Peugeot 205. Manual - part 22

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 coolant pump (see
illustration). For better access, remove the air
cleaner and inlet cowl, with reference to the
relevant Part of Chapter 4.
3 Unscrew the mounting bolts and remove
the coolant pump from the cylinder block.
Remove the O-ring (see illustrations).
4 If the coolant pump is worn, noisy or leaks
coolant it must be renewed, as repair is not
possible. However, if either of the half casings
is individually damaged it may be renewed,
together with the central gasket. 

Refitting

5 Refitting is a reversal of removal, bearing in
mind the following points:

a) Renew the pump O-ring.
b) Refit the auxiliary drivebelt and refill the

cooling system as described in Chapter 1.

XU series engines

Removal

6 Drain the cooling system (Chapter 1).
7 Remove the timing belt and tensioner, as
described in Chapter 2B.
8 Remove the plastic shield, noting the
locations of the different types of bolt (see
illustration).
9 Unscrew the five mounting bolts and
remove the coolant pump from the cylinder
block. Remove the gasket (see illustration).

Cooling, heating and air conditioning systems  3•5

3

8.2 Radiator and heater hose connections

on the coolant pump - XV, XW and XY

series engines

8.3a  Undo the mounting bolts . . .

8.3b  . . . withdraw the pump from the

cylinder block . . .

8.3c  . . . and recover the O-ring - arrowed

(XV, XW and XY series engines

8.9 Coolant pump assembly fitted to XU

series engines

1 Gasket

2 Coolant pump

8.8  Timing belt inner plastic shield and special bolt locations on early XU series engines

Apply sealant to bolt threads A

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 1).

TU series aluminium block
engines

Removal

12 Drain the cooling system as described in
Chapter 1.
13 Remove the timing belt as described in
Chapter 2C.
14 Unscrew the nut from the right-hand
engine mounting.
15 Using a trolley jack and block of wood, lift
the right-hand side of the engine as far as
possible.
16 Unscrew the nuts and remove the engine
mounting bracket from the coolant pump
housing.
17 Disconnect the hoses from the housing,
then unbolt the housing from the block.

Remove the O-ring seal (see illustrations).
18 Unbolt the coolant pump from the
housing, and remove the O-ring (see
illustrations). If necessary, similarly remove
the inlet elbow.
19 If the coolant pump is worn, noisy or leaks
coolant it must be renewed, as repair is not
possible.

Refitting

20 Refitting is a reversal of removal, bearing
in mind the following points:

a) Renew the O-rings.
b) Make sure that the housing-to-block

location dowels are in position.

c) Refit and tension the timing belt as

described in Chapter 2C.

d) Refill the cooling system as described in

Chapter 1.

TU series cast-iron block engines

Removal

21 Drain the cooling system as described in
Chapter 1.
22 Remove the timing belt as described in
Chapter 2C.
23 Unscrew the two securing bolts, and
withdraw the coolant pump from the cylinder
block (see illustration). Recover the O-ring.
24 If the coolant pump is worn, noisy or leaks

coolant it must be renewed, as repair is not
possible.

Refitting

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

a) Renew the pump O-ring.
b) Refit and tension the timing belt, as

described in Chapter 2C.

c) Refill the cooling system (Chapter 1).

9

Heater assembly - removal,
dismantling, reassembly and
refitting

4

Removal

1 Remove the facia panel, as described in
Chapter 11. On later models this procedure
also covers removal of the vents and control
panel. If further dismantling is necessary
proceed as follows.
2 Disconnect the lower air vents.
3 Note the position of the wiring loom and
switches then remove the clips and move the
wiring clear. Lower the fuse board with
reference to Chapter 12.
4 Drain the cooling system as described in
Chapter 1, and disconnect the heater hoses
on the bulkhead in the engine compartment.

3•6 Cooling, heating and air conditioning systems

8.18a  With the housing removed, undo the

bolts and remove the coolant pump . . .

8.18b  . . . then recover the O-ring seal

(arrowed)

8.23  Coolant pump securing bolt (arrowed)

on TU series cast iron block engines

8.17a  On TU series aluminium block engines, disconnect the

hoses (arrowed) from the coolant pump housing

8.17b  . . . then undo the bolts (arrowed) and remove the housing

from the block

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 outside of accumulated debris.
7 To remove the heater blower, unscrew the
mounting screws and lift the unit from the
casing (see illustration).

8 If necessary remove the heater control
panel and cable.

Reassembly and refitting

9 Reassembly and refitting is a reversal of
removal and dismantling, but fill the cooling
system as described in Chapter 1 on
completion.

10 Air conditioning system -

general information and
precautions

General information

1 Air conditioning is available as an option on
later models. In conjunction with the heater,
the system enables any reasonable air
temperature to be achieved inside the car. It
also reduces the humidity of the incoming air,
aiding demisting even when cooling is not
required (see illustration).

Cooling, heating and air conditioning systems  3•7

3

9.6a  Remove the heater matrix mounting

screws and pipe clip (arrowed) . . .

9.6b  . . . then withdraw the matrix from the

heater casing

9.7  Removing the heater blower motor

10.1  Air conditioning system layout

a

Outside air

b

Outside or recirculated air

c

Fresh and dried air

GHP

High-pressure gas

LHP

High-pressure liquid

GBP

Low-pressure gas

1

Condenser

2

Dehydrator

3

Compressor

4

Expansion chamber

5

Evaporator

6

Pressostat

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
refrigerant returns to the evaporator where it
absorbs heat from air passing over the
evaporator fins. The refrigerant becomes a
gas again and the cycle is repeated.
3 Various subsidiary controls and sensors
protect the system against excessive
temperature and pressures. Additionally,
engine idle speed is increased when the
system is in use to compensate for the
additional load imposed by the compressor.

Precautions

4 When an air conditioning system is fitted, it
is necessary to observe special precautions
whenever dealing with any part of the system,
or its associated components. If for any
reason the system must be discharged,
entrust this task to your Peugeot dealer or air
conditioning specialist.

Warning: The refrigeration
circuit may contain a liquid
refrigerant (Freon), and it is
therefore dangerous to

disconnect any part of the system without
specialised knowledge and equipment.
5 The refrigerant is potentially dangerous,
and should only be handled by qualified
persons. If it is splashed onto the skin, it can

cause frostbite. It is not itself poisonous, but
in the presence of a naked flame (including a
cigarette) it forms a poisonous gas.
Uncontrolled discharging of the refrigerant is
dangerous, and potentially damaging to the
environment.
6 Components of the air conditioning system
may obstruct work being undertaken in other
areas on or around the engine. In many
instances, it may be possible to unbolt and
move these components aside, within the
limits of their flexible connecting pipes, to gain
the necessary access. Apart from this,
complete removal and refitting or fault
diagnosis, of any air conditioning system
components, must be left to a specialist.

3•8 Cooling, heating and air conditioning systems