Peugeot 205 (954 cc, 1124 cc, 1360 cc, 1580 cc & 1905 cc). Manual - part 23

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
and flush with the front wings. If necessary
loosen the hinge bolts and move it within the
elongated holes to reposition it, then adjust
the bonnet lock and striker, as described in
Section 7.

7

Bonnet lock and remote
control cable - removal,
refitting and adjustment

2

Removal

1 Remove the front grille, as described in
Section 8.
2 Unbolt the lock from the crossmember and
disconnect the control cable (see
illustration).
3 Working inside the car, remove the screws
from the cable release lever located below the
left-hand end of the facia.
4 Unclip the cable and withdraw it from inside
the car.
5 If necessary the bonnet striker may be
unscrewed from the bonnet and the safety
spring unclipped.

Refitting

6 Refitting is a reversal of removal, but check
that the striker enters the lock centrally and
holds the front of the bonnet level with the
front wings. If necessary loosen the lock bolts
and move the lock within the elongated holes.
Adjust the bonnet height by screwing the
striker pin in or out. Adjust the rubber buffers
to support the front corners of the bonnet.

8

Front grille - removal and
refitting

1

Removal

1 Open the bonnet and support with the stay.
2 Remove the screws from the top of the
grille then lift it upwards from the lower
mounting holes (see illustrations).

Refitting

3 Refitting is a reversal of removal.

9

Bumpers - removal and
refitting

3

Removal

Front bumper

1 The bumper is removed complete with the
front spoiler.

2 Working under the vehicle, unscrew the two
front bumper mounting nuts at the brackets
(see illustration).
3 On non-GTI models, unscrew the side
mounting nuts beneath the front wheel arches
and withdraw the bumper from the car,
together with the side mounting rubbers.
4 On GTI models, disconnect the battery
negative lead, and disconnect the wiring from
the front driving lamps.
5 Remove the clip securing the front wing
trim to the bumper.
6 Unscrew the bolts securing the driving lamp
brackets to the body, loosen the side bumper
mounting nuts beneath the front wheel
arches, and withdraw the bumper from the
car.
7 The brackets may be removed separately if
required. 

Rear bumper

8 Unscrew the rear, side and bottom
mounting nuts and withdraw the bumper
rearwards  (see illustration). On certain
models, additional fixing clips must also be
released and a lower moulding removed
before the bumper can be withdrawn.
9 The brackets may be removed separately if
required. 

Refitting

10 Refitting both the front and rear bumpers
is a reversal of removal.

11•4 Bodywork and fittings

6.2  Bonnet hinge

6.3  Braided lead fitted to the bonnet

7.2  Bonnet lock retaining bolts

8.2a  Remove the screws . . .

8.2b  . . . and lift the front grille from the

outer . . .

8.2c  . . .  and inner mounting holes

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 buffer
6 Bracket
7 Mounting bolt
8 Nuts
9 Bracket nut and washers
10 Bracket

10 Door - removal and refitting

3

Removal

1 The door hinges are welded to the body
pillar and bolted to the door.
2 Remove the plastic caps from the hinge
pivot pins. 
3 Drive out the roll pin from the door check
strap. 
4 Where applicable, remove the trim panel
(Section 11) and disconnect the loudspeaker
wiring from the door. 
5 Support the door in the fully open position
by placing blocks, or a jack and a pad of rag,
under its lower edge. 
6 Drive out the hinge pivot pins and remove
the door. 

Refitting

7 Refit by reversing the removal operations. 
8 Where necessary, the striker on the body
pillar may be adjusted to ensure correct
closure of the door.

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 the
position of the window regulator handle, then
pull the handle from the spindle (see
illustration). 

5 Prise out the interior door handle surround
(see illustration). 
6 Using a wide-bladed screwdriver, or similar
tool, prise the trim panel from the door -
working progressively from the bottom
upwards and inserting the screwdriver
adjacent to each clip. Where applicable,
disconnect the electric window switch wiring
and door speaker wiring as the panel is
withdrawn, on models so equipped.

Rear doors 

7 The procedure is as given for the front
doors, but there are slight trim differences.

Refitting

8 Refitting the front and rear door panels is a
reversal of removal, but first make sure that
the clips are correctly located in the panel.

12 Door (Hatchback and Van

models) - dismantling and
reassembly

3

Dismantling

1 Remove the trim panel, as described in
Section 11.

Window regulator

2 To remove the window regulator, unscrew
the mounting nuts, slide the two lifting arms
from the channels, and withdraw the regulator
through the access aperture (see
illustrations). Support the glass during this
operation.

Door lock

3 To remove the door lock and inner remote
handle, disconnect the link rods as necessary
and, unscrew the Torx screws retaining the
lock (see illustrations).

Exterior handle

4 To remove the exterior handle, disconnect
the link rod and unscrew the bolts. The private
lock is removed by disconnecting the link rod
and pulling out the retaining clip (see
illustration).

Door glass

5 To remove the door glass, first remove the
window regulator then unbolt the glass side
channels, tilt the glass and withdraw it
upwards.

11•6 Bodywork and fittings

11.2  Removing the armrest

11.3  Removing the side pocket

11.4  Removing the window regulator

handle

12.2b  The window regulator lifting arms

and window glass channel

12.3a  Door lock and mounting screws

12.3b  Door inner remote handle

12.2a  Window regulator mounting nuts

(arrowed)

11.5  Removing the interior door handle

surround

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, then feed the
rubber grommet through the hole and withdraw
the mirror from outside (see illustration).

Reassembly

9 Reassembly of the door is a reversal of the
dismantling procedure. However, when
refitting the door glass, adjust the position of
the side channels so that the glass moves
smoothly without excessive play.

13 Door (Cabriolet models) -

dismantling and reassembly

3

Dismantling

Note: Refer to Section 12 for door lock,
exterior handle and exterior mirror dismantling
and reassembly procedures.

Window regulator

1 Remove the trim panel as described in
Section 11.
2 Where applicable, disconnect the battery,
then disconnect the wiring from the window
regulator motor.
3 Unscrew the nuts and withdraw the
regulator from the door.

Door glass

4 Remove the regulator then detach the
weatherstrips from the top edge of the door.
5 Raise the glass, and lift it from the door.
6 Unscrew the mounting nuts, and remove
the fixed quarterlight glass through the sliding
glass location.

Reassembly

7 Reassembly is a reversal of dismantling, but
carry out the following adjustments. Temporarily
refit the window regulator handle, or reconnect
the regulator motor wiring, as applicable, then
close the window, and if necessary adjust the
height of the window by reaching in through the
speaker aperture and turning the screw
indicated (see illustration). (The illustration
shows the regulator part-removed - with the
regulator installed, access to the adjustment
screw is possible through the speaker aperture.)
Close the door, and check that the rear edge of
the door glass seals correctly with the hood. If
not, remove the cap and turn the screw shown
(see illustration).

Bodywork and fittings  11•7

11

12.4  Pull out the retaining clip to remove

the private lock

12.6a  On early models, remove the inner

cover . . .

12.6b  . . . and remove the exterior mirror

mounting screws

12.7  On later models, prise the trim cover

from the control lever . . .

12.8  . . . remove the screws and withdraw

the mirror

13.7a  Door glass height adjustment screw (1) shown during

removal of regulator assembly - Cabriolet models

13.7b  Door glass rear edge adjustment screw (1) on Cabriolet models

a   Switch wiring

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 down the rear seats and remove the
parcel shelf, then slide off the retaining strips
and unclip the edges of the hood lining.
5 Release the three press-studs, prise off the
rear hood crossmember trim strip, then
extract the crossmember securing screws
and withdraw the crossmember.
6 Unzip the rear window, and release the

Velcro securing strips from the hood, then
withdraw the window from outside the
vehicle.
7 Unclip the tensioners, then remove the
indicated bracket securing bolts (see
illustration).
8 Fold the hood down, remove the remaining
hood frame securing bolts, then lift the frame
from the vehicle.

Refitting

9 Place the hood in its compartment, and refit
the lower frame securing bolts (see
illustration). Do not tighten the screws at this
stage.
10 Partially unfold the hood, then loosely refit
the bracket securing bolts. Note: Ensure that
the brackets are not lodged in the hinges,
which may cause scratching of the paint on
the rear wings.
11 Fully unfold the hood, and check that the
hooks at the front corners of the hood line up
with their strikers. If the hooks and strikers are

not aligned, move the hood support brackets
(the securing bolt holes are elongated) until
satisfactory alignment is obtained.
12 Open and close the hood a number of
times to ensure that it operates correctly, then
tighten the lower frame securing bolts.
13 The effort required to operate the handle
can be adjusted by loosening the locknuts
and adjusting the length of the hooks.
14 Partially fold the hood, and refit the rear
window and the hood rear crossmember and
trim strip.
15 Clip the tensioners to their lugs, then refit
the bracket securing bolts.
16 Fold the hood completely flat, and check
that the stops are in contact with the rear
stretcher. If adjustment is required, loosen the
locknuts and adjust the length of the stops as
necessary.
17 Partially raise the hood, then clip the
edges of the hood lining in place, and refit the
retaining strips.
18 Clip the hood lining side strips in place.

11•8 Bodywork and fittings

14.2  Prise off the trim caps (1) and unscrew the hinge cover

securing screw (2) - Cabriolet models

14.3  Hood bracket securing bolt (3) and lower hood securing

bolts (4 and 5) - Cabriolet models

14.7  Unclip the tensioners (11) and remove the bracket securing

bolts (12 and 13) - Cabriolet models

14.9  Refit  and lower the frame securing bolts (1), then partially

unfold the hood and loosely refit the bolts (2) - Cabriolet models

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 Peugeot dealer.

16 Tailgate - removal and

refitting

3

Removal

1 Open the tailgate and have an assistant
support it.
2 Disconnect the struts from the body by
prising out the plastic clips and pulling off the
sockets (see illustration).
3 Disconnect the wiring for the heated rear
window and tailgate wiper motor. Also
disconnect the washer tube.
4 Prise the blanking plates from the rear of
the headlining, then unscrew the mounting
nuts and lift the tailgate from the car (see
illustration). 

Refitting

5 Refitting is a reversal of removal, but
before fully tightening the mounting nuts
check that the tailgate is positioned centrally
in the body aperture and make any
adjustments to the lock and striker, as
described in Section 17.

17 Tailgate lock - removal and

refitting

3

Removal

1 Open the tailgate and prise off the trim
panel using a wide-bladed screwdriver (see
illustration). 
2 Unbolt the latch and disconnect the
operating rod. 
3 Slide out the spring clip and withdraw the
lock barrel and escutcheon (see illustration). 

Refitting

4 Refitting is a reversal of removal. Check
that the latch engages the striker correctly
and, if necessary, adjust the striker position
within the elongated bolt holes. Adjust the
rubber stops so that the tailgate is supported
firmly at the corners when shut.

18 Windscreen and tailgate

glass - general information

Both the windscreen and tailgate glass are

bonded in position and therefore it is
recommended that a professional fitter is
employed in the event of breakage. Special
equipment and adhesive are required for
removal of the old glass and fitting of the new,
which may not be readily available to the
home mechanic.

19 Rear quarter glass (GTI

models) - removal and
refitting

1

Removal

1 Open the quarter window and remove the
screw securing the glass to the latch. Remove
the special nut from the glass. 
2 Open the window further then support it
and remove the screws securing the glass to
the front hinges. Remove the special nuts. 

Refitting

3 Refitting is a reversal of removal.

20 Rear quarter glass and

regulator (Cabriolet models)
- removal and refitting

3

Removal

1 Fold down the front and rear seats, then
open the hood a little way.
2 Fully close the quarter glass.
3 Unbolt the seat belt lower anchor.
4 Note the position of the regulator handle,
then remove it by easing it off from behind
using pliers, or an alternative similar tool.
5 Using a wide-bladed screwdriver, release
the plastic clips and withdraw the trim panel.
6 Pull off the polythene sheet.

Bodywork and fittings  11•9

11

17.3  Tailgate lock and lock barrel

17.1  Tailgate trim panel clip

16.2  Disconnecting the tailgate struts

16.4  Tailgate mounting nuts behind the headlining

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 quarter glass
weatherstrip and clips.
12 Push the plastic rivet centre pins and
remove the stretcher support.
13 Lift the glass and remove it.

Refitting

14 Refitting is a reversal of removal. If a new
glass is being fitted, position the lower channel
as shown (see illustration). Remove the guide
pads from the old glass by drilling out the rivet
heads. Fit them to the new glass using the
special sleeves and screws obtainable from a
Peugeot dealer (see illustration). Apply a little
locking fluid to the screw threads before
inserting and tightening them. Unlike the door
glass, there are no adjustment points.

21 Seats - removal and refitting

2

Removal

Front seat

1 Move the seat fully forward and remove the
rear inner mounting bolts (see illustration).
2 Remove the remaining mounting bolts from
under the car and from the brackets, then
remove the seat from the car.

Rear seat

3 Fold the cushion forwards and unbolt it
from the hinges (see illustration).
4 Fold the backrest down, unscrew the nuts
from the outer pivot bracket(s) and withdraw
the backrest from the inner pivot (where
applicable).

Refitting

5 Refitting the front and rear seats is a
reversal of removal.

22 Grab handles - removal and

refitting

1

Removal

1 Prise up the cover plates for access to the
screws at each end. 
2 Remove the screws and the grab handles. 

Refitting

3 Refitting is a reversal of removal.

23 Sunroof - general information

The sunroof fitted to some models

incorporates an outer glass and inner cover.
The control handle operates lock latches
located at the rear of the sunroof. The handle
also operates a vacuum seal system which

holds and seals the sunroof in any desired
position.

The vacuum seal is operated by engine

vacuum. With the handle shut, the vacuum
valve is closed and the seal exerts pressure
under the periphery of the glass. When the
handle is opened, the vacuum valve opens
and causes the seal to collapse, enabling the
glass to be moved. 

11•10 Bodywork and fittings

20.14a  Channel position on the rear

quarterlight glass - Cabriolet models

x = 145.0 mm

1   Guide pads

20.14b  Screw (a) and sleeve (b) for fitting

the guide pads to the rear quarterlight

glass on Cabriolet models

21.3  Rear seat cushion hinge

21.1  Front seat rear inner mounting bolts

20.10  Removing the rear quarterlight glass regulator mechanism on Cabriolet models

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
sunroof rearwards. Take care not to damage
the top edge of the tailgate.

Refitting

5 Refitting is a reversal of removal, but lightly
grease the guide channels. Should resonance

be a problem when the sunroof is open, a
modified rubber seal or a wind deflector is
available to eliminate the trouble.

25 Glovebox - removal and

refitting

2

Removal

1 Open the glovebox. 
2 Remove the pivot retainers from under the
facia, disconnect the pivots from the hinge
plates and withdraw the glovebox. 
3 If necessary the striker can be unbolted and
removed. 

Refitting

4 Refitting is a reversal of removal.

26 Facia panel - removal and

refitting

4

Removal

Pre-1988 models

1 Disconnect the battery negative lead then
remove the steering wheel (Chapter 10) and
instrument panel (Chapter 12). 
2 Remove the screws and withdraw the
steering column lower shroud. 
3 Remove the ashtray. 
4 Prise out the central air vents (see
illustration). 
5 Prise out the digital clock which is retained
by plastic barbs (see illustration).
6 Using a hooked instrument, withdraw the
rear of the oddments recess (see
illustration). 
7 Remove the radio, as described in Chap-
ter 12, or prise out the blank (as required). 
8 Remove the gear lever surround and centre
console, noting that the console is held at the
top by plastic clips (see illustration). 
9 Remove the screw from inside the ashtray
recess (see illustration). 
10 Unscrew the facia bottom mounting bolts
including the one on the bonnet release
handle (see illustration). 
11 With the glovebox open, remove the
mounting screw located near the glovebox
lamp (see illustration). 
12 Remove the central lower panels (see
illustration). 

Bodywork and fittings  11•11

11

26.4  Removing the central air vents

26.5  Digital clock and retaining barbs

(arrowed)

26.6  Removing the rear of the oddments

tray

26.10  A facia bottom mounting bolt

26.11  Removing a facia mounting screw

26.12  Facia central lower panels and

bracket

26.8  Centre console upper clip (arrowed)

26.9  Facia mounting screw located in the

ashtray recess (arrowed)