Peugeot 205 manual

Peugeot 205 Service and Repair Manual Models covered All Peugeot 205 models with petrol engines (inc. GTi, Cabriolet, Automatic & special/limited editions) 954 cc, 1124 cc, 1360 cc, 1580 cc & 1905 cc Covers mechanical features of Vans Does not cover diesel engine or T16 Turbo models A K Legg LAE MIMI and John S Mead © Haynes Publishing 199[...]

LIVING WITH YOUR PEUGEOT 205 Introduction Page 0•4 Safety First! Page 0•5 ROADSIDE REP AIRS Introduction Page 0•6 If your car won’t start Page 0•6 Jump starting Page 0•7 Wheel changing Page 0•8 Identifying leaks Page 0•9 Towing Page 0•9 WEEKL Y CHECKS Introduction Page 0•10 Underbonnet check points Page 0•10 Engine oil level P[...]

REP AIRS & OVERHAUL Engine and Associated Systems XV, XW and XY engines in-car repair procedures Page 2A•1 XU series engine in-car repair procedures Page 2B•1 TU series engine in-car repair procedures Page 2C•1 Engine removal and overhaul procedures Page 2D•1 Cooling, heating and air conditioning systems Page 3•1 Fuel system - carbure[...]

The Peugeot 205 was introduced in the UK in September 1983 as a five- door Hatchback with a transversely-mounted engine and trans- mission assembly driving the front wheels. The suspension is of front coil springs and rear transverse torsion bars. Three engine sizes were originally available, featuring a chain driven overhead camshaft design mounte[...]

Safety first! 0•5 W orking on your car can be dangerous. This page shows just some of the potential risks and hazards, with the aim of cr eating a safety-conscious attitude. General hazar ds Scalding • Don’t r emove the radiator or expansion tank cap while the engine is hot. • Engine oil, automatic transmission fluid or power steering fluid[...]

0•6 Roadside r epairs The following pages are intended to help in dealing with common roadside emergencies and breakdowns. You will find more detailed fault finding information at the back of the manual, and repair information in the main chapters. If your car won’ t start and the starter motor doesn’ t tur n M If it’s a model with automati[...]

Roadside repairs 0•7 When jump-starting a car using a booster battery , observe the following precautions: 4 Before connecting the booster battery , make sure that the ignition is switched of f. 4 Ensure that all electrical equipment (lights, heater , wipers, etc) is switched of f. 4 Make sure that the booster battery is the same voltage as the d[...]

0•8 Roadside r epairs Wheel changing Some of the details shown here will vary accor ding to model. For instance, the location of the spare wheel and jack is not the same on all cars. However , the basic principles apply to all vehicles. M When a puncture occurs, stop as soon as it is safe to do so. M Park on firm level ground, if possible, and we[...]

Roadside repairs 0•9 When all else fails, you may find yourself having to get a tow home – or of course you may be helping somebody else. Long-distance recovery should only be done by a garage or breakdown service. For shorter distances, DIY towing using another car is easy enough, but observe the following points: M Use a proper tow-rope – t[...]

0•10 W eekly checks There are some very simple checks which need only take a few minutes to carry out, but which could save you a lot of inconvenience and expense. These "Weekly checks" require no great skill or special tools, and the small amount of time they take to perform could prove to be very well spent, for example; M Keeping an [...]

W eekly checks 0•11 Engine oil level Before you start 4 Make sure that your car is on level ground. 4 Check the oil level before the car is driven, or at least 5 minutes after the engine has been switched off. The correct oil Modern engines place great demands on their oil. It is very important that the correct oil for your car is used (See “Lu[...]

0•12 W eekly checks Brake fluid level Warning: l Brake fluid can harm your eyes and damage painted surfaces, so use extreme caution when handling and pouring it. l Do not use fluid that has been standing open for some time, as it absorbs moisture from the air, which can cause a dangerous loss of braking effectiveness. Safety First! l If the reser[...]

W eekly checks 0•13 Screenwash additives not only keep the winscreen clean during foul weather, they also prevent the washer system freezing in cold weather - which is when you are likely to need it most. Don’t top up using plain water as the screenwash will become too diluted, and will freeze during cold weather. On no account use coolant anti[...]

0•14 W eekly checks T yre condition and pr essur e It is very important that tyres are in good condition, and at the correct pressure - having a tyre failure at any speed is highly dangerous. Tyre wear is influenced by driving style - harsh braking and acceleration, or fast cornering, will all produce more rapid tyre wear. As a general rule, the [...]

W eekly checks 0•15 Bulbs and fuses 4 Check all external lights and the horn. Refer to the appropriate Sections of Chap- ter 12 for details if any of the circuits are found to be inoperative. 4 Visually check all accessible wiring connectors, harnesses and retaining clips for security, and for signs of chafing or damage. If you need to check your[...]

0•16 Lubricants, fluids and tyr e pressur es Lubricants and fluids Engine . . . . . . . . . . . . . . . . . . . . . . . Multigrade engine oil, viscosity SAE 10W/40, or 15W/40, to API SG/CD (Duckhams QXR, QS or Hypergrade Plus) Cooling system . . . . . . . . . . . . . . . . Ethylene glycol-based antifreeze (Duckhams Antifreeze and Summer Coolant) [...]

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 ren[...]

1•2 Servicing Specifications Lubricants and fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to end of “ Weekly checks ” Capacities Engine oil XV and XW series engines (including filter) . . . . . . . . . . . . . . . . . . . . 4.5 litres XY and XU series engines (including filter) . . . . . . . . . . . . . . . [...]

Maintenance schedule 1•3 1 Every 250 miles (400 km) or weekly m m Refer to “Weekly checks”. Every 36 000 miles (58 000 km) or 3 years - whichever comes sooner In addition to all the items listed above, carry out the following: m m Renew the timing belt (Section 31). Note: Although the normal interval for timing belt renewal is 72 000 miles (1[...]

1•4 Maintenance - component location Underbonnet view of a 1360 cc GT model (XY8 series engine) 1 Right-hand front engine mounting 2 Jack 3 Drivebelt 4 Oil filter 5 Bottom hose 6 Water pump 7 Throttle cable 8 Fuel pump 9 Brake master cylinder 10 Brake fluid reservoir filler cap 11 Vehicle identification plate 12 Choke cable 13 Heater hose 14 Oil [...]

Maintenance - component location 1•5 1 Underbonnet view of a 1360 cc XS model (TU series engine) 1 Brake fluid reservoir filler cap 2 Brake master cylinder 3 Brake vacuum servo unit 4 Servo vacuum hose 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 [...]

1•6 Maintenance - component location Fr ont underside view of a 1360 cc GT model 1 Bottom hose 2 Reverse lamp switch 3 Engine/transmission oil drain plug 4 Radiator 5 Gear linkage 6 Clutch housing 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[...]

Maintenance - component location 1•7 1 Rear underside view of a 1360 cc GT model 1 Exhaust front pipe 2 Handbrake cables 3 Heatshield 4 Rear suspension cross-tube 5 Brake hydraulic flexible hose 6 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 1[...]

1 Introduction This Chapter is designed to help the home mechanic maintain his/her vehicle for safety, economy, long life and peak performance. This Chapter contains a master maintenance schedule, followed by Sections dealing specifically with each task in the schedule. Visual checks, adjustments, component renewal and other helpful items are inclu[...]

4 Allow the oil to drain into the container, and check the condition of the plug’s sealing washer; renew it if worn or damaged. 5 Allow some time for the old oil to drain, noting that it may be necessary to reposition the container as the oil flow slows to a trickle; when the oil has completely drained, wipe clean the drain plug and its threads i[...]

6 Underbonnet check for fluid leaks and hose condition 1 Warning : Renewal of any air conditioning hoses (where fitted) must be left to a dealer service department or air conditioning specialist who has the equipment to depressurise the system safely. Never remove air conditioning components or hoses until the system has been depressurised. General[...]

Keep the socket aligned with the spark plug - if it is forcibly moved to one side, the ceramic insulator may be broken off. As each plug is removed, examine it as follows. 5 Examination of the spark plugs will give a good indication of the condition of the engine. If the insulator nose of the spark plug is clean and white, with no deposits, this is[...]

by moving the alternator by hand, or tightening the adjuster bolt. 11 Tension the drivebelt as described in the following paragraphs. Tensioning 12 If not already done, proceed as described in paragraphs 2 and 3. 13 Correct tensioning of the drivebelt will ensure that it has a long life. A belt which is too slack will slip and perhaps squeal. Bewar[...]

2 Check the pipes and connections for evidence of leaks, severe corrosion, or damage. Make sure that all brackets and rubber mountings are in good condition, and tight; if any of the mountings are to be renewed, ensure that the replacements are of the correct type. Leakage at any of the joints or in other parts of the system will usually show up as[...]

4 The oil level should reach the lower edge of the filler/level hole. A certain amount of oil will have gathered behind the filler/level plug, and will trickle out when it is removed; this does not necessarily indicate that the level is correct. To ensure that a true level is established, wait until the initial trickle has stopped, then add oil as [...]

the inner joint and attempting to rotate the driveshaft. Any appreciable movement indicates wear in the joints, wear in the driveshaft splines, or a loose driveshaft retaining nut. 25 Steering and suspension check 2 Front suspension and steering check 1 Apply the handbrake then jack up the front of the vehicle and support it on axle stands (see “[...]

of air cleaner, the end (or top) cover is retained by a number of spring clips. 6 Extract the element (see illustration) . 7 Discard the element and wipe the casing interior clean. 8 Insert the new element then refit the end cover and air duct. Ensure that the cover is correctly seated, to prevent air leaks, before fastening with the nuts or the cl[...]

Carburettor models Idle speed adjustment - single carburettor engines 3 Ensure that all electrical loads are switched off and, where applicable, the choke is pushed fully in; if the car does not have a tachometer (rev counter), connect one to the engine, following its manufacturer’s instructions. Note the idle speed, and compare it with that spec[...]

10 With the engine idling, turn the idle speed screw on the interconnecting linkage as necessary until the engine speed is 1000 rpm. 11 Note the reading on the vacuum gage, then transfer the gauge pipe to the vacuum pipe stub on the right-hand carburettor. If the reading is not as previously recorded, turn the synchronising screw on the linkage as [...]

Peugeot dealer, for diagnosis. On all single- point fuel injection models, the idle speed and mixture CO content is controlled by the engine management ECU and cannot be adjusted. If the idle speed and/or CO level is incorrect, there is likely to be a fault in the engine management system (see Chapter 4B). Multi-point fuel injection models Idle spe[...]

9 Check that the clutch action is smooth and progressive, that the drive is taken up smoothly, and that the pedal travel is not excessive. Also listen for any noises when the clutch pedal is depressed. 10 Check that all gears can be engaged smoothly, without noise, and that the gear lever action is not abnormally vague or “notchy”. 11 Listen fo[...]

7 Remove the drain plug, and allow the coolant to drain into the container. 8 If the coolant has been drained for a reason other than renewal, then provided it is clean and less than two years old, it can be re-used, though this is not recommended. 9 Refit the radiator and cylinder block drain plugs on completion of draining. Cooling system flushin[...]

Slacken and retighten the bleed screws to allow any air that has risen to escape. Note: Take great care not to scald yourself with the hot coolant during this operation. 26 Stop the engine and allow it engine to cool, then remove the “header tank” or refit the expansion bottle/tank to its original location. 27 When the engine has cooled, check [...]

2A Chapter 2 Part A: XV , XW and XY engines in-car r epair pr ocedur es Engine general Code and displacement: XV8 (108C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 954 cc XW7 (109F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1124 cc XY7 (150D) . . . . . . [...]

Torque wrench settings Nm lbf ft Engine mounting nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 25 Oil pump screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5 Cylinder head bolts: Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

bi- metal rockers consisting of an aluminium arm and steel pad, have different valve clearances than earlier engines. Ensure that the correct figures are used according to engine type. 6 If the feeler blade is a tight or loose fit then the clearance must be adjusted. To do this, loosen the locknut of the adjustment stud and screw the adjuster stud [...]

9 Remove the crankshaft oil pump drivegear and its Woodruff key. 10 Unbolt the oil pump. Some socket- headed screws are accessible through the holes in the driven gear (see illustration) . Lift off the pump and spacer plate (see illustration) . 11 Jam the camshaft sprocket and unscrew the sprocket retaining bolt. Take off the fuel pump operating ec[...]

24 Using a very thin screwdriver blade, turn the lock on the chain tensioner fully clockwise to release the slipper (see illustration) . 25 Check that the locating dowel is in position and fit the oil pump with spacer plate. If the pump driven sprocket is hard to turn, release the pump mounting bolts and turn the pump slightly on its locating dowel[...]

4 To dismantle the rocker arm assembly, carefully prise off the circlip from the end of the rocker shaft; retain the rocker pedestal, to prevent it being sprung off the end of the shaft. Slide the various components off the end of the shaft, keeping all components in their correct fitted order (see illustrations) . Make a note of each component’s[...]

sprocket, or fabricate a suitable alternative. If it will not be necessary to rotate the crankshaft, the home-made tool described in the text will suffice. Removal 1 Disconnect and remove the battery, as described in Chapter 5A. 2 Remove the air cleaner, complete with mounting brackets, hot air hose and inlet hose, with reference to Chapter 4A. Als[...]

26 Remove the head bolts and lift off the rocker shaft assembly (see illustration) . It may be necessary to leave one or two bolts in the assembly if they foul the bulkhead due to insufficient engine height. 27 Loosen the camshaft thrust plate bolt, pull out the plate and temporarily retighten the bolt (see illustration) . 28 The camshaft sprocket [...]

plastic or wood scraper to remove all traces of gasket and carbon; also clean the piston crowns. Refer to paragraph 32 before turning the crankshaft. Take particular care during the cleaning operations, as aluminium alloy is easily damaged. Also, make sure that the carbon is not allowed to enter the oil and water passages - this is particularly imp[...]

6 Note the fitted depth of the seal as a guide to refitting the new seal, then punch or drill two small holes opposite each other in the seal. Screw a self-tapping screw into each, and pull on the screws with pliers to extract the seal. Alternatively, the seal can be levered out of position using a suitable flat-bladed screwdriver, taking great car[...]

2B Chapter 2 Part B: XU series engine in-car r epair pr ocedur es Engine general Code and displacement: XU5J (180A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1580 cc XU5JA (B6D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1580 cc XU5JA/K (B6E) . . . . . . . . [...]

Torque wrench settings Nm lbf ft Camshaft cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7 Camshaft bearing caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 11 Camshaft sprocket bolt (M10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 30 Camshaft spr[...]

2 Valve clearances - checking and adjustment 3 Note : The valve clearances must be checked and adjusted only when the engine is cold. 1 The importance of having the valve clearances correctly adjusted cannot be overstressed, as they vitally affect the performance of the engine. If the clearances are too big, the engine will be noisy (characteristic[...]

3 Compression test - description and interpretation Refer to Part A, Section 3 but on engines with a static distributorless ignition system, disable the ignition by depressing the retaining clip and disconnecting the wiring connector from the ignition module. 4 Timing belt - general information, removal and refitting 3 General information 1 The tim[...]

13 Slacken the two nuts on the front of the timing belt tensioner and the single nut at the rear. Use a spanner on the square end of the tensioner cam spindle to turn the cam to the horizontal position and so compress the tensioner spring (see illustrations) . Tighten the cam locknut. 14 Remove the timing belt, taking care not to kink it or contami[...]

is available, it should be refitted to the tensioned run of the belt. The reading should now be between 42 and 46 units. 37 If the tension is not as specified, repeat the tensioning operation. 38 Refit the belt covers and the crankshaft pulley. Apply thread locking compound to the crankshaft pulley bolt threads, and tighten the bolt to the specifie[...]

7 Camshaft and followers - removal, inspection and refitting 4 Removal 1 Remove the camshaft sprocket as described in Section 5. Remove the rear cover plate behind the sprocket. 2 Remove the camshaft cover. For ease of access, remove the distributor cap and HT leads, air cleaner assembly and brake servo vacuum hose. 3 Remove the distributor as desc[...]

21 Fit a new camshaft oil seal, using the information given in Section 6, then refit the sprocket rear cover plate. Align the cover plate using a 10 mm dowel or drill bit then secure with the retaining bolt (see illustration) . 22 Refit the camshaft sprocket as described in Section 5. 23 Check the valve clearances as described in Section 2. 24 Refi[...]

21 If warpage of the cylinder head gasket surface is suspected, use a straight-edge to check it for distortion. Refer to Part D of this Chapter if necessary. 22 Check the condition of the cylinder head bolts, and particularly their threads, whenever they are removed. Wash the bolts in suitable solvent, and wipe them dry. Check each for any sign of [...]

39 Check the valve clearances and adjust, if necessary (see Section 2). 40 Refit the remaining components in the reverse order of removal and with reference to the relevant Sections and Chapters of this manual as applicable. Make sure that the correct inlet manifold gasket is fitted. A gasket for carburettor versions is included in the gasket overh[...]

Unbolt the oil seal carrier from the cylinder block. The sprocket, spacer (where fitted) and chain can then be slid off the end of the crankshaft. 5 Slacken and remove the bolts (along with the baffle plate, where fitted) securing the strainer cover to the pump body. Lift off the strainer cover, and take out the relief valve piston and spring, noti[...]

Refitting 15 Refitting is a reversal of removal, but tighten the union nuts carefully to the specified torque while holding the connection stubs stationary. Check and if necessary top- up the engine oil as described in “Weekly checks”. 12 Crankshaft oil seals - renewal 4 Right-hand oil seal 1 Remove the crankshaft sprocket and, where fitted, th[...]

2C Chapter 2 Part C: TU series engine in-car r epair pr ocedur es Engine general Code and displacement: TU9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 954 cc TU1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1124 cc TU1M/L . . . . . . [...]

Torque wrench settings Nm lbf ft Camshaft sprocket retaining bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 59 Camshaft thrust fork retaining bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 12 Crankshaft pulley retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6 Crankshaft sprocket [...]

2 Compression test - description and interpretation Refer to Part A, Section 3 but on engines with a static distributorless ignition system, disable the ignition by depressing the retaining clip and disconnecting the wiring connector from the ignition module. 3 Engine assembly/valve timing holes - general information and usage Note : Do not attempt[...]

Examine the seal for signs of damage and deterioration, and if necessary, renew it. 6 Remove the spacer from each stud, and lift off the oil baffle plate (see illustrations) . Refitting 7 Carefully clean the cylinder head and cover mating surfaces, and remove all traces of oil. 8 Fit the rubber seal over the edge of the cylinder head cover, ensurin[...]

Centre cover 2 Remove the upper cover as described in paragraph 1, then free the wiring from its retaining clips on the centre cover. 3 Slacken and remove the three retaining bolts (one at the rear of the cover, beneath the engine mounting plate, and two directly above the crankshaft pulley), and manoeuvre the centre cover out from the engine compa[...]

pulley rotates freely, without any sign of roughness. If necessary, renew the tensioner pulley as described in Section 8. Make sure that the locking tools are still in place, as described in Section 3. 11 Manoeuvre the timing belt into position, ensuring that the arrows on the belt are pointing in the direction of rotation (clockwise, when viewed f[...]

Removal 1 Disconnect the battery negative lead. 2 Position the engine assembly/valve timing holes as described in Section 3, and lock both the camshaft sprocket and flywheel in position. Do not attempt to rotate the engine whilst the pins are in position. Camshaft sprocket 3 Remove the centre timing belt cover as described in Section 6. 4 Loosen th[...]

21 Loosen the tensioner pulley retaining nut. Rotate the pulley anti-clockwise to remove all free play from the timing belt, then retighten the nut. 22 Tension the belt as described in paragraphs 14 to 19 of Section 7. 23 Refit the timing belt covers as described in Section 6. Crankshaft sprocket 24 Where removed, locate the Woodruff key in the cra[...]

which contact the camshaft lobes for wear ridges and scoring. Renew any rocker arms on which these conditions are apparent. If a rocker arm bearing surface is badly scored, also examine the corresponding lobe on the camshaft for wear, as it is likely that both will be worn. Renew worn components as necessary. The rocker arm assembly can be dismantl[...]

12 Disengage the timing belt from the camshaft sprocket, and position the belt clear of the sprocket. Ensure that the belt is not bent or twisted sharply. 13 Slacken the retaining clips, and disconnect the coolant hoses from the thermostat housing (on the left-hand end of the cylinder head). 14 Depress the retaining clip(s), and disconnect the wiri[...]

which is fitted at the factory, and a slightly thicker “repair” gasket (+ 0.2 mm), for use once the head gasket face has been machined. If the cylinder head has been machined, it should have the letter “R” stamped adjacent to the No 3 exhaust port, and the gasket should also have the letter “R” stamped adjacent to No 3 cylinder on its f[...]

41 Refit the timing belt to the camshaft sprocket. Ensure that the “front run” of the belt is taut - ie, ensure that any slack is on the tensioner pulley side of the belt. Do not twist the belt sharply while refitting it, and ensure that the belt teeth are seated centrally in the sprockets. 42 Loosen the tensioner pulley retaining nut. Pivot th[...]

5 Examine the pump rotors and body for signs of wear ridges and scoring. If worn, the complete pump assembly must be renewed. 6 Examine the relief valve piston for signs of wear or damage, and renew if necessary. The condition of the relief valve spring can only be measured by comparing it with a new one; if there is any doubt about its condition, [...]

Renewal Right-hand mounting 5 Disconnect the battery negative lead. 6 Place a jack beneath the engine, with a block of wood on the jack head. Raise the jack until it is supporting the weight of the engine. 7 Slacken and remove the three nuts securing the right-hand engine mounting upper bracket to the bracket on the cylinder block. Remove the nut s[...]

2D Chapter 2 Part D: Engine r emoval and overhaul pr ocedur es Note: At the time of writing, many specifications for certain engines were not available. Where the relevant specifications are not given here, refer to your Peugeot dealer for further information. Cylinder head Maximum gasket face distortion . . . . . . . . . . . . . . . . . . . . . . [...]

Valve stem diameter (continued): Exhaust: XV, XW and XY series engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 mm XU5J series engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.96 mm XU5JA and XU9J series engines . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.98 mm XU51 and XU5M series eng[...]

Big-end bearing journal diameter: XV, XW and XY series engines: Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.975 to 44.991 mm Undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.675 to 44.691 mm XU5 series engines: Standard . . . . . . . . . . [...]

Torque wrench settings (continued) Nm lbf ft Main bearing ladder casting - aluminium block engines (models with grooved No 5 main bearing half-shell fitted to cylinder block - see text): 11 mm bolts: Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15 Stage 2 . . . . . . . . . . . . . . . . . . [...]

3 Engine/manual transmission - removal, separation, reconnection and refitting 4 Removal Note: The engine can be removed from the car only as a complete unit with the transmission; the two are then separated for overhaul. 1 Park the vehicle on firm, level ground. Chock the rear wheels, then firmly apply the handbrake. Jack up the front of the vehic[...]

twisting them anti-clockwise and disconnect the connectors. Also, where applicable, trace the harness lead(s) back to the relay box, situated beside the battery. Unclip the wiring connector plate from the front of the relay box cover, then undo the retaining nut and remove the cover. Lift up the engine harness lead cover; then undo the nut(s) and r[...]

41 Fit the sump cover to the transmission using a new gasket. 42 Tighten the tighten the cover bolts and drain plug to the specified torque. 43 Fit the protective cover plate to the sump cover. 44 Apply jointing compound to the mating surfaces on the engine and transmission. 45 On the transmission, locate a new O-ring seal and check that the locati[...]

Reconnection 11 Ensure that the bush fitted to the centre of the crankshaft is in good condition. Apply a little Molykote G1 grease (available from your Peugeot dealer) to the torque converter centring pin. Do not apply too much, otherwise there is a possibility of the grease contaminating the torque converter. 12 Ensure that the locating dowels ar[...]

7 It is essential that each valve is stored together with its collets, retainer, spring, and spring seat. The valves should also be kept in their correct sequence, unless they are so badly worn that they are to be renewed. If they are going to be kept and used again, place each valve assembly in a labelled polythene bag or similar small container ([...]

lifting the valve occasionally to redistribute the grinding compound. A light spring placed under the valve head will greatly ease this operation. 22 If coarse grinding compound is being used, work only until a dull, matt even surface is produced on both the valve seat and the valve, then wipe off the used compound, and repeat the process with fine[...]

10 Turn the crankshaft to bring pistons 1 and 4 to BDC (bottom dead centre). 11 Unscrew the nuts from No 1 piston big- end bearing cap. Take off the cap, and recover the bottom half bearing shell (see illustration) . If the bearing shells are to be re- used, tape the cap and the shell together. 12 To prevent the possibility of damage to the cranksh[...]

and then zero the gauge. Push the crankshaft fully the other way, and check the endfloat. The result can be compared with the specified amount, and will give an indication as to whether new thrustwashers are required. 7 If a dial gauge is not available, feeler blades can be used. First push the crankshaft fully towards the flywheel end of the engin[...]

27 Before removing the crankshaft it is advisable to check the endfloat as described in paragraphs 6 and 7. 28 Unbolt and remove the crankshaft left- and right-hand oil seal housings from each end of the cylinder block, noting the correct fitted locations of the locating dowels. If the locating dowels are a loose fit, remove them and store them wit[...]

When all the liners are released, tip the cylinder block/crankcase on its side and remove each liner from the top of the block. As each liner is removed, stick masking tape on its left-hand (transmission side) face, and write the cylinder number on the tape. No 1 cylinder is at the transmission (flywheel/ driveplate) end of the engine. Remove the p[...]

33 Prior to installing the liners, thoroughly clean the liner mating surfaces in the cylinder block, and use fine abrasive paper to polish away any burrs or sharp edges which might damage the liner base seals. Clean the liners and wipe dry, then fit the O-ring seals to the base of each liner. To aid installation, apply a smear of oil to the base of[...]

leakage (from excessive bearing clearances, worn oil pump or high engine speeds) all contribute to lubrication breakdown. Blocked oil passages, which usually are the result of misaligned oil holes in a bearing shell, will also starve a bearing of oil, and destroy it. When lack of lubrication is the cause of bearing failure, the bearing material is [...]

XU series engines 3 On some early engines, both the upper and lower bearing shells were of the same thickness. 4 However, on later engines the main bearing running clearance was significantly reduced. To enable this to be done, four different grades of bearing shell were introduced. The grades are indicated by a colour-coding marked on the edge of [...]

10 Repeat this procedure so that the required bearing shell grade is obtained for each of the five main bearing journals. 11 Seek the advice of your Peugeot dealer on parts availability, and on the best course of action when ordering new bearing shells. Note : On early models, at overhaul it is recommended that the later bearing shell arrangement i[...]

17 Repeat this procedure so that the required bearing shell grade is obtained for each of the five main bearing journals. 18 Seek the advice of your Peugeot dealer for the latest information on parts availability when ordering new bearing shells. Main bearing running clearance check XU series engines 19 On early engines, if the modified bearing she[...]

be fitted, obtain a set of new Black (Class B) upper bearing shells and new Blue (Class A) lower bearing shells. On later (mid-1993 on) engines where the modified bearing shells are already fitted, the running clearance check can be carried out using the original bearing shells, although it is preferable to use a new set as described above, since t[...]

53 Lower the crankshaft into position so that Nos 2 and 3 cylinder crankpins are at TDC; Nos 1 and 4 cylinder crankpins will be at BDC, ready for fitting No 1 piston. 54 Lubricate the lower bearing shells in the main bearing caps with clean engine oil. Make sure that the locating lugs on the shells engage with the corresponding recesses in the caps[...]

72 Refit the Woodruff key, then slide on the oil pump drive sprocket, and locate the drive chain on the sprocket (see illustration) . Lower the crankshaft into position so that Nos 2 and 3 cylinder crankpins are at TDC; Nos 1 and 4 cylinder crankpins will be at BDC, ready for fitting No 1 piston. 73 Thoroughly degrease the mating surfaces of the cy[...]

87 Fit the main bearing caps to their correct locations, ensuring that they are fitted the correct way round (the bearing shell lug recesses in the block and caps must be on the same side). Insert the bolts loosely. 88 Tighten the main bearing cap bolts to the specified Stage 1 torque wrench setting. Once all the bolts have been tightened to the St[...]

crankpin and both bearing shells. Taking care not to mark the cylinder/liner bores, pull the piston/connecting rod assembly down the bore and onto the crankpin. Refit the big-end bearing cap, tightening its retaining nuts finger-tight at first. Note that the faces with the identification marks must match (which means that the bearing shell locating[...]

3 Chapter 3 Cooling, heating and air conditioning systems General System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressurised with expansi on tank/bottle and front-mounted radiator, electric cooling fan, coolant pump and thermostat Pressure cap setting . . . . . . . . . . . . . . . . . . . . .[...]

1 General information and precautions The cooling system is of pressurised type incorporating an expansion bottle or expansion tank according to model. The system includes a front-mounted cross-flow radiator, thermoswitch controlled electric cooling fan, coolant pump and thermostat. The car interior heater matrix is incorporated into the coolant ci[...]

coolant mixtures are likely to cause damage, and encourage the formation of corrosion and scale in the system. 3 Before adding antifreeze, check all hoses and hose connections, because antifreeze tends to leak through very small openings. Engines don’t normally consume coolant, so if the level goes down, find the cause and correct it. 4 Ideally, [...]

5 Disconnect the top mountings, as applicable, then lift the radiator, complete with cooling fan, from the car - taking care not to damage the matrix (see illustration) . The base of the radiator incorporates pins which locate in rubber mountings. 6 If necessary separate the cooling fan, with reference to Section 6. Refitting 7 Refitting is a rever[...]

8 Coolant pump - removal and refitting 3 Note: Refer to the warnings given in Section 1 of this Chapter before proceeding. XV, XW, and XY series engines Removal 1 Drain the cooling system and remove the auxiliary drivebelt as described in Chapter 1. 2 Disconnect the radiator bottom hose, heater return hose, and inlet manifold return hose from the c[...]

10 If the coolant pump is worn, noisy or leaks coolant it must be renewed, as repair is not possible. Refitting 11 Refitting is a reversal of removal, bearing in mind the following points: a) Thoroughly clean the mating faces and use a new gasket. c) Refit and tension the timing belt as described in Chapter 2B. d) Refill the cooling system (Chapter[...]

5 Unscrew the heater assembly mounting nuts and withdraw it from the car. Dismantling 6 To remove the matrix, disconnect the pipe clip and unscrew the mounting screws then slide the matrix from the casing (see illustrations) . If necessary the pipes can be removed by unscrewing the flange screws. Use water from a hose to clean both the inside and o[...]

2 The refrigeration side of the air conditioning system functions in a similar way to a domestic refrigerator. A compressor, belt- driven from the crankshaft pulley, draws refrigerant in its gaseous phase from an evaporator. The compound refrigerant passes through a condenser where it loses heat and enters its liquid phase. After dehydration the re[...]

4A Chapter 4 Part A: Fuel system - carbur ettor engines General System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear-mounted fuel tank, mechanical or electric fuel pump, single or twin carburettor Carburettor Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

Carburettor data (continued) Calibrations and settings: XY8 XY8 XU51C Solex Weber Venturi diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 mm 26 mm 28 mm Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 ± 10 130 ± 5 137/42 Air correction jet .[...]

1 General information and precautions General information The fuel system consists of a fuel tank mounted under the rear of the car, a mechanical fuel pump, and a single or twin downdraught carburettor. On manual transmission and early automatic transmission models, the fuel pump is operated by an eccentric on the camshaft, and is mounted on the re[...]

7 Release the spring clips, and lift the element and ducting from the air cleaner body (see illustrations) . 8 Disconnect the fuel pump inlet hose, and release it from the clip on the ducting. 9 Disconnect the hose from the vacuum motor (see illustration) . 10 Disconnect the inlet and warm air hoses. 11 Remove the special clip, then lift the air cl[...]

9 Remove the upper body. 10 Drive out the operating arm pivot pin, withdraw the arm and lift out the diaphragm. 11 Obtain a repair kit which will contain a new diaphragm and the necessary gaskets. 12 If the valves are damaged, reassemble the pump and obtain a new one complete. 13 If the valves are in good condition, locate the diaphragm, push the o[...]

9 Carburettor - removal and refitting 2 Note: Observe the precautions in Section 1 before working on any component in the fuel system . Removal 1 Remove the air cleaner assembly, as described in Section 2. 2 Unscrew the bolts or nuts and remove the air inlet duct from the top of the carburettor(s). 3 Disconnect the throttle cable or ball-jointed th[...]

Solex 32 and 34 PBISA adjustments Idle speed and mixture 16 Refer to Chapter 1. Fast idle setting 17 To adjust this accurately it will be necessary to measure the angular movement of the throttle valve. The use of a piece of card with the angle drawn on it will provide the necessary setting. 18 Fully close the choke valve then check that the thrott[...]

4A•8 Fuel system - carburettor engines 10.39 Checking the choke opening setting on the Weber 35 IBSH carburettor 2 Adjustment screw on vacuum capsule 10.42 Float level setting on 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 scr[...]

Choke opening setting 38 This adjustment can be made with the carburettor removed using a vacuum pump, or with the carburettor fitted and the engine running. 39 Turn the choke lever so that the choke is fully closed (see illustration) . 40 With the engine running or vacuum applied, check that the gap between the lower edge of the choke valve and th[...]

Throttle damper 53 Refer to the procedures contained in paragraphs 29 and 30 Additional adjustments 54 At the time of writing, not further information was available relating to any further adjustment of these carburettors. 11 Inlet manifold - removal and refitting 3 Removal 1 Disconnect the battery negative lead. 2 Drain the cooling system as descr[...]

4B Chapter 4 Part B: Fuel system - single-point fuel injection engines General System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear-mounted fuel tank, electric fuel pump, single-point fuel injection system System application: TU1M/Z, TU3M/Z and TU3FM/L engines. . . . . . . . . . . . . . . . . [...]

2 Air cleaner assembly - removal and refitting 1 Refer to the procedures in Chapter 4A, Section 2, substituting “throttle body” for all references to the carburettor. 3 Throttle cable - removal, refitting and adjustment 2 Removal and refitting 1 Refer to Chapter 4A, Section 3 substituting “throttle body” for all references to the carburetto[...]

8 Unleaded petrol - general information and usage Note: The information given in this Chapter is correct at the time of writing. If updated information is thought to be required, check with a Peugeot dealer. If travelling abroad, consult one of the motoring organisations (or a similar authority) for advice on the fuel available. All Peugeot 205 sin[...]

c) Before refitting the injector securing screw, apply a few drops of a suitable thread-locking compound to the threads. d) On completion, switch on the ignition and check carefully for signs of fuel leaks; if any signs of leakage are detected the problem must be rectified before the engine is started. Inlet air temperature sensor 9 The sensor is l[...]

19 Do not attempt to adjust the throttle switch setting or that of the stop screw on the throttle valve external linkage; if the accurately matched relationship between these components is lost, the components must be replaced. At the time of writing this means renewing the entire throttle body assembly. Throttle body Note : Refer to the warning no[...]

12 MMFD Mono-point G5 and G6 system components - removal and refitting 3 Note : Check the availability of individual components with your Peugeot dealer before dismantling . Fuel pressure regulator 1 Refer to Section 11, Paragraphs 1 to 3 noting the revised component arrangement (see illustration) . Fuel injector Note : Refer to the warning note in[...]

Inlet air temperature sensor 22 The sensor is screwed into the top of the inlet manifold. 23 Disconnect the battery negative lead. 24 Release the securing clip, and disconnect the wiring plug from the sensor. 25 Unscrew the sensor and withdraw it. 26 Refitting is a reversal of removal. Throttle body Note : Refer to the warning note in Section 1 bef[...]

4B•8 Notes[...]

4C Chapter 4 Part C: Fuel system - multi-point fuel injection engines General System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear-mounted fuel tank, electric fuel pump, multi-point fuel injection system System application: XU5J, XU5JA, XU5JA/K, XU51C/K, XU9JA, XU9JA/K . . . . . . . . . . . . [...]

Note: Residual pressure will remain in the fuel lines long after the vehicle was last used. When disconnecting any fuel line, first depressurise the fuel system as described in Section 4. 2 Air cleaner assembly - removal and refitting 1 Removal 1 Disconnect the inlet and outlet ducts. 2 Unscrew the mounting bolts and lift the air cleaner from the e[...]

Bosch Motronic M1.3 system The Bosch Motronic fuel injection system is designed to meet stringent emission control legislation whilst still providing excellent engine performance and fuel economy. The system is under the overall control of the Motronic M1.3 engine management system, which also controls the ignition timing. The principle of operatio[...]

23 Check the full throttle operation by connecting an ohmmeter between terminals 18 and 3, then fully opening the throttle so that dimension X is 4.0 mm (see illustration) . The internal contacts should close and the ohmmeter reading be zero. 24 If the switch does not operate correctly it should be renewed. Throttle switch - LU2-Jetronic and Motron[...]

Coolant temperature sensor 31 Refer to Chapter 3, Section 7. Electronic control unit (ECU) 32 Refer to Part B, Section 11. Fuel injection system fuses and relays 33 Refer to Part B, Section 11. 12 Inlet manifold - removal and refitting 3 Note : The following procedure is applicable to all three multi-point fuel injection systems, but slight differe[...]

4C•6 Notes[...]

4D Chapter 4 Part D: Exhaust and emission contr ol systems Air inlet heating system components - removal and refitting . . . . . . 4 Catalytic converter - general information and precautions . . . . . . . . 7 Crankcase ventilation system components - removal and refitting . 5 Electro-pneumatic ignition timing retarding system components - removal a[...]

Crankcase ventilation system 7 This system is fitted to all models, and prevents the gases produced in the crankcase from being released into the atmosphere, at the same time preventing a build-up of pressure in the crankcase (see illustration) . 8 Crankcase gases are drawn into the air inlet tract, where they are mixed with clean air. The gases ar[...]

Fuel vapour recirculation system 14 This system has been introduced progressively on all fuel injection models, and prevents fuel vapour from the fuel tank from being ejected into the atmosphere (see illustration) . 15 The fuel filler cap is sealed, and the fuel vapours from the tank pass into a carbon canister, via a calibrated orifice and a pipe.[...]

2 In many cases it will be found easier to remove the complete system from the car and then to renew individual sections on the bench. 3 To remove the complete system, raise and support the vehicle at a convenient working height (see “Jacking and vehicle support” ). Apply penetrating oil to the nuts, bolts and clamps which will have to be undon[...]

4 Air inlet heating system components - removal and refitting 2 Note : The components of the system vary slightly according to engine type. The following procedures depict one of the more common systems, but all are similar. Vacuum switch Removal 1 Remove the air cleaner housing-to- carburettor inlet duct. 2 Bend up the tangs on the switch retainin[...]

3 Unscrew the clamp bolt, and lift the canister from its clamp on the body panel. Refitting 4 Refitting is a reversal of removal, but ensure that the hoses are correctly reconnected, as noted before removal. Solenoid valve Removal 5 The solenoid valve is mounted on a bracket next to the carbon canister, at the rear left-hand corner of the engine co[...]

5A Chapter 5 Part A: Starting and char ging systems System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-volt, negative earth Battery Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low maintenance or “maintenance-free” sealed for life C[...]

Never use an ohmmeter of the type incorporating a hand-cranked generator for circuit or continuity testing. Always ensure that the battery negative lead is disconnected when working on the electrical system. Before using electric-arc welding equipment on the car, disconnect the battery, alternator and components such as the fuel injection/ignition [...]

3 If the alternator output is suspect even though the warning light functions correctly, the regulated voltage may be checked as follows. 4 Connect a voltmeter across the battery terminals and start the engine. 5 Increase the engine speed until the voltmeter reading remains steady; the reading should be approximately 12 to 13 volts, and no more tha[...]

Refitting 8 Refitting is a reversal of removal, but first insert all mounting bolts finger tight, then tighten the flywheel end bolts followed by the brush end bolts. 10 Starter motor - testing and overhaul 5 If the starter motor is thought to be suspect, it should be removed from the vehicle and taken to an auto-electrician for testing. Most auto-[...]

5B Chapter 5 Part B: Ignition system System type All engines except XU5M2/Z, XU5M3/Z, XU5M3/L and TU1M/L . . . . . . Electronic breakerless ignition system XU5M2/Z, XU5M3/Z, XU5M3/L and TU1M/L engines . . . . . . . . . . . . . . Static distributorless ignition system Distributor Rotor arm rotation . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

1 General information Electronic breakerless ignition system A number of different breakerless ignition systems are used on 205 models according to engine type and fuel system fitted. Some are simple self-contained systems and some work in conjunction with the fuel system to form an integrated engine management package. In order that the engine may[...]

plugs. Use a timing light (paragraph 4 above) to check whether HT voltage is present at all leads. 13 If HT voltage is not present on any particular lead, the fault will be in that lead or in the distributor cap. If HT is present on all leads, the fault will be in the spark plugs; check and renew them if there is any doubt about their condition. 14[...]

9 Unscrew the mounting nuts, remove the small plates, and withdraw the distributor (see illustrations) . 10 Check the condition of the O-ring on the mounting flange and renew it if necessary. TU series engines 11 Remove the ignition HT coil (Section 3). 12 Identify the HT leads for position, then disconnect them from the spark plugs. 13 Unbolt the [...]

4 Depress the retaining clip and disconnect the wiring connector from the module. 5 Make a note of the correct fitted positions of the HT leads then disconnect them from the module terminals (see illustration) . 6 Undo the four retaining screws securing the module to its mounting bracket and remove it from the engine. Refitting 7 Refitting is a rev[...]

10 To check the vacuum advance unit, run the engine at a fast idle speed and reconnect the vacuum pipe. The flywheel mark should again advance. 11 Stop the engine, disconnect the tachometer and timing light and reconnect the vacuum pipe. Refit the timing aperture cover. XU series engines 12 To set the ignition timing statically so that the engine c[...]

28 Connect the timing light to No 1 cylinder spark plug lead (No 1 cylinder is at the transmission end of the engine) as described in the timing light manufacturer’s instructions. 29 Start the engine, allowing it to idle at the specified speed, and point the timing light at the transmission housing aperture. The flywheel timing mark should be ali[...]

5B•8 Notes[...]

9 Chapter 9 Braking system System type: Footbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual-circuit hydraulic with servo assistance on all non-basic models. Anti-lock braking (ABS) optional on certain later models. Handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

Torque wrench settings Nm lbf ft Girling front caliper mounting bolts: All models except 1.9 GTI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 72 1.9 GTI models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 74 Girling front caliper guide bolts (1.9 GTI models) . . . . . . . . . . . [...]

Bleeding - basic (two-man) method 13 Collect a clean glass jar of reasonable size and a suitable length of plastic or rubber tubing, which is a tight fit over the bleed screw, and a ring spanner to fit the screws. The help of an assistant will also be required. 14 If not already done, remove the dust cap from the bleed screw of the first wheel to b[...]

3 Hydraulic pipes and hoses - renewal 2 Note : Before starting work, refer to the warning at the beginning of Section 2 concerning the dangers of hydraulic fluid . 1 If any pipe or hose is to be renewed, minimise hydraulic fluid loss by removing the master cylinder reservoir cap, placing a piece of plastic film over the reservoir and sealing it wit[...]

9 With the caliper pushed inwards, insert the inner pad then push the caliper outwards and insert the outer pad. If offset pads are fitted, it is important to fit these pads in the correct positions as shown (see illustration) . The inner pads with pad wear wires must be located at the top of the caliper. 10 Check that the pads are correctly positi[...]

18 Disconnect the wire for the pad wear warning light. 19 Hold the lower guide stationary with one spanner, then unscrew the bolt (see illustration) . 20 Swivel the caliper upwards, then withdraw the two brake pads from the caliper bracket (see illustrations) . 21 Clean and check the caliper, as described in paragraph 7. 22 Push the piston fully in[...]

7 Expand the shoes over the wheel cylinder then release them from the bottom anchor. 8 Unhook the lever return spring and the handbrake cable. 9 If necessary, position a rubber band over the wheel cylinder to prevent the pistons coming out. Should there be evidence of brake fluid leakage from the wheel cylinder, renew it or overhaul it, as describe[...]

contact the brake pads or disc. Also refer to the warning at the start of Section 2 concerning the dangers of hydraulic fluid. 1 Chock the front wheels then jack up the rear of the car and support it on axle stands (see “Jacking and vehicle support” ). Remove the rear roadwheels and ensure that the handbrake is released. 2 Extract the spring cl[...]

9 Prise the seal from inside the cylinder, taking care not to damage the cylinder wall. 10 If required, dismantle the sliding guides. On the Bendix type unbolt the endplate from the guides and remove the rubber dust covers. Keep the guides identified for location. 11 Clean all the components using methylated spirit or clean brake fluid then examine[...]

8 Rear brake caliper (1.9 GTI models) - removal, overhaul and refitting 3 Note : Before starting work, refer to the warning at the beginning of Section 2 concerning the dangers of hydraulic fluid, and to the warning at the beginning of Section 6 concerning the dangers of asbestos dust . Removal 1 Remove the brake pads as described in Section 6. 2 T[...]

Overhaul 9 Pull off the dust excluders (see illustration) . 10 Extract the pistons, seals and return spring; keeping each component identified for location. 11 Check the surfaces of the cylinder bore and pistons for scoring and corrosion and, if evident, renew the complete wheel cylinder. If the components are in good condition discard the seals an[...]

Inspection 4 Brush the dust and dirt from the brake drum and carefully inspect the drum interior. 5 If the drum is grooved, owing to failure to renew worn brake shoes or after a very high mileage has been covered, then it may be possible to regrind it, provided the maximum internal diameter is not exceeded. 6 Even if only one drum is in need of gri[...]

Refitting 6 Refitting is a reversal of removal, but note that the nose of the unit must face forwards and be inclined upwards at an angle of 22° to the horizontal. Provided that the mounting bracket is undamaged, this angle will automatically be achieved. Finally bleed the rear hydraulic circuit, as described in Section 2. 1.9 GTI models General i[...]

15 Handbrake - adjustment 2 All models except 1.9 GTI 1 The handbrake is normally kept adjusted by the action of the automatic adjusters on the rear brake shoes. However, in due course, the cables will stretch and will have to be adjusted in order to fully apply the handbrake. 2 To adjust, first place the handbrake lever onto the seventh notch. 3 C[...]

2 Remove the clevis pin and disconnect the pushrod from the brake pedal. Note that on models with a vacuum servo unit the pushrod is on the lower hole, whereas the upper hole is used for models without a servo unit. 3 Unscrew the self-locking nut from the pivot bolt, pull out the bolt and lower the brake pedal. Note that on non-servo models a retur[...]

9• 16 Notes[...]

10 Chapter 10 Suspension and steering Front suspension Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Independent, MacPherson struts, coil springs, anti-roll bar Rear suspension Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I[...]

Torque wrench settings Nm lbf ft Front suspension Driveshaft/hub nut: Non-GTI models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 185 GTI models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 192 Automatic transmission models . . . . . . . . . . . . . . . . . . [...]

3 If the hub nut has yet to be loosened, fabricate a tool from two lengths of steel strip (one long, one short) and a nut and bolt; the nut and bolt form the pivot of a forked tool. Bolt the tool to the hub flange using two wheel bolts, and hold the tool to prevent the hub from rotating (see Chapter 8, Section 2). Slacken the hub nut using a socket[...]

the front suspension tower and engaged with further holes in the bottom coil spring seat. If available use these, otherwise fit universal coil spring compressors (see illustration) . Do not attempt to use any makeshift tool, as considerable damage could occur if the spring breaks free. To fit either type of tool it will be necessary to turn the fro[...]

2 On non-GTI models, unscrew the nut securing the anti-roll bar to the suspension arm and remove the washer (see illustration) . 3 Unscrew the clamp bolt securing the front suspension lower balljoint to the bottom of the hub carrier then pull the lower suspension arm down from the carrier. Recover the balljoint guard plate, where fitted. 4 Unscrew [...]

7 The guide bar length must be adjusted to the dimension shown when refitting (see illustration) . Note that a full-circle clamp is fitted to early models with a 6.0 mm diameter anti-roll bar, whereas a split clamp is fitted to later models with a 7.0 mm diameter bar. On the later type, position the clamp centrally on the turned-back end of the bar[...]

mounting in a vice and attempting to extend and retract it. If the resistance is not firm and even in both directions, or if there are signs of leakage or damage, the shock absorber must be renewed. Refitting 6 Refitting is a reversal of removal, but renew the self-locking nuts. The nuts must be tightened when the distance between the mounting bolt[...]

7 If necessary, the intermediate shaft can be removed after prising out the grommet and unscrewing the bottom clamp bolt (see illustration) . 8 To remove the steering lock, unscrew the retaining bolt then, with the ignition key aligned with the small arrow between the ‘A’ and ‘M’ positions, depress the plunger in the housing and withdraw th[...]

engagement rods, and support them in an upright position out of the way, using wire or string. 14 Remove the two steering gear securing bolts, and recover the spacer tubes from the subframe, then disconnect the steering gear pinion from the steering column shaft. 15 Support the front subframe using a trolley jack and interposed block of wood positi[...]

3 With the engine stopped, slowly move the steering from lock-to-lock several times to purge out the trapped air, then top-up the level in the fluid reservoir. Repeat this procedure until the fluid level in the reservoir does not drop any further. 4 Start the engine, then slowly move the steering from lock-to-lock several times to purge out any rem[...]

21 Wheel alignment and steering angles - general information 1 A car’s steering and suspension geometry is defined in four basic settings - all angles are expressed in degrees (toe settings are also expressed as a measurement); the relevant settings are camber, castor, steering axis inclination, and toe-setting. With the exception of front wheel [...]

10•12 Notes[...]

11 Chapter 11 Bodywork and fittings Bodywork, paint and exterior trim check . . . . . . . . . . . .See Chapter 1 Bonnet - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Bonnet lock and remote control cable - removal, refitting and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

not available, there are one or two excellent grease solvents available which can be brush applied; the dirt can then be simply hosed off. Note that these methods should not be used on vehicles with wax-based underbody protective coating or the coating will be removed. Such vehicles should be inspected annually, preferably just prior to winter, whe[...]

Aluminium tape should be used for small or very narrow holes. Pull a piece off the roll and trim it to the approximate size and shape required, then pull off the backing paper (if used) and stick the tape over the hole; it can be overlapped if the thickness of one piece is insufficient. Burnish down the edges of the tape with the handle of a screwd[...]

4 While an assistant supports the bonnet, unscrew the nut and remove the bottom of the stay from the right-hand suspension tower. 5 Place some cloth beneath the rear corners of the bonnet, unscrew the hinge bolts and withdraw it from the car. Refitting 6 Refitting is a reversal of removal, but check that the bonnet is central within its aperture an[...]

Bodywork and fittings 11•5 11 9.2 Front bumper components 1 Side mounting (non-GTI) 2 Side mounting (GTI) 3 Side bracket (non-GTI) 4 Bracket 5 Side bracket (GTI) 6 Seal clip 7 Seal 8 Bumper 9 Moulding 10 Mounting plate 11 Headlight washer bracket 9.8 Rear bumper components 1 Moulding 2 Mounting plates 3 Bumper 4 Side mounting and nut 5 Rubber buf[...]

11 Door trim panel - removal and refitting 3 Removal Front doors 1 If electric windows are fitted, disconnect the battery negative lead. 2 Remove the two screws and withdraw the armrest (see illustration) . 3 Remove the screws and withdraw the side pocket (see illustration) . 4 On models with manually operated windows, fully close the window, note [...]

Exterior mirror (early models) 6 To remove the early type mirror, prise off the inner cover and use an Allen key to remove the mounting screws (see illustrations) . Exterior mirror (later models) 7 To remove the later type mirror, carefully prise the trim cover from the interior mirror control lever (see illustration) . 8 Remove the mounting screws[...]

14 Hood and rear window (Cabriolet models) - removal and refitting 4 Removal 1 Open the hood to the point where it is in balance. 2 Working inside the vehicle, prise off the trim caps, and unscrew the hinge cover securing screws (see illustration) . 3 Working outside the vehicle, unscrew the brackets and securing bolts (see illustration) . 4 Fold d[...]

15 Power-operated hood components (Cabriolet models) - general information Whenever any work is carried out which involves disconnecting the hood hydraulic fluid pipes, the hydraulic fluid circuit must be bled. At the time of writing, little information was available regarding this procedure, and it is recommended that the task is entrusted to a Pe[...]

7 Unscrew the five bolts securing the regulator mechanism. 8 Remove the casing from the hood hinge. 9 Remove the pad from the quarter glass lower channel. 10 Push in the regulator mechanism, then tilt it and withdraw it through the aperture, complete with the cable (see illustration) . Take care not to damage the seat belt reel. 11 Remove the inner[...]

24 Sunroof glass - removal and refitting 3 Removal 1 Working inside the car, remove the roof console. Then remove the screws from the sunroof handle and latch. 2 From outside the car, remove the front cover and the corner screws. 3 Slide off the side covers to the rear, while exerting outward pressure. 4 Remove the rear stops, then withdraw the sun[...]

13 With the bonnet open, remove the plastic grille and unscrew the front facia mounting nuts (see illustration) . 14 Withdraw the facia panel at the same time disconnecting the relevant switches and cigar lighter. Reconnect the switch wiring immediately to ensure correct refitting. 1988 models onward 15 Disconnect the battery negative lead. 16 Remo[...]

32 Prise the small tray from the centre console (see illustration) . 33 Remove the screws, and slide the surround up the gear lever (see illustration) . 34 Remove the upper and lower nuts, and withdraw the centre console (see illustrations) . 35 Unclip the felt cover from under the facia. 36 Remove the screws and withdraw the front facia panel. Dis[...]

11•14 Notes[...]

12 Chapter 12 Body electrical system General System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-volt negative earth Fuses (early models) No Circuit protected Rating (amp) 1 Reverse light, cooling fan relay, tachometer (GTI) . . . . . . . . . . . . . 10 2 Accessories, indicators, fuel gauge, wa[...]

Fuses (1986 to 1988 GTI and CTI models) No Circuit protected Rating (amp) 1 Reversing lights, tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2 Direction indicators, heater blower motor, oil pressure gauge, oil temperature gauge, heated seats, fuel gauge, coolant temperature gauge, low battery charge warning, oil pressure wa[...]

Fuses (1989 to 1991 - all models) No Circuit protected Rating (amp) 1 Reversing lights, tachometer, fuel gauge, warning lights (low battery charge, coolant temperature, oil pressure, low coolant level, brake system, choke). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2 Direction indicators, gauges (fuel, oil temperature, . . . . [...]

12•4 Body electrical system 1 General information and precautions General information The electrical system is of 12-volt negative earth type. Power for the lights and all electrical accessories is supplied by a lead/acid battery which is charged by the alternator. This Chapter covers repair and service procedures for the various electrical compo[...]

22 If an earth connection is thought to be faulty, dismantle the connection, and clean both the bodyshell and the wire terminal (or the component earth connection mating surface) back to bare metal. Be careful to remove all traces of dirt and corrosion, then use a knife to trim away any paint, so that a clean metal-to-metal joint is made. On reasse[...]

Facia switches (1988 models onward) 10 Disconnect the battery negative lead. 11 Open the ashtray. 12 Unclip the bottom of the clock surround (where fitted) and remove it. 13 Remove the screws from the bottom of the switch panel, then insert lengths of welding rod (or similar) into the special holes, and remove the switch panel surround (see illustr[...]

36 Unscrew the locknut nearest the pedal, and withdraw the switch from the bracket. 37 Refitting is a reversal of removal, but adjust the locknuts so that the distance between the end of the switch threaded body and the pedal (fully released) is 3.5 mm. 5 Instrument panel - removal and refitting 2 Removal Pre-1988 models 1 Disconnect the battery ne[...]

12•8 Body electrical system 5.7a Exploded diagram of non-GTI instrument panel 5.7b Exploded diagram of GTI instrument panel[...]

13 Remove the screws and withdraw the centre vents. 14 Using a screwdriver through the steering column lower shroud, unscrew the visor locating studs. 15 Remove the side screw, then lift away the visor. 16 Remove the mounting screws from each side of the instrument panel (see illustration) . 17 Tilt the instrument panel and disconnect the wiring pl[...]

7 Release the spring clips and withdraw the bulb (see illustrations) . 8 Fit the new bulb with the locating tab uppermost. Front parking lights 9 Pull the bulbholder from the rear of the headlight then depress and twist the bulb to remove it (see illustration) . Front direction indicator 10 Turn the bulbholder anti-clockwise and withdraw it from th[...]

21 Depress and twist the bulb to remove it (see illustration) . Number plate light 22 Twist off the lens (see illustration) . 23 Depress and twist the bulb to remove it (see illustration) . Reversing light (1991 models onward) 24 On later models, a single reversing light is mounted in the rear valance, instead of the twin lights in the rear light c[...]

Heater control panel illumination bulbs (pre-1988 models) 12 Remove the facia centre air vents, with reference to Chapter 11. 13 Pull the bulbholder from the rear of the panel and extract the bulb (see illustration) . Heater control panel illumination bulbs (1988 models onward) 14 Disconnect the battery negative lead. 15 Remove the trapezium-shaped[...]

When the ignition is switched on with the sidelights also switched on, the relay is energised, closing the internal contacts and supplying current to the dipped beam circuit via the resistor. This causes the dip filaments in the headlights to be illuminated at one-sixth dipped beam brightness. The relay winding is earthed through the headlight main[...]

the wheel arch. The reservoir supplies both the windscreen and tailgate jets. On some models a headlight washer system is installed with the reservoir in the right-hand front corner of the engine compartment. The washer jets are adjustable by inserting a pin into their nozzles and moving them to give an acceptable pattern on the glass. The use of a[...]

Wiring diagrams 12•15 12 Key to wiring diagrams[...]

12•16 Wiring diagrams Key to wiring diagrams (continued)[...]

Wiring diagrams 12•17 12 Diagram1: Typical starting, charging, ignition, cooling fan, warning lamps and gauges (XV8, XW7, XY8 and XU51C engine models)[...]

12•18 Wiring diagrams Diagram1a: Typical starting, charging, ignition, cooling fan, warning lamps and gauges (TU1, TU3 and TU9 engine models)[...]

Wiring diagrams 12•19 12 Diagram1b: Typical engine management, warning lamps and gauges (XU5J/JA and XU9JA engine models)[...]

12•20 Wiring diagrams Diagram 2: Typical exterior lighting - reversing lamps, foglamps, sidelamps and headlamps[...]

Wiring diagrams 12•21 12 Diagram 2a: Typical exterior lighting - direction indicators and stop-lamps; typical interior lighting and associated circuits[...]

12•22 Wiring diagrams Diagram 3: Typical ancillary circuits - wash/wipe, horn, heater blower and heated rear window[...]

Wiring diagrams 12•23 12 Diagram 3a: Typical ancillary circuits - electric windows, central locking and radio/cassette[...]

12•24 Wiring diagrams Supplementary diagram A: Typical engine management (TU3M/Z and TU3FM/L engine models)[...]

Wiring diagrams 12•25 12 Supplementary diagram B: Typical engine management (TU1M/L and XU5M3/Z/L engine models)[...]

12•26 Wiring diagrams Supplementary diagram C: Typical engine management (XU9J1/Z/L engine models)[...]

Wiring diagrams 12•27 12 Supplementary diagram D: Typical engine management (XU9JA/L engine models)[...]

REF Dimensions and weights Note: All figures are approximate, and may vary according to model. Refer to manufacturer’s data for exact figures. Dimensions Overall length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3705 mm Overall width: Basic, GL, GE and Van . . . . . . . . . . . . . . . . . . . . . . [...]

REF•2 Conversion factors Length (distance) Inches (in) x 25.4 = Millimetres (mm) x 0.0394 = Inches (in) Feet (ft) x 0.305 = Metres (m) x 3.281 = Feet (ft) Miles x 1.609 = Kilometres (km) x 0.621 = Miles V olume (capacity) Cubic inches (cu in; in 3 ) x 16.387 = Cubic centimetres (cc; cm 3 ) x 0.061 = Cubic inches (cu in; in 3 ) Imperial pints (Imp[...]

Buying spare parts Spare parts are available from many sources, including maker’s appointed garages, accessory shops, and motor factors. To be sure of obtaining the correct parts, it will sometimes be necessary to quote the vehicle identification number. If possible, it can also be useful to take the old parts along for positive identification. I[...]

REF•4 General r epair pr ocedur es Whenever servicing, repair or overhaul work is carried out on the car or its components, observe the following procedur es and instructions. This will assist in carrying out the operation efficiently and to a pr ofessional standar d of workmanship. Joint mating faces and gaskets When separating components at the[...]

The jack supplied with the vehicle tool kit should only be used for changing the roadwheels - see “Wheel changing” at the front of this manual. When carrying out any other kind of work, raise the vehicle using a hydraulic (or “trolley”) jack, and always supplement the jack with axle stands. The sill jacking points or their adjacent re- info[...]

REF•6 T ools and working facilities Introduction A selection of good tools is a fundamental requirement for anyone contemplating the maintenance and repair of a motor vehicle. For the owner who does not possess any, their purchase will prove a considerable expense, offsetting some of the savings made by doing-it-yourself. However, provided that t[...]

T ools and working facilities REF•7 REF Special tools The tools in this list are those which are not used regularly, are expensive to buy, or which need to be used in accordance with their manufacturers’ instructions. Unless relatively difficult mechanical jobs are undertaken frequently, it will not be economic to buy many of these tools. Where[...]

REF•8 MOT test checks This is a guide to getting your vehicle through the MOT test. Obviously it will not be possible to examine the vehicle to the same standar d as the pr ofessional MOT tester . However , working through the following checks will enable you to identify any problem ar eas befor e submitting the vehicle for the test. Wher e a tes[...]

MOT test checks REF•9 REF Seat belts and seats Note: The following checks are applicable to all seat belts, front and rear . M Examine the webbing of all the belts (including rear belts if fitted) for cuts, serious fraying or deterioration. Fasten and unfasten each belt to check the buckles. If applicable, check the retracting mechanism. Check th[...]

REF•10 MOT test checks Exhaust system M Start the engine. With your assistant holding a rag over the tailpipe, check the entir e system for leaks. Repair or renew leaking sections. Jack up the front and rear of the vehicle, and securely support it on axle stands. Position the stands clear of the suspension assemblies. Ensure that the wheels are c[...]

MOT test checks REF•11 REF M Examine the handbrake mechanism, checking for frayed or broken cables, excessive corrosion, or wear or insecurity of the linkage. Check that the mechanism works on each relevant wheel, and r eleases fully , without binding. M It is not possible to test brake efficiency without special equipment, but a road test can be[...]

The vehicle owner who does his or her own maintenance according to the recommended service schedules should not have to use this section of the manual very often. Modern component reliability is such that, provided those items subject to wear or deterioration are inspected or renewed at the specified intervals, sudden failure is comparatively rare.[...]

failure of components such as fuses or spark plugs may only be pointers to some underlying fault. The pages which follow provide an easy- reference guide to the more common problems which may occur during the operation of the vehicle. These problems and their possible causes are grouped under headings denoting various components or systems, such as[...]

REF•14 Fault finding Engine (continued) Engine misfires throughout the driving speed range m m Fuel filter choked - fuel-injected models (Chapter 1). m m Fuel pump faulty, or delivery pressure low (Chapter 4A, 4B or 4C). m m Fuel tank vent blocked, or fuel pipes restricted (Chapter 4A, 4B or 4C). m m Vacuum leak at the carburettor/throttle body, [...]

Fault finding REF•15 REF 2 Cooling system 3 Fuel and exhaust systems Overheating m m Insufficient coolant in system ( “Weekly checks” ). m m Thermostat faulty (Chapter 3). m m Radiator core blocked, or grille restricted (Chapter 3). m m Electric cooling fan or thermoswitch faulty (Chapter 3). m m Pressure cap faulty (Chapter 3). m m Ignition [...]

REF•16 Fault finding 7 Driveshafts Clicking or knocking noise on turns (at slow speed on full-lock) m m Lack of constant velocity joint lubricant, possibly due to damaged bellows (Chapter 8). m m Worn outer constant velocity joint (Chapter 8). Vibration when accelerating or decelerating m m Worn inner constant velocity joint (Chapter 8). m m Bent[...]

Fault finding REF•17 REF 9 Suspension and steering Note: Before diagnosing suspension or steering faults, be sure that the trouble is not due to incorrect tyre pressures, mixtures of tyre types, or binding brakes. Vehicle pulls to one side m m Defective tyre ( “Weekly checks” ). m m Excessive wear in suspension or steering components (Chapter[...]

REF•18 Fault finding 10 Electrical system Note: For problems associated with the starting system, refer to the faults listed under “Engine” earlier in this Section. Battery will not hold a charge for more than a few days m m Battery defective internally (Chapter 5A). m m Battery terminal connections loose or corroded( “Weekly checks” ). m[...]

Windscreen/tailgate wipers inoperative, or unsatisfactory in operation Wipers fail to operate, or operate very slowly m m Wiper blades stuck to screen, or linkage seized or binding ( “Weekly checks” and Chapter 12). m m Blown fuse (Chapter 12). m m Cable or cable connections loose, broken or disconnected (Chapter 12). m m Faulty relay (Chapter [...]

REF•20 Glossary of technical terms A ABS (Anti-lock brake system) A system, usually electronically contr olled, that senses incipient wheel lockup during braking and r elieves hydraulic pr essure at wheels that are about to skid. Air bag An inflatable bag hidden in the steering wheel (driver’ s side) or the dash or glovebox (passenger side). In[...]

Glossary of technical terms REF•21 REF Camshaft A rotating shaft on which a series of cam lobes operate the valve mechanisms. The camshaft may be driven by gears, by spr ockets and chain or by spr ockets and a belt. Canister A container in an evaporative emission control system; contains activated char coal granules to trap vapours fr om the fuel[...]

REF•22 Glossary of technical terms E EGR valve A valve used to introduce exhaust gases into the intake air stream. Electr onic contr ol unit (ECU) A computer which controls (for instance) ignition and fuel injection systems, or an anti-lock braking system. For more information r efer to the Haynes Automotive Electrical and Electronic Systems Manu[...]

Glossary of technical terms REF•23 REF J Jump start Starting the engine of a vehicle with a discharged or weak battery by attaching jump leads from the weak battery to a charged or helper battery . L Load Sensing Proportioning V alve (LSPV) A brake hydraulic system control valve that works like a proportioning valve, but also takes into considera[...]

REF•24 Glossary of technical terms automatic transmission, a switch that pr events starting if the vehicle is not in Neutral or Park. Strut See MacPherson strut. T T appet A cylindrical component which transmits motion from the cam to the valve stem, either directly or via a pushr od and r ocker arm. Also called a cam follower . Thermostat A heat[...]

Index REF•25 REF Note : References throughout this index are in the form - “Chapter number” • “page number” A Accelerator cable - 1•11, 4A•4, 4B•2, 4C•2 Acknowledgements - 0•4 Air cleaner - 1•15, 4A•3, 4B•2, 4C•2 Air conditioning system - 1•13, 3•7 Alternator - 5A•3 Anti-lock braking system - 9•15 Anti-roll bar[...]

D Dents - 11•2 Dim-dip lighting system - 12•12 Dimensions and weights - REF•1 Distributor - 5B•3 Door - 11•5, 11•6, 11•7 Door trim panel - 11•6 Drivebelt - 1•11 Driveshafts - 8•1 et seq bellows check - 1•14 fault finding - REF•12, REF•16 intermediate bearing - 8•4 joint bellows - 8•1 overhaul - 8•4 removal and refitt[...]

G Gearbox oil (manual) - 0•16, 1•13, 7A•2 Gearbox oil (automatic) - 0•16, 1•9, 1•14 Gearchange linkage manual transmission - 7A•4 Glass - 11•9 Glossary of technical terms - REF•20 Glovebox - 11•11 Grille - 11•4 H Handbrake : adjustment - 9•14 cables - 9•14 lever - 9•15 Headlight unit - 12•12 Headlight beam alignment - [...]

R Radiator - 3•3 Radiator cooling fan - 3•4 Radio - 12•14 Radio/cassette anti-theft system - REF•5 Relays - 12•5 Repair procedures - REF•4 Respraying paintwork - 11•3 Reversing light switch - 12•6 Reversing light switch (automatic transmission) - 7B•5 Routine maintenance and servicing - 1•1 et seq Rust - 11•2 S Safety first - [...]

REF•29 REF Notes[...]

Left blank for manual listing pages[...]

REF Left blank for manual listing pages[...]

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