if necessary.

Check the security of all the fuel injection system wiring Check the security and condition of the battery terminals. C connectors (where applicable). D

Check that electrical connections are secure (with the ignition switched off) and spray them with a water dispersant spray like WD40 if you suspect a problem due to damp 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 1 repeated attempts to start, or by 4 Before connecting the booster 4 If the battery is being jump-started leaving the lights on. battery, make sure that the ignition is from the battery in another vehicle, switched off. the two vehcles MUST NOT TOUCH The charging system is not working each other. 2 properly (alternator drivebelt slack 4 Ensure that all electrical equipment or broken, alternator wiring fault or (lights, heater, wipers, etc) is 4 Make sure that the transmission is in alternator itself faulty). switched off. neutral (or PARK, in the case of automatic transmission). The battery itself is at fault 3 (electrolyte low, or battery worn out).

1 Connect one end of the red jump lead to 2 Connect the other end of the red lead to 3 Connect one end of the black jump lead the positive (+) terminal of the flat the positive (+) terminal of the booster to the negative (-) terminal of the battery battery. booster battery

4 Connect the other end of the black jump lead to a bolt or bracket on the engine block, well away from the battery, on the vehicle to be started.

Make sure that the jump leads will not 5 come into contact with the fan, drive- belts or other moving parts of the engine.

Start the engine using the booster 6 battery, then with the engine running at idle speed, disconnect the jump leads in the reverse order of connection. 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 Ⅺ When a puncture occurs, stop as soon Ⅺ If you have one, use a warning triangle to one being removed – a couple of large as it is safe to do so. alert other drivers of your presence. stones will do for this. Ⅺ Park on firm level ground, if possible, Ⅺ Apply the handbrake and engage first or Ⅺ If the ground is soft, use a flat piece of and well out of the way of other traffic. reverse gear. wood to spread the load under the foot Ⅺ Use hazard warning lights if necessary. Ⅺ Chock the wheel diagonally opposite the of the jack. Changing the wheel

From inside the boot area, use the Slide the spare wheel out from the For safety in the event of the jack 1 wheelbrace to lower the spare wheel 2 underside of the car. 3 slipping, position the spare wheel under cradle. the sill, close to the jacking point.

Remove the wheel trim (where fitted) Locate the jack below the reinforced Turn the jack handle clockwise until the 4 then slacken each wheel bolt by a half 5 jacking point and on firm ground (don’t 6 wheel is raised clear of the ground, turn. jack the car at any other point on the sill). remove the bolts and lift the wheel clear. Finally...

Ⅺ Remove the wheel chocks. Stow the jack and tools in the appropriate locations in the car. Ⅺ Don’t leave the spare wheel cradle empty and unsecured – it could drop onto the ground while the car is moving. Ⅺ Check the tyre pressure on the wheel just fitted. If it is low, or if you don’t have a pressure gauge with you, drive slowly to the nearest garage and inflate the tyre Position the spare wheel and fit the Tighten the wheel bolts in the sequence to the correct pressure. Have the 7 bolts. Tighten moderately with the wheel- 8 shown, fit the wheel trim, and secure the damaged tyre or wheel repaired, or brace, then lower the car to the ground. punctured wheel in the spare wheel renew it, as soon as possible. cradle. 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. It may help to clean the car especially if the engine bay is very dirty carefully and to park it over some clean already. Leaking oil or fluid can also be blown paper overnight as an aid to locating the rearwards by the passage of air under the car, source of the leak. giving a false impression of where the problem lies. Remember that some leaks may only occur while the engine is running.

Sump oil Oil from filter Gearbox oil

Engine oil may leak from the drain plug...... or from the base of the oil filter. Gearbox oil can leak from the seals at the inboard ends of the driveshafts. Antifreeze Brake fluid Power steering fluid

Leaking antifreeze often leaves a crystalline A leak occurring at a wheel is almost Power steering fluid may leak from the pipe deposit like this. certainly brake fluid. connectors on the steering rack. Towing When all else fails, you may find yourself Ⅺ Only attach the tow-rope to the towing Ⅺ Only drive at moderate speeds and keep having to get a tow home – or of course you eyes provided. the distance towed to a minimum. Drive may be helping somebody else. Long-distance Ⅺ Before being towed, release the handbrake smoothly and allow plenty of time for slowing recovery should only be done by a garage or and select neutral on the transmission. down at junctions. breakdown service. For shorter distances, DIY Ⅺ Note that greater-than-usual pedal Ⅺ On models with automatic transmission, towing using another car is easy enough, but pressure will be required to operate the special precautions apply. If in doubt, do not observe the following points: brakes, since the vacuum servo unit is only tow, or transmission damage may result. Ⅺ Use a proper tow-rope – they are not operational with the engine running. Ⅺ Do not tow BH type gearbox models with expensive. The vehicle being towed must Ⅺ On models with power steering, greater- the front wheels on the ground for long display an ‘ON TOW’ sign in its rear window. than-usual steering effort will also be required. distances, as the engine lubrication system Ⅺ Always turn the ignition key to the ‘on’ Ⅺ The driver of the car being towed must keep also supplies pressure-fed oil to the gears and position when the vehicle is being towed, so the tow-rope taut at all times to avoid snatching. differential bearings Unnecessary wear may that the steering lock is released, and that the Ⅺ Make sure that both drivers know the route occur if the car is towed with the engine direction indicator and brake lights will work. before setting off. stopped. 0•10 Weekly checks

Introduction

There are some very simple checks which Ⅺ Keeping an eye on tyre condition and Ⅺ 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 kind of problem. These "Weekly checks" require no great skill Ⅺ Many breakdowns are caused by electrical or special tools, and the small amount of time problems. Battery-related faults are particularly Ⅺ If the oil or coolant levels run low, the cost they take to perform could prove to be very common, and a quick check on a regular basis of repairing any engine damage will be far well spent, for example; will often prevent the majority of these. greater than fixing the leak, for example.

Underbonnet check points

ᮤ TU series

Other engine similar

A Engine oil level dipstick B Engine oil filler cap C Coolant expansion tank D Brake fluid reservoir E Screen washer fluid reservoir F Battery