Peugeot 205. Manual - part 11

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, noting which way round
they are fitted (see illustrations).
6 Examine the pump rotors and body for
signs of wear ridges or scoring. If worn, the
complete pump assembly must be renewed.
7 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, it
should also be renewed. Both the piston and
spring are available individually.
8 Thoroughly clean the oil pump strainer with
a suitable solvent, and check it for signs of
clogging or splitting. If the strainer is
damaged, the strainer and cover assembly
must be renewed.
9 Locate the relief valve spring and piston in
the strainer cover. Refit the cover to the pump
body, aligning the relief valve piston with its
bore in the pump. Refit the baffle plate (where
fitted) and the cover retaining bolts, and
tighten them securely.

Refitting

10 Offer up the spacer plate (where fitted),
then locate the pump sprocket with its drive
chain. Seat the pump on the base of the
cylinder block/crankcase. Refit the pump
retaining bolts, and tighten them to the
specified torque setting.
11 Where necessary, slide the sprocket
cover into position on the pump. Refit its
retaining bolts, tightening them securely.
12 Refit the sump as described in Section 9.

11 Oil cooler - removal and

refitting

2

Cylinder block-mounted oil cooler

Removal

1 Certain models may be fitted with an oil
cooler mounted between the cylinder block
and the oil filter.
2 To prevent the oil cooler from being
unscrewed as the oil filter is removed, on later
models, a retaining lug is provided on the
cylinder block, which engages with a fork on
the oil cooler.
3 To remove the oil cooler, first remove the oil
filter and partially drain the cooling system as
described in Chapter 1.

4 Disconnect the coolant hoses from the
filter. Be prepared for coolant spillage, and
plug the open ends of the hoses to prevent
dirt ingress and further coolant loss.
5 Unscrew the oil filter mounting stub, then
withdraw the oil cooler from the engine (see
illustration).

Refitting

6 Refitting is a reversal of removal, bearing in
mind the following points.

a) When refitting the oil cooler, where

applicable, ensure that the fork on the cooler
engages with the lug on the cylinder block.

b) Before refitting the oil filter mounting stub,

thoroughly clean the threads, and coat
them with thread-locking compound.

c) Tighten the mounting stub to the

specified torque.

d) Fit a new oil filter and fill the engine with

oil as described in Chapter 1.

e) On completion, refill the coolant level as

described in or Chapter 1.

Remotely mounted oil cooler

Removal

7 On models with a remotely mounted oil
cooler, this is located in front of the radiator.
8 Remove the radiator grille and front bumper
as described in Chapter 11.
9 Unbolt the engine compartment front
crossmember, and position it to one side,
leaving the bonnet release cable still attached.
10 Remove the air inlet hose.
11 Remove the stone guard from the front
cowling.
12 Unscrew the retaining bolts, then release
the clips and move the front cowling forwards
for access to the oil cooler.
13 Place rags or a container beneath the oil
cooler to collect any spilled oil. Unscrew the
union nuts while holding the connection stubs
stationary. Plug the stubs, or tie them to one
side.
14 Unscrew the nuts, release the oil cooler
from the front cowling, and remove it from the
car (see illustration).

XU series engine in-car repair procedures  2B•11

2B

10.5a  Lift off the pump strainer cover . . .

10.5b  . . . and take out the relief valve

piston and spring

11.14  Removing the remotely mounted oil cooler (1)

11.5  Cylinder block mounted oil cooler mounting stub (A) and

locating notch (B)

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, the spacer as described in
Section 5.
2 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. Use a flat-bladed
screwdriver, and take great care not to damage
the crankshaft shoulder or seal housing.
3 Clean the seal housing, and polish off any
burrs or raised edges, which may have
caused the seal to fail in the first place.
4 Lubricate the lips of the new seal with clean
engine oil, and carefully locate the seal on the
end of crankshaft. Note that its sealing lip
must be facing inwards. Take care not to
damage the seal lips during fitting.
5 Fit the new seal using a suitable tubular
drift, such as a socket, which bears only on
the hard outer edge of the seal. Tap the seal
into position, to the same depth in the housing
as the original was prior to removal.
6 Wash off any traces of oil, then refit the
crankshaft sprocket as described in Section 5.

Left-hand oil seal

7 Remove the flywheel/driveplate as
described in Section 13. Make a note of the
correct fitted depth of the seal in its housing.
8 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.
9 Clean the seal housing, and polish off any
burrs or raised edges, which may have
caused the seal to fail in the first place.

10 Lubricate the lips of the new seal with
clean engine oil, and carefully locate the seal
on the end of the crankshaft.
11 Fit the new seal using a suitable tubular
drift, which bears only on the hard outer edge
of the seal. Drive the seal into position, to the
same depth in the housing as the original was
prior to removal.
12 Wash off any traces of oil, then refit the
flywheel/driveplate as described in Section 13.

13 Flywheel/driveplate -

removal, inspection and
refitting

4

Removal

Flywheel (models with manual
transmission)

1 Remove the transmission as described in
Chapter 7A, then remove the clutch assembly
as described in Chapter 6.
2 Prevent the flywheel from turning by locking
the ring gear teeth with a screwdriver or
similar tool.
3 Slacken and remove the flywheel retaining
bolts, and remove the flywheel from the end
of the crankshaft. Be careful not to drop it; it is
heavy. If the flywheel locating dowel is a loose
fit in the crankshaft end, remove it and store it
with the flywheel for safe-keeping. Discard the
flywheel bolts; new ones must be used on
refitting.

Driveplate (models with automatic
transmission)

4 Remove the transmission as described in
Chapter 7B. Lock the driveplate as described
in paragraph 2. Mark the relationship between
the torque converter plate and the driveplate,
and slacken all the driveplate retaining bolts.
5 Remove the retaining bolts, along with the
torque converter plate and the two shims
(where fitted). Note that the shims are of
different thickness, the thicker one being on
the outside of the torque converter plate.
Discard the driveplate retaining bolts; new
ones must be used on refitting.
6 Remove the driveplate from the end of the
crankshaft. If the locating dowel is a loose fit
in the crankshaft end, remove it and store it
with the driveplate for safe-keeping.

Inspection

7 On models with manual transmission,
examine the flywheel for scoring of the clutch
face, and for wear or chipping of the ring gear
teeth. If the clutch face is scored, the flywheel
may be surface-ground, but renewal is
preferable. Seek the advice of a Peugeot
dealer or engine reconditioning specialist to
see if machining is possible. If the ring gear is
worn or damaged, the flywheel must be
renewed, as it is not possible to renew the
ring gear separately.
8 On models with automatic transmission,
check the torque converter driveplate

carefully for signs of distortion. Look for any
hairline cracks around the bolt holes or
radiating outwards from the centre, and
inspect the ring gear teeth for signs of wear or
chipping. If any sign of wear or damage is
found, the driveplate must be renewed.

Refitting

Flywheel - models with manual
transmission

9 Clean the mating surfaces of the flywheel
and crankshaft. Remove any remaining
locking compound from the threads of the
crankshaft holes, using the correct-size tap, if
available.
10 If the new flywheel retaining bolts are not
supplied with their threads already pre-
coated, apply a suitable thread-locking
compound to the threads of each bolt (see
illustration).
11 Ensure that the locating dowel is in
position. Offer up the flywheel, locating it on
the dowel, and fit the new retaining bolts.
12 Lock the flywheel using the method
employed on dismantling, and tighten the
retaining bolts to the specified torque.
13 Refit the clutch as described in Chapter 6,
and refit the transmission as described in
Chapter 7A.

Driveplate - models with automatic
transmission

14 Carry out the operations described above
in paragraphs 9 and 10, substituting
“driveplate” for all references to the flywheel.
15 Locate the driveplate on its locating
dowel.
16 Offer up the torque converter plate, with
the thinner shim positioned behind the plate
and the thicker shim on the outside, and align
the marks made prior to removal.
17 Fit the new retaining bolts, then lock the
driveplate using the method employed on
dismantling. Tighten the retaining bolts to the
specified torque wrench setting.
18 Refit the transmission as described in
Chapter 7B.

14 Engine/transmission

mountings - inspection and
renewal

3

Refer to Part A, Section 10 but note that on

early models, shims are fitted between the
right-hand mounting rubber buffers and the
mounting top plate. These should be added or
removed as necessary to provide a clearance
of 1.0 mm between the buffers and top plate.
On later models, the shims have been deleted
and the rubber buffers are increased in
thickness to compensate. To prevent scuffing
noises from the buffers, it is recommended
that the inner surfaces which contact the
engine bracket are lubricated with rubber
grease.

2B•12 XU series engine in-car repair procedures

13.10  Apply thread locking compound to

the flywheel bolts if not already pre-coated

2C

Chapter 2  Part C:
TU series engine in-car repair procedures

Engine general

Code and displacement:

TU9  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

954 cc

TU1  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1124 cc

TU1M/L  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1124 cc

TU1M/Z  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1124 cc

TU3  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1360 cc

TU3A  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1360 cc

TU3A/K  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1360 cc

TU3M/Z  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1360 cc

TU3FM/L  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1360 cc

TU3S  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1360 cc

TU3S/K  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1360 cc

Bore:

TU9 series  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70.0 mm

TU1 series  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72.0 mm

TU3 series  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75.0 mm

Stroke:

TU9 series  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62.0 mm

TU1 series  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

69.0 mm

TU3 series  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

77.0 mm

Compression ratio:

TU9 and TU1 series  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.4 : 1

TU3 series  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.3 : 1

Direction of crankshaft rotation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clockwise (viewed from right-hand side of vehicle)

Firing order  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3-4-2 (No 1 cylinder at flywheel end of engine)

Valve clearances (engine cold)

Inlet  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.15 to 0.25 mm

Exhaust  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.35 to 0.45 mm

Lubrication system

Oil pump type  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gear-type, chain-driven off the crankshaft

Minimum oil pressure at 90°C  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 bars at 4000 rpm

Oil pressure warning switch operating pressure  . . . . . . . . . . . . . . . . . .

0.8 bars

Auxiliary drivebelt check and renewal  . . . . . . . . . . . . . . .See Chapter 1
Camshaft and rocker arms - removal, inspection and refitting  . . . . . 10
Camshaft oil seal - renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Compression test - description and interpretation  . . . . . . . . . . . . . . 2
Crankshaft oil seals - renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Cylinder head - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . 11
Cylinder head cover - removal and refitting  . . . . . . . . . . . . . . . . . . . 4
Engine assembly/valve timing holes - general information 

and usage  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Engine oil and filter renewal . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Engine oil level check  . . . . . . . . . . . . . . . . . . . . . .See “Weekly checks”

Engine/transmission mountings - inspection and renewal  . . . . . . . . 16
Flywheel - removal, inspection and refitting  . . . . . . . . . . . . . . . . . . . 15
General information  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Oil pump - removal, inspection and refitting  . . . . . . . . . . . . . . . . . . . 13
Sump - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Timing belt - general information, removal and refitting  . . . . . . . . . . 7
Timing belt covers - removal and refitting  . . . . . . . . . . . . . . . . . . . . . 6
Timing belt tensioner and sprockets - removal, inspection 

and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Valve clearances - checking and adjustment  . . . . . . . . . . . . . . . . . . 5

2C•1

Specifications

Contents

Easy, suitable for
novice with little
experience

Fairly easy, suitable
for beginner with
some experience

Fairly difficult,
suitable for competent
DIY mechanic

Difficult, suitable for
experienced  DIY
mechanic

Very difficult,
suitable for expert DIY
or  professional

Degrees of difficulty

5

4

3

2

1

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 retaining bolt  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

110

81

Cylinder head bolts (aluminium block engine):

Stage 1  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

15

Stage 2  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tighten through a further 240°

Cylinder head bolts (cast-iron block engine):

Stage 1  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

15

Stage 2  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tighten through a further 120°

Stage 3  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tighten through a further 120°

Cylinder head cover nuts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

12

Flywheel retaining nuts and bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

65

48

Engine-to-transmission bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35

26

Engine/transmission left-hand mounting:

Mounting bracket-to-transmission nuts  . . . . . . . . . . . . . . . . . . . . . . .

20

15

Mounting bracket-to-body bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

18

Mounting rubber nuts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

15

Centre nut  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

65

48

Engine/transmission rear mounting:

Mounting-to-cylinder block bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40

30

Mounting link-to-mounting bolt  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70

52

Mounting link-to-body bolt  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50

37

Engine/transmission right-hand mounting bracket nuts  . . . . . . . . . . . .

45

33

Oil pump retaining bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

6

Sump retaining nuts and bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

6

Timing belt cover bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

6

Timing belt tensioner pulley nut  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

17

1

General information

How to use this Chapter

This Part of Chapter 2 describes those

repair procedures that can reasonably be
carried out on the TU series engine while it
remains in the car. If the engine has been
removed from the car and is being dismantled
as described in Part D, any preliminary
dismantling procedures can be ignored. Refer
to Part A and B for information on the XV, XW
and XY series and XU series engines.

Part D describes the removal of the

engine/transmission from the vehicle, and the
full overhaul procedures that can then be
carried out.

Engine description

The engine is of the in-line four-cylinder,

overhead camshaft type, mounted
transversely at the front of the car and inclined
forward by 6°. The clutch and transmission
are attached to its left-hand end. The 205
range is fitted with 954 cc (TU9), 1124 cc
(TU1), and 1360 cc (TU3) versions of the
engine in either carburettor or fuel-injected
configuration.

The crankshaft runs in five main bearings.

Thrustwashers are fitted to No 2 main bearing
(upper half) to control crankshaft endfloat.

The connecting rods rotate on horizontally-

split bearing shells at their big-ends. The

pistons are attached to the connecting rods
by gudgeon pins, which are an interference fit
in the connecting rod small-end eyes. The
aluminium-alloy pistons are fitted with three
piston rings - two compression rings and an
oil control ring.

On all except TU3FM engines, the cylinder

block is made of aluminium, and replaceable
wet liners are fitted to the cylinder bores.
Sealing O-rings are fitted at the base of each
liner, to prevent the escape of coolant into the
sump.

On TU3FM engines, the cylinder block is

made from cast-iron, and the cylinder bores
are an integral part of the cylinder block. On
this type of engine, the cylinder bores are
sometimes referred to as having dry liners.

The inlet and exhaust valves are each

closed by coil springs, and operate in guides
pressed into the cylinder head; the valve seat
inserts are also pressed into the cylinder
head, and can be renewed separately if worn.

The camshaft is driven by a toothed timing

belt, and operates the eight valves via rocker
arms. Valve clearances are adjusted by a
screw-and-locknut arrangement. The
camshaft rotates directly in the cylinder head.
The timing belt also drives the coolant pump.

Lubrication is by means of an oil pump,

which is driven (via a chain and sprocket) off
the right-hand end of the crankshaft. It draws
oil through a strainer located in the sump, and
then forces it through an externally-mounted
filter into galleries in the cylinder
block/crankcase. From there, the oil is

distributed to the crankshaft (main bearings)
and camshaft. The big-end bearings are
supplied with oil via internal drillings in the
crankshaft, while the camshaft bearings also
receive a pressurised supply. The camshaft
lobes and valves are lubricated by splash, as
are all other engine components.

Repair operations possible with
the engine in the car

The following work can be carried out with

the engine in the car:

a) Compression pressure - testing.
b) Cylinder head cover - removal and

refitting.

c) Valve clearances - adjustment.
d) Timing belt covers - removal and refitting 
e) Timing belt - removal, refitting and

adjustment.

f) Timing belt tensioner and sprockets -

removal, inspection and refitting.

g) Camshaft oil seal - renewal.
h) Camshaft and rocker arms - removal,

inspection and refitting.

i) Cylinder head - removal and refitting. 
j) Cylinder head and pistons -

decarbonising.

k) Sump - removal and refitting.
l) Oil pump - removal, inspection and

refitting.

m) Crankshaft oil seals - renewal.
n) Flywheel - removal, inspection and

refitting.

o) Engine/transmission mountings -

inspection and renewal.

2C•2 TU series engine in-car repair procedures