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PEUGEOT 205 Cabriolet, Manual

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1

Chapter 1
Routine maintenance and servicing

Air cleaner filter element renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Air conditioning system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Automatic transmission fluid level check  . . . . . . . . . . . . . . . . . . . . . 5
Automatic transmission fluid renewal  . . . . . . . . . . . . . . . . . . . . . . . . 23
Auxiliary drivebelt check and renewal  . . . . . . . . . . . . . . . . . . . . . . . . 9
Bodywork, paint and exterior trim check . . . . . . . . . . . . . . . . . . . . . . 18
Brake fluid renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Clutch pedal stroke adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Coolant renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Driveshaft bellows check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Engine oil and filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Exhaust system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Emissions control systems check  . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Front brake pad check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel filter renewal - fuel injection models  . . . . . . . . . . . . . . . . . . . . . 32
Handbrake check and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Headlight beam alignment check   . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Idle speed and mixture check and adjustment  . . . . . . . . . . . . . . . . . 28
Ignition system check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Intensive maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Introduction  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Lock and hinge check and lubrication . . . . . . . . . . . . . . . . . . . . . . . . 12
Manual transmission oil level check  . . . . . . . . . . . . . . . . . . . . . . . . . 21
Manual transmission oil renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Rear brake pad condition check - models with rear disc brakes  . . . 14
Rear brake shoe check - models with rear drum brakes  . . . . . . . . . 13
Road test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Seat belt check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Spark plug renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Steering and suspension check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Throttle and choke cable lubrication and adjustment  . . . . . . . . . . . . 8
Timing belt renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Underbody and fuel/brake line check  . . . . . . . . . . . . . . . . . . . . . . . . 16
Underbonnet check for fluid leaks and hose condition  . . . . . . . . . . . 6

1•1

Contents

Easy, suitable for
novice with little
experience

Fairly easy, suitable
for beginner with
some experience

Fairly difficult,
suitable for competent
DIY mechanic

Difficult, suitable for
experienced  DIY
mechanic

Very difficult,
suitable for expert DIY
or  professional

Degrees of difficulty

5

4

3

2

1

Summary of Contents for 205 Cabriolet

Page 1: ... 28 Ignition system check 27 Intensive maintenance 2 Introduction 1 Lock and hinge check and lubrication 12 Manual transmission oil level check 21 Manual transmission oil renewal 22 Rear brake pad condition check models with rear disc brakes 14 Rear brake shoe check models with rear drum brakes 13 Road test 30 Seat belt check 11 Spark plug renewal 7 Steering and suspension check 25 Throttle and ch...

Page 2: ...1 Fuel injection engines Champion W175 Fuel filter Champion L205 Idle speed and mixture CO content Refer to Chapter 4A 4B and 4C Specifications Ignition system Spark plugs XV8 XW7 and XY7 engines Champion RS9YCC or S281YC XY8 and XU5J engines Champion S7YCC or S279YC XU51C engines up to 1988 Champion S9YCC or S281YC XU51C engines from 1988 Champion RC9YCC or C9YCX XU5JA engines up to 1988 Champion...

Page 3: ...ion 14 m m Check the operation of the handbrake Section 15 m m Inspect the underbody and the brake hydraulic pipes and hoses Section 16 m m Check the condition of the fuel lines Section 16 m m Check the condition and security of the exhaust system Section 17 m m Check the condition of the exterior trim and paintwork Section 18 m m Check the headlight beam alignment Section 19 m m Check the operati...

Page 4: ... 12 Choke cable 13 Heater hose 14 Oil filler cap crankcase ventilation filter 15 Windscreen wiper arm 16 Hydraulic brake lines 17 Cooling fan motor resistor 18 Front suspension shock absorber top mounting nut 19 Ignition coil cover 20 Distributor 21 Bottom hose 22 Clutch release fork 23 Clutch housing 24 Washer reservoir 25 Battery 26 Ignition timing aperture 27 Diagnostic socket 28 Radiator fille...

Page 5: ...Cooling system bleed screw 6 Air cleaner cover 7 Fuel pump 8 Cooling system expansion bottle 9 Fuel filter 10 Washer fluid reservoir 11 Battery 12 Air temperature control unit 13 Auxiliary fusebox 14 Radiator filler cap 15 Ignition coil 16 Bonnet lock 17 Engine oil filler cap 18 Exhaust manifold hot air shroud 19 Alternator 20 Engine oil level dipstick 21 Inlet manifold 22 Right hand engine mounti...

Page 6: ...e transmission oil drain plug 4 Radiator 5 Gear linkage 6 Clutch housing and transfer gear assembly 7 Washer reservoir 8 Disc caliper 9 Lower suspension arm 10 Anti roll bar 11 Track rod 12 Guide bar 13 Exhaust front pipe 14 Fuel feed and return pipes 15 Hydraulic brake lines 16 Subframe 17 Driveshaft 18 Front towing eye ...

Page 7: ... 1 Exhaust front pipe 2 Handbrake cables 3 Heatshield 4 Rear suspension cross tube 5 Brake hydraulic flexible hose 6 Rear shock absorber 7 Trailing arm 8 Side member 9 Exhaust rubber mounting 10 Exhaust rear silencer 11 Spare wheel 12 Rear towing eye 13 Torsion bars 14 Fuel tank ...

Page 8: ...series of operations are those often required to improve the performance of a generally poor running engine Primary operations a Clean inspect and test the battery See Weekly checks b Check all the engine related fluids See Weekly checks c Check the condition of the auxiliary drivebelt Section 9 d Inspect the distributor cap rotor arm and HT leads Section 27 e Renew the spark plugs Section 7 f Che...

Page 9: ... oil circulated and the filter completely full recheck the level on the dipstick and add more oil as necessary 14 Dispose of the used engine oil safely with reference to General repair procedures in the preliminary Sections of this manual 4 Front brake pad check 1 1 Jack up the front of the vehicle and support it on axle stands see Jacking and vehicle support 2 For better access to the brake calip...

Page 10: ... and fittings listening for the hissing sound characteristic of a vacuum leak Warning When probing with the vacuum hose stethoscope be very careful not to come into contact with moving engine components such as the auxiliary drivebelt radiator electric cooling fan etc Fuel hoses Warning Before carrying out the following operation refer to the precautions given in Safety first at the beginning of t...

Page 11: ...osed ends of the choke cable where fitted 3 Check that there is a small amount of slackness in the cable so that the throttle linkage closes fully with the accelerator pedal released Also check that full throttle can be obtained with the accelerator pedal fully depressed 4 If there is any doubt about the cable adjustment refer to the relevant Parts of Chapter 4 for the full adjustment procedure 9 ...

Page 12: ...ittle oil or grease 3 If any of the doors bonnet or tailgate boot lid do not close effectively or appear not to be flush with the surrounding panels carry out the relevant adjustment procedures contained in Chapter 11 13 Rear brake shoe check models with rear drum brakes 3 Remove the rear brake drums and check the brake shoes for signs of wear or contamination At the same time also inspect the whe...

Page 13: ...or leaks renew the hose s c Inspect the condenser fins for leaves insects and other debris Use a fin comb or compressed air to clean the condenser Warning Wear eye protection when using compressed air d Check that the drain tube from the front of the evaporator is clear note that it is normal to have clear fluid water dripping from this while the system is in operation to the extent that quite a l...

Page 14: ... housing see illustration Warning If the fluid is hot take precautions against scalding 4 Unscrew both drain plugs and allow the fluid to drain completely into the container Clean the drain plugs being especially careful to wipe any metallic particles off the magnetic insert Discard the original sealing washers these should be renewed whenever they are disturbed 5 When the fluid has finished drain...

Page 15: ...tween the relevant suspension component and its attachment point Some movement is to be expected as the mountings are made of rubber but excessive wear should be obvious Also check the condition of any visible rubber bushes looking for splits cracks or contamination of the rubber 8 With the vehicle standing on its wheels have an assistant turn the steering wheel back and forth about an eighth of a...

Page 16: ... pressure and making good contact with the rotor arm Also inspect the cap seal for signs of wear or damage and renew if necessary Remove the rotor arm from the distributor shaft and inspect the rotor arm see illustration It is common practice to renew the cap and rotor arm whenever new spark plug HT leads are fitted When fitting a new cap remove the leads from the old cap one at a time and fit the...

Page 17: ...ough both is the same before adjusting the idling speed To do this a vacuum gauge or carburettor synchronising tool will be required 7 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 Note the idle speed and compare it with that sp...

Page 18: ...his is not available the car must be taken to a Peugeot dealer for the work to be carried out 17 If an exhaust gas analyser is available follow its manufacturer s instructions to check the exhaust gas CO level If adjustment is required it is made by turning the mixture adjustment screw as necessary As with the idle speed screw the mixture adjusting screw is situated in various locations according ...

Page 19: ...s required prise out the tamperproof cap on the airflow sensor and use an Allen key to adjust the mixture see illustration Turn the screw in to richen the mixture and out to weaken it 25 Blip the throttle two or three times and then recheck that the idle speed and mixture is correct 26 When adjustments are complete disconnect the test equipment and fit a new tamperproof plug to the mixture adjustm...

Page 20: ...ise the fuel system see Chapter 4B or 4C 2 To renew the fuel filter first disconnect the fuel hose or unscrew the union bolt from the top of the unit then place the bolt union and washers to one side and cover to prevent ingress of dirt see illustration Unscrew the clamp bolt then lift the filter and unscrew the bottom union Dispose safely of the old filter it will be highly inflammable and may ex...

Page 21: ...ake sure that all hoses and clips are in good condition and that the clips are tight Note that an antifreeze mixture must be used all year round to prevent corrosion of the engine components see following sub Section Also check that the radiator and cylinder block drain plugs are in place and tight 21 Remove the expansion tank filler cap 22 Open all the cooling system bleed screws see paragraph 4 ...

Page 22: ...tion of antifreeze 32 Do not use engine antifreeze in the windscreen tailgate washer system as it will cause damage to the vehicle paintwork A screenwash additive should be added to the washer system in the quantities stated by the makers 34 Brake fluid renewal 2 Warning Brake hydraulic fluid can harm your eyes and damage painted surfaces so use extreme caution when handling and pouring it Do not ...

Page 23: ...dy clearance 0 064 mm Auxiliary drivebelt check and renewal See Chapter 1 Camshaft and rocker arms removal inspection and refitting 6 Compression test description and interpretation 3 Crankshaft oil seals renewal 8 Cylinder head removal and refitting 7 Engine transmission mountings inspection and renewal 10 Engine oil and filter renewal See Chapter 1 Engine oil level check See Weekly checks Flywhe...

Page 24: ...valve The pump is driven by gears from the crankshaft Oil from the pump passes via an oilway to the oil filter and thence to the crankshaft main bearings connecting rod bearings and transmission components Another oilway from the filter delivers oil to the overhead camshaft and rocker components Oil from the cylinder head passes to the transfer gear housing and then back to the sump contained with...

Page 25: ...r a blown head gasket a cracked head could also be the cause Deposits on the undersides of the valve heads can also cause low compression 8 Although Peugeot do not specify exact compression pressures as a guide any cylinder pressure of below 10 bars can be considered as less than healthy Refer to a Peugeot dealer or other specialist if in doubt as to whether a particular pressure reading is accept...

Page 26: ...ld in position by two bolts If the tensioner is removed note the fine mesh filter screen located behind the tensioner body Ensure that it is clean and in place when refitting the tensioner 18 Inspect the oil pump drive gears for wear or damage and renew if necessary Always fit a new timing cover oil seal see Section 8 Refitting 19 Check that the crankshaft is positioned correctly by observing the ...

Page 27: ...d gear teeth must be rectified by renewal of the gear 5 Check the endfloat of the gears using a straight edge and feeler blades see illustration 6 Check the clearance between the tip of the gear lobes and the oil pump body see illustration 7 If any of these clearances exceed the specified limit renew the pump 8 Remove the retaining pin from the relief valve housing and withdraw the cup spring guid...

Page 28: ...t bearing surfaces and cam lobes for signs of wear ridges and scoring Renew the camshaft if any of these conditions are apparent Examine the condition of the bearing surfaces both on the camshaft journals and in the cylinder head If the head bearing surfaces are worn excessively the cylinder head will need to be renewed If the necessary measuring equipment is available camshaft bearing journal wea...

Page 29: ...screw and remove the two bolts securing the right hand rear engine mounting to the subframe see illustration 18 Using a suitable long bar inserted through the right hand rear engine mounting bracket lever up the rear of the engine as far as possible without damaging the radiator and support with a block of wood see illustration If necessary loosen the left hand engine mounting to gain extra height...

Page 30: ... Remove the four timing cover to cylinder head bolts then move the flywheel end of the cylinder head sideways slightly to release the gasket 32 Lift the cylinder head from the block and remove the gasket without disturbing the liners Do not turn the engine over as this also will break the liner bottom seals If further work is to be carried out on the engine such as cleaning the tops of the cylinde...

Page 31: ...ng bolt and tighten it with an Allen key while holding the sprocket with a bar through one of the holes resting on packing pieces 48 Apply a silicone sealing compound to the access plate then refit it and tighten the bolts 49 Refit the rocker shaft assembly with the two location pegs towards the front 50 Insert the head bolts threads and heads oiled and tighten them in two stages to the specified ...

Page 32: ...se damaged the flywheel must be renewed However it may be possible to have it surface ground seek the advice of a Peugeot dealer or engine reconditioning specialist 4 If the ring gear is badly worn or has missing teeth it must be renewed This job is best left to a Peugeot dealer or engine reconditioning specialist The temperature to which the new ring gear must be heated for installation is critic...

Page 33: ... pressure warning light switch operating pressure 0 44 to 0 58 bar Auxiliary drivebelt check and renewal See Chapter 1 Camshaft and followers removal inspection and refitting 7 Camshaft oil seal renewal 6 Compression test description and interpretation 3 Crankshaft oil seals renewal 12 Cylinder head removal and refitting 8 Engine oil and filter renewal See Chapter 1 Engine transmission mountings i...

Page 34: ...ft hand end of the engine The final drive unit is integral with the transmission and transmits drive to the front wheels via driveshafts The engine has four wet liner cylinders a five bearing crankshaft and an overhead camshaft The connecting rods rotate on horizontally split bearing shells at their big ends The pistons are attached to the connecting rods by gudgeon pins The gudgeon pins are an in...

Page 35: ...t the timing belt end on certain engines Adjustment 11 To adjust the clearances remove the camshaft as described in Section 7 12 Lift off a cam follower and its shim Be careful that the shim does not fall out of the follower Clean the shim and measure its thickness with a micrometer see illustrations 13 Refer to the clearance recorded for the valve concerned If the clearance was larger than specif...

Page 36: ...shaft sprocket 8 Remove the plastic covers from the front of the timing belt Note the location of the various bolts 9 Observe the timing belt tensioner assembly and ascertain whether it is of the spring loaded type or the later eccentric roller type see illustration Proceed as follows under the appropriate sub heading according to type fitted Models with spring loaded tensioner 10 Turn the cranksh...

Page 37: ...crankshaft through two full turns in the normal direction of rotation Turn the crankshaft further to bring No 1 piston to TDC on the firing stroke 23 Slacken the tensioner front nuts and the cam locknut then retighten them 24 Turn the crankshaft further and make sure that the timing dowels can still be inserted If not remove the drivebelt and start again 25 If a new belt has been fitted it must be...

Page 38: ...e the sprocket on the end of the camshaft ensuring that the locating peg is correctly engaged with the cut out in the camshaft end 14 Refit the sprocket retaining bolt and washer and tighten it to the specified torque Retain the sprocket with the tool used on removal Note that on early models the sprocket is secured with an M12 bolt whereas this has been reduced to M10 on later engines Ensure that...

Page 39: ...ft journals and in the cylinder head bearing caps If the head bearing surfaces are worn excessively the cylinder head will need to be renewed 12 Examine the cam follower bearing surfaces which contact the camshaft lobes for wear ridges and scoring Renew any follower on which these conditions are apparent If a follower bearing surface is badly scored also examine the corresponding lobe on the camsh...

Page 40: ...there is also a possibility of the bottom seals being disturbed causing leakage after refitting the head 15 To break the joint obtain two L shaped metal bars which fit into the cylinder head bolt holes and gently rock the cylinder head free towards the front of the car Do not try to swivel the head on the cylinder block crankcase it is located by dowels as well as by the tops of the liners 16 When...

Page 41: ...o bolt type 28 Raise the engine slightly and refit the two bolts which secure the right hand mounting bracket to the cylinder head Tighten these bolts and slacken the one which holds the same bracket to the engine block Lower the engine and tighten the right hand mounting nut and the lower mounting rubber nut and bolt Engines with hexagon head type cylinder head bolts 29 Slacken cylinder head bolt...

Page 42: ...s plate is fitted undo the two retaining screws from diagonally opposite corners of the plate Remove the plate from the base of the engine noting which way round it is fitted Refitting 9 Clean all traces of sealant gasket from the mating surfaces of the cylinder block crankcase and sump then use a clean rag to wipe out the sump and the engine s interior 10 Where a spacer plate is fitted remove all...

Page 43: ...oved on later models a retaining lug is provided on the cylinder block which engages with a fork on the oil cooler 3 To remove the oil cooler first remove the oil filter and partially drain the cooling system as described in Chapter 1 4 Disconnect the coolant hoses from the filter Be prepared for coolant spillage and plug the open ends of the hoses to prevent dirt ingress and further coolant loss ...

Page 44: ...taining bolts along with the torque converter plate and the two shims where fitted Note that the shims are of different thickness the thicker one being on the outside of the torque converter plate Discard the driveplate retaining bolts new ones must be used on refitting 6 Remove the driveplate from the end of the crankshaft If the locating dowel is a loose fit in the crankshaft end remove it and s...

Page 45: ... removal inspection and refitting 10 Camshaft oil seal renewal 9 Compression test description and interpretation 2 Crankshaft oil seals renewal 14 Cylinder head removal and refitting 11 Cylinder head cover removal and refitting 4 Engine assembly valve timing holes general information and usage 3 Engine oil and filter renewal See Chapter 1 Engine oil level check See Weekly checks Engine transmissio...

Page 46: ...in the connecting rod small end eyes The aluminium alloy pistons are fitted with three piston rings two compression rings and an oil control ring On all except TU3FM engines the cylinder block is made of aluminium and replaceable wet liners are fitted to the cylinder bores Sealing O rings are fitted at the base of each liner to prevent the escape of coolant into the sump On TU3FM engines the cylin...

Page 47: ...he crankshaft sprocket bolt noting that it should always be rotated in a clockwise direction viewed from the right hand end of the engine 4 With the camshaft sprocket hole correctly positioned insert a 6 mm diameter bolt or drill through the hole in the front left hand flange of the cylinder block and locate it in the timing hole in the rear of the flywheel see illustration Note that it may be nec...

Page 48: ... 4 It is important that the clearance of each valve is checked and adjusted only when the valve is fully closed with the rocker arm resting on the heel of the cam directly opposite the peak This can be ensured by carrying out the adjustments in the following sequence noting that No 1 cylinder is at the transmission end of the engine The correct valve clearances are given in the Specifications at t...

Page 49: ...n the front of the crankshaft If the belt breaks or slips in service the pistons are likely to hit the valve heads resulting in extensive and expensive damage 2 The timing belt should be renewed at the specified intervals see Chapter 1 or earlier if it is contaminated with oil or if it is at all noisy in operation a scraping noise due to uneven wear 3 If the timing belt is being removed it is a wi...

Page 50: ...ewed from the right hand end of the engine Do not at any time rotate the crankshaft anti clockwise 18 Slacken the tensioner pulley nut re tension the belt as described in paragraph 14 or 15 then tighten the tensioner pulley nut to the specified torque 19 Rotate the crankshaft through a further two turns clockwise and check that both the camshaft sprocket and flywheel timing holes are still correct...

Page 51: ...l 12 If the Woodruff key is a loose fit in the crankshaft remove it and store it with the sprocket for safe keeping If necessary also slide the flanged spacer off the end of the crankshaft see illustration Examine the crankshaft oil seal for signs oil leakage and if necessary renew as described in Section 14 Tensioner pulley 13 Remove the centre timing belt cover as described in Section 6 14 Slack...

Page 52: ... lips of the new seal with clean engine oil and drive it into position until it seats on its locating shoulder Use a suitable tubular drift such as a socket which bears only on the hard outer edge of the seal Take care not to damage the seal lips during fitting Note that the seal lips should face inwards 5 Refit the camshaft sprocket as described in Section 8 10 Camshaft and rocker arms removal in...

Page 53: ...urface Refit the housing to the left hand end of the head and securely tighten its retaining bolts 20 Lubricate the lips of the new seal with clean engine oil then drive it into position until it seats on its locating shoulder Use a suitable tubular drift such as a socket which bears only on the hard outer edge of the seal Take care not to damage the seal lips during fitting Note that the seal lip...

Page 54: ...not taken and the liners are moved there is also a possibility of the bottom seals being disturbed causing leakage after refitting the head When the joint is broken lift the cylinder head away seek assistance if possible as it is a heavy assembly especially if it is being removed complete with the manifolds 22 On all models remove the gasket from the top of the block noting the two locating dowels...

Page 55: ...each end of the cylinder block crankcase surface and if necessary remove the cylinder liner clamps 32 Position a new gasket on the cylinder block crankcase surface ensuring that its identification cut outs are at the left hand end of the gasket 33 Check that the flywheel and camshaft sprocket are still correctly locked in position with their respective tools then with the aid of an assistant caref...

Page 56: ...ipe as described in the relevant Part of Chapter 4 4 Progressively slacken and remove all the sump retaining nuts and bolts On cast iron block engines it may be necessary to unbolt the flywheel cover plate from the transmission to gain access to the left hand sump fasteners 5 Break the joint by striking the sump with the palm of your hand then lower the sump and withdraw it from underneath the veh...

Page 57: ...ny traces of oil then refit the flywheel as described in Section 15 15 Flywheel removal inspection and refitting 4 Removal 1 Remove the transmission as described in Chapter 7A then remove the clutch assembly as described in Chapter 6 2 Prevent the flywheel from turning by locking the ring gear teeth with a screwdriver or a similar arrangement to that shown in illustration 8 10 Alternatively bolt a...

Page 58: ... of the transmission 18 Check carefully for signs of wear or damage on all components and renew them where necessary 19 Refit the bracket to the transmission tightening its mounting nuts to the specified torque Reconnect the clutch cable and adjust as described in Chapter 6 Refit the mounting bracket to the vehicle body and tighten its bolts to the specified torque 20 Fit the mounting rubber to th...

Page 59: ...es 8 0 mm XU51 and XU5M series engines 7 30 mm All other XU series engines 7 98 mm TU series engines 6 99 mm Crankshaft refitting and main bearing running clearance check 13 Crankshaft removal and inspection 8 Cylinder block crankcase cleaning and inspection 9 Cylinder head dismantling cleaning inspection and reassembly 6 Engine initial start up after overhaul 15 Engine automatic transmission remo...

Page 60: ... 18 mm With O ring type base seals 0 10 to 0 17 mm XU series engines Pre 1987 models 0 08 to 0 15 mm 1987 models onward 0 03 to 0 10 mm TU series aluminium block engines 0 03 to 0 10 mm Maximum difference between any two liners XV XW and XY series engines with paper type base seals 0 04 mm All other engines 0 05 mm These are suggested figures typical for this type of engine no exact values are sta...

Page 61: ...s are stated by Peugeot On XU series engines and TU series aluminium block engines the bearing clearance was modified on later models see text for further information Torque wrench settings Nm lbf ft XV XW and XY series engines Main bearing crankcase housing bolts Stage 1 36 27 Stage 2 51 38 Big end cap nuts 36 27 Engine transmission connecting bolts 9 7 Engine mounting nuts 34 25 XU series engine...

Page 62: ... Clean the engine compartment and engine transmission before beginning the removal procedure this will help visibility and help to keep tools clean The help of an assistant should be available there are certain instances when one person cannot safely perform all of the operations required to remove the engine from the vehicle Safety is of primary importance considering the potential hazards involv...

Page 63: ...arburettor models carry out the following operations using the information given in the relevant Part of Chapter 4 a Disconnect the fuel feed and return hoses b Disconnect the throttle and where applicable the choke cables from the carburettor c Where fitted disconnect the braking system servo vacuum hose from the inlet manifold d Disconnect the exhaust system downpipe from the exhaust manifold an...

Page 64: ...n bolts and two nuts altogether Note that an engine lifting lug and earth strap are fitted under some of the bolts 25 Refer to Chapter 6 and remove the clutch assembly ignoring any procedures that have already been carried out as part of the engine transmission removal sequence 26 Unbolt and remove the flywheel Chap ter 2A then slacken and remove the retaining bolts and remove the starter motor 27...

Page 65: ... rear mounting link and install both its bolts 63 Rock the engine to settle it on its mountings then go around and tighten all the mounting nuts and bolts to their specified torque settings The hoist can then be detached from the engine and removed 64 The remainder of the refitting procedure is a direct reversal of the removal sequence noting the following points a Ensure that the wiring loom is c...

Page 66: ... arm ignition module HT leads and spark plugs Chapters 1 and 5 d Power steering pump and air conditioning compressor brackets where fitted e Thermostat and housing coolant pump coolant outlet chamber elbow Chapter 3 f Dipstick tube g Carburettor fuel system components Chapter 4 h All electrical switches and sensors i Inlet and exhaust manifolds Chapter 4 j Oil filter Chapter 1 k Fuel pump carburet...

Page 67: ...compound as described below 15 Check the valve guides for wear by inserting the relevant valve and checking for side to side motion of the valve A very small amount of movement is acceptable If the movement seems excessive remove the valve Measure the valve stem diameter see below and renew the valve if it is worn If the valve stem is not worn the wear must be in the valve guide and the guide must...

Page 68: ...nterposed block of wood tap the end of each valve stem to settle the components 32 Refit the camshaft followers and shims as applicable as described in Part A B or C of this Chapter 33 The cylinder head can then be refitted as described in Part A B or C of this Chapter 7 Piston connecting rod assembly removal and inspection 4 Removal XV XW and XY series engines 1 With the cylinder head removed uns...

Page 69: ...ow by has occurred A hole in the piston crown or burned areas at the edge of the piston crown indicates that abnormal combustion pre ignition knocking or detonation has been occurring If any of the above problems exist the causes must be investigated and corrected or the damage will occur again The causes may include incorrect ignition timing or a carburettor or fuel injection system fault 25 Corr...

Page 70: ...stration Remove the rubber sealing strips from the sides of No 1 main bearing cap and discard them 17 Lift out the crankshaft and discard the rear oil seal 18 Recover the upper bearing shells from the cylinder block and tape them to their respective caps for safe keeping Remove the upper thrustwasher halves from the side of No 2 main bearing and store them with the lower halves TU series aluminium...

Page 71: ...eep groove in the surface of the crankshaft consult an engine overhaul specialist repair may be possible but otherwise a new crankshaft will be required 42 At the time of writing it was not clear whether Peugeot produce oversize bearing shells for all of these engines On some engines if the crankshaft journals have not already been reground it may be possible to have the crankshaft reconditioned a...

Page 72: ... with paper type base seals 20 If the cylinder liners had paper type base seals the liner protrusion must be measured and seals of the correct thickness selected 21 Paper base seals are available in four different thicknesses Blue 0 087 mm White 0 102 mm Red 1 122 mm Yellow 0 147 mm 22 The correct protrusion for each liner above the surface of the cylinder block is given in the Specifications and ...

Page 73: ...t the same three locations at right angles to the crankshaft axis As no tolerance figures are actually stated by Peugeot if there is any doubt about the condition of the cylinder bores seek the advice of a Peugeot dealer or suitable engine reconditioning specialist 44 At the time of writing it was not clear whether oversize pistons were available for all models Consult your Peugeot dealer for the ...

Page 74: ...the top of the piston This will ensure that the ring remains square with the cylinder walls Position the ring near the bottom of the cylinder bore at the lower limit of ring travel Note that the top and second compression rings are different The second ring is easily identified by the step on its lower surface and by the fact that its outer face is tapered 4 Measure the end gap using feeler blades...

Page 75: ...in see illustration These marks can be used to select bearing shells of the required thickness as follows 8 On both the crankshaft and block there are two lines of identification a bar code which is used by Peugeot during production and a row of five characters letters and numbers The first character in the sequence refers to the relevant size of No 1 bearing at the flywheel driveplate end and the...

Page 76: ...869 2 019 13 New bearing shells can be selected using the reference marks on the cylinder block crankcase The cylinder block marks identify the diameter of the bearing bores and the crankshaft marks the diameter of the crankshaft journals On early engines the correct size of bearing shell must be selected by measuring the running clearance as described under the sub heading below 14 The cylinder b...

Page 77: ...ge supplied with the kit The running clearance is determined from this gauge Plastigage should be available from your Peugeot dealer otherwise enquiries at one of the larger specialist quality motor factors should produce the name of a stockist in your area The procedure for using Plastigage is as follows 25 With the main bearing upper shells in place carefully lay the crankshaft in position Do no...

Page 78: ...cting rods to the crankshaft as described in Section 14 41 Fit a new O ring seal to the crankcase flange and check that the locating dowels are in position see illustration 42 Apply jointing compound to the flange 43 Clean the recesses in the remaining crankcase housing section and fit the main bearing shells Note that the grooved shells are located in positions 2 and 4 44 Locate the housing takin...

Page 79: ...fit the piston connecting rod assemblies to the crankshaft as described in Section 14 63 Refit the Woodruff key then slide on the oil pump drive sprocket and spacer where fitted and locate the drive chain on the sprocket 64 Ensure that the mating surfaces of the front oil seal carrier and cylinder block are clean and dry Note the correct fitted depth of the oil seal then using a large flat bladed ...

Page 80: ...tighten to the Stage 3 and then Stage 4 torque wrench settings 77 Refit the piston connecting rod assemblies to the crankshaft as described in Section 14 78 Ensuring that the drive chain is correctly located on the sprocket refit the oil pump and sump as described in Part A of this Chapter 79 Fit two new crankshaft oil seals as described in Part A 80 Refit the flywheel as described in Part A of th...

Page 81: ...d pair of bearing shells If the diameter of each corresponding crankshaft journal is measured and then subtracted from the bearing internal diameter the result will be the big end bearing running clearance 7 The second and more accurate method is to use Plastigage see Section 13 8 Ensure that the bearing shells are correctly fitted Place a strand of Plastigage on each cleaned crankpin journal 9 Re...

Page 82: ...ble the ignition system by disconnecting the ignition HT coil lead from the distributor cap and earthing it on the cylinder block Use a jumper lead or similar wire to make a good connection On models with a static distributorless ignition system disable the ignition system by disconnecting the LT wiring connector from the ignition module referring to Chapter 5B for further information 3 Turn the e...

Page 83: ... iron block engines 15 11 Air conditioning system check See Chapter 1 Air conditioning system general information and precautions 10 Antifreeze general information 3 Auxiliary drivebelt check and renewal See Chapter 1 Coolant level check See Weekly checks Coolant pump removal and refitting 8 Cooling system draining See Chapter 1 Cooling system filling See Chapter 1 Cooling system flushing See Chap...

Page 84: ...ts stubs The hoses can be removed with relative ease when new on an older vehicle they may have stuck 4 If a hose proves to be difficult to remove try to release it by rotating it on its unions before attempting to work it off Gently prise the end of the hose with a blunt instrument such as a flat bladed screwdriver but do not apply too much force and take care not to damage the pipe stubs or hose...

Page 85: ...the thermostat starts to open at the specified temperature and is fully open also at the specified temperature 8 Remove the thermostat from the water and allow it to cool The valve plate should close smoothly 9 If the unit fails to operate as described or is stuck open or shut renew it with one of similar temperature rating see illustration Refitting 10 Refitting is a reversal of removal but use n...

Page 86: ...sor may be located in the left hand end of the cylinder head on or beneath the thermostat housing or below the distributor according to engine type see illustration On some engines two sensors may be fitted one for the temperature gauge and another for the engine management system Testing should be carried out by an auto electrician or by substitution with a known good unit 6 Partially drain the c...

Page 87: ... 5 Refitting is a reversal of removal bearing in mind the following points a Renew the pump O ring b Refit the auxiliary drivebelt and refill the cooling system as described in Chapter 1 XU series engines Removal 6 Drain the cooling system Chapter 1 7 Remove the timing belt and tensioner as described in Chapter 2B 8 Remove the plastic shield noting the locations of the different types of bolt see ...

Page 88: ...r 1 TU series cast iron block engines Removal 21 Drain the cooling system as described in Chapter 1 22 Remove the timing belt as described in Chapter 2C 23 Unscrew the two securing bolts and withdraw the coolant pump from the cylinder block see illustration Recover the O ring 24 If the coolant pump is worn noisy or leaks coolant it must be renewed as repair is not possible Refitting 25 Refitting i...

Page 89: ...ribed in Chapter 1 on completion 10 Air conditioning system general information and precautions General information 1 Air conditioning is available as an option on later models In conjunction with the heater the system enables any reasonable air temperature to be achieved inside the car It also reduces the humidity of the incoming air aiding demisting even when cooling is not required see illustra...

Page 90: ...f for any reason the system must be discharged entrust this task to your Peugeot dealer or air conditioning specialist Warning The refrigeration circuit may contain a liquid refrigerant Freon and it is therefore dangerous to disconnect any part of the system without specialised knowledge and equipment 5 The refrigerant is potentially dangerous and should only be handled by qualified persons If it ...

Page 91: ...tle opening 20 40 30 20 40 30 20 40 30 Idling speed 650 50 rpm 650 50 rpm 650 50 rpm CO 1 5 0 5 1 5 0 5 1 5 0 5 Air cleaner assembly removal and refitting 2 Air cleaner element renewal See Chapter 1 Carburettor fault diagnosis overhaul and adjustments 10 Carburettor removal and refitting 9 Choke cable removal and refitting 4 Fuel gauge sender unit removal and refitting 6 Fuel pump removal overhaul...

Page 92: ...rpm CO 1 5 1 5 0 5 TU1 TU1 TU1 Weber 32IBS15 Weber 32IBSH17 Solex Venturi diameter 26 25 25 Main jet 140 5 132 127 5 2 5 Air correction jet 180 15 165 175 10 Emulsion tube F102 F100 EM Enrichener drilling 50 10 50 35 5 Idling fuel jet 45 5 45 46 4 Idling air jet 170 165 10 Accelerator pump injector 45 10 40 40 10 Fuel inlet needle valve 1 5 1 5 1 6 Float setting 8 0 mm Idling speed 700 rpm 700 rpm...

Page 93: ...ar this in mind if you are working in an area where such appliances are present Always keep a suitable fire extinguisher close to the work area and familiarise yourself with its operation before starting work Wear eye protection when working on fuel systems and wash off any fuel spilt on bare skin immediately with soap and water Note that fuel vapour is just as dangerous as liquid fuel a vessel th...

Page 94: ...t see illustration 3 Release the cable from the clips in the engine compartment 4 Working inside the car disconnect the warning lamp wiring and detach the cable from the support bracket Refitting 5 Refitting is a reversal of removal but adjust the cable at the carburettor end so that when the control knob is pushed fully in the choke valve plate is fully open 5 Fuel pump removal overhaul and refit...

Page 95: ...e lead 3 Using a hand pump or syphon inserted through the filler neck remove any remaining fuel from the bottom of the tank 4 Chock the front wheels then jack up the rear of the car and support it on axle stands see Jacking and vehicle support 5 Either remove the complete exhaust system or on later models release the support band on the silencer and lower the system using a jack under the tailpipe...

Page 96: ...most cases it will be sufficient to dismantle the carburettor and to clean the jets and passages Overhaul Note Refer to the warning note in Section 1 before proceeding The following procedures are typical for the various carburettors encountered on 205 models Refer to the accompanying illustrations for details of specific carburettor types and component locations 4 Remove the carburettor from the ...

Page 97: ...ist drill check that the gap between the choke flap and barrel is 3 0 mm If not turn the adjusting screw in the end of the opener Throttle damper 29 Certain models may have a throttle damper assembly fitted to the carburettor on a modified throttle cable support bracket to prevent engine stalling during gearchanges 30 The assembly should not require any adjustment but if the throttle is held open ...

Page 98: ... the Weber 36 TLC carburettor 1 Gasket x 28 0 mm 10 44 Choke opening after starting adjustment on the Weber 36 TLC carburettor 1 Locknut 2 Hole 3 Roller 4 Adjusting screw 5 Can 6 Peg on special tool 10 45 Choke opening after starting adjusting screw 1 on the Weber 36 TLC carburettor 10 46 Choke opening after starting adjustment on the Weber 36 TLC carburettor 1 Roller 2 Lever ...

Page 99: ...justing screw see illustration 46 Disconnect and plug the diaphragm vacuum hose and using a 5 5 mm twist drill check that the choke flap has opened by 5 5 mm if not loosen the clamp screw then hold the roller against the top of the cam and adjust the lever until the drill will just pass see illustration Tighten the screw and reconnect the hose on completion Positive throttle opening 47 With the ch...

Page 100: ... remove it from the cylinder head see illustration Where fitted recover the gasket or seals Refitting 7 Refitting is a reversal of removal bearing in mind the following points a Ensure that the manifold and cylinder head mating faces are perfectly clean and use a new gasket or seals on models so equipped On TU engines apply a thin coating of suitable sealing compound to the manifold mating face be...

Page 101: ...nd return lines and the throttle body assembly which incorporates the single fuel injector and the fuel pressure regulator In addition there is an Electronic Control Unit ECU and various sensors electrical components and related wiring The air cleaner contains a disposable paper filter element and incorporates a flap valve air temperature control system This allows cold air from the outside of the...

Page 102: ... Disconnect the battery negative lead 3 If possible place a suitable container beneath the connection or union to be disconnected and have a large rag ready to soak up any escaping fuel not being caught by the container 4 Slowly loosen the connection or union nut to avoid a sudden release of pressure and position the rag around the connection to catch any fuel spray which may be expelled Once the ...

Page 103: ...arances are correctly adjusted the cylinder compression pressures are correct the ignition timing is correct where adjustable and that the engine breather hoses are clear and undamaged referring to Chapters 1 2 and 5 for further information 2 If these checks fail to reveal the cause of the problem the vehicle should be taken to a suitably equipped Peugeot dealer for testing A wiring block connecto...

Page 104: ... wiring connector to the top of the throttle body then carefully lift off the connector see illustration Idle speed control motor 14 Disconnect the battery negative lead 15 Release the securing clip and disconnect the wiring plug from the motor see illustration 16 Unscrew the securing screws and withdraw the motor from the throttle body assembly see illustration 17 Refitting is the reverse of the ...

Page 105: ...c Ensure that all vacuum hoses and pipes are correctly reconnected as noted before removal d Ensure that the fuel hoses are correctly reconnected The direction of fuel flow is indicated by arrows cast into the throttle body next to each union e On completion switch on the ignition and check for signs of fuel leaks from all disturbed unions If any signs of leakage are detected the problem must be r...

Page 106: ...nd withdraw the switch 10 Refitting is a reversal of removal noting the following points a Before refitting the switch ensure that the throttle valve is fully closed b Ensure that the switch wiper engages correctly with the throttle shaft Idle speed control valve MMFD G5 system 11 For improved access remove the air cleaner trunking 12 Disconnect the battery negative lead 13 Release the securing cl...

Page 107: ...nnected as noted before removal d When reconnecting the manifold absolute pressure sensor hose ensure that it is routed so that it falls steadily from the sensor to the throttle body This is necessary to prevent any fuel droplets from entering the sensor no fuel vapour trap is fitted allowing them to drain into the throttle body instead e Ensure that the fuel hoses are correctly reconnected as not...

Page 108: ...4B 8 Notes ...

Page 109: ...al Degrees of difficulty 5 4 3 2 1 1 General information and precautions General information The fuel supply system consists of a fuel tank which is mounted under the rear of the car with an electric fuel pump immersed in it a fuel filter fuel feed and return lines The fuel pump supplies fuel to the fuel rail which acts as a reservoir for the four fuel injectors which inject fuel into the inlet tr...

Page 110: ...entry of dirt into the fuel system 5 Fuel pump removal and refitting 3 Refer to Part B Section 5 6 Fuel gauge sender unit removal and refitting 3 Refer to Part A Section 6 7 Fuel tank removal and refitting 3 Refer to Part A Section 7 noting that it will be necessary to depressurise the fuel system as the feed and return hoses are disconnected from the fuel pump which is located inside the tank It ...

Page 111: ... be correctly adjusted as described in Chapter 5B 5 Connect a vacuum gauge to the test point in the distributor vacuum advance line see illustration 6 Check that the throttle movement is smooth 7 With the engine stopped turn the air screw fully in see illustration 8 Prise the tamperproof cap from the throttle stop screw see illustration 9 Unscrew the throttle stop screw then retighten it until it ...

Page 112: ...hat no dirt is allowed to enter the system during the procedure 7 For improved access to the lower pressure regulator securing nut proceed as described in paragraphs 3 and 4 8 If not already done disconnect the vacuum hose from the top of the pressure regulator 9 Slacken the hose clip and disconnect the fuel return hose from the bottom of the pressure regulator Be prepared for fuel spillage and ta...

Page 113: ... hoses to ensure that they are connected correctly on refitting 6 Bearing in mind the information given in Section 4 slacken the retaining clips and disconnect the fuel feed and return hoses from the fuel rail 7 Depress the retaining tangs and disconnect the wiring connectors from the four injectors Free the wiring from any relevant retaining clips and position it clear of the manifold 8 Where nec...

Page 114: ...4C 6 Notes ...

Page 115: ...ed joint incorporating compression springs or by a single spherical joint On TU series engines a ball and socket type joint is provided between the front downpipe and intermediate pipes to allow for engine movement 2 Later fuel injected models are equipped with a catalytic converter as part of the exhaust emission control system Emission control systems 3 Various systems may be fitted to reduce th...

Page 116: ... the solenoid valve Under certain engine temperature conditions the solenoid valve cuts off the vacuum to the distributor vacuum capsule therefore reducing the ignition advance Catalytic converter 11 Catalytic converters have been introduced progressively on all models in the range to meet emissions regulations 12 The catalytic converter is located in the exhaust system and operates in conjunction...

Page 117: ...between the canister and the inlet manifold prevents the system from operating when the engine is cold The solenoid valve is controlled by the electronic control unit on the basis of information received from the coolant temperature sensor 2 Exhaust system removal and refitting 2 Removal 1 Details of exhaust system routing and mounting will vary with model and year but the principles of removal an...

Page 118: ...ly 22 0 mm d Prior to tightening the exhaust system fasteners ensure that all rubber mountings are correctly located and that there is adequate clearance between the exhaust system and vehicle underbody 3 Exhaust manifold removal and refitting 3 Removal 1 Disconnect the battery negative lead 2 Where applicable disconnect the hot air inlet hose from the manifold shroud and remove it from the vehicl...

Page 119: ... then disconnect the wiring and unscrew and remove the sensor Refitting 7 When refitting the sensor ensure that the seal is in good condition and take care not to overtighten the switch Refill the cooling system on completion as described in Chapter 1 and Weekly checks 7 Catalytic converter general information and precautions The catalytic converter is a reliable and simple device which needs no m...

Page 120: ...r of the engine compartment 6 To remove the valve first disconnect the battery negative lead 7 Unbolt the bracket from the body panel then disconnect the wiring plug see illustrations 8 Disconnect the hoses from the valve noting their locations to ensure correct refitting then withdraw the valve Refitting 9 Refitting is a reversal of removal ensuring that the hoses are correctly reconnected as not...

Page 121: ...e starter motor is of the pre engaged type incorporating an integral solenoid On starting the solenoid moves the drive pinion into engagement with the flywheel ring gear before the starter motor is energised Once the engine has started a one way clutch prevents the motor armature being driven by the engine until the pinion disengages from the flywheel Precautions Further details of the various sys...

Page 122: ...ry charging Note The following is intended as a guide only Always refer to the manufacturer s recommendations often printed on a label attached to the battery before charging a battery 8 Charge the battery at a rate of 3 5 to 4 amps and continue to charge the battery at this rate until no further rise in specific gravity is noted over a four hour period 9 Alternatively a trickle charger charging a...

Page 123: ...the lights If they dim then this indicates that current is reaching the starter motor therefore the fault must lie in the starter motor If the lights continue to glow brightly and no clicking sound can be heard from the starter motor solenoid this indicates that there is a fault in the circuit or solenoid see following paragraphs If the starter motor turns slowly when operated but the battery is i...

Page 124: ...e or deterioration and if necessary renew 6 Refit the switch complete with washer and tighten it securely Reconnect the wiring connector 7 Lower the vehicle to the ground then check and if necessary top up the engine oil as described in Weekly checks 13 Electronic oil level sensor general information 1 Some 1985 XU series engine models have an oil level sensor fitted to the engine sump together wi...

Page 125: ...s Not adjustable controlled by MMFD Mono point G6 engine management system Ignition coil Ignition HT coil resistances Electronic breakerless ignition systems Primary windings 0 8 ohms Secondary windings 6 5 K ohms Static distributorless ignition systems Primary windings 0 5 to 0 8 ohms Secondary windings Bosch coil 14 6 K ohms Secondary windings Valeo coil 8 6 K ohms The above results are approxim...

Page 126: ...ep well clear of the ignition circuits components and test equipment Models with electronic breakerless ignition systems Note Refer to the warning given in Section 1 of Part A of this Chapter before starting work Always switch off the ignition before disconnecting or connecting any component and when using a multi meter to check resistances General 1 The components of electronic ignition systems a...

Page 127: ... the cylinder head above the distributor 7 Disconnect the battery negative lead 8 Refer to the relevant Part of Chapter 4 and remove the air cleaner assembly Once the air cleaner is removed move aside any pipes hoses or wiring as necessary for improved access 9 Where applicable disconnect the wiring connector from the capacitor mounted on the coil mounting bracket and release the TDC sensor wiring...

Page 128: ... unit is located at the left hand side of the engine compartment mounted on the side of the suspension strut tower 2 Disconnect the battery negative lead 3 Slide the cover off the ignition HT coil and amplifier 4 Disconnect the amplifier wiring harness 5 Remove the screws and withdraw the amplifier from the mounting plate TU series engines 6 The amplifier unit is attached to the side of the distri...

Page 129: ...first remove No 2 spark plug and turn the engine in the normal rotational direction until pressure is felt indicating that the piston is commencing the compression stroke The pressure can be felt using a suitable wooden rod or a piece of cork placed over the spark plug hole 2 Remove the plastic cover from the timing aperture then continue turning the crankshaft until the mark on the flywheel is op...

Page 130: ... double mark on the flywheel should be aligned with the TDC mark on the timing plate indicating that the ignition is advanced by 30 see illustration On engines without double timing marks refer to the Specifications for the relevant ignition timing setting and engine speed then check that the single mark on the flywheel is aligned with the appropriate mark on the timing plate 20 If adjustment is n...

Page 131: ...y increase if the vacuum diaphragm is functioning correctly 32 When the ignition timing is correct stop the engine and disconnect the timing light 9 TDC sensor removal and refitting 2 Removal 1 Depending on engine type the TDC sensor is for use with the diagnostic socket located on the clutch housing or for the provision of information on crankshaft position to the engine management system ECU Whe...

Page 132: ...5B 8 Notes ...

Page 133: ...20 Brake disc inspection removal and refitting 9 Brake fluid level check See Weekly checks Brake fluid renewal See Chapter 1 Brake pad wear check See Chapter 1 Brake pedal removal and refitting 17 Front brake caliper removal overhaul and refitting 7 Front brake pads renewal 4 General information 1 Handbrake adjustment 15 Handbrake cables renewal 16 Handbrake lever removal and refitting 18 Hydrauli...

Page 134: ... The correct functioning of the brake hydraulic system is only possible after removing all air from the components and circuit this is achieved by bleeding the system 2 During the bleeding procedure add only clean fresh hydraulic fluid of the specified type never re use fluid that has already been bled from the system Ensure that sufficient fluid is available before starting work 3 If there is any...

Page 135: ... can be positioned so that the air bubbles can be more easily seen flowing from the end of the tube 23 The kit is connected to the bleed screw which is then opened The user returns to the driver s seat depresses the brake pedal with a smooth steady stroke and slowly releases it this is repeated until the expelled fluid is clear of air bubbles When using one of these kits on 1 6 GTI models remember...

Page 136: ...ce to obtain a sound joint 6 If flexible rubber hoses are renewed ensure that the pipes and hoses are correctly routed with no kinks or twists and that they are secured in the clips or brackets provided 7 After fitting bleed the hydraulic system as described in Section 2 wash off any spilt fluid and check carefully for fluid leaks 4 Front brake pads renewal 2 Warning Disc brake pads must be renewe...

Page 137: ...y be fitted to earlier models by tapping the inner pad control rivet through the backing plate so that the clip may be located on both sides see illustration 14 With the caliper pushed inwards insert the inner pad then push the caliper outwards and insert the outer pad Note that from chassis no 5 600 000 an anti squeal shim was fitted between the inner pads and the caliper pistons being located on...

Page 138: ...arning Brake shoes must be renewed on both rear wheels at the same time never renew the shoes on only one wheel as uneven braking may result Also the dust created by wear of the shoes may contain asbestos which is a health hazard Never blow it out with compressed air and don t inhale any of it An approved filtering mask should be worn when working on the brakes DO NOT use petrol or petroleum based...

Page 139: ...pper return spring 16 Move the serrated automatic adjuster lever quadrant against the spring tension to set the shoes at their minimum diameter 17 Check that the handbrake lever on the rear brake shoe is positioned with the lug on the edge of the shoe web and not behind the shoe 18 Refit the hub drum as described in Section 11 but do not lower the car to the ground at this stage 19 Apply the footb...

Page 140: ...ds in their normal position 11 Repeat the operations on the opposite disc caliper 12 Check the fluid level in the master cylinder reservoir and top up if necessary 13 Refit the roadwheels and lower the car to the ground 7 Front brake caliper 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...

Page 141: ... refit them together with the new seals On the Bendix type refit the endplate and tighten the bolts 16 On the Bendix type refit the caliper frame and tighten the bolts Refitting 17 To refit the caliper first screw it onto the flexible hose and locate it over the brake disc so that the hose is not twisted 18 Clean the mounting bolt threads and apply locking fluid Insert the mounting bolts or upper ...

Page 142: ...ickness variation can also cause judder Check this using a micrometer No actual thickness variation figures are provided by the manufacturer but as a general guide 0 010 mm should be considered a maximum Removal 5 On certain models it may be necessary to remove the brake caliper with reference to Section 7 or 8 in order to allow sufficient clearance to remove the disc Note that there is no need to...

Page 143: ...tarting work refer to the warning at the beginning of Section 5 concerning the dangers of asbestos dust Removal 1 Chock the front wheels then jack up the rear of the car and support it on axle stands see Jacking and vehicle support Remove the rear roadwheels and ensure that the handbrake is released 2 Tap off the grease cap taking care not to damage its outer lip then relieve the staking on the re...

Page 144: ...istons for scoring and corrosion and if evident renew the complete master cylinder If the components are in good condition remove and discard the seals and obtain a repair kit which will contain all the necessary renewable components 9 Dip the new seals in fresh brake fluid and fit them to the pistons using the fingers only to manipulate them 10 Reassemble the master cylinder in reverse order to d...

Page 145: ...ed for 30 seconds during which period the pedal should neither rise nor drop 4 Start the engine whilst the brake pedal is released run it for a minute and switch off Give several applications of the brake pedal The pedal travel should decrease with each application 5 Failure of the brake pedal to act in the way described will indicate a fault in the servo unit 6 The servo unit should not be servic...

Page 146: ... and return positively to their stops 15 Now tighten the nut on the handbrake lever so that the handbrake is fully applied between 7 and 9 notches Do not over adjust so that the handbrake is fully applied over fewer notches otherwise the automatic adjusters will not operate correctly 16 Refit the cover over the handbrake lever 16 Handbrake cables renewal 2 All models except 1 9 GTI 1 Remove the re...

Page 147: ...d in conjunction with specialist diagnostic equipment available to a Peugeot dealer to determine the nature of the fault The brake components used on models fitted with ABS are similar to those used on models with a conventional braking system Rear disc brakes are fitted to all ABS equipped models and all procedures for the rear brake and handbrake components are as described for 1 9 GTI models in...

Page 148: ...9 16 Notes ...

Page 149: ...ront lower suspension arm removal and refitting 6 Front suspension hub carrier removal and refitting 2 Front suspension strut overhaul 5 Front suspension strut removal and refitting 4 General information 1 Power steering fluid level check See Weekly checks Power steering pump removal and refitting 18 Power steering system bleeding 17 Rear hub drum and bearings general information 8 Rear shock abso...

Page 150: ...ch end and supported on needle or plain bearings Torsion bars are fitted to the trailing arms and on certain models an anti roll bar located inside the cross tube stabilises the car when cornering The telescopic shock absorbers are inclined with their top mountings attached to the suspension side members The steering system is of rack and pinion type with side track rods connected to the hub carri...

Page 151: ...d to remove it A new bearing retaining circlip must be used on refitting 1 Remove the hub carrier assembly as described in Section 2 2 Support the hub carrier securely on blocks or in a vice Using a tubular spacer which bears only on the inner end of the hub flange press the hub flange out of the bearing If the bearing s outboard inner race remains on the hub remove it using a bearing puller see n...

Page 152: ...pring 3 Fit the spring compressors to the coils of the spring Ensure that the compressors used are of a type that incorporate a method for positively locking them to the spring usually by a small clamp bolt Any other type may slip off or slide round the spring as they are tightened Tighten the compressors until the load is taken off the spring seats If applicable remove the Peugeot cables 4 Unscre...

Page 153: ...he suspension 7 Front anti roll bar removal and refitting 4 Non GTI models Removal 1 Remove the lower suspension arm from one side as described in Section 6 2 Unscrew the nut securing the remaining end of the anti roll bar to the other suspension arm and recover the washer 3 Unbolt the guide bar from the subframe see illustration 4 Unscrew the mounting clamp bolts see illustration and withdraw the...

Page 154: ... pressing in the new one with a metal tube Clean and grease the seal contact surface on the trailing arm before refitting the hub drum Models manufactured from early 1986 are fitted with modified rear hub drum assemblies which does allow separate renewal of the bearings Bearing renewal requires the use of a press in conjunction with special tools to remove the old bearing and this is best entruste...

Page 155: ...ing system components and bleed the brake hydraulic system on completion 12 Vehicle ride height checking 5 Checking of the vehicle ride height requires the use of Peugeot special tools to accurately compress the suspension in a suspension checking bay The operation should be entrusted to a Peugeot dealer as it not possible to carry out checking accurately without the use of the appropriate tools 1...

Page 156: ...rsal of removal but tighten all nuts and bolts to the specified torque On completion have the front wheel toe setting checked see Section 21 Power assisted steering gear Removal 7 Chock the rear wheels then jack up the front of the car and support it on axle stands see Jacking and vehicle support Remove the front roadwheels 8 Prepare a suitable container then disconnect the fluid pipes from the st...

Page 157: ...d pipes to the steering gear the high pressure fluid pipe must be vertical see illustration e Secure the hose to the high pressure fluid pipe using a cable tie f Check the gearchange mechanism for correct operation after reconnecting the linkages g On completion bleed the power steering hydraulic system as described in Section 17 and have the front wheel toe setting checked see Section 21 16 Steer...

Page 158: ...fitting 5 Screw on the locknut then screw the new track rod end the same number of turns onto the track rod 6 Clean the taper surfaces then fit the balljoint shank to the hub carrier steering arm and tighten the nut to the specified torque 7 Tighten the locknut on the track rod end 8 Refit the roadwheel and lower the car to the ground 9 On completion have the front wheel toe setting checked see Se...

Page 159: ...rt it securely on axle stands see Jacking and vehicle support Turn the steering wheel onto full left lock and record the number of exposed threads on the right hand track rod end Now turn the steering onto full right lock and record the number of threads on the left hand side If there are the same number of threads visible on both sides then subsequent adjustment should be made equally on both sid...

Page 160: ...10 12 Notes ...

Page 161: ...anels are of lightweight high strength steel The front wings are bolted to the main body for ease of removal The complete body is given an extensive anti corrosion treatment during manufacture including stone chip protection and wax injection Peugeot guarantee the body against perforation as a result of corrosion for a period of six years provided the car is given periodic inspections by a Peugeot...

Page 162: ...l for filling narrow scratches Before the stopper paste in the scratch hardens wrap a piece of smooth cotton rag around the top of a finger Dip the finger in cellulose thinners and then quickly sweep it across the surface of the stopper paste in the scratch this will ensure that the surface of the stopper paste is slightly hollowed The scratch can now be painted over as described earlier in this S...

Page 163: ...an old tin or similar until the technique is mastered Cover the repair area with a thick coat of primer the thickness should be built up using several thin layers of paint rather than one thick one Using 400 grade wet and dry paper rub down the surface of the primer until it is really smooth While doing this the work area should be thoroughly doused with water and the wet and dry paper periodicall...

Page 164: ...ront grille removal and refitting 1 Removal 1 Open the bonnet and support with the stay 2 Remove the screws from the top of the grille then lift it upwards from the lower mounting holes see illustrations Refitting 3 Refitting is a reversal of removal 9 Bumpers removal and refitting 3 Removal Front bumper 1 The bumper is removed complete with the front spoiler 2 Working under the vehicle unscrew th...

Page 165: ...val and refitting 3 Removal 1 The door hinges are welded to the body pillar and bolted to the door 2 Remove the plastic caps from the hinge pivot pins 3 Drive out the roll pin from the door check strap 4 Where applicable remove the trim panel Section 11 and disconnect the loudspeaker wiring from the door 5 Support the door in the fully open position by placing blocks or a jack and a pad of rag und...

Page 166: ...ocated in the panel 12 Door Hatchback and Van models dismantling and reassembly 3 Dismantling 1 Remove the trim panel as described in Section 11 Window regulator 2 To remove the window regulator unscrew the mounting nuts slide the two lifting arms from the channels and withdraw the regulator through the access aperture see illustrations Support the glass during this operation Door lock 3 To remove...

Page 167: ...from the top edge of the door 5 Raise the glass and lift it from the door 6 Unscrew the mounting nuts and remove the fixed quarterlight glass through the sliding glass location Reassembly 7 Reassembly is a reversal of dismantling but carry out the following adjustments Temporarily refit the window regulator handle or reconnect the regulator motor wiring as applicable then close the window and if n...

Page 168: ...ings 11 Fully unfold the hood and check that the hooks at the front corners of the hood line up with their strikers If the hooks and strikers are not aligned move the hood support brackets the securing bolt holes are elongated until satisfactory alignment is obtained 12 Open and close the hood a number of times to ensure that it operates correctly then tighten the lower frame securing bolts 13 The...

Page 169: ...Check that the latch engages the striker correctly and if necessary adjust the striker position within the elongated bolt holes Adjust the rubber stops so that the tailgate is supported firmly at the corners when shut 18 Windscreen and tailgate glass general information Both the windscreen and tailgate glass are bonded in position and therefore it is recommended that a professional fitter is emplo...

Page 170: ... cushion forwards and unbolt it from the hinges see illustration 4 Fold the backrest down unscrew the nuts from the outer pivot bracket s and withdraw the backrest from the inner pivot where applicable Refitting 5 Refitting the front and rear seats is a reversal of removal 22 Grab handles removal and refitting 1 Removal 1 Prise up the cover plates for access to the screws at each end 2 Remove the ...

Page 171: ... 10 and instrument panel Chapter 12 2 Remove the screws and withdraw the steering column lower shroud 3 Remove the ashtray 4 Prise out the central air vents see illustration 5 Prise out the digital clock which is retained by plastic barbs see illustration 6 Using a hooked instrument withdraw the rear of the oddments recess see illustration 7 Remove the radio as described in Chap ter 12 or prise ou...

Page 172: ... or oddments compartment as applicable 24 Remove the screws and withdraw the trim quadrants from each side of the facia 25 Remove the ashtray and disconnect the wiring from the cigar lighter see illustration Identify the wiring 26 Unclip the clock surround see illustration 27 Insert lengths of welding rod or similar into the holes at the top of the switch surround to release the upper clips then u...

Page 173: ...nting screws and nuts and withdraw the facia sufficiently to disconnect the wiring Access to the front mounting nuts is gained by removing the wiper arms and the plastic guard from the plenum chamber in the engine compartment Identify each wire for location 43 Unclip the fuse and relay panel and withdraw the facia panel from the car Refitting All models 44 Refitting is a reversal of removal but on...

Page 174: ...11 14 Notes ...

Page 175: ...k removal and refitting 6 Dim dip lighting system general information 13 Electrical fault finding general information 2 Front direction indicator light unit removal and refitting 11 Fuses and relays general information 3 General information and precautions 1 Headlight beam alignment checking and adjusting 12 Headlight unit removal and refitting 10 Horn removal and refitting 20 Instrument panel rem...

Page 176: ...t warning lights coolant temperature oil pressure coolant level handbrake choke 25 4 Spare 5 Hazard warning 10 6 Spare 7 Cigarette lighter clock interior lights boot light central door locking radio 25 8 Horns heated rear window 25 9 Electrically operated windows 20 10 Rear fog light 5 11 Tail lights number plate light 5 12 Spare 13 Instrument panel illumination side lights 5 14 Fuel pump 15 Fuses...

Page 177: ...ter fuel gauge warning lights low battery charge coolant temperature oil pressure low coolant level brake system choke 10 2 Direction indicators gauges fuel oil temperature coolant temperature oil pressure heater blower motor warning lights low battery charge coolant temperature oil pressure low coolant level brake system choke ABS 25 3 Map reading light stop lights windscreen and tailgate wash wi...

Page 178: ...blems due to poor connections two basic types of fault can occur in an electrical circuit open circuit or short circuit 7 Open circuit faults are caused by a break somewhere in the circuit which prevents current from flowing An open circuit fault will prevent a component from working 8 Short circuit faults are caused by a short somewhere in the circuit which allows the current flowing in the circu...

Page 179: ...otected Where more than one circuit is involved switch on one item at a time until the fuse blows so showing in which circuit the fault lies 7 Besides a fault in the electrical component concerned a blown fuse can also be caused by a short circuit in the wiring to the component Look for trapped or frayed wires allowing a live wire to touch vehicle metal and for loose or damaged connectors 8 The fu...

Page 180: ...are disconnected tape them to the pillar to prevent them from slipping inside the pillar cavity 23 It is recommended that the metal contacts of the switch are smeared with petroleum jelly as a precaution against corrosion 24 Refit by reversing the removal operation Glovebox illumination switch 25 Disconnect the battery negative lead 26 Open the glovebox then reach up and release the switch from th...

Page 181: ...oud see illustration 5 Withdraw the surround from the facia 6 Pull out the instrument panel while depressing the lower spring supports then disconnect the multi plugs and speedometer cable see illustrations 7 If necessary the individual components can be removed for repair or renewal see illustrations 1988 models onward 8 Disconnect the battery negative lead 9 Remove the trapezium shaped coin comp...

Page 182: ...12 8 Body electrical system 5 7a Exploded diagram of non GTI instrument panel 5 7b Exploded diagram of GTI instrument panel ...

Page 183: ...nnect the wiring plug from the rear of the clock then release the clock from the lower front panel surround Refitting 13 On all models refitting is a reversal of removal 7 Speedometer cable renewal 2 1 Disconnect the speedometer cable from the transmission by removing the retaining bolt or rubber plug 2 Remove the instrument panel as described in Section 5 3 Prise the rubber grommet from the bulkh...

Page 184: ...nt driving light GTI models 15 Remove the two lens surround retaining screws and withdraw the surround lens and reflector see illustration 16 Release the spring clips and remove the bulb assembly see illustration 17 Detach the bulb feed wire at the connector Rear light cluster bulbs 18 Remove the lens upper retaining screws then tilt the lens back and release it from the lower tabs see illustratio...

Page 185: ...ment panel as described in Section 5 7 Two types of bulb are fitted Pull out the square type bulbholder and remove the wedge type bulb see illustration Twist the round type bulbholder through 90 to remove it but on this type the bulb cannot be separated from the holder Glovebox light 8 On pre 1988 models remove the switch with reference to Section 4 then depress and twist the bulb to remove it 9 O...

Page 186: ...ng 2 Removal 1 Remove the headlight as described in Section 10 2 Remove the indicator bulb see Section 8 3 Remove the screw securing the light to the headlight adjustment assembly and withdraw the light unit see illustrations Refitting 4 Refitting is a reversal of removal 12 Headlight beam alignment checking and adjusting 1 It is recommended that beam alignment is be carried out by a Peugeot deale...

Page 187: ...crew the nuts from the wiper spindle bodies see illustration 5 Disconnect the wiper motor wiring connector 6 Unscrew the mounting bolt and disengage the wiper motor from the upper location pins 7 The motor can be separated from the linkage by removing the nut securing the crank to the spindle Refitting 8 Refitting is a reversal of removal but use a screwdriver to lift the weatherstrip as the grill...

Page 188: ...y wire 4 Unbolt and remove the compressor or horn as required Refitting 5 Refitting is a reversal of removal 22 Radio removal and refitting 2 Removal Note If the radio incorporates an anti theft system once the battery has been disconnected the radio unit cannot be re activated until the appropriate security code has been entered Do not remove the unit unless the appropriate code is known Early mo...

Page 189: ...Wiring diagrams 12 15 12 Key to wiring diagrams ...

Page 190: ...12 16 Wiring diagrams Key to wiring diagrams continued ...

Page 191: ...Wiring diagrams 12 17 12 Diagram1 Typical starting charging ignition cooling fan warning lamps and gauges XV8 XW7 XY8 and XU51C engine models ...

Page 192: ...12 18 Wiring diagrams Diagram1a Typical starting charging ignition cooling fan warning lamps and gauges TU1 TU3 and TU9 engine models ...

Page 193: ...Wiring diagrams 12 19 12 Diagram1b Typical engine management warning lamps and gauges XU5J JA and XU9JA engine models ...

Page 194: ...12 20 Wiring diagrams Diagram 2 Typical exterior lighting reversing lamps foglamps sidelamps and headlamps ...

Page 195: ...Wiring diagrams 12 21 12 Diagram 2a Typical exterior lighting direction indicators and stop lamps typical interior lighting and associated circuits ...

Page 196: ...12 22 Wiring diagrams Diagram 3 Typical ancillary circuits wash wipe horn heater blower and heated rear window ...

Page 197: ...Wiring diagrams 12 23 12 Diagram 3a Typical ancillary circuits electric windows central locking and radio cassette ...

Page 198: ...12 24 Wiring diagrams Supplementary diagram A Typical engine management TU3M Z and TU3FM L engine models ...

Page 199: ...Wiring diagrams 12 25 12 Supplementary diagram B Typical engine management TU1M L and XU5M3 Z L engine models ...

Page 200: ...12 26 Wiring diagrams Supplementary diagram C Typical engine management XU9J1 Z L engine models ...

Page 201: ...Wiring diagrams 12 27 12 Supplementary diagram D Typical engine management XU9JA L engine models ...

Page 202: ...except SR GT Cabriolet and GTI 1300 mm SR and GT models 1314 mm 1 6 GTI and Cabriolet models 1328 mm 1 9 GTI models 1344 mm Weights Kerb weight 740 to 935 kg Maximum towing weight TU9 and TU1 engines 700 kg All other engines 800 kg Maximum roof rack load 50 kg Exact kerb weight varies depending on model refer to VIN plate for details Dimensions and weights REF 1 Conversion factors REF 2 Buying spa...

Page 203: ...er square inch psi lbf in2 lb in2 psi lbf in2 lb in2 Kilopascals kPa x 0 01 Kilograms force per square x 98 1 Kilopascals kPa centimetre kgf cm2 kg cm2 Millibar mbar x 100 Pascals Pa x 0 01 Millibar mbar Millibar mbar x 0 0145 Pounds force per square inch x 68 947 Millibar mbar psi lbf in2 lb in2 Millibar mbar x 0 75 Millimetres of mercury mmHg x 1 333 Millibar mbar Millibar mbar x 0 401 Inches of...

Page 204: ...tlets may be independent or members of a local or national chain They frequently offer competitive prices when compared with a main dealer or local garage but it will pay to obtain several quotes before making a decision When researching prices also ask what extras may be added for instance fitting a new valve and balancing the wheel are both commonly charged on top of the price of a new tyre Othe...

Page 205: ...installing the bolt or stud Failure to do this could cause the housing to crack due to the hydraulic action of the bolt or stud as it is screwed in When tightening a castellated nut to accept a split pin tighten the nut to the specified torque where applicable and then tighten further to the next split pin hole Never slacken the nut to align the split pin hole unless stated in the repair procedure...

Page 206: ...as standard or optional equipment may be equipped with a built in security code to deter thieves If the power source to the unit is cut the anti theft system will activate Even if the power source is immediately reconnected the radio cassette unit will not function until the correct security code has been entered Therefore if you do not know the correct security code for the radio cassette unit do...

Page 207: ...rs Metric 8 to 19 mm inclusive M Adjustable spanner 35 mm jaw approx M Spark plug spanner with rubber insert petrol models M Spark plug gap adjustment tool petrol models M Set of feeler gauges M Brake bleed nipple spanner M Screwdrivers Flat blade 100 mm long x 6 mm dia Cross blade 100 mm long x 6 mm dia M Combination pliers M Hacksaw junior M Tyre pump M Tyre pressure gauge M Oil can M Oil filter...

Page 208: ...gains offered on market stalls or at car boot sales There are plenty of good tools around at reasonable prices but always aim to purchase items which meet the relevant national safety standards If in doubt ask the proprietor or manager of the shop for advice before making a purchase Care and maintenance of tools Having purchased a reasonable tool kit it is necessary to keep the tools in a clean an...

Page 209: ...or indicating a master cylinder fault Release the pedal wait a few seconds then depress it again If the pedal travels nearly to the floor before firm resistance is felt brake adjustment or repair is necessary If the pedal feels spongy there is air in the hydraulic system which must be removed by bleeding M Check that the brake pedal is secure and in good condition Check also for signs of fluid lea...

Page 210: ...r M Check the operation of the rear foglight s including the warning light on the instrument panel or in the switch Footbrake M Examine the master cylinder brake pipes and servo unit for leaks loose mountings corrosion or other damage M The fluid reservoir must be secure and the fluid level must be between the upper A and lower B markings M Inspect both front brake flexible hoses for cracks or det...

Page 211: ...rry out all the above checks at the other front wheel and then at both rear wheels Springs and shock absorbers M Examine the suspension struts when applicable for serious fluid leakage corrosion or damage to the casing Also check the security of the mounting points M If coil springs are fitted check that the spring ends locate in their seats and that the spring is not corroded cracked or broken M ...

Page 212: ...sure that it is in good tune ignition system in good order air filter element clean etc M Before any measurements are carried out raise the engine speed to around 2500 rpm and hold it at this speed for 20 seconds Allow the engine speed to return to idle and watch for smoke emissions from the exhaust tailpipe If the idle speed is obviously much too high or if dense blue or clearly visible black smo...

Page 213: ...uel odour m m Excessive noise or fumes from exhaust system Clutch 4 m m Pedal travels to floor no pressure or very little resistance m m Clutch fails to disengage unable to select gears m m Clutch slips engine speed increases with no increase in vehicle speed m m Judder as clutch is engaged m m Noise when depressing or releasing clutch pedal Manual transmission 5 m m Noisy in neutral with engine r...

Page 214: ...or incorrectly gapped spark plugs Chapter 1 m m Choke mechanism incorrectly adjusted worn or sticking carburettor models Chapter 4A m m Faulty fuel cut off solenoid carburettor models Chapter 4A m m Fuel injection system fault fuel injected models Chapter 4B or 4C m m Major mechanical failure eg camshaft drive Chapter 2A 2B or 2C Engine difficult to start when cold m m Battery discharged Chapter 5...

Page 215: ...fuel injected models Chapter 4B or 4C m m Brakes binding Chapters 1 and 9 m m Clutch slipping Chapter 6 Engine backfires m m Timing chain or belt incorrectly fitted or tensioned Chapter 2A 2B or 2C m m Vacuum leak at the carburettor throttle body inlet manifold or associated hoses Chapter 4A 4B or 4C m m Blocked carburettor jet s or internal passages carburettor models Chapter 4A m m Blocked injec...

Page 216: ...urettor models Chapter 4A Excessive noise or fumes from exhaust system m m Leaking exhaust system or manifold joints Chapters 1 and 4D m m Leaking corroded or damaged silencers or pipe Chapters 1 and 4D m m Broken mountings causing body or suspension contact Chapter 1 4 Clutch Pedal travels to floor no pressure or very little resistance m m Broken clutch cable Chapter 6 m m Incorrect clutch pedal ...

Page 217: ...k or Neutral d Poor gear shift quality or erratic gear changes m m Refer to Chapter 7B for the selector cable adjustment procedure Transmission will not downshift kickdown with accelerator pedal fully depressed m m Low transmission fluid level Chapter 1 m m Incorrect selector cable adjustment Chapter 7B Engine will not start in any gear or starts in gears other than Park or Neutral m m Incorrect s...

Page 218: ... Vehicle pulls to one side under braking m m Worn defective damaged or contaminated brake pads shoes on one side Chapters 1 and 9 m m Seized or partially seized front brake caliper wheel cylinder piston Chapters 1 and 9 m m A mixture of brake pad shoe lining materials fitted between sides Chapters 1 and 9 m m Brake caliper or backplate mounting bolts loose Chapter 9 m m Worn or damaged steering or...

Page 219: ... reading m m Faulty gauge sender unit Chapters 3 and 4A 4B 4C and 4D m m Wiring short circuit Chapter 12 m m Faulty gauge Chapter 12 Horn inoperative or unsatisfactory in operation Horn operates all the time m m Horn push either earthed or stuck down Chapter 12 m m Horn cable to horn push earthed Chapter 12 Horn fails to operate m m Blown fuse Chapter 12 m m Cable or cable connections loose broken...

Page 220: ...apter 12 m m Faulty washer switch Chapter 12 m m Faulty washer pump Chapter 12 Washer pump runs for some time before fluid is emitted from jets m m Faulty one way valve in fluid supply hose Chapter 12 Electric windows inoperative or unsatisfactory in operation Window glass will only move in one direction m m Faulty switch Chapter 12 Window glass slow to move m m Regulator seized or damaged or in n...

Page 221: ...ake systems should never be inhaled or ingested Axle A shaft on which a wheel revolves or which revolves with a wheel Also a solid beam that connects the two wheels at one end of the vehicle An axle which also transmits power to the wheels is known as a live axle Axleshaft A single rotating shaft on either side of the differential which delivers power from the final drive assembly to the drive whe...

Page 222: ...me when the piston is at top dead centre and cylinder volume when the piston is at bottom dead centre Constant velocity CV joint A type of universal joint that cancels out vibrations caused by driving power being transmitted through an angle Core plug A disc or cup shaped metal device inserted in a hole in a casting through which core was removed when the casting was formed Also known as a freeze ...

Page 223: ...cuit against accidental overload The typical fuse contains a soft piece of metal which is calibrated to melt at a predetermined current flow expressed as amps and break the circuit Fusible link A circuit protection device consisting of a conductor surrounded by heat resistant insulation The conductor is smaller than the wire it protects so it acts as the weakest link in the circuit Unlike a blown ...

Page 224: ...alve which limits the amount of pressure to the rear brakes during panic stops to prevent wheel lock up R Rack and pinion steering A steering system with a pinion gear on the end of the steering shaft that mates with a rack think of a geared wheel opened up and laid flat When the steering wheel is turned the pinion turns moving the rack to the left or right This movement is transmitted through the...

Page 225: ... up A process of accurate and careful adjustments and parts replacement to obtain the best possible engine performance Turbocharger A centrifugal device driven by exhaust gases that pressurises the intake air Normally used to increase the power output from a given engine displacement but can also be used primarily to reduce exhaust emissions as on VW s Umwelt Diesel engine U Universal joint or U j...

Page 226: ... 9 4 rear brake caliper 9 10 rear brake compensator 9 12 rear wheel cylinder 9 10 rear brake hub drum 9 11 rear brake pads 1 12 9 7 rear brake shoes 1 12 9 6 vacuum servo unit 9 13 Bulbs and fuses 0 15 12 1 Bulbs exterior lights 12 9 Bulbs interior lights 12 11 Bumpers 11 4 C Cables automatic transmission 7B 3 choke 1 11 4A 4 clutch 6 2 handbrake 9 14 kickdown 7B 4 speedometer 12 9 throttle 1 11 4...

Page 227: ...l transmission removal separation refitting 2D 5 Engine transmission mountings 2A 10 2B 12 2C 13 Engine transmission removal 2D 4 et seq Exhaust and emission control systems 4D 1 et seq air inlet heating system components 4D 5 catalytic converter 4D 5 crankcase ventilation system components 4D 5 emission check 1 19 exhaust check 1 12 exhaust manifold 4D 4 exhaust system removal and refitting 4D 3 ...

Page 228: ...cle support REF 5 Jump starting 0 7 K Kickdown cable 7B 4 L Leaks and hose condition 0 9 1 10 Lubricants and fluids 0 16 M Main and big end bearings 2D 15 Maintenance schedule 1 3 Manifold 4A 10 4B 7 4C 5 4D 4 Manual transmission 7A 1 et seq fault finding REF 12 REF 16 gearchange linkage 7A 4 oil 0 16 1 13 7A 2 oil seals 7A 5 overhaul 7A 7 removal and refitting 7A 6 transfer gears 7A 4 Master cyli...

Page 229: ...10 4 front suspension strut 10 3 10 4 rear components 10 6 rear hub drum and bearings 10 6 rear shock absorber 10 6 suspension assembly 10 7 vehicle ride height 10 7 Switches brake light 12 6 cooling system electrical 3 4 facia 12 5 glovebox 12 6 handbrake warning 12 6 instrument panel 12 6 oil pressure warning light 5A 4 reversing light 12 6 reversing light automatic transmission 7B 5 steering co...

Page 230: ...REF 29 REF Notes ...

Page 231: ...Left blank for manual listing pages ...

Page 232: ...REF Left blank for manual listing pages ...

Page 233: ...ies for ever You will also find an impressive array of motoring memorabilia a comfortable 70 seat video cinema and one of the most extensive transport book shops in Britain The Pit Stop Cafe serves everything from a cup of tea to wholesome home made meals or if you prefer you can enjoy the large picnic area nestled in the beautiful rural surroundings of Somerset The Museum is situated on the A359 ...

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