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 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 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 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 fuel injection 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 transmission Page 7A•1 Automatic transmission 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 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 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 Talbot 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.