Peugeot 205. Manual - part 37

 

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Peugeot 205. Manual - part 37

 

 

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.
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 return
spring is also fitted to the pedal. 
Examine the pedal bushes for wear and
renew them if necessary. 

Refitting

Refitting is a reversal of removal, but lightly
grease the bushes and clevis pin and renew
the self-locking nut.

18 Handbrake lever - removal

and refitting

2

Removal

Move the front seats fully forward then
remove the screw and lift the cover from the
handbrake lever.
Fully release the handbrake then unscrew
the adjustment nut on the rear of the cable
compensator until both cables can be
unhooked. 
Unbolt and remove the handbrake lever
assembly from the floor (see illustration)

Refitting

Refitting is a reversal of removal, but adjust
the handbrake, as described in Section 15 on
completion.

19 Anti-lock braking system

(ABS) - general information

From 1991, the Bendix anti-lock braking

system is available as an option on certain
models.

The system is fail-safe, and is fitted in

conjunction with the conventional braking
system, which allows the vehicle to retain
conventional braking In the event of a failure
in the ABS system.

To prevent wheel locking, the system

provides pressure modulation in the brake
circuits. To achieve this, sensors mounted at
each front wheel monitor the rotational
speeds of the wheels, and are thus able to
detect when there is a risk of wheel locking
(low rotational speed). Solenoid valves are
positioned in the brake circuits to all four
wheels and the solenoid valves are
incorporated in the regulator unit, which is
controlled by an electronic control unit. The
electronic control unit controls modulation of
the braking effort applied to each wheel,
according to the information supplied by the
wheel sensors.

Should a fault develop in the system, a

self-diagnostic facility is incorporated in the
electronic control unit, which can be used in
conjunction with specialist diagnostic
equipment available to a Peugeot dealer to
determine the nature of the fault.

The brake components used on models

fitted with ABS are similar to those used on
models with a conventional braking system.
Rear disc brakes are fitted to all
ABS-equipped models, and all procedures for
the rear brake and handbrake components
are as described for 1.9 GTI models in the
relevant Sections of this Chapter. 

20 Anti-lock braking system

(ABS) components - removal
and refitting

3

Warning: It is strongly
recommended that any work
involving components of the
braking system on a vehicle

equipped with ABS is entrusted to a

Peugeot dealer, who will have the
necessary specialist knowledge and
equipment to carry out the work safely and
effectively.

Regulator unit

At the time of writing, no information was
available regarding removal and refitting of
the regulator unit.

Wheel sensor

Removal

The wheel sensors are mounted in the rear
of the hub carriers. To remove a wheel sensor,
proceed as follows.
Disconnect the battery negative lead.
Chock the rear wheels then jack up the
front of the car and support it on axle stands
(see “Jacking and vehicle support”). Remove
the roadwheel.
Carefully pull the sensor wiring from its
retaining clips, and working under the wing,
disconnect the sensor wiring connector.
Unscrew the securing bolt, and withdraw
the sensor from the hub carrier.

Refitting

Refitting is a reversal of removal, but ensure
that the front face of the sensor is perfectly
clean, and ensure that the wiring is correctly
routed. Clean the sensor securing bolt
threads, then apply suitable thread-locking
fluid and tighten the bolt securely.

Electronic control unit

Removal

The electronic control unit is located on the
left-hand side of the luggage compartment.
To remove the control unit, proceed as
follows.
Disconnect the battery negative lead.
10 Open the tailgate, and carefully pull the
trim from the left-hand side of the luggage
compartment to reveal the control unit.
11 Unscrew the securing nuts, and withdraw
the cover from the control unit.
12 Disconnect the control unit wiring plug.
13 Unscrew the securing nuts, and withdraw
the control unit from its mounting bracket.

Refitting

14 Refitting is reversal of removal.

Braking system  9•15

9

18.3  Handbrake lever mounting bolts

(arrowed)

9•16

Notes

10

Chapter 10
Suspension and steering

Front suspension

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

Independent, MacPherson struts, coil springs, anti-roll bar

Rear suspension

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

Independent, cross-tube with trailing arms, torsion bars, inclined
shock absorbers, anti-roll bar

Steering

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

Rack-and-pinion. Power-assistance optional on certain models 

Power steering fluid type  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See “Weekly checks”

Wheel alignment and steering angles

Front wheel toe setting:

All models, except GTI and automatic transmission - up to 1988  . . .

3.0 ± 1.0 mm toe-in

1.6 GTI models - up to 1988 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.0 ± 1.0 mm toe-in

1.9 GTI models - up to 1988 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5 ± 1.0 mm toe-in

Automatic transmission models - up to 1988 . . . . . . . . . . . . . . . . . . .

3.5 ± 1.0 mm toe-in

All models from 1988 onward  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.0 ± 0.5 mm toe-in

Roadwheels

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

Pressed-steel or aluminium alloy (depending on model)

Size  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 B x 13, 4.5J x 13, 5 B x 13, 5.5J x 14 or 6.6J x 15 (depending on
model)

Tyres

Size  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

135 SR 13, 145 SR 13, 165/70 SR 13, 185/60 HR 14 or 185/55 VR 15
(depending on model)

Tyre pressures  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See “Weekly checks”

Auxiliary drivebelt check and renewal  . . . . . . . . . . . . . . .See Chapter 1
Front anti-roll bar - removal and refitting . . . . . . . . . . . . . . . . . . . . . . 7
Front hub bearings - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Front lower suspension arm - removal and refitting  . . . . . . . . . . . . . 6
Front suspension hub carrier - removal and refitting  . . . . . . . . . . . . 2
Front suspension strut - overhaul  . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Front suspension strut - removal and refitting  . . . . . . . . . . . . . . . . . 4
General information  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Power steering fluid level check  . . . . . . . . . . . . . .See “Weekly checks”
Power steering pump - removal and refitting  . . . . . . . . . . . . . . . . . . 18
Power steering system - bleeding  . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Rear hub/drum and bearings - general information  . . . . . . . . . . . . . 8
Rear shock absorber - removal and refitting  . . . . . . . . . . . . . . . . . . . 10

Rear suspension assembly - removal and refitting  . . . . . . . . . . . . . . 11
Rear suspension components - general information . . . . . . . . . . . . . 9
Steering and suspension check  . . . . . . . . . . . . . . . . . . .See Chapter 1
Steering column and lock - removal and refitting  . . . . . . . . . . . . . . . 14
Steering gear - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . 15
Steering gear rubber bellows - renewal . . . . . . . . . . . . . . . . . . . . . . . 16
Steering wheel - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 13
Track rod - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Track rod end - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . 19
Tyre condition and pressure checks  . . . . . . . . . .See “Weekly checks”
Vehicle ride height - checking  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Wheel alignment and steering angles - general information  . . . . . . . 21

10•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

Front suspension

Driveshaft/hub nut:

Non-GTI models  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

250

185

GTI models  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

260

192

Automatic transmission models  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

265

196

Strut top mounting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

9

Shock absorber piston rod nut:

Self-locking type  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45

33

Crimped type  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70

52

Strut clamp bolt  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58

43

Anti-roll bar clamp  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35

26

Anti-roll bar end (non-GTI models)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75

55

Lower balljoint clamp bolt:

Manual transmission models  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35

26

Automatic transmission models  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45

33

Anti-roll bar guide bar  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30

22

Lower suspension arm pivot bolt  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35

26

Anti-roll bar end (GTI models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58

43

Lower suspension arm rear pivot bolt (GTI models) . . . . . . . . . . . . . . . .

78

58

Rear suspension

Shock absorber upper mounting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75

55

Shock absorber lower mounting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

118

87

Anti-roll bar arm  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35

26

Torsion bar plug  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

15

Suspension top mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45

33

Suspension front mounting pivot bolt  . . . . . . . . . . . . . . . . . . . . . . . . . .

80

59

Steering

Steering gear mounting bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35

26

Power steering fluid pipe unions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

17

Column-to-pinion clamp bolt  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

11

Track rod end balljoint nut  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35

26

Track rod inner joint  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50

37

Steering wheel nut  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30

22

Roadwheels

Roadwheel bolts (all wheel types)*  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

85

63

*On alloy wheels, oil the ends of the bolt threads over a maximum length of 10 mm before fitting.

1

General information

The front suspension is of independent

type; incorporating MacPherson struts with
coil springs and integral shock absorbers. On
non-GTI models the lower suspension arm
movement is controlled by the anti-roll bar,
but on GTI models the arm has two inner pivot
points and the anti-roll bar operates
separately on the struts.

The rear suspension is also of independent

type; incorporating a cross-tube with trailing
arms set in each end and supported on
needle or plain bearings. Torsion bars are
fitted to the trailing arms and, on certain
models, an anti-roll bar located inside the
cross-tube stabilises the car when cornering.
The telescopic shock absorbers are inclined
with their top mountings attached to the
suspension side-members.

The steering system is of rack and pinion

type with side track rods connected to the
hub carriers by track rod end balljoints.

Further balljoints on the inner ends of the
track rods are screwed into the rack. Power-
assisted steering is available as an option on
later models. Power assistance is derived
from a hydraulic pump, belt-driven from the
crankshaft pulley.

The steering column incorporates a single

universal joint at its lower end connected to
an intermediate shaft which also incorporates
a universal joint at its connection to the pinion
on the steering gear. The steering column is
angled to prevent direct movement into the
passenger compartment in the event of a front
end impact.

2

Front suspension hub carrier
- removal and refitting

4

Removal

Fully apply the handbrake then, where
possible, remove the front wheel centre trim.
Tap up the staking securing the hub nut to the
driveshaft groove or, on later models, extract
the R-clip and withdraw the locking collar

(see illustration). Using a socket and a long
extension bar, slacken the hub nut. On
models without a centre trim, the hub nut
must be loosened after removing the front
wheel. Do not apply the footbrake when
loosening the nut as damage can occur to the
brake disc retaining screws.
Chock the rear wheels then jack up the
front of the car and support it on axle stands
(see “Jacking and vehicle support”). Remove
the front roadwheel.

10•2 Suspension and steering

2.1  R-clip and locking collar fitted to hub

nut on later models

 

 

 

 

 

 

 

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