Peugeotメーカー205の使用説明書/サービス説明書
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Peugeot 205 Service and Repair Manual Models covered All Peugeot 205 models with petrol engines (inc. GTi, Cabriolet, Automatic & special/limited editions) 954 cc, 1124 cc, 1360 cc, 1580 cc & .
LIVING WITH YOUR PEUGEOT 205 Introduction Page 0•4 Safety First! Page 0•5 ROADSIDE REP AIRS Introduction Page 0•6 If your car won’t start Page 0•6 Jump starting Page 0•7 Wheel changing Pag.
REP AIRS & 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 pr.
The Peugeot 205 was introduced in the UK in September 1983 as a five- door Hatchback with a transversely-mounted engine and trans- mission assembly driving the front wheels.
Safety first! 0•5 W orking on your car can be dangerous. This page shows just some of the potential risks and hazards, with the aim of cr eating a safety-conscious attitude. General hazar ds Scalding • Don’t r emove the radiator or expansion tank cap while the engine is hot.
0•6 Roadside r epairs 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.
Roadside repairs 0•7 When jump-starting a car using a booster battery , observe the following precautions: 4 Before connecting the booster battery , make sure that the ignition is switched of f. 4 Ensure that all electrical equipment (lights, heater , wipers, etc) is switched of f.
0•8 Roadside r epairs Wheel changing Some of the details shown here will vary accor ding to model. For instance, the location of the spare wheel and jack is not the same on all cars. However , the basic principles apply to all vehicles. M When a puncture occurs, stop as soon as it is safe to do so.
Roadside repairs 0•9 When all else fails, you may find yourself having to get a tow home – or of course you may be helping somebody else. Long-distance recovery should only be done by a garage or breakdown service.
0•10 W eekly checks There are some very simple checks which need only take a few minutes to carry out, but which could save you a lot of inconvenience and expense.
W eekly 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. The correct oil Modern engines place great demands on their oil.
0•12 W eekly 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 dangerous loss of braking effectiveness.
W eekly checks 0•13 Screenwash additives not only keep the winscreen clean during foul weather, they also prevent the washer system freezing in cold weather - which is when you are likely to need it most. Don’t top up using plain water as the screenwash will become too diluted, and will freeze during cold weather.
0•14 W eekly checks T yre condition and pr essur e It is very important that tyres are in good condition, and at the correct pressure - having a tyre failure at any speed is highly dangerous. Tyre wear is influenced by driving style - harsh braking and acceleration, or fast cornering, will all produce more rapid tyre wear.
W eekly checks 0•15 Bulbs and fuses 4 Check all external lights and the horn. Refer to the appropriate Sections of Chap- ter 12 for details if any of the circuits are found to be inoperative. 4 Visually check all accessible wiring connectors, harnesses and retaining clips for security, and for signs of chafing or damage.
0•16 Lubricants, fluids and tyr e pressur es 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 . . . .
1 Chapter 1 Routine maintenance and servicing Air cleaner filter element renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Air conditioning system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Automatic transmission fluid level check .
1•2 Servicing Specifications Lubricants and fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to end of “ Weekly checks ” Capacities Engine oil XV and XW series engines (including filter) . . . . . . . . . . . . . .
Maintenance schedule 1•3 1 Every 250 miles (400 km) or weekly m m Refer to “Weekly checks”. Every 36 000 miles (58 000 km) or 3 years - whichever comes sooner In addition to all the items listed above, carry out the following: m m Renew the timing belt (Section 31).
1•4 Maintenance - component location Underbonnet view of a 1360 cc GT model (XY8 series engine) 1 Right-hand front engine mounting 2 Jack 3 Drivebelt 4 Oil filter 5 Bottom hose 6 Water pump 7 Thrott.
Maintenance - component location 1•5 1 Underbonnet view of a 1360 cc XS model (TU series engine) 1 Brake fluid reservoir filler cap 2 Brake master cylinder 3 Brake vacuum servo unit 4 Servo vacuum h.
1•6 Maintenance - component location Fr ont underside view of a 1360 cc GT model 1 Bottom hose 2 Reverse lamp switch 3 Engine/transmission oil drain plug 4 Radiator 5 Gear linkage 6 Clutch housing a.
Maintenance - component location 1•7 1 Rear underside view of a 1360 cc GT model 1 Exhaust front pipe 2 Handbrake cables 3 Heatshield 4 Rear suspension cross-tube 5 Brake hydraulic flexible hose 6 R.
1 Introduction This Chapter is designed to help the home mechanic maintain his/her vehicle for safety, economy, long life and peak performance. This Chapter contains a master maintenance schedule, followed by Sections dealing specifically with each task in the schedule.
4 Allow the oil to drain into the container, and check the condition of the plug’s sealing washer; renew it if worn or damaged. 5 Allow some time for the old oil to drain, noting that it may be nece.
6 Underbonnet check for fluid leaks and hose condition 1 Warning : Renewal of any air conditioning hoses (where fitted) must be left to a dealer service department or air conditioning specialist who has the equipment to depressurise the system safely.
Keep the socket aligned with the spark plug - if it is forcibly moved to one side, the ceramic insulator may be broken off. As each plug is removed, examine it as follows. 5 Examination of the spark plugs will give a good indication of the condition of the engine.
by moving the alternator by hand, or tightening the adjuster bolt. 11 Tension the drivebelt as described in the following paragraphs. Tensioning 12 If not already done, proceed as described in paragraphs 2 and 3. 13 Correct tensioning of the drivebelt will ensure that it has a long life.
2 Check the pipes and connections for evidence of leaks, severe corrosion, or damage. Make sure that all brackets and rubber mountings are in good condition, and tight; if any of the mountings are to be renewed, ensure that the replacements are of the correct type.
4 The oil level should reach the lower edge of the filler/level hole. A certain amount of oil will have gathered behind the filler/level plug, and will trickle out when it is removed; this does not necessarily indicate that the level is correct.
the inner joint and attempting to rotate the driveshaft. Any appreciable movement indicates wear in the joints, wear in the driveshaft splines, or a loose driveshaft retaining nut.
of air cleaner, the end (or top) cover is retained by a number of spring clips. 6 Extract the element (see illustration) . 7 Discard the element and wipe the casing interior clean.
Carburettor models Idle speed adjustment - single carburettor engines 3 Ensure that all electrical loads are switched off and, where applicable, the choke is pushed fully in; if the car does not have a tachometer (rev counter), connect one to the engine, following its manufacturer’s instructions.
10 With the engine idling, turn the idle speed screw on the interconnecting linkage as necessary until the engine speed is 1000 rpm. 11 Note the reading on the vacuum gage, then transfer the gauge pipe to the vacuum pipe stub on the right-hand carburettor.
Peugeot dealer, for diagnosis. On all single- point fuel injection models, the idle speed and mixture CO content is controlled by the engine management ECU and cannot be adjusted. If the idle speed and/or CO level is incorrect, there is likely to be a fault in the engine management system (see Chapter 4B).
9 Check that the clutch action is smooth and progressive, that the drive is taken up smoothly, and that the pedal travel is not excessive. Also listen for any noises when the clutch pedal is depressed. 10 Check that all gears can be engaged smoothly, without noise, and that the gear lever action is not abnormally vague or “notchy”.
7 Remove the drain plug, and allow the coolant to drain into the container. 8 If the coolant has been drained for a reason other than renewal, then provided it is clean and less than two years old, it can be re-used, though this is not recommended. 9 Refit the radiator and cylinder block drain plugs on completion of draining.
Slacken and retighten the bleed screws to allow any air that has risen to escape. Note: Take great care not to scald yourself with the hot coolant during this operation. 26 Stop the engine and allow it engine to cool, then remove the “header tank” or refit the expansion bottle/tank to its original location.
2A Chapter 2 Part A: XV , XW and XY engines in-car r epair pr ocedur es Engine general Code and displacement: XV8 (108C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 954 cc XW7 (109F) . . . . . . . . . . . .
Torque wrench settings Nm lbf ft Engine mounting nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 25 Oil pump screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5 Cylinder head bolts: Stage 1 .
bi- metal rockers consisting of an aluminium arm and steel pad, have different valve clearances than earlier engines. Ensure that the correct figures are used according to engine type. 6 If the feeler blade is a tight or loose fit then the clearance must be adjusted.
9 Remove the crankshaft oil pump drivegear and its Woodruff key. 10 Unbolt the oil pump. Some socket- headed screws are accessible through the holes in the driven gear (see illustration) . Lift off the pump and spacer plate (see illustration) . 11 Jam the camshaft sprocket and unscrew the sprocket retaining bolt.
24 Using a very thin screwdriver blade, turn the lock on the chain tensioner fully clockwise to release the slipper (see illustration) . 25 Check that the locating dowel is in position and fit the oil pump with spacer plate.
4 To dismantle the rocker arm assembly, carefully prise off the circlip from the end of the rocker shaft; retain the rocker pedestal, to prevent it being sprung off the end of the shaft. Slide the various components off the end of the shaft, keeping all components in their correct fitted order (see illustrations) .
sprocket, or fabricate a suitable alternative. If it will not be necessary to rotate the crankshaft, the home-made tool described in the text will suffice. Removal 1 Disconnect and remove the battery, as described in Chapter 5A. 2 Remove the air cleaner, complete with mounting brackets, hot air hose and inlet hose, with reference to Chapter 4A.
26 Remove the head bolts and lift off the rocker shaft assembly (see illustration) . It may be necessary to leave one or two bolts in the assembly if they foul the bulkhead due to insufficient engine height. 27 Loosen the camshaft thrust plate bolt, pull out the plate and temporarily retighten the bolt (see illustration) .
plastic or wood scraper to remove all traces of gasket and carbon; also clean the piston crowns. Refer to paragraph 32 before turning the crankshaft. Take particular care during the cleaning operations, as aluminium alloy is easily damaged.
6 Note the fitted depth of the seal as a guide to refitting the new seal, then punch or drill two small holes opposite each other in the seal. Screw a self-tapping screw into each, and pull on the screws with pliers to extract the seal.
2B Chapter 2 Part B: XU series engine in-car r epair pr ocedur es Engine general Code and displacement: XU5J (180A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1580 cc XU5JA (B6D) . . . . . . . . . . . . . .
Torque wrench settings Nm lbf ft Camshaft cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7 Camshaft bearing caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 11 Camshaft sprocket bolt (M10) .
2 Valve clearances - checking and adjustment 3 Note : The valve clearances must be checked and adjusted only when the engine is cold. 1 The importance of having the valve clearances correctly adjusted cannot be overstressed, as they vitally affect the performance of the engine.
3 Compression test - description and interpretation Refer to Part A, Section 3 but on engines with a static distributorless ignition system, disable the ignition by depressing the retaining clip and disconnecting the wiring connector from the ignition module.
13 Slacken the two nuts on the front of the timing belt tensioner and the single nut at the rear. Use a spanner on the square end of the tensioner cam spindle to turn the cam to the horizontal position and so compress the tensioner spring (see illustrations) .
is available, it should be refitted to the tensioned run of the belt. The reading should now be between 42 and 46 units. 37 If the tension is not as specified, repeat the tensioning operation.
7 Camshaft and followers - removal, inspection and refitting 4 Removal 1 Remove the camshaft sprocket as described in Section 5. Remove the rear cover plate behind the sprocket. 2 Remove the camshaft cover. For ease of access, remove the distributor cap and HT leads, air cleaner assembly and brake servo vacuum hose.
21 Fit a new camshaft oil seal, using the information given in Section 6, then refit the sprocket rear cover plate. Align the cover plate using a 10 mm dowel or drill bit then secure with the retaining bolt (see illustration) . 22 Refit the camshaft sprocket as described in Section 5.
21 If warpage of the cylinder head gasket surface is suspected, use a straight-edge to check it for distortion. Refer to Part D of this Chapter if necessary. 22 Check the condition of the cylinder head bolts, and particularly their threads, whenever they are removed.
39 Check the valve clearances and adjust, if necessary (see Section 2). 40 Refit the remaining components in the reverse order of removal and with reference to the relevant Sections and Chapters of this manual as applicable. Make sure that the correct inlet manifold gasket is fitted.
Unbolt the oil seal carrier from the cylinder block. The sprocket, spacer (where fitted) and chain can then be slid off the end of the crankshaft. 5 Slacken and remove the bolts (along with the baffle plate, where fitted) securing the strainer cover to the pump body.
Refitting 15 Refitting is a reversal of removal, but tighten the union nuts carefully to the specified torque while holding the connection stubs stationary.
2C Chapter 2 Part C: TU series engine in-car r epair pr ocedur es Engine general Code and displacement: TU9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 954 cc TU1 . . . . . . . . . . . . . . . .
Torque wrench settings Nm lbf ft Camshaft sprocket retaining bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 59 Camshaft thrust fork retaining bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 12 Crankshaft pulley retaining bolts .
2 Compression test - description and interpretation Refer to Part A, Section 3 but on engines with a static distributorless ignition system, disable the ignition by depressing the retaining clip and disconnecting the wiring connector from the ignition module.
Examine the seal for signs of damage and deterioration, and if necessary, renew it. 6 Remove the spacer from each stud, and lift off the oil baffle plate (see illustrations) . Refitting 7 Carefully clean the cylinder head and cover mating surfaces, and remove all traces of oil.
Centre cover 2 Remove the upper cover as described in paragraph 1, then free the wiring from its retaining clips on the centre cover. 3 Slacken and remove the three retaining bolts (one at the rear of.
pulley rotates freely, without any sign of roughness. If necessary, renew the tensioner pulley as described in Section 8. Make sure that the locking tools are still in place, as described in Section 3.
Removal 1 Disconnect the battery negative lead. 2 Position the engine assembly/valve timing holes as described in Section 3, and lock both the camshaft sprocket and flywheel in position. Do not attempt to rotate the engine whilst the pins are in position.
21 Loosen the tensioner pulley retaining nut. Rotate the pulley anti-clockwise to remove all free play from the timing belt, then retighten the nut. 22 Tension the belt as described in paragraphs 14 to 19 of Section 7. 23 Refit the timing belt covers as described in Section 6.
which contact the camshaft lobes for wear ridges and scoring. Renew any rocker arms on which these conditions are apparent. If a rocker arm bearing surface is badly scored, also examine the corresponding lobe on the camshaft for wear, as it is likely that both will be worn.
12 Disengage the timing belt from the camshaft sprocket, and position the belt clear of the sprocket. Ensure that the belt is not bent or twisted sharply. 13 Slacken the retaining clips, and disconnect the coolant hoses from the thermostat housing (on the left-hand end of the cylinder head).
which is fitted at the factory, and a slightly thicker “repair” gasket (+ 0.2 mm), for use once the head gasket face has been machined. If the cylinder head has been machined, it should have the l.
41 Refit the timing belt to the camshaft sprocket. Ensure that the “front run” of the belt is taut - ie, ensure that any slack is on the tensioner pulley side of the belt. Do not twist the belt sharply while refitting it, and ensure that the belt teeth are seated centrally in the sprockets.
5 Examine the pump rotors and body for signs of wear ridges and scoring. If worn, the complete pump assembly must be renewed. 6 Examine the relief valve piston for signs of wear or damage, and renew if necessary.
Renewal Right-hand mounting 5 Disconnect the battery negative lead. 6 Place a jack beneath the engine, with a block of wood on the jack head. Raise the jack until it is supporting the weight of the engine. 7 Slacken and remove the three nuts securing the right-hand engine mounting upper bracket to the bracket on the cylinder block.
2D Chapter 2 Part D: Engine r emoval and overhaul pr ocedur es Note: At the time of writing, many specifications for certain engines were not available. Where the relevant specifications are not given here, refer to your Peugeot dealer for further information.
Valve stem diameter (continued): Exhaust: XV, XW and XY series engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 mm XU5J series engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.96 mm XU5JA and XU9J series engines .
Big-end bearing journal diameter: XV, XW and XY series engines: Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.975 to 44.991 mm Undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque wrench settings (continued) Nm lbf ft Main bearing ladder casting - aluminium block engines (models with grooved No 5 main bearing half-shell fitted to cylinder block - see text): 11 mm bolts: Stage 1 . . . . . . . . . . . . . . . . . . . . . .
3 Engine/manual transmission - removal, separation, reconnection and refitting 4 Removal Note: The engine can be removed from the car only as a complete unit with the transmission; the two are then separated for overhaul. 1 Park the vehicle on firm, level ground.
twisting them anti-clockwise and disconnect the connectors. Also, where applicable, trace the harness lead(s) back to the relay box, situated beside the battery. Unclip the wiring connector plate from the front of the relay box cover, then undo the retaining nut and remove the cover.
41 Fit the sump cover to the transmission using a new gasket. 42 Tighten the tighten the cover bolts and drain plug to the specified torque. 43 Fit the protective cover plate to the sump cover. 44 Apply jointing compound to the mating surfaces on the engine and transmission.
Reconnection 11 Ensure that the bush fitted to the centre of the crankshaft is in good condition. Apply a little Molykote G1 grease (available from your Peugeot dealer) to the torque converter centring pin. Do not apply too much, otherwise there is a possibility of the grease contaminating the torque converter.
7 It is essential that each valve is stored together with its collets, retainer, spring, and spring seat. The valves should also be kept in their correct sequence, unless they are so badly worn that they are to be renewed.
lifting the valve occasionally to redistribute the grinding compound. A light spring placed under the valve head will greatly ease this operation. 22 If coarse grinding compound is being used, work on.
10 Turn the crankshaft to bring pistons 1 and 4 to BDC (bottom dead centre). 11 Unscrew the nuts from No 1 piston big- end bearing cap. Take off the cap, and recover the bottom half bearing shell (see illustration) . If the bearing shells are to be re- used, tape the cap and the shell together.
and then zero the gauge. Push the crankshaft fully the other way, and check the endfloat. The result can be compared with the specified amount, and will give an indication as to whether new thrustwashers are required. 7 If a dial gauge is not available, feeler blades can be used.
27 Before removing the crankshaft it is advisable to check the endfloat as described in paragraphs 6 and 7. 28 Unbolt and remove the crankshaft left- and right-hand oil seal housings from each end of the cylinder block, noting the correct fitted locations of the locating dowels.
When all the liners are released, tip the cylinder block/crankcase on its side and remove each liner from the top of the block. As each liner is removed, stick masking tape on its left-hand (transmission side) face, and write the cylinder number on the tape.
33 Prior to installing the liners, thoroughly clean the liner mating surfaces in the cylinder block, and use fine abrasive paper to polish away any burrs or sharp edges which might damage the liner base seals. Clean the liners and wipe dry, then fit the O-ring seals to the base of each liner.
leakage (from excessive bearing clearances, worn oil pump or high engine speeds) all contribute to lubrication breakdown. Blocked oil passages, which usually are the result of misaligned oil holes in a bearing shell, will also starve a bearing of oil, and destroy it.
XU series engines 3 On some early engines, both the upper and lower bearing shells were of the same thickness. 4 However, on later engines the main bearing running clearance was significantly reduced. To enable this to be done, four different grades of bearing shell were introduced.
10 Repeat this procedure so that the required bearing shell grade is obtained for each of the five main bearing journals. 11 Seek the advice of your Peugeot dealer on parts availability, and on the best course of action when ordering new bearing shells.
17 Repeat this procedure so that the required bearing shell grade is obtained for each of the five main bearing journals. 18 Seek the advice of your Peugeot dealer for the latest information on parts availability when ordering new bearing shells.
be fitted, obtain a set of new Black (Class B) upper bearing shells and new Blue (Class A) lower bearing shells. On later (mid-1993 on) engines where the modified bearing shells are already fitted, th.
53 Lower the crankshaft into position so that Nos 2 and 3 cylinder crankpins are at TDC; Nos 1 and 4 cylinder crankpins will be at BDC, ready for fitting No 1 piston. 54 Lubricate the lower bearing shells in the main bearing caps with clean engine oil.
72 Refit the Woodruff key, then slide on the oil pump drive sprocket, and locate the drive chain on the sprocket (see illustration) . Lower the crankshaft into position so that Nos 2 and 3 cylinder crankpins are at TDC; Nos 1 and 4 cylinder crankpins will be at BDC, ready for fitting No 1 piston.
87 Fit the main bearing caps to their correct locations, ensuring that they are fitted the correct way round (the bearing shell lug recesses in the block and caps must be on the same side). Insert the bolts loosely. 88 Tighten the main bearing cap bolts to the specified Stage 1 torque wrench setting.
crankpin and both bearing shells. Taking care not to mark the cylinder/liner bores, pull the piston/connecting rod assembly down the bore and onto the crankpin.
3 Chapter 3 Cooling, heating and air conditioning systems General System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressurised with expansi on tank/bottle and front-mounted radiator, electric cooling fan, coolant pump and thermostat Pressure cap setting .
1 General information and precautions The cooling system is of pressurised type incorporating an expansion bottle or expansion tank according to model. The system includes a front-mounted cross-flow radiator, thermoswitch controlled electric cooling fan, coolant pump and thermostat.
coolant mixtures are likely to cause damage, and encourage the formation of corrosion and scale in the system. 3 Before adding antifreeze, check all hoses and hose connections, because antifreeze tends to leak through very small openings. Engines don’t normally consume coolant, so if the level goes down, find the cause and correct it.
5 Disconnect the top mountings, as applicable, then lift the radiator, complete with cooling fan, from the car - taking care not to damage the matrix (see illustration) . The base of the radiator incorporates pins which locate in rubber mountings. 6 If necessary separate the cooling fan, with reference to Section 6.
8 Coolant pump - removal and refitting 3 Note: Refer to the warnings given in Section 1 of this Chapter before proceeding. XV, XW, and XY series engines Removal 1 Drain the cooling system and remove the auxiliary drivebelt as described in Chapter 1.
10 If the coolant pump is worn, noisy or leaks coolant it must be renewed, as repair is not possible. Refitting 11 Refitting is a reversal of removal, bearing in mind the following points: a) Thoroughly clean the mating faces and use a new gasket. c) Refit and tension the timing belt as described in Chapter 2B.
5 Unscrew the heater assembly mounting nuts and withdraw it from the car. Dismantling 6 To remove the matrix, disconnect the pipe clip and unscrew the mounting screws then slide the matrix from the casing (see illustrations) . If necessary the pipes can be removed by unscrewing the flange screws.
2 The refrigeration side of the air conditioning system functions in a similar way to a domestic refrigerator. A compressor, belt- driven from the crankshaft pulley, draws refrigerant in its gaseous phase from an evaporator. The compound refrigerant passes through a condenser where it loses heat and enters its liquid phase.
4A Chapter 4 Part A: Fuel system - carbur ettor engines General System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear-mounted fuel tank, mechanical or electric fuel pump, single or twin carburettor Carburettor Type .
Carburettor data (continued) Calibrations and settings: XY8 XY8 XU51C Solex Weber Venturi diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 mm 26 mm 28 mm Main jet . . . . . . . . . . . . . . . . . . . . . .
1 General information and precautions General information The fuel system consists of a fuel tank mounted under the rear of the car, a mechanical fuel pump, and a single or twin downdraught carburettor.
7 Release the spring clips, and lift the element and ducting from the air cleaner body (see illustrations) . 8 Disconnect the fuel pump inlet hose, and release it from the clip on the ducting. 9 Disconnect the hose from the vacuum motor (see illustration) .
9 Remove the upper body. 10 Drive out the operating arm pivot pin, withdraw the arm and lift out the diaphragm. 11 Obtain a repair kit which will contain a new diaphragm and the necessary gaskets. 12 If the valves are damaged, reassemble the pump and obtain a new one complete.
9 Carburettor - removal and refitting 2 Note: Observe the precautions in Section 1 before working on any component in the fuel system . Removal 1 Remove the air cleaner assembly, as described in Section 2. 2 Unscrew the bolts or nuts and remove the air inlet duct from the top of the carburettor(s).
Solex 32 and 34 PBISA adjustments Idle speed and mixture 16 Refer to Chapter 1. Fast idle setting 17 To adjust this accurately it will be necessary to measure the angular movement of the throttle valve. The use of a piece of card with the angle drawn on it will provide the necessary setting.
4A•8 Fuel system - carburettor engines 10.39 Checking the choke opening setting on the Weber 35 IBSH carburettor 2 Adjustment screw on vacuum capsule 10.
Choke opening setting 38 This adjustment can be made with the carburettor removed using a vacuum pump, or with the carburettor fitted and the engine running.
Throttle damper 53 Refer to the procedures contained in paragraphs 29 and 30 Additional adjustments 54 At the time of writing, not further information was available relating to any further adjustment of these carburettors. 11 Inlet manifold - removal and refitting 3 Removal 1 Disconnect the battery negative lead.
4B Chapter 4 Part B: Fuel system - single-point fuel injection engines General System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear-mounted fuel tank, electric fuel pump, single-point fuel injection system System application: TU1M/Z, TU3M/Z and TU3FM/L engines.
2 Air cleaner assembly - removal and refitting 1 Refer to the procedures in Chapter 4A, Section 2, substituting “throttle body” for all references to the carburettor.
8 Unleaded petrol - general information and usage Note: The information given in this Chapter is correct at the time of writing. If updated information is thought to be required, check with a Peugeot dealer. If travelling abroad, consult one of the motoring organisations (or a similar authority) for advice on the fuel available.
c) Before refitting the injector securing screw, apply a few drops of a suitable thread-locking compound to the threads. d) On completion, switch on the ignition and check carefully for signs of fuel leaks; if any signs of leakage are detected the problem must be rectified before the engine is started.
19 Do not attempt to adjust the throttle switch setting or that of the stop screw on the throttle valve external linkage; if the accurately matched relationship between these components is lost, the components must be replaced. At the time of writing this means renewing the entire throttle body assembly.
12 MMFD Mono-point G5 and G6 system components - removal and refitting 3 Note : Check the availability of individual components with your Peugeot dealer before dismantling . Fuel pressure regulator 1 Refer to Section 11, Paragraphs 1 to 3 noting the revised component arrangement (see illustration) .
Inlet air temperature sensor 22 The sensor is screwed into the top of the inlet manifold. 23 Disconnect the battery negative lead. 24 Release the securing clip, and disconnect the wiring plug from the sensor. 25 Unscrew the sensor and withdraw it. 26 Refitting is a reversal of removal.
4B•8 Notes.
4C Chapter 4 Part C: Fuel system - multi-point fuel injection engines General System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear-mounted fuel tank, electric fuel pump, multi-point fuel injection system System application: XU5J, XU5JA, XU5JA/K, XU51C/K, XU9JA, XU9JA/K .
Note: Residual pressure will remain in the fuel lines long after the vehicle was last used. When disconnecting any fuel line, first depressurise the fuel system as described in Section 4. 2 Air cleaner assembly - removal and refitting 1 Removal 1 Disconnect the inlet and outlet ducts.
Bosch Motronic M1.3 system The Bosch Motronic fuel injection system is designed to meet stringent emission control legislation whilst still providing excellent engine performance and fuel economy. The system is under the overall control of the Motronic M1.
23 Check the full throttle operation by connecting an ohmmeter between terminals 18 and 3, then fully opening the throttle so that dimension X is 4.0 mm (see illustration) . The internal contacts should close and the ohmmeter reading be zero. 24 If the switch does not operate correctly it should be renewed.
Coolant temperature sensor 31 Refer to Chapter 3, Section 7. Electronic control unit (ECU) 32 Refer to Part B, Section 11. Fuel injection system fuses and relays 33 Refer to Part B, Section 11.
4C•6 Notes.
4D Chapter 4 Part D: Exhaust and emission contr ol systems Air inlet heating system components - removal and refitting . . . . . . 4 Catalytic converter - general information and precautions . . . . . . . . 7 Crankcase ventilation system components - removal and refitting .
Crankcase ventilation system 7 This system is fitted to all models, and prevents the gases produced in the crankcase from being released into the atmosphere, at the same time preventing a build-up of pressure in the crankcase (see illustration) . 8 Crankcase gases are drawn into the air inlet tract, where they are mixed with clean air.
Fuel vapour recirculation system 14 This system has been introduced progressively on all fuel injection models, and prevents fuel vapour from the fuel tank from being ejected into the atmosphere (see illustration) . 15 The fuel filler cap is sealed, and the fuel vapours from the tank pass into a carbon canister, via a calibrated orifice and a pipe.
2 In many cases it will be found easier to remove the complete system from the car and then to renew individual sections on the bench. 3 To remove the complete system, raise and support the vehicle at a convenient working height (see “Jacking and vehicle support” ).
4 Air inlet heating system components - removal and refitting 2 Note : The components of the system vary slightly according to engine type. The following procedures depict one of the more common systems, but all are similar. Vacuum switch Removal 1 Remove the air cleaner housing-to- carburettor inlet duct.
3 Unscrew the clamp bolt, and lift the canister from its clamp on the body panel. Refitting 4 Refitting is a reversal of removal, but ensure that the hoses are correctly reconnected, as noted before removal.
5A Chapter 5 Part A: Starting and char ging systems System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-volt, negative earth Battery Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Never use an ohmmeter of the type incorporating a hand-cranked generator for circuit or continuity testing. Always ensure that the battery negative lead is disconnected when working on the electrical system.
3 If the alternator output is suspect even though the warning light functions correctly, the regulated voltage may be checked as follows. 4 Connect a voltmeter across the battery terminals and start the engine.
Refitting 8 Refitting is a reversal of removal, but first insert all mounting bolts finger tight, then tighten the flywheel end bolts followed by the brush end bolts. 10 Starter motor - testing and overhaul 5 If the starter motor is thought to be suspect, it should be removed from the vehicle and taken to an auto-electrician for testing.
5B Chapter 5 Part B: Ignition system System type All engines except XU5M2/Z, XU5M3/Z, XU5M3/L and TU1M/L . . . . . . Electronic breakerless ignition system XU5M2/Z, XU5M3/Z, XU5M3/L and TU1M/L engines . . . . . . . . . . . . . . Static distributorless ignition system Distributor Rotor arm rotation .
1 General information Electronic breakerless ignition system A number of different breakerless ignition systems are used on 205 models according to engine type and fuel system fitted. Some are simple self-contained systems and some work in conjunction with the fuel system to form an integrated engine management package.
plugs. Use a timing light (paragraph 4 above) to check whether HT voltage is present at all leads. 13 If HT voltage is not present on any particular lead, the fault will be in that lead or in the distributor cap. If HT is present on all leads, the fault will be in the spark plugs; check and renew them if there is any doubt about their condition.
9 Unscrew the mounting nuts, remove the small plates, and withdraw the distributor (see illustrations) . 10 Check the condition of the O-ring on the mounting flange and renew it if necessary. TU series engines 11 Remove the ignition HT coil (Section 3).
4 Depress the retaining clip and disconnect the wiring connector from the module. 5 Make a note of the correct fitted positions of the HT leads then disconnect them from the module terminals (see illustration) . 6 Undo the four retaining screws securing the module to its mounting bracket and remove it from the engine.
10 To check the vacuum advance unit, run the engine at a fast idle speed and reconnect the vacuum pipe. The flywheel mark should again advance. 11 Stop the engine, disconnect the tachometer and timing light and reconnect the vacuum pipe. Refit the timing aperture cover.
28 Connect the timing light to No 1 cylinder spark plug lead (No 1 cylinder is at the transmission end of the engine) as described in the timing light manufacturer’s instructions. 29 Start the engine, allowing it to idle at the specified speed, and point the timing light at the transmission housing aperture.
5B•8 Notes.
9 Chapter 9 Braking system System type: Footbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual-circuit hydraulic with servo assistance on all non-basic models. Anti-lock braking (ABS) optional on certain later models.
Torque wrench settings Nm lbf ft Girling front caliper mounting bolts: All models except 1.9 GTI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 72 1.9 GTI models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bleeding - basic (two-man) method 13 Collect a clean glass jar of reasonable size and a suitable length of plastic or rubber tubing, which is a tight fit over the bleed screw, and a ring spanner to fit the screws. The help of an assistant will also be required.
3 Hydraulic pipes and hoses - renewal 2 Note : Before starting work, refer to the warning at the beginning of Section 2 concerning the dangers of hydraulic fluid .
9 With the caliper pushed inwards, insert the inner pad then push the caliper outwards and insert the outer pad. If offset pads are fitted, it is important to fit these pads in the correct positions as shown (see illustration) . The inner pads with pad wear wires must be located at the top of the caliper.
18 Disconnect the wire for the pad wear warning light. 19 Hold the lower guide stationary with one spanner, then unscrew the bolt (see illustration) . 20 Swivel the caliper upwards, then withdraw the two brake pads from the caliper bracket (see illustrations) .
7 Expand the shoes over the wheel cylinder then release them from the bottom anchor. 8 Unhook the lever return spring and the handbrake cable. 9 If necessary, position a rubber band over the wheel cylinder to prevent the pistons coming out.
contact the brake pads or disc. Also refer to the warning at the start of Section 2 concerning the dangers of hydraulic fluid. 1 Chock the front wheels then jack up the rear of the car and support it on axle stands (see “Jacking and vehicle support” ).
9 Prise the seal from inside the cylinder, taking care not to damage the cylinder wall. 10 If required, dismantle the sliding guides. On the Bendix type unbolt the endplate from the guides and remove the rubber dust covers. Keep the guides identified for location.
8 Rear brake caliper (1.9 GTI models) - removal, overhaul and refitting 3 Note : Before starting work, refer to the warning at the beginning of Section 2 concerning the dangers of hydraulic fluid, and to the warning at the beginning of Section 6 concerning the dangers of asbestos dust .
Overhaul 9 Pull off the dust excluders (see illustration) . 10 Extract the pistons, seals and return spring; keeping each component identified for location. 11 Check the surfaces of the cylinder bore and pistons for scoring and corrosion and, if evident, renew the complete wheel cylinder.
Inspection 4 Brush the dust and dirt from the brake drum and carefully inspect the drum interior. 5 If the drum is grooved, owing to failure to renew worn brake shoes or after a very high mileage has been covered, then it may be possible to regrind it, provided the maximum internal diameter is not exceeded.
Refitting 6 Refitting is a reversal of removal, but note that the nose of the unit must face forwards and be inclined upwards at an angle of 22° to the horizontal. Provided that the mounting bracket is undamaged, this angle will automatically be achieved.
15 Handbrake - adjustment 2 All models except 1.9 GTI 1 The handbrake is normally kept adjusted by the action of the automatic adjusters on the rear brake shoes. However, in due course, the cables will stretch and will have to be adjusted in order to fully apply the handbrake.
2 Remove the clevis pin and disconnect the pushrod from the brake pedal. Note that on models with a vacuum servo unit the pushrod is on the lower hole, whereas the upper hole is used for models without a servo unit. 3 Unscrew the self-locking nut from the pivot bolt, pull out the bolt and lower the brake pedal.
9• 16 Notes.
10 Chapter 10 Suspension and steering Front suspension Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Independent, MacPherson struts, coil springs, anti-roll bar Rear suspension Type . . . .
Torque wrench settings Nm lbf ft Front suspension Driveshaft/hub nut: Non-GTI models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 185 GTI models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 If the hub nut has yet to be loosened, fabricate a tool from two lengths of steel strip (one long, one short) and a nut and bolt; the nut and bolt form the pivot of a forked tool. Bolt the tool to the hub flange using two wheel bolts, and hold the tool to prevent the hub from rotating (see Chapter 8, Section 2).
the front suspension tower and engaged with further holes in the bottom coil spring seat. If available use these, otherwise fit universal coil spring compressors (see illustration) . Do not attempt to use any makeshift tool, as considerable damage could occur if the spring breaks free.
2 On non-GTI models, unscrew the nut securing the anti-roll bar to the suspension arm and remove the washer (see illustration) . 3 Unscrew the clamp bolt securing the front suspension lower balljoint to the bottom of the hub carrier then pull the lower suspension arm down from the carrier.
7 The guide bar length must be adjusted to the dimension shown when refitting (see illustration) . Note that a full-circle clamp is fitted to early models with a 6.0 mm diameter anti-roll bar, whereas a split clamp is fitted to later models with a 7.0 mm diameter bar.
mounting in a vice and attempting to extend and retract it. If the resistance is not firm and even in both directions, or if there are signs of leakage or damage, the shock absorber must be renewed. Refitting 6 Refitting is a reversal of removal, but renew the self-locking nuts.
7 If necessary, the intermediate shaft can be removed after prising out the grommet and unscrewing the bottom clamp bolt (see illustration) . 8 To remove the steering lock, unscrew the retaining bolt .
engagement rods, and support them in an upright position out of the way, using wire or string. 14 Remove the two steering gear securing bolts, and recover the spacer tubes from the subframe, then disconnect the steering gear pinion from the steering column shaft.
3 With the engine stopped, slowly move the steering from lock-to-lock several times to purge out the trapped air, then top-up the level in the fluid reservoir.
21 Wheel alignment and steering angles - general information 1 A car’s steering and suspension geometry is defined in four basic settings - all angles are expressed in degrees (toe settings are also expressed as a measurement); the relevant settings are camber, castor, steering axis inclination, and toe-setting.
10•12 Notes.
11 Chapter 11 Bodywork and fittings Bodywork, paint and exterior trim check . . . . . . . . . . . .See Chapter 1 Bonnet - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Bonnet lock and remote control cable - removal, refitting and adjustment .
not available, there are one or two excellent grease solvents available which can be brush applied; the dirt can then be simply hosed off. Note that these methods should not be used on vehicles with wax-based underbody protective coating or the coating will be removed.
Aluminium tape should be used for small or very narrow holes. Pull a piece off the roll and trim it to the approximate size and shape required, then pull off the backing paper (if used) and stick the tape over the hole; it can be overlapped if the thickness of one piece is insufficient.
4 While an assistant supports the bonnet, unscrew the nut and remove the bottom of the stay from the right-hand suspension tower. 5 Place some cloth beneath the rear corners of the bonnet, unscrew the hinge bolts and withdraw it from the car.
Bodywork and fittings 11•5 11 9.2 Front bumper components 1 Side mounting (non-GTI) 2 Side mounting (GTI) 3 Side bracket (non-GTI) 4 Bracket 5 Side bracket (GTI) 6 Seal clip 7 Seal 8 Bumper 9 Moulding 10 Mounting plate 11 Headlight washer bracket 9.
11 Door trim panel - removal and refitting 3 Removal Front doors 1 If electric windows are fitted, disconnect the battery negative lead. 2 Remove the two screws and withdraw the armrest (see illustration) . 3 Remove the screws and withdraw the side pocket (see illustration) .
Exterior mirror (early models) 6 To remove the early type mirror, prise off the inner cover and use an Allen key to remove the mounting screws (see illustrations) . Exterior mirror (later models) 7 To remove the later type mirror, carefully prise the trim cover from the interior mirror control lever (see illustration) .
14 Hood and rear window (Cabriolet models) - removal and refitting 4 Removal 1 Open the hood to the point where it is in balance. 2 Working inside the vehicle, prise off the trim caps, and unscrew the hinge cover securing screws (see illustration) . 3 Working outside the vehicle, unscrew the brackets and securing bolts (see illustration) .
15 Power-operated hood components (Cabriolet models) - general information Whenever any work is carried out which involves disconnecting the hood hydraulic fluid pipes, the hydraulic fluid circuit must be bled.
7 Unscrew the five bolts securing the regulator mechanism. 8 Remove the casing from the hood hinge. 9 Remove the pad from the quarter glass lower channel. 10 Push in the regulator mechanism, then tilt it and withdraw it through the aperture, complete with the cable (see illustration) .
24 Sunroof glass - removal and refitting 3 Removal 1 Working inside the car, remove the roof console. Then remove the screws from the sunroof handle and latch. 2 From outside the car, remove the front cover and the corner screws. 3 Slide off the side covers to the rear, while exerting outward pressure.
13 With the bonnet open, remove the plastic grille and unscrew the front facia mounting nuts (see illustration) . 14 Withdraw the facia panel at the same time disconnecting the relevant switches and cigar lighter. Reconnect the switch wiring immediately to ensure correct refitting.
32 Prise the small tray from the centre console (see illustration) . 33 Remove the screws, and slide the surround up the gear lever (see illustration) . 34 Remove the upper and lower nuts, and withdraw the centre console (see illustrations) . 35 Unclip the felt cover from under the facia.
11•14 Notes.
12 Chapter 12 Body electrical system General System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-volt negative earth Fuses (early models) No Circuit protected Rating (amp) 1 Reverse light, cooling fan relay, tachometer (GTI) .
Fuses (1986 to 1988 GTI and CTI models) No Circuit protected Rating (amp) 1 Reversing lights, tachometer . . . . . . . . . . . . . . . . . . . . . . . .
Fuses (1989 to 1991 - all models) No Circuit protected Rating (amp) 1 Reversing lights, tachometer, fuel gauge, warning lights (low battery charge, coolant temperature, oil pressure, low coolant level, brake system, choke). . . . . . . . . . . . . . .
12•4 Body electrical system 1 General information and precautions General information The electrical system is of 12-volt negative earth type. Power for the lights and all electrical accessories is supplied by a lead/acid battery which is charged by the alternator.
22 If an earth connection is thought to be faulty, dismantle the connection, and clean both the bodyshell and the wire terminal (or the component earth connection mating surface) back to bare metal. Be careful to remove all traces of dirt and corrosion, then use a knife to trim away any paint, so that a clean metal-to-metal joint is made.
Facia switches (1988 models onward) 10 Disconnect the battery negative lead. 11 Open the ashtray. 12 Unclip the bottom of the clock surround (where fitted) and remove it.
36 Unscrew the locknut nearest the pedal, and withdraw the switch from the bracket. 37 Refitting is a reversal of removal, but adjust the locknuts so that the distance between the end of the switch threaded body and the pedal (fully released) is 3.5 mm.
12•8 Body electrical system 5.7a Exploded diagram of non-GTI instrument panel 5.7b Exploded diagram of GTI instrument panel.
13 Remove the screws and withdraw the centre vents. 14 Using a screwdriver through the steering column lower shroud, unscrew the visor locating studs. 15 Remove the side screw, then lift away the visor. 16 Remove the mounting screws from each side of the instrument panel (see illustration) .
7 Release the spring clips and withdraw the bulb (see illustrations) . 8 Fit the new bulb with the locating tab uppermost. Front parking lights 9 Pull the bulbholder from the rear of the headlight then depress and twist the bulb to remove it (see illustration) .
21 Depress and twist the bulb to remove it (see illustration) . Number plate light 22 Twist off the lens (see illustration) . 23 Depress and twist the bulb to remove it (see illustration) .
Heater control panel illumination bulbs (pre-1988 models) 12 Remove the facia centre air vents, with reference to Chapter 11. 13 Pull the bulbholder from the rear of the panel and extract the bulb (see illustration) . Heater control panel illumination bulbs (1988 models onward) 14 Disconnect the battery negative lead.
When the ignition is switched on with the sidelights also switched on, the relay is energised, closing the internal contacts and supplying current to the dipped beam circuit via the resistor. This causes the dip filaments in the headlights to be illuminated at one-sixth dipped beam brightness.
the wheel arch. The reservoir supplies both the windscreen and tailgate jets. On some models a headlight washer system is installed with the reservoir in the right-hand front corner of the engine compartment. The washer jets are adjustable by inserting a pin into their nozzles and moving them to give an acceptable pattern on the glass.
Wiring diagrams 12•15 12 Key to wiring diagrams.
12•16 Wiring diagrams Key to wiring diagrams (continued).
Wiring diagrams 12•17 12 Diagram1: Typical starting, charging, ignition, cooling fan, warning lamps and gauges (XV8, XW7, XY8 and XU51C engine models).
12•18 Wiring diagrams Diagram1a: Typical starting, charging, ignition, cooling fan, warning lamps and gauges (TU1, TU3 and TU9 engine models).
Wiring diagrams 12•19 12 Diagram1b: Typical engine management, warning lamps and gauges (XU5J/JA and XU9JA engine models).
12•20 Wiring diagrams Diagram 2: Typical exterior lighting - reversing lamps, foglamps, sidelamps and headlamps.
Wiring diagrams 12•21 12 Diagram 2a: Typical exterior lighting - direction indicators and stop-lamps; typical interior lighting and associated circuits.
12•22 Wiring diagrams Diagram 3: Typical ancillary circuits - wash/wipe, horn, heater blower and heated rear window.
Wiring diagrams 12•23 12 Diagram 3a: Typical ancillary circuits - electric windows, central locking and radio/cassette.
12•24 Wiring diagrams Supplementary diagram A: Typical engine management (TU3M/Z and TU3FM/L engine models).
Wiring diagrams 12•25 12 Supplementary diagram B: Typical engine management (TU1M/L and XU5M3/Z/L engine models).
12•26 Wiring diagrams Supplementary diagram C: Typical engine management (XU9J1/Z/L engine models).
Wiring diagrams 12•27 12 Supplementary diagram D: Typical engine management (XU9JA/L engine models).
REF Dimensions and weights Note: All figures are approximate, and may vary according to model. Refer to manufacturer’s data for exact figures. Dimensions Overall length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REF•2 Conversion factors Length (distance) Inches (in) x 25.4 = Millimetres (mm) x 0.0394 = Inches (in) Feet (ft) x 0.305 = Metres (m) x 3.281 = Feet (ft) Miles x 1.609 = Kilometres (km) x 0.621 = Miles V olume (capacity) Cubic inches (cu in; in 3 ) x 16.
Buying spare parts Spare parts are available from many sources, including maker’s appointed garages, accessory shops, and motor factors. To be sure of obtaining the correct parts, it will sometimes be necessary to quote the vehicle identification number.
REF•4 General r epair pr ocedur es Whenever servicing, repair or overhaul work is carried out on the car or its components, observe the following procedur es and instructions. This will assist in carrying out the operation efficiently and to a pr ofessional standar d of workmanship.
The jack supplied with the vehicle tool kit should only be used for changing the roadwheels - see “Wheel changing” at the front of this manual. When carrying out any other kind of work, raise the vehicle using a hydraulic (or “trolley”) jack, and always supplement the jack with axle stands.
REF•6 T ools and working facilities Introduction A selection of good tools is a fundamental requirement for anyone contemplating the maintenance and repair of a motor vehicle. For the owner who does not possess any, their purchase will prove a considerable expense, offsetting some of the savings made by doing-it-yourself.
T ools and working facilities REF•7 REF Special tools The tools in this list are those which are not used regularly, are expensive to buy, or which need to be used in accordance with their manufacturers’ instructions. Unless relatively difficult mechanical jobs are undertaken frequently, it will not be economic to buy many of these tools.
REF•8 MOT test checks This is a guide to getting your vehicle through the MOT test. Obviously it will not be possible to examine the vehicle to the same standar d as the pr ofessional MOT tester . However , working through the following checks will enable you to identify any problem ar eas befor e submitting the vehicle for the test.
MOT test checks REF•9 REF Seat belts and seats Note: The following checks are applicable to all seat belts, front and rear . M Examine the webbing of all the belts (including rear belts if fitted) for cuts, serious fraying or deterioration. Fasten and unfasten each belt to check the buckles.
REF•10 MOT test checks Exhaust system M Start the engine. With your assistant holding a rag over the tailpipe, check the entir e system for leaks. Repair or renew leaking sections. Jack up the front and rear of the vehicle, and securely support it on axle stands.
MOT test checks REF•11 REF M Examine the handbrake mechanism, checking for frayed or broken cables, excessive corrosion, or wear or insecurity of the linkage. Check that the mechanism works on each relevant wheel, and r eleases fully , without binding.
The vehicle owner who does his or her own maintenance according to the recommended service schedules should not have to use this section of the manual very often. Modern component reliability is such that, provided those items subject to wear or deterioration are inspected or renewed at the specified intervals, sudden failure is comparatively rare.
failure of components such as fuses or spark plugs may only be pointers to some underlying fault. The pages which follow provide an easy- reference guide to the more common problems which may occur during the operation of the vehicle.
REF•14 Fault finding Engine (continued) Engine misfires throughout the driving speed range m m Fuel filter choked - fuel-injected models (Chapter 1). m m Fuel pump faulty, or delivery pressure low (Chapter 4A, 4B or 4C). m m Fuel tank vent blocked, or fuel pipes restricted (Chapter 4A, 4B or 4C).
Fault finding REF•15 REF 2 Cooling system 3 Fuel and exhaust systems Overheating m m Insufficient coolant in system ( “Weekly checks” ). m m Thermostat faulty (Chapter 3). m m Radiator core blocked, or grille restricted (Chapter 3). m m Electric cooling fan or thermoswitch faulty (Chapter 3).
REF•16 Fault finding 7 Driveshafts Clicking or knocking noise on turns (at slow speed on full-lock) m m Lack of constant velocity joint lubricant, possibly due to damaged bellows (Chapter 8). m m Worn outer constant velocity joint (Chapter 8). Vibration when accelerating or decelerating m m Worn inner constant velocity joint (Chapter 8).
Fault finding REF•17 REF 9 Suspension and steering Note: Before diagnosing suspension or steering faults, be sure that the trouble is not due to incorrect tyre pressures, mixtures of tyre types, or binding brakes. Vehicle pulls to one side m m Defective tyre ( “Weekly checks” ).
REF•18 Fault finding 10 Electrical system Note: For problems associated with the starting system, refer to the faults listed under “Engine” earlier in this Section. Battery will not hold a charge for more than a few days m m Battery defective internally (Chapter 5A).
Windscreen/tailgate wipers inoperative, or unsatisfactory in operation Wipers fail to operate, or operate very slowly m m Wiper blades stuck to screen, or linkage seized or binding ( “Weekly checks” and Chapter 12). m m Blown fuse (Chapter 12). m m Cable or cable connections loose, broken or disconnected (Chapter 12).
REF•20 Glossary of technical terms A ABS (Anti-lock brake system) A system, usually electronically contr olled, that senses incipient wheel lockup during braking and r elieves hydraulic pr essure at wheels that are about to skid. Air bag An inflatable bag hidden in the steering wheel (driver’ s side) or the dash or glovebox (passenger side).
Glossary of technical terms REF•21 REF Camshaft A rotating shaft on which a series of cam lobes operate the valve mechanisms. The camshaft may be driven by gears, by spr ockets and chain or by spr ockets and a belt.
REF•22 Glossary of technical terms E EGR valve A valve used to introduce exhaust gases into the intake air stream. Electr onic contr ol unit (ECU) A computer which controls (for instance) ignition and fuel injection systems, or an anti-lock braking system.
Glossary of technical terms REF•23 REF J Jump start Starting the engine of a vehicle with a discharged or weak battery by attaching jump leads from the weak battery to a charged or helper battery .
REF•24 Glossary of technical terms automatic transmission, a switch that pr events starting if the vehicle is not in Neutral or Park. Strut See MacPherson strut. T T appet A cylindrical component which transmits motion from the cam to the valve stem, either directly or via a pushr od and r ocker arm.
Index REF•25 REF Note : References throughout this index are in the form - “Chapter number” • “page number” A Accelerator cable - 1•11, 4A•4, 4B•2, 4C•2 Acknowledgements - 0•4 Ai.
D Dents - 11•2 Dim-dip lighting system - 12•12 Dimensions and weights - REF•1 Distributor - 5B•3 Door - 11•5, 11•6, 11•7 Door trim panel - 11•6 Drivebelt - 1•11 Driveshafts - 8•1 e.
G Gearbox oil (manual) - 0•16, 1•13, 7A•2 Gearbox oil (automatic) - 0•16, 1•9, 1•14 Gearchange linkage manual transmission - 7A•4 Glass - 11•9 Glossary of technical terms - REF•20 Gl.
R Radiator - 3•3 Radiator cooling fan - 3•4 Radio - 12•14 Radio/cassette anti-theft system - REF•5 Relays - 12•5 Repair procedures - REF•4 Respraying paintwork - 11•3 Reversing light swi.
REF•29 REF Notes.
Left blank for manual listing pages.
REF Left blank for manual listing pages.
Almost ever y car you’ve ever loved, loathed or desired is gathered under one roof at the Haynes Motor Museum. Over 300 immaculately presented cars and motorbikes represent ever y aspect of our motoring heritage, from elegant reminders of bygone days, such as the superb Model J Duesenberg to curiosities like the bug-eyed BMW Isetta.
デバイスPeugeot 205の購入後に（又は購入する前であっても）重要なポイントは、説明書をよく読むことです。その単純な理由はいくつかあります：
Peugeot 205をまだ購入していないなら、この製品の基本情報を理解する良い機会です。まずは上にある説明書の最初のページをご覧ください。そこにはPeugeot 205の技術情報の概要が記載されているはずです。デバイスがあなたのニーズを満たすかどうかは、ここで確認しましょう。Peugeot 205の取扱説明書の次のページをよく読むことにより、製品の全機能やその取り扱いに関する情報を知ることができます。Peugeot 205で得られた情報は、きっとあなたの購入の決断を手助けしてくれることでしょう。
Peugeot 205を既にお持ちだが、まだ読んでいない場合は、上記の理由によりそれを行うべきです。そうすることにより機能を適切に使用しているか、又はPeugeot 205の不適切な取り扱いによりその寿命を短くする危険を犯していないかどうかを知ることができます。
ですが、ユーザガイドが果たす重要な役割の一つは、Peugeot 205に関する問題の解決を支援することです。そこにはほとんどの場合、トラブルシューティング、すなわちPeugeot 205デバイスで最もよく起こりうる故障・不良とそれらの対処法についてのアドバイスを見つけることができるはずです。たとえ問題を解決できなかった場合でも、説明書にはカスタマー・サービスセンター又は最寄りのサービスセンターへの問い合わせ先等、次の対処法についての指示があるはずです。
