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1984-1997 PEUGEOT 205 Service Repair Manual

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🏷️ Basic Information Identification Make: Peugeot Model: 205 Year Range Covered: 1984-1997 Codes Chassis Code General: Type 205 Engine Codes General: Various (e.g., XU series, TU series) 👋 Introduction Market Position Vehicle Segment: Supermini / Subcompact hatchback Reputation: Known for its distinctive styling, excellent handling, and practicality. A beloved icon of the 1980s and 1990s. Competitive Analysis Key Competitors: Ford Fiesta, Volkswagen Golf, Renault 5, Opel/Vauxhall Corsa, Fiat Uno. Key Features Design Influence: Designed by Gérard Welter, featuring a distinctive and aerodynamic shape that remained largely unchanged throughout its production run. Handling Dynamics: Renowned for its sophisticated and engaging chassis dynamics, particularly the renowned '205 handling'. Performance Variants: Included iconic hot hatch variants like the 205 GTI and 205 T16. 📋 Manual Details Coverage Areas Manual Coverage Overview: Comprehensive service and repair procedures for all models and engines of the Peugeot 205 from 1984 to 1997. Page Count Page Count Estimate: Likely extensive, estimated 1000+ pages given the breadth of coverage. Manual Type Manual Type: Service and Repair Workshop Manual Language Language: English Format File Format: PDF Compatibility: All Versions of Windows & Mac Printability: All pages are printable Accessibility: Instant Download 📖 Manual Coverage Systems Covered Maintenance: Scheduled maintenance, fluid changes, filter replacements, general inspections. Engine: Engine overhaul, internal component repair, timing belt replacement, cylinder head service, piston and ring replacement. Cooling Heating Air Conditioning: Radiator service, water pump replacement, thermostat diagnostics, heater core repair, A/C system recharge and leak detection. Fuel System: Fuel pump testing, injector service, carburetor adjustment/rebuild (for earlier models), fuel filter replacement, fuel tank service. Exhaust Emission Control: Exhaust system repair and replacement, catalytic converter service, emission control component testing and replacement. Starting Charging Systems: Alternator testing and replacement, starter motor diagnostics and repair, battery service and testing. Ignition System: Spark plug replacement, ignition coil testing, distributor service (if applicable), ignition timing adjustment. Braking System: Brake pad and rotor replacement, brake caliper service, brake line replacement, bleeding procedures, ABS diagnostics (if equipped). Suspension Steering: Shock absorber and strut replacement, ball joint and tie rod end replacement, wheel alignment, power steering system service. Bodywork Fittings: Panel repair and replacement, door and window mechanism service, interior trim removal and installation, bumper repair. Body Electrical System: Lighting system diagnostics, wiring harness repair, switch and sensor testing, fuse and relay identification, power window/lock repair. Procedures Included Diagnostics: Step-by-step diagnostic procedures for all major systems. Repair: Complete repair procedures for all components and systems. Troubleshooting: Troubleshooting guides and common fault identification. Assembly Disassembly: Detailed instructions for component removal and reinstallation. Technical Depth Depth Of Information: Covers routine maintenance, component-level repair, and detailed system overhauls. Visual Aid Quality: Highly detailed exploded pictures and diagrams. 📊 Manual Specifications File Format File Type: PDF Software Requirements: Adobe PDF Reader Compression Utility: WinZip (or similar) Print Quality Print Resolution: High resolution, suitable for clear printing. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Options Gasoline: 1.0L, 1.1L, 1.4L, 1.6L, 1.9L (all gasoline) Engine Families Common: TU series (e.g., TU1, TU3, TU5) and XU series (e.g., XU5, XU7, XU9). Performance Typical Horsepower Range: Approx. 45 hp (1.0L) to 130 hp (1.9 GTI). Typical Torque Range: Approx. 74 Nm (1.0L) to 161 Nm (1.9 GTI). Fuel System Fuel Delivery Early Models: Carburetor (e.g., Solex, Weber) for smaller displacement engines. Fuel Delivery Later Models: Electronic Fuel Injection (EFI/MPI) for larger displacement and performance variants. Fuel Type: Unleaded Gasoline (RON 95 or higher recommended for performance models). 🔧 Transmission Standard Standard Transmission Type: 5-speed Manual Optional Optional Transmission Type: 4-speed Automatic (available on certain models/engines). Features Clutch Type: Hydraulically operated single dry plate clutch. 📐 Dimensions Exterior Body Styles: 3-door hatchback, 5-door hatchback. Length Approx: 3700-3850 mm (depending on model/year) Width Approx: 1600-1650 mm Height Approx: 1350-1400 mm Weights Curb Weight Approx: 800-1050 kg (depending on engine and equipment) 🛡️ Safety Features Ratings Crash Test Ratings Era: Era-appropriate safety standards. Later models may have benefited from incremental safety improvements. Active Features Active Safety Features Standard: Disc brakes (front), Drum brakes (rear). Some later models may feature ABS as an option. Passive Features Passive Safety Features Standard: Seat belts (front), reinforced safety cage, collapsible steering column. 💡 Technology Features Infotainment Infotainment Features Era: Basic radio/cassette players were common. Higher trims might have featured improved sound systems. Driver Assistance Driver Assistance Systems Availability: Very limited by modern standards. ABS was an option on later, higher-spec models. No advanced driver aids. Connectivity Connectivity Features: None. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 10,000 km or 12 months, whichever comes first (check manual for specific engine). Timing Belt Replacement: Crucial service item, typically every 80,000 km or 5 years (consult manual for exact interval per engine). Fluid Specifications Engine Oil Viscosity Typical: 10W-40 or 5W-40 (API SG/SH, ACEA...
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Sku: 211613
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1984-1997 PEUGEOT 205 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Peugeot
Model:
205
Year Range Covered:
1984-1997
Codes
Chassis Code General:
Type 205
Engine Codes General:
Various (e.g., XU series, TU series)
👋 Introduction
Market Position
Vehicle Segment:
Supermini / Subcompact hatchback
Reputation:
Known for its distinctive styling, excellent handling, and practicality. A beloved icon of the 1980s and 1990s.
Competitive Analysis
Key Competitors:
Ford Fiesta, Volkswagen Golf, Renault 5, Opel/Vauxhall Corsa, Fiat Uno.
Key Features
Design Influence:
Designed by Gérard Welter, featuring a distinctive and aerodynamic shape that remained largely unchanged throughout its production run.
Handling Dynamics:
Renowned for its sophisticated and engaging chassis dynamics, particularly the renowned '205 handling'.
Performance Variants:
Included iconic hot hatch variants like the 205 GTI and 205 T16.
📋 Manual Details
Coverage Areas
Manual Coverage Overview:
Comprehensive service and repair procedures for all models and engines of the Peugeot 205 from 1984 to 1997.
Page Count
Page Count Estimate:
Likely extensive, estimated 1000+ pages given the breadth of coverage.
Manual Type
Manual Type:
Service and Repair Workshop Manual
Language
Language:
English
Format
File Format:
PDF
Compatibility:
All Versions of Windows & Mac
Printability:
All pages are printable
Accessibility:
Instant Download
📖 Manual Coverage
Systems Covered
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, general inspections.
Engine:
Engine overhaul, internal component repair, timing belt replacement, cylinder head service, piston and ring replacement.
Cooling Heating Air Conditioning:
Radiator service, water pump replacement, thermostat diagnostics, heater core repair, A/C system recharge and leak detection.
Fuel System:
Fuel pump testing, injector service, carburetor adjustment/rebuild (for earlier models), fuel filter replacement, fuel tank service.
Exhaust Emission Control:
Exhaust system repair and replacement, catalytic converter service, emission control component testing and replacement.
Starting Charging Systems:
Alternator testing and replacement, starter motor diagnostics and repair, battery service and testing.
Ignition System:
Spark plug replacement, ignition coil testing, distributor service (if applicable), ignition timing adjustment.
Braking System:
Brake pad and rotor replacement, brake caliper service, brake line replacement, bleeding procedures, ABS diagnostics (if equipped).
Suspension Steering:
Shock absorber and strut replacement, ball joint and tie rod end replacement, wheel alignment, power steering system service.
Bodywork Fittings:
Panel repair and replacement, door and window mechanism service, interior trim removal and installation, bumper repair.
Body Electrical System:
Lighting system diagnostics, wiring harness repair, switch and sensor testing, fuse and relay identification, power window/lock repair.
Procedures Included
Diagnostics:
Step-by-step diagnostic procedures for all major systems.
Repair:
Complete repair procedures for all components and systems.
Troubleshooting:
Troubleshooting guides and common fault identification.
Assembly Disassembly:
Detailed instructions for component removal and reinstallation.
Technical Depth
Depth Of Information:
Covers routine maintenance, component-level repair, and detailed system overhauls.
Visual Aid Quality:
Highly detailed exploded pictures and diagrams.
📊 Manual Specifications
File Format
File Type:
PDF
Software Requirements:
Adobe PDF Reader
Compression Utility:
WinZip (or similar)
Print Quality
Print Resolution:
High resolution, suitable for clear printing.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Options Gasoline:
1.0L, 1.1L, 1.4L, 1.6L, 1.9L (all gasoline)
Engine Families Common:
TU series (e.g., TU1, TU3, TU5) and XU series (e.g., XU5, XU7, XU9).
Performance
Typical Horsepower Range:
Approx. 45 hp (1.0L) to 130 hp (1.9 GTI).
Typical Torque Range:
Approx. 74 Nm (1.0L) to 161 Nm (1.9 GTI).
Fuel System
Fuel Delivery Early Models:
Carburetor (e.g., Solex, Weber) for smaller displacement engines.
Fuel Delivery Later Models:
Electronic Fuel Injection (EFI/MPI) for larger displacement and performance variants.
Fuel Type:
Unleaded Gasoline (RON 95 or higher recommended for performance models).
🔧 Transmission
Standard
Standard Transmission Type:
5-speed Manual
Optional
Optional Transmission Type:
4-speed Automatic (available on certain models/engines).
Features
Clutch Type:
Hydraulically operated single dry plate clutch.
📐 Dimensions
Exterior
Body Styles:
3-door hatchback, 5-door hatchback.
Length Approx:
3700-3850 mm (depending on model/year)
Width Approx:
1600-1650 mm
Height Approx:
1350-1400 mm
Weights
Curb Weight Approx:
800-1050 kg (depending on engine and equipment)
🛡️ Safety Features
Ratings
Crash Test Ratings Era:
Era-appropriate safety standards. Later models may have benefited from incremental safety improvements.
Active Features
Active Safety Features Standard:
Disc brakes (front), Drum brakes (rear). Some later models may feature ABS as an option.
Passive Features
Passive Safety Features Standard:
Seat belts (front), reinforced safety cage, collapsible steering column.
💡 Technology Features
Infotainment
Infotainment Features Era:
Basic radio/cassette players were common. Higher trims might have featured improved sound systems.
Driver Assistance
Driver Assistance Systems Availability:
Very limited by modern standards. ABS was an option on later, higher-spec models. No advanced driver aids.
Connectivity
Connectivity Features:
None.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000 km or 12 months, whichever comes first (check manual for specific engine).
Timing Belt Replacement:
Crucial service item, typically every 80,000 km or 5 years (consult manual for exact interval per engine).
Fluid Specifications
Engine Oil Viscosity Typical:
10W-40 or 5W-40 (API SG/SH, ACEA A2/A3, check manual for precise specification).
Coolant Type:
Ethylene glycol based antifreeze, mixed with distilled water (50/50 ratio). Refer to manual for specific Peugeot coolant type.
Brake Fluid Type:
DOT 3 or DOT 4 (check manual).
Transmission Fluid Manual:
API GL-4, SAE 75W-80 or 75W-90 gear oil (check manual for capacity and specific type).
Transmission Fluid Automatic:
ATF Dexron II (check manual for specific type and capacity).
Known Issues
Common Wear Items:
Suspension components (wishbones, anti-roll bar links), clutch, exhaust system, ignition components, rust on sills and wheel arches.
Electrical Gremlins:
Can suffer from minor electrical issues over time, particularly with wiring harnesses and switchgear.
Engine Specifics:
Some earlier carburetors can be troublesome; timing belt integrity is critical.
📚 Vehicle History
Brand Heritage
Peugeot Heritage:
Peugeot has a long history of producing popular and dynamic small cars, building on the success of models like the 204 and 304.
Model Evolution
Introduction Year:
1983
Facelifts Updates:
Received minor facelifts and updates throughout its lifespan, including revised interior trim, lighting, and engine options.
Production
Production Period:
1983-1998 (continued production in some markets after 1997)
Manufacturing Locations:
Primarily France, but also produced in other PSA Peugeot Citroën plants globally.
Sales Success:
One of Peugeot's most successful models, selling over 2.8 million units worldwide.
🏆 Awards & Recognition
Recognitions
Car Of The Year Nominations:
Named European Car of the Year in 1988.
Performance Awards:
The 205 GTI was widely lauded by automotive journalists for its exceptional handling and driving dynamics.
Certifications
Homologation Motorsport:
The 205 T16 was a highly successful rally car, dominating the World Rally Championship.
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