Peugeot 205. Manual - part 30

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 retaining
clip, then remove the clip, along with its seal,
and withdraw the switch from inside the duct.
Examine the seal for signs of damage or
deterioration, and renew if necessary.

Refitting

3 On refitting, ensure that the switch and duct
mating surfaces are clean and dry, and
position the switch inside the duct.
4 Fit the seal over the switch unions, and refit
the retaining clip. Ensure that the switch is
pressed firmly against the duct, and secure it
in position by bending down the retaining clip
tangs. Refit the duct.

Air temperature control valve

Removal

5 Disconnect the vacuum pipe from the air
temperature control valve, then slacken the
retaining clips securing the inlet ducts to the
valve.
6 Disconnect both inlet ducts and the hot-air
inlet hose from the control valve assembly,
and remove it from the vehicle.

Refitting

7 Refitting is the reverse of the removal
procedure, noting that the air temperature
control valve assembly can only be renewed
as a complete unit.

5

Crankcase ventilation
system components -
removal and refitting

2

The crankcase ventilation system consists

simply of a number of ventilation hoses, and a

wire mesh filter in the engine oil filler cap on
certain models. Removal and refitting is self-
explanatory, but it may be necessary to
detach surrounding components for improved
access. Refer to the various Chapters of this
manual as necessary if problems are
encountered.

6

Electro-pneumatic ignition
retarding system components
- removal and refitting

2

Solenoid valve

Removal

1 The valve is located on a bracket at the rear
of the engine compartment. To remove the
valve, proceed as follows.
2 Disconnect the battery negative lead, then
disconnect the wiring plug from the valve (see
illustration).
3 Note the orientation of the valve, then
disconnect the hoses from the valve, and pull
the valve from its bracket.

Refitting

4 Refitting is a reversal of removal, ensuring
that the valve is correctly orientated, as noted
before removal.

Coolant temperature sensor

Removal

5 The sensor is located in the left-hand end of
the cylinder head, below the engine coolant
temperature sensor for the fuel injection
system.
6 To remove the sensor, partially drain the
cooling system (see Chapter 1), then
disconnect the wiring, and unscrew and
remove the sensor.

Refitting

7 When refitting the sensor, ensure that the
seal is in good condition, and take care not to
overtighten the switch. Refill the cooling
system on completion as described in
Chapter 1 and “Weekly checks”.

7

Catalytic converter - general
information and precautions

The catalytic converter is a reliable and

simple device, which needs no maintenance
in itself, but there are some facts of which an
owner should be aware if the converter is to
function properly for its full service life.

a) DO NOT use leaded petrol in a vehicle

equipped with a catalytic converter - the
lead will coat the precious metals,
reducing their converting efficiency, and
will eventually destroy the converter.

b) Always keep the ignition and fuel systems

well-maintained in accordance with the
manufacturer’s schedule (see Chapter 1).

c) If the engine develops a misfire, do not

drive the vehicle at all (or at least as little
as possible) until the fault is cured.

d) DO NOT push - or tow-start the vehicle -

this will soak the catalytic converter in
unburned fuel, causing it to overheat
when the engine does start.

e) DO NOT switch off the ignition at high

engine speeds, ie do not “blip” the
throttle immediately before switching off.

f) DO NOT use fuel or engine oil additives -

these may contain substances harmful to
the catalytic converter.

g) DO NOT continue to use the vehicle if the

engine burns oil to the extent of leaving a
visible trail of blue smoke.

h) Remember that the catalytic converter

operates at very high temperatures. DO
NOT, therefore, park the vehicle in dry
undergrowth, over long grass or piles of
dead leaves, after a long run.

I) Remember that the catalytic converter is

FRAGILE. Do not strike it with tools
during servicing work.

j) In some cases, a sulphurous smell (like

that of rotten eggs) may be noticed from
the exhaust. This is common to many
catalytic converter-equipped vehicles.
Once the vehicle has covered a few
thousand miles, the problem should
disappear - in the meantime, try changing
the brand of petrol used.

k) The catalytic converter used on a well-

maintained and well-driven vehicle should
last for between 50 000 and 100 000
miles. If the converter is no longer
effective, it must be renewed.

8

Fuel vapour recirculation
system components -
removal and refitting

2

Carbon canister

Removal

1 The carbon canister is located at the rear
left-hand corner of the engine compartment
(see illustration).
2 To remove the canister, first disconnect the
hoses, noting their locations to ensure correct
refitting.

Exhaust and emission control systems  4D•5

4D

6.2  Disconnecting wiring plug from

ignition retarding system solenoid valve

8.1 Fuel vapour recirculation system

carbon canister (A) and solenoid valve (B)

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 compartment.
6 To remove the valve, first disconnect the
battery negative lead.
7 Unbolt the bracket from the body panel,
then disconnect the wiring plug (see
illustrations).

8 Disconnect the hoses from the valve, noting
their locations to ensure correct refitting, then
withdraw the valve.

Refitting

9 Refitting is a reversal of removal, ensuring
that the hoses are correctly reconnected, as
noted before removal.

4D•6 Exhaust and emission control systems

8.7a  Unscrew the securing nut . . .

8.7b . . . and withdraw the solenoid bracket

5A

Chapter 5  Part A:
Starting and charging systems

System type

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12-volt, negative earth

Battery

Type  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low maintenance or “maintenance-free” sealed for life

Capacity  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 to 33 Ah (depending on model)

Charge condition:

Poor  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12.5 volts

Normal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12.6 volts

Good  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12.7 volts

Alternator - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Alternator - testing and overhaul  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Auxiliary drivebelt check and renewal  . . . . . . . . . . . . . . .See Chapter 1
Battery - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Battery - testing and charging  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Battery, bulbs and fuses . . . . . . . . . . . . . . . . . . . .See “Weekly checks”
Charging system - testing  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Electrical fault finding - general information  . . . . . . . . . . . . . . . . . . . 2

Electronic oil level sensor - general information  . . . . . . . . . . . . . . . . 13
General information and precautions  . . . . . . . . . . . . . . . . . . . . . . . . 1
Ignition switch - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . 11
Oil pressure warning light switch - removal and refitting  . . . . . . . . . 12
Starter motor - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . 9
Starter motor - testing and overhaul  . . . . . . . . . . . . . . . . . . . . . . . . . 10
Starting system - testing  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5A•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

1

General information and
precautions

General information

The engine electrical system consists

mainly of the charging and starting systems.
Because of their engine-related functions,
these components are covered separately
from the body electrical devices such as the
lights, instruments, etc (which are covered in
Chapter 12). Information on the ignition
system is covered in Part B of this Chapter.

The electrical system is of the 12-volt

negative earth type.

The battery is of the low maintenance or

“maintenance-free” (sealed for life) type and is
charged by the alternator, which is belt-driven
from the crankshaft pulley.

The starter motor is of the pre-engaged

type incorporating an integral solenoid. On
starting, the solenoid moves the drive pinion
into engagement with the flywheel ring gear

before the starter motor is energised. Once
the engine has started, a one-way clutch
prevents the motor armature being driven by
the engine until the pinion disengages from
the flywheel.

Precautions

Further details of the various systems are

given in the relevant Sections of this Chapter.
While some repair procedures are given, the
usual course of action is to renew the
component concerned. The owner whose
interest extends beyond mere component
renewal should obtain a copy of the
“Automobile Electrical & Electronic Systems
Manual”, available from the publishers of this
manual.

It is necessary to take extra care when

working on the electrical system to avoid
damage to semi-conductor devices (diodes
and transistors), and to avoid the risk of
personal injury. In addition to the precautions
given in “Safety first!” at the beginning of this
manual, observe the following when working
on the system:

Always remove rings, watches, etc before

working on the electrical system. Even with
the battery disconnected, capacitive
discharge could occur if a component’s live
terminal is earthed through a metal object.
This could cause a shock or nasty burn.

Do not reverse the battery connections.

Components such as the alternator, electronic
control units, or any other components having
semi-conductor circuitry could be irreparably
damaged.

If the engine is being started using jump

leads and a slave battery, connect the
batteries positive-to-positive and negative-to-
negative

(see  “Booster battery (jump)

starting”). This also applies when connecting
a battery charger.

Never disconnect the battery terminals, the

alternator, any electrical wiring or any test
instruments when the engine is running.

Do not allow the engine to turn the

alternator when the alternator is not
connected.

Never “test” for alternator output by

“flashing” the output lead to earth.

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 electronic control unit to
protect them from the risk of damage.

The radio/cassette units fitted as standard

or optional equipment may be equipped with a
built-in security code to deter thieves. If the
power source to the unit is cut, the anti-theft
system will activate. Even if the power source
is immediately reconnected, the radio/cassette
unit will not function until the correct security
code has been entered. Therefore, if you do
not know the correct security code for the
radio/cassette unit do not disconnect the
negative terminal of the battery or remove the
radio/cassette unit from the car. Refer to the
Owner’s Manual, or your Peugeot dealer for
further information on security codes.

2

Electrical fault finding -
general information

Refer to Chapter 12.

3

Battery - testing and charging

1

Standard and low maintenance
battery - testing

1 If the vehicle covers a small annual mileage,
it is worthwhile checking the specific gravity
of the electrolyte every three months to
determine the state of charge of the battery.
Use a hydrometer to make the check and
compare the results with the following table.

Above

Below

25°C (77°F)

25°C (77°F)

Fully-charged 1.210 to 1.230 1.270 to 1.290
70% charged 1.170 to 1.190 1.230 to 1.250
Discharged

1.050 to 1.070 1.110 to 1.130

Note that the specific gravity readings assume
an electrolyte temperature of 15°C (60°F); for
every 10°C (50°F) below 15°C (60°F) subtract
0.007. For every 10°C (50°F) above 15°C
(60°F) add 0.007.
2 If the battery condition is suspect, first
check the specific gravity of electrolyte in
each cell. A variation of 0.040 or more
between any cells indicates loss of electrolyte
or deterioration of the internal plates.
3 If the specific gravity variation is 0.040 or
more, the battery should be renewed. If the
cell variation is satisfactory but the battery is
discharged, it should be charged as
described later in this Section.

Maintenance-free battery -
testing

4 In cases where a “sealed for life”
maintenance-free battery is fitted, topping-up
and testing of the electrolyte in each cell is not
possible. The condition of the battery can
therefore only be tested using a battery
condition indicator or a voltmeter.
5 If testing the battery using a voltmeter,
connect the voltmeter across the battery and
compare the result with those given in the
Specifications under “charge condition”. The
test is only accurate if the battery has not
been subjected to any kind of charge for the
previous six hours. If this is not the case,
switch on the headlights for 30 seconds, then
wait four to five minutes before testing the
battery after switching off the headlights. All
other electrical circuits must be switched off,
so check that the doors and tailgate are fully
shut when making the test.
6 If the voltage reading is less than 12.2 volts,
then the battery is discharged, whilst a
reading of 12.2 to 12.4 volts indicates a
partially discharged condition.
7 If the battery is to be charged, remove it
from the vehicle (Section 4) and charge it as
described later in this Section.

Standard and low maintenance
battery - charging

Note: The following is intended as a guide
only. Always refer to the manufacturer’s
recommendations (often printed on a label
attached to the battery) before charging a
battery.
8 Charge the battery at a rate of 3.5 to 4
amps and continue to charge the battery at
this rate until no further rise in specific gravity
is noted over a four hour period.
9 Alternatively, a trickle charger charging at
the rate of 1.5 amps can safely be used
overnight.
10 Specially rapid “boost” charges which are
claimed to restore the power of the battery in 1
to 2 hours are not recommended, as they can
cause serious damage to the battery plates
through overheating.
11 While charging the battery, note that the
temperature of the electrolyte should never
exceed 37.8°C (100°F).

Maintenance-free battery -
charging

Note: The following is intended as a guide
only. Always refer to the manufacturer’s
recommendations (often printed on a label
attached to the battery) before charging a
battery.
12 This battery type takes considerably
longer to fully recharge than the standard
type, the time taken being dependent on the
extent of discharge, but it can take anything
up to three days.
13 A constant voltage type charger is
required, to be set, when connected, to 13.9
to 14.9 volts with a charger current below 25
amps. Using this method, the battery should

be usable within three hours, giving a voltage
reading of 12.5 volts, but this is for a partially
discharged battery and, as mentioned, full
charging can take considerably longer.
14 If the battery is to be charged from a fully
discharged state (condition reading less than
12.2 volts), have it recharged by your Peugeot
dealer or local automotive electrician, as the
charge rate is higher and constant supervision
during charging is necessary.

4

Battery - removal and refitting

1

Note: Make sure that you have a copy of the
radio/cassette unit security code number
(where applicable) before disconnecting the
battery.

Removal

1 The battery is located in the front left-hand
corner of the engine compartment.
2 Slacken the clamp bolts and disconnect the
clamp from the battery negative (earth)
terminal.
3 Remove the insulation cover (where fitted)
and disconnect the positive terminal lead(s) in
the same way.
4 Release the battery clamp and lift the battery
carefully from the engine compartment.
5 If required, the battery tray can be removed
after undoing the retaining bolts.

Refitting

6 Refitting is a reversal of removal, but smear
petroleum jelly on the terminals when
reconnecting the leads, and always reconnect
the positive lead first, and the negative lead last.

5

Charging system - testing

1

Note: Refer to the warnings given in “Safety
first!” and in Section 1 of this Chapter before
starting work.
1 If the ignition warning light fails to illuminate
when the ignition is switched on, first check
the alternator wiring connections for security.
If satisfactory, check that the warning light
bulb has not blown, and that the bulbholder is
secure in its location in the instrument panel.
If the light still fails to illuminate, check the
continuity of the warning light feed wire from
the alternator to the bulbholder. If all is
satisfactory, the alternator is at fault and
should be renewed or taken to an auto-
electrician for testing and repair.
2 If the ignition warning light illuminates when
the engine is running, stop the engine and
check that the drivebelt is correctly tensioned
(see Chapter 1) and that the alternator
connections are secure. If all is so far
satisfactory, have the alternator checked by
an auto-electrician for testing and repair.

5A•2 Starting and charging systems