Tài liệu ô tô Haynes Peugeot 205 (Phần Service And Repair Manual).pdf

Tài liệu ô tô Haynes Peugeot 205 (Phần Service And Repair Manual).

1Chapter 1Routine maintenance and servicingAir cleaner filter element renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Air conditioning system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Automatic transmission fluid level check . . . . . . . . . . . . . . . . . . . . . 5Automatic transmission fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . 23Auxiliary drivebelt check and renewal . . . . . . . . . . . . . . . . . . . . . . . . 9Bodywork, paint and exterior trim check . . . . . . . . . . . . . . . . . . . . . . 18Brake fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Clutch pedal stroke adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Coolant renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Driveshaft bellows check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Engine oil and filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Exhaust system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Emissions control systems check . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Front brake pad check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Fuel filter renewal - fuel injection models . . . . . . . . . . . . . . . . . . . . . 32Handbrake check and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Headlight beam alignment check . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Idle speed and mixture check and adjustment . . . . . . . . . . . . . . . . . 28Ignition system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Intensive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Lock and hinge check and lubrication . . . . . . . . . . . . . . . . . . . . . . . . 12Manual transmission oil level check . . . . . . . . . . . . . . . . . . . . . . . . . 21Manual transmission oil renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Rear brake pad condition check - models with rear disc brakes . . . 14Rear brake shoe check - models with rear drum brakes . . . . . . . . . 13Road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Seat belt check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Spark plug renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Steering and suspension check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Throttle and choke cable lubrication and adjustment . . . . . . . . . . . . 8Timing belt renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Underbody and fuel/brake line check . . . . . . . . . . . . . . . . . . . . . . . . 16Underbonnet check for fluid leaks and hose condition . . . . . . . . . . . 61•1ContentsEasy, suitable fornovice with littleexperienceFairly easy, suitablefor beginner withsome experienceFairly difficult,suitable for competentDIY mechanicDifficult, suitable forexperienced DIYmechanicVery difficult,suitable for expert DIYor professionalDegrees of difficulty54321 1•2Servicing SpecificationsLubricants and fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to end of “Weekly checks”CapacitiesEngine oilXV and XW series engines (including filter) . . . . . . . . . . . . . . . . . . . . 4.5 litresXY and XU series engines (including filter) . . . . . . . . . . . . . . . . . . . . 5.0 litresTU series engines (including filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 litresCooling systemXV8, XW7, TU9 and TU3 series engines . . . . . . . . . . . . . . . . . . . . . . . 5.8 litresXY7 and XY8 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 litresXU engines (except automatic transmission models) . . . . . . . . . . . . . 6.6 litresXU engines (automatic transmission models) . . . . . . . . . . . . . . . . . . . 6.7 litresTU1 series engine (except Van models) . . . . . . . . . . . . . . . . . . . . . . . 7.0 litresTU1 series engine (Van models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8 litresManual transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 litresAutomatic transmissionFrom dry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 litresDrain and refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 litresFuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 litresEngineOil filter:XV, XW and XY series engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion C204XU and TU series engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion F104Cooling systemAntifreeze mixture:Protection down to - 15ºC (5ºF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27% antifreezeProtection down to - 35ºC (- 31ºF) . . . . . . . . . . . . . . . . . . . . . . . . . . . 50% antifreezeNote: Refer to Chapter 3 for further details.Fuel systemAir cleaner filter element:Pre-1988 carburettor engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W1381988 onward carburettor engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion U401Fuel injection engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W175Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion L205Idle speed and mixture CO content . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to Chapter 4A, 4B and 4C SpecificationsIgnition systemSpark plugs:XV8, XW7 and XY7 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RS9YCC or S281YC*XY8 and XU5J engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion S7YCC or S279YC*XU51C engines (up to 1988) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion S9YCC or S281YC*XU51C engines (from 1988) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RC9YCC or C9YCX*XU5JA engines (up to 1988) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion S7YCC or S279YC*XU5JA (from 1988), XU5JA/K, XU9JA, XU9JA/K, XU9JA/Z andXU9JA/L engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RC7YCC or C7YCX*TU9 series, TU1 series, TU3 and TU3A engines . . . . . . . . . . . . . . . . . Champion RC9YCC or C9YCX*TU3S engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RC7YCC or C7YCX**Peugeot recommendationSpark plug electrode gap** . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7 to 0.8 mm**The spark plug electrode gap quoted is that recommended by Champion for their specified plugs listed above. If spark plugs of any other typeare to be fitted, refer to their manufacturer’s recommendations.BrakesFront brake pad minimum lining thickness . . . . . . . . . . . . . . . . . . . . . . . 2.0 mmRear brake shoe minimum lining thickness . . . . . . . . . . . . . . . . . . . . . . 1.0 mmRear brake pad minimum lining thickness . . . . . . . . . . . . . . . . . . . . . . . 2.0 mmTyre pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See “Weekly checks”Torque wrench settingsNm lbf ftSpark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 13Manual transmission drain/filler plugsBE1 and BE3 transmissions:Main gearbox drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7Final drive drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 22MA transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 19 Maintenance schedule 1•31Every 250 miles (400 km) or weeklyⅥⅥ˛ Refer to “Weekly checks”.Every 36 000 miles (58 000 km) or 3 years - whichever comes soonerIn addition to all the items listed above, carry out the following:ⅥⅥ˛ Renew the timing belt (Section 31).Note: Although the normal interval for timing belt renewal is 72 000miles (120 000 km), It is strongly recommended that the timing beltrenewal interval is halved to 36 000 miles (60 000 km) on vehicleswhich are subjected to intensive use, ie. mainly short journeys or a lotof stop-start driving. The actual belt renewal interval is therefore verymuch up to the individual owner, but bear in mind that severe enginedamage will result if the belt breaks.Every 6000 miles (9000 km) or 6 months - whichever comes soonerIn addition to all the items listed above, carry out the following:ⅥⅥ Renew the engine oil and filter (Section 3)*.ⅥⅥ˛ Check the condition of the front brake pads, and renew ifnecessary (Section 4).ⅥⅥ˛ Check the automatic transmission fluid level and top-up ifnecessary (Section 5).Note: Renewal of the engine oil filter at this service interval is onlynecessary on models fitted with the XU9J1/L engine and automatictransmission. On all other models, oil filter renewal is recommendedat every second oil change (ie 12 000 miles/12 months).Every 48 000 miles (80 000 km) or 4 years - whichever comes soonerⅥⅥ˛ Renew the fuel filter - fuel injection models (Section 32).Every 12 000 miles (18 000 km) or 12 months - whichever comes soonerIn addition to all the items listed above, carry out the following:ⅥⅥ˛ Check all underbonnet components and hoses for fluid leaks(Section 6).ⅥⅥ˛ Renew the spark plugs (Section 7).ⅥⅥ˛ Check, adjust and lubricate the throttle and choke cables(Section 8).ⅥⅥ˛ Check the condition of the auxiliary drivebelt, and renew ifnecessary (Section 9).ⅥⅥ˛ Check the clutch pedal stroke adjustment (Section 10).ⅥⅥ˛ Check the condition of the seat belts (Section 11).ⅥⅥ˛ Lubricate the locks and hinges (Section 12).ⅥⅥ˛ Check the condition of the rear brake shoes and renew ifnecessary - rear drum brake models (Section 13).ⅥⅥ˛ Check the condition of the rear brake pads and renew ifnecessary - rear disc brake models (Section 14).ⅥⅥ˛ Check the operation of the handbrake (Section 15).ⅥⅥ˛ Inspect the underbody and the brake hydraulic pipes and hoses(Section 16).ⅥⅥ˛ Check the condition of the fuel lines (Section 16).ⅥⅥ˛ Check the condition and security of the exhaust system (Section 17).ⅥⅥ˛ Check the condition of the exterior trim and paintwork (Section 18).ⅥⅥ˛ Check the headlight beam alignment (Section 19).ⅥⅥ˛ Check the operation of the air conditioning system (Section 20).Every 72 000 miles (120 000 km)In addition to all the items listed above, carry out the following:ⅥⅥ˛ Renew the timing belt (Section 31).Note: This is the interval recommended by Peugeot, but werecommend that the belt is changed more frequently, at 36 000 miles(60 000 km) - see aboveEvery 24 000 miles (36 000 km) or 2 years - whichever comes soonerIn addition to all the items listed above, carry out the following:ⅥⅥ˛ Check the manual transmission oil level, and top-up if necessary(Section 21).ⅥⅥ˛ Renew the manual transmission oil (pre-1988 BE1 transmissionsonly) (Section 22).ⅥⅥ˛ Renew the automatic transmission fluid (Section 23).ⅥⅥ˛ Check the condition of the driveshaft bellows (Section 24).ⅥⅥ˛ Check the steering and suspension components for conditionand security (Section 25).ⅥⅥ˛ Renew the air cleaner filter element (Section 26).ⅥⅥ˛ Check the ignition system (Section 27).ⅥⅥ˛ Check the idle speed and mixture adjustment (Section 28).ⅥⅥ˛ Check the condition of the emissions control system hoses andcomponents (Section 29).ⅥⅥ˛ Carry out a road test (Section 30).Every 2 years (regardless of mileage)ⅥⅥ˛ Renew the coolant (Section 33).ⅥⅥ˛ Renew the brake fluid (Section 34).The maintenance intervals in this manualare provided with the assumption that you,not the dealer, will be carrying out the work.These are the average maintenance intervalsrecommended for vehicles driven daily undernormal conditions. Obviously some variationof these intervals may be expected dependingon territory of use, and conditionsencountered. If you wish to keep your vehiclein peak condition at all times, you may wish toperform some of these procedures moreoften. We encourage frequent maintenancebecause it enhances the efficiency,performance and resale value of your vehicle.If the vehicle is driven in dusty areas, usedto tow a trailer, driven frequently at slowspeeds (idling in traffic) or on short journeys,more frequent maintenance intervals arerecommended. 1•4Maintenance - component locationUnderbonnet view of a 1360 cc GT model (XY8 series engine)1 Right-hand front engine mounting2 Jack3 Drivebelt4 Oil filter5 Bottom hose6 Water pump7 Throttle cable8 Fuel pump9 Brake master cylinder10 Brake fluid reservoir filler cap11 Vehicle identification plate12 Choke cable13 Heater hose14 Oil filler cap/crankcase ventilation filter15 Windscreen wiper arm16 Hydraulic brake lines17 Cooling fan motor resistor18 Front suspension shock absorber topmounting nut19 Ignition coil cover20 Distributor21 Bottom hose22 Clutch release fork23 Clutch housing24 Washer reservoir25 Battery26 Ignition timing aperture27 Diagnostic socket28 Radiator filler cap29 Air cleaner30 Bonnet lock31 Oil pressure switch32 Alternator33 Cooling system expansion bottle Maintenance - component location 1•51Underbonnet view of a 1360 cc XS model (TU series engine)1 Brake fluid reservoir filler cap2 Brake master cylinder3 Brake vacuum servo unit4 Servo vacuum hose5 Cooling system bleed screw6 Air cleaner cover7 Fuel pump8 Cooling system expansion bottle9 Fuel filter10 Washer fluid reservoir11 Battery12 Air temperature control unit13 Auxiliary fusebox14 Radiator filler cap15 Ignition coil16 Bonnet lock17 Engine oil filler cap18 Exhaust manifold hot air shroud19 Alternator20 Engine oil level dipstick21 Inlet manifold22 Right-hand engine mounting 1•6Maintenance - component locationFront underside view of a 1360 cc GT model1 Bottom hose2 Reverse lamp switch3 Engine/transmission oil drain plug4 Radiator5 Gear linkage6 Clutch housing and transfer gearassembly7 Washer reservoir8 Disc caliper9 Lower suspension arm10 Anti-roll bar11 Track rod12 Guide bar13 Exhaust front pipe14 Fuel feed and return pipes15 Hydraulic brake lines16 Subframe17 Driveshaft18 Front towing eye Maintenance - component location 1•71Rear underside view of a 1360 cc GT model1 Exhaust front pipe2 Handbrake cables3 Heatshield4 Rear suspension cross-tube5 Brake hydraulic flexible hose6 Rear shock absorber7 Trailing arm8 Side-member9 Exhaust rubber mounting10 Exhaust rear silencer11 Spare wheel12 Rear towing eye13 Torsion bars14 Fuel tank 1 IntroductionThis Chapter is designed to help the homemechanic maintain his/her vehicle for safety,economy, long life and peak performance.This Chapter contains a mastermaintenance schedule, followed by Sectionsdealing specifically with each task in theschedule. Visual checks, adjustments,component renewal and other helpful itemsare included. Refer to the accompanyingillustrations of the engine compartment andthe underside of the vehicle for the locationsof the various components.Servicing your vehicle in accordance withthe mileage/time maintenance schedule andthe following Sections will provide a plannedmaintenance programme, which should resultin a long and reliable service life. This is acomprehensive plan, so maintaining someitems but not others at the specified serviceintervals will not produce the same results.As you service your vehicle, you willdiscover that many of the procedures can -and should - be grouped together, because ofthe particular procedure being performed, orbecause of the close proximity of twootherwise-unrelated components to oneanother. For example, if the vehicle is raisedfor any reason, the exhaust should beinspected at the same time as the suspensionand steering components.The first step of this maintenanceprogramme is to prepare yourself before theactual work begins. Read through all theSections relevant to the work to be carriedout, then make a list and gather together allthe parts and tools required. If a problem isencountered, seek advice from a partsspecialist or a dealer service department.2 Intensive maintenance1 If, from the time the vehicle is new, theroutine maintenance schedule is followedclosely, and frequent checks are made of fluidlevels and high-wear items, as suggestedthroughout this manual, the engine will bekept in relatively good running condition, andthe need for additional work will be minimised.2 It is possible that there will be some timeswhen the engine is running poorly due to thelack of regular maintenance. This is even morelikely if a used vehicle, which has not receivedregular and frequent maintenance checks, ispurchased. In such cases, additional workmay need to be carried out, outside of theregular maintenance intervals.3 If engine wear is suspected, a compressiontest (refer to Chapter 2A, B or C) will providevaluable information regarding the overallperformance of the main internal components.Such a test can be used as a basis to decideon the extent of the work to be carried out. If,for example, a compression test indicatesserious internal engine wear, conventionalmaintenance as described in this Chapter willnot greatly improve the performance of theengine, and may prove a waste of time andmoney, unless extensive overhaul work(Chapter 2D) is carried out first.4 The following series of operations are thoseoften required to improve the performance ofa generally poor-running engine:Primary operationsa) Clean, inspect and test the battery (See“Weekly checks”).b) Check all the engine-related fluids (See“Weekly checks”).c) Check the condition of the auxiliarydrivebelt (Section 9).d) Inspect the distributor cap, rotor arm andHT leads (Section 27).e) Renew the spark plugs (Section 7).f) Check the condition of the air cleanerfilter element and renew if necessary(Section 26).g) Renew the fuel filter - fuel injectionmodels (Section 32).h) Check the condition of all hoses, andcheck for fluid leaks (Section 6).5 If the above operations do not prove fullyeffective, carry out the following operations:Secondary operationsAll the items listed under “Primaryoperations”, plus the following:a) Check the charging system (Chapter 5A).b) Check the ignition system (Chapter 5B).c) Check the fuel system (Chapter 4A, B andC).d) Renew the distributor cap and rotor arm(Section 27).e) Renew the ignition HT leads (Section 27).3 Engine oil and filter renewal1Note: A suitable square-section wrench maybe required to undo the sump drain plug onsome models. These wrenches can beobtained from most motor factors or yourPeugeot dealer.1 Frequent oil changes are the bestpreventive maintenance the home mechaniccan give the engine, because ageing oilbecomes diluted and contaminated, whichleads to premature engine wear.2 Make sure that you have all the necessarytools before you begin this procedure. Youshould also have plenty of rags ornewspapers handy, for mopping up any spills.The oil should preferably be changed whenthe engine is still fully warmed-up to normaloperating temperature, just after a run; warmoil and sludge will flow out more easily. Takecare, however, not to touch the exhaust orany other hot parts of the engine whenworking under the vehicle. To avoid anypossibility of scalding, and to protect yourselffrom possible skin irritants and other harmfulcontaminants in used engine oils, it isadvisable to wear gloves when carrying outthis work. Access to the underside of thevehicle is greatly improved if the vehicle canbe lifted on a hoist, driven onto ramps, orsupported by axle stands. (see “Jacking andvehicle support”). Whichever method ischosen, make sure that the vehicle remainslevel, or if it is at an angle, that the drain pointis at the lowest point.3 Position the draining container under thedrain plug, and unscrew the plug. On somemodels, a square-section wrench may beneeded to slacken the plug (see illustration).If possible, try to keep the plug pressed intothe sump while unscrewing it by hand the lastcouple of turns (see Haynes Hint).1•8Maintenance procedures3.3 Slackening the sump drain plug with asquare section wrenchEvery 6000 miles or 6 monthsKeep the drain plug pressed into thesump while unscrewing it by hand thelast couple of turns. As the plug releases,move it away sharply so that the streamof oil issuing from the sump runs into thecontainer, not up your sleeve! 4 Allow the oil to drain into the container, andcheck the condition of the plug’s sealingwasher; renew it if worn or damaged.5 Allow some time for the old oil to drain,noting that it may be necessary to repositionthe container as the oil flow slows to a trickle;when the oil has completely drained, wipeclean the drain plug and its threads in thesump and refit the plug, tightening it securely.6 If the filter is also to be renewed, move thecontainer into position under the oil filter,which is located on the front side of thecylinder block. On XV, XW and XY seriesengines, place some rag around the filterotherwise the oil that runs out as the filter isunscrewed will make a mess all over the frontof the engine.7 Using an oil filter removal tool if necessary,slacken the filter initially, then unscrew it byhand the rest of the way (see illustration).Empty the oil in the old filter into thecontainer.8 Use a clean rag to remove all oil, dirt andsludge from the filter sealing area on theengine. Check the old filter to make sure thatthe rubber sealing ring hasn’t stuck to theengine. If it has, carefully remove it.9 Apply a light coating of clean engine oil tothe sealing ring on the new filter, then screw itinto position on the engine. Tighten the filterfirmly by hand only - do not use any tools.10 Remove the old oil and all tools fromunder the car, then lower the car to theground (if applicable).11 Remove the dipstick, then unscrew the oilfiller cap from the rocker/cylinder head coveror oil filler/breather neck (as applicable). Fillthe engine, using the correct grade and typeof oil (see “Lubricants and fluids, andcapacities”). An oil can spout or funnel mayhelp to reduce spillage. Pour in half thespecified quantity of oil first, then wait a fewminutes for the oil to fall to the sump.Continue adding oil a small quantity at a timeuntil the level is up to the lower mark on thedipstick. Adding approximately 1.5 litres willbring the level up to the upper mark on thedipstick. Refit the filler cap.12 Start the engine and run it for a fewminutes; check for leaks around the oil filterseal and the sump drain plug. Note that theremay be a delay of a few seconds before the oilpressure warning light goes out when theengine is first started, as the oil circulatesthrough the engine oil galleries and the new oilfilter (if fitted) before the pressure builds up.13 Switch off the engine, and wait a fewminutes for the oil to settle in the sump oncemore. With the new oil circulated and the filtercompletely full, recheck the level on thedipstick, and add more oil as necessary.14 Dispose of the used engine oil safely, withreference to “General repair procedures” inthe preliminary Sections of this manual.4 Front brake pad check11 Jack up the front of the vehicle, andsupport it on axle stands (see “Jacking andvehicle support”).2 For better access to the brake calipers,remove the roadwheels.3 If any of the pads friction material is worn tothe specified thickness or less, all four padsmust be renewed as a set.4 For a comprehensive check, the brake padsshould be removed and cleaned. Theoperation of the caliper can then also bechecked, and the condition of the brake discitself can be fully examined on both sides.Refer to Chapter 9 for further information.5 Automatic transmission fluidlevel check11 Take the vehicle on a short journey, towarm the transmission up to normal operatingtemperature, then park the vehicle on levelground. The fluid level is checked using thedipstick located at the front of the enginecompartment, directly in front of the engine(see illustration). The dipstick top is brightly-coloured for easy identification.2 With the engine idling and the selector leverin the “P” (Park) position, withdraw thedipstick from the tube, and wipe all the fluidfrom its end with a clean rag or paper towel.Insert the clean dipstick back into the tube asfar as it will go, then withdraw it once more.Note the fluid level on the end of the dipstick;it should be between the upper and lowermarks (see illustration).3 If topping-up is necessary, add the requiredquantity of the specified fluid to the transmissionvia the dipstick tube. Use a funnel with a fine-mesh gauze, to avoid spillage, and to ensurethat no foreign matter enters the transmission.Note: Never overfill the transmission so that thefluid level is above the upper mark.4 After topping-up, take the vehicle on a shortrun to distribute the fresh fluid, then recheckthe level again, topping-up if necessary.5 Always maintain the level between the twodipstick marks. If the level is allowed to fallbelow the lower mark, fluid starvation mayresult, which could lead to severetransmission damage.6 Frequent need for topping-up indicates thatthere is a leak, which should be found andcorrected before it becomes serious.Every 6000 miles or 6 months 1•915.2 Automatic fluid dipstick lower (a) andupper (b) fluid level markingsFor a quick check, thethickness of the frictionmaterial on each brake padcan be measured throughthe aperture in the caliper body3.7 Using an oil filter removal tool to slacken the filter 5.1 Withdrawing the automatic transmission fluid dipstick 6 Underbonnet check for fluidleaks and hose condition1Warning: Renewal of any airconditioning hoses (wherefitted) must be left to a dealerservice department or airconditioning specialist who has theequipment to depressurise the systemsafely. Never remove air conditioningcomponents or hoses until the system hasbeen depressurised.General1 High temperatures in the enginecompartment can cause the deterioration ofthe rubber and plastic hoses used for engine,accessory and emission systems operation.Periodic inspection should be made for cracks,loose clamps, material hardening and leaks.2 Carefully check the large top and bottomradiator hoses, along with the other smaller-diameter cooling system hoses and metalpipes; do not forget the heater hoses/pipeswhich run from the engine to the bulkhead.Inspect each hose along its entire length,replacing any that are cracked, swollen orshows signs of deterioration. Cracks maybecome more apparent if the hose issqueezed (see Haynes Hint).3 Make sure that all hose connections aretight. If the spring clamps that are used tosecure some of the hoses appear to beslackening, they should be renewed toprevent the possibility of leaks.4 Some other hoses are secured to theirfittings with screw type clips. Where screwtype clips are used, check to be sure theyhaven’t slackened, allowing the hose to leak.If clamps or screw type clips aren’t used,make sure the hose has not expanded and/orhardened where it slips over the fitting,allowing it to leak.5 Check all fluid reservoirs, filler caps, drainplugs and fittings etc, looking for any signs ofleakage of oil, transmission and/or brakehydraulic fluid, coolant and power steeringfluid. If the vehicle is regularly parked in thesame place, close inspection of the groundunderneath will soon show any leaks; ignorethe puddle of water which will be left if the airconditioning system is in use. As soon as aleak is detected, its source must be tracedand rectified. Where oil has been leaking forsome time, it is usually necessary to use asteam cleaner, pressure washer or similar, toclean away the accumulated dirt, so that theexact source of the leak can be identified.Vacuum hoses6 It’s quite common for vacuum hoses,especially those in the emissions system, tobe numbered or colour-coded, or to beidentified by coloured stripes moulded intothem. Various systems require hoses withdifferent wall thicknesses, collapse resistanceand temperature resistance. When renewinghoses, be sure the new ones are made of thesame material.7 Often the only effective way to check ahose is to remove it completely from thevehicle. If more than one hose is removed, besure to label the hoses and fittings to ensurecorrect installation.8 When checking vacuum hoses, be sure toinclude any plastic T-fittings in the check.Inspect the fittings for cracks, and check thehose where it fits over the fitting for distortion,which could cause leakage.9 A small piece of vacuum hose can be usedas a stethoscope to detect vacuum leaks.Hold one end of the hose to your ear, andprobe around vacuum hoses and fittings,listening for the “hissing” sound characteristicof a vacuum leak.Warning: When probing with thevacuum hose stethoscope, bevery careful not to come intocontact with moving enginecomponents such as the auxiliary drivebelt,radiator electric cooling fan, etc.Fuel hosesWarning: Before carrying out thefollowing operation, refer to theprecautions given in “Safetyfirst!” at the beginning of thismanual, and follow them implicitly. Petrolis a highly dangerous and volatile liquid,and the precautions necessary whenhandling it cannot be overstressed.10 Check all fuel hoses for deterioration andchafing. Check especially for cracks in areaswhere the hose bends, and also just beforefittings, such as where a hose attaches to thecarburettor or fuel rail.11 High-quality fuel line, usually identified bythe word “Fluoroelastomer” printed on thehose, should be used for fuel line renewal.Never, under any circumstances, useunreinforced vacuum line, clear plastic tubingor water hose for fuel lines.12 Spring-type clamps are commonly usedon fuel lines. These clamps often lose theirtension over a period of time, and can be“sprung” during removal. Replace all spring-type clamps with screw clips whenever a hoseis replaced.Metal lines13 Sections of metal piping are often usedfor fuel line between the fuel filter and theengine. Check carefully to be sure the pipinghas not been bent or crimped, and that crackshave not started in the line.14 If a section of metal fuel line must berenewed, only seamless steel piping shouldbe used, since copper and aluminium pipingdon’t have the strength necessary towithstand normal engine vibration.15 Check the metal brake lines where theyenter the master cylinder and ABS hydraulicunit for cracks in the lines or loose fittings.Any sign of brake fluid leakage calls for animmediate and thorough inspection of thebrake system.7 Spark plug renewal21 The correct functioning of the spark plugs isvital for the correct running and efficiency ofthe engine. It is essential that the plugs fittedare appropriate for the engine (a suitable typeis specified at the beginning of this Chapter). Ifthis type is used and the engine is in goodcondition, the spark plugs should not needattention between scheduled replacementintervals. Spark plug cleaning is rarelynecessary, and should not be attempted unlessspecialised equipment is available, as damagecan easily be caused to the firing ends.2 If the marks on the original-equipment sparkplug (HT) leads cannot be seen, mark the leads“1” to “4”, to correspond to the cylinder the leadserves (No 1 cylinder is at the transmission endof the engine). Pull the leads from the plugs bygripping the end fitting, not the lead, otherwisethe lead connection may be fractured.3 It is advisable to remove the dirt from thespark plug recesses using a clean brush,vacuum cleaner or compressed air beforeremoving the plugs, to prevent dirt droppinginto the cylinders.4 Unscrew the plugs using a spark plugspanner, suitable box spanner or a deepsocket and extension bar (see illustration).1•10Every 12 000 miles or 12 months7.4 Tools required for spark plug removal,gap adjustment and refittingA leak in the cooling system will usuallyshow up as white or rust-coloureddeposits on the area adjoining the leak [...]... 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)... to be checked, and the condition of the brake disc itself to be fully examined on both sides. Refer to Chapter 9 for further information. 15 Handbrake check and adjustment 2 Refer to Chapter 9. 16 Underbody and fuel/brake line check 1 1 With the vehicle raised and supported on axle stands (see “Jacking and vehicle support”), or over an inspection pit, thoroughly inspect the underbody and wheel arches... wheel arches for signs of damage and corrosion. In particular, examine the bottom of the side sills, and any concealed areas where mud can collect. Where corrosion and rust is evident, press and tap firmly on the panel with a screwdriver, and check for any serious corrosion which would necessitate repairs. If the panel is not seriously corroded, clean away the rust, and apply a new coating of underseal.... clip, and disconnect the breather hose from the left-hand end of the cylinder head cover (see illustration). Where the original crimped-type Peugeot hose clip is still fitted, cut it off and discard it. Use a standard worm-drive clip on refitting. 4 Undo the two retaining nuts, and remove the washer from each of the cylinder head cover studs (see illustration). 5 Lift off the cylinder head cover, and. .. plug exterior surfaces and threads are clean (see Haynes Hint). 12 Remove the rubber hose (if used), and tighten the plug to the specified torque using the spark plug socket and a torque wrench. Refit the remaining spark plugs in the same manner. 13 Connect the HT leads in their correct order, and refit any components removed for access. 8 Throttle and choke cable lubrication and adjustment 1 1 The... assembly) and eccentric roller type tensioner (later assembly) 1 Right-hand engine mounting 2 Timing belt 3 Tensioner roller 4 Tensioner roller nut Examine the seal for signs of damage and deterioration, and if necessary, renew it. 6 Remove the spacer from each stud, and lift off the oil baffle plate (see illustrations). Refitting 7 Carefully clean the cylinder head and cover mating surfaces, and remove... fully open, and check the clearances of the next two specified valves. 7 Repeat the procedure until all eight valve clearances have been checked (and if necessary, adjusted), then refit the cylinder head cover as described in Section 4. 6 Timing belt covers - removal and refitting 1 Removal Upper cover 1 Slacken and remove the two retaining bolts (one at the front and one at the rear), and remove the... 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) 39 Check the valve clearances and adjust, if necessary... crankshaft to the TDC position, No 1 cylinder firing, then slacken and retighten the tensioner nuts once more. 29 Remove the auxiliary drivebelt and the crankshaft pulley. Refit and secure the plastic covers, then refit the pulley and tighten its bolts to the specified torque. Refit and tension the auxiliary drivebelt. 30 Check the ignition timing and adjust if necessary (Chapter 5B). Models with eccentric... once more. With the new oil circulated and the filter completely full, recheck the level on the dipstick, and add more oil as necessary. 14 Dispose of the used engine oil safely, with reference to “General repair procedures” in the preliminary Sections of this manual. 4 Front brake pad check 1 1 Jack up the front of the vehicle, and support it on axle stands (see “Jacking and vehicle support”). 2 For better . information.15 Handbrake check andadjustment2Refer to Chapter 9.16 Underbody and fuel/brakeline check11 With the vehicle raised and supported onaxle stands (see. ignition and apply the handbrake firmly.For improved access, jack up the front of thecar and support it securely on axle stands.Note that, when refilling and