🏷️ Basic Information

Make:

Peugeot

Model:

205

Covered Years:

1983-1995

Product Name:

PEUGEOT 205 GL GE VAN SR GT 1.6 GTI 1.9 GTI Service Repair Manual 83-95

Chassis Codes:

205, 741A, 741B, 741C, 741D, 741E, 741F

Engine Codes:

XU5, XU9, XUD7, XUD9, TU3, TU1

👋 Introduction

Vehicle Segment:

Subcompact/Compact Hatchback

Target Audience:

Enthusiasts and owners seeking to perform maintenance, repairs, and restoration on their Peugeot 205.

Key Competitors:

Volkswagen Golf, Ford Escort, Opel Kadett, Renault 5, Fiat Uno.

Model Legacy:

The Peugeot 205 is a legendary hatchback, particularly lauded for its GTI variants, which set benchmarks for performance and handling in their class.

Manual Utility:

Provides essential information for maintaining and repairing a wide range of 205 models, crucial for preserving its classic status.

📋 Manual Details

Trim Levels Covered:

GL, GE, Van, SR, GT, 1.6 GTI, 1.9 GTI

Estimated Page Count:

Hundreds of Pages (specific number not provided in product info, but indicative of comprehensive coverage)

Manual Type:

Service and Repair Manual

Language:

English (assumed based on product title and description common for this market)

Format:

PDF

📖 Manual Coverage

Engine:

Detailed diagnosis, repair, and overhaul procedures for petrol and diesel engines, including timing belt replacement, cylinder head service, piston and ring installation, crankshaft and bearing inspection.

Fuel System:

Carburetor (Weber, Solex) and Fuel Injection (Bosch LE2-Jetronic, Motronic) system diagnostics, repair, fuel pump testing, injector servicing, fuel filter replacement.

Ignition System:

Ignition coil testing, spark plug replacement, distributor servicing, electronic ignition module troubleshooting, timing adjustments.

Cooling System:

Radiator service, water pump replacement, thermostat testing, coolant flush and refill procedures, fan clutch and electric fan diagnosis.

Exhaust System:

Catalytic converter inspection, muffler and pipe replacement, exhaust manifold gasket service, oxygen sensor replacement.

Transmission Manual:

Gearbox overhaul, clutch replacement, linkage adjustment, differential inspection and repair, shift mechanism troubleshooting.

Transmission Automatic:

ATF fluid change and level checks, torque converter inspection, basic troubleshooting for automatic transmission issues (if applicable to covered models).

Drivetrain:

CV joint and driveshaft inspection and replacement, wheel bearing service, differential housing seal replacement.

Braking System:

Disc brake pad and rotor replacement, drum brake shoe relining, brake caliper overhaul, master cylinder replacement, brake bleeding procedures, ABS system diagnostics (if equipped).

Suspension System:

Shock absorber and strut replacement, control arm bush inspection and replacement, ball joint servicing, torsion bar adjustment (if applicable), steering rack overhaul.

Steering System:

Power steering pump and hose replacement, steering column inspection, tie rod end replacement, wheel alignment specifications.

Electrical System:

Battery testing and replacement, starter motor and alternator testing, wiring harness diagrams, fuse and relay identification and testing, lighting system troubleshooting.

Instrumentation:

Dashboard component diagnosis and repair, speedometer, tachometer, fuel gauge, temperature gauge troubleshooting.

Body And Chassis:

Body panel repair, door and window mechanism adjustment, interior trim removal and installation, bumper repair, rust prevention and repair techniques.

HVAC:

Heater core replacement, A/C system refrigerant handling (with safety precautions), blower motor testing, ventilation system ducting inspection.

Safety Systems:

Seat belt inspection and repair, airbag system basic information (though diagnostics may be limited for this era).

Routine Maintenance:

Oil and filter changes, air filter replacement, spark plug replacement, fuel filter replacement, coolant checks and changes, brake fluid checks and changes.

Troubleshooting:

Diagnostic flowcharts for common drivability issues, starting problems, electrical faults, and braking system malfunctions.

Repair And Rebuild:

Detailed step-by-step instructions for component removal, overhaul, and installation, including engine rebuilds, transmission overhauls, and suspension component replacement.

Diagnostics:

Identification of diagnostic trouble codes (where applicable for the era), basic electrical testing using multimeters, pressure testing for fuel and cooling systems.

Adjustments:

Carburetor idle and mixture adjustments, ignition timing settings, clutch pedal free play adjustment, handbrake adjustment.

Torque Specifications:

Critical torque values for engine components, suspension fasteners, wheel lug nuts, and driveline components.

Depth Of Coverage:

Comprehensive (covers basic maintenance to full engine and transmission rebuilds, including electrical schematics).

Detail Level:

Detailed illustrations, diagrams, and step-by-step instructions suitable for both professional mechanics and experienced DIY enthusiasts.

📊 Manual Specifications

File Format:

PDF

Searchability:

Likely searchable text, allowing for quick access to specific information.

Image Resolution:

High quality scans expected for a professional PDF manual, ensuring clarity of diagrams and text.

Binding Type:

N/A (Digital PDF format)

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Engine Variants Covered:

Covers multiple engine options including 1.6L petrol (XU5), 1.9L petrol (XU9), 1.6L petrol (TU3), 1.1L petrol (TU1), 1.7L Diesel (XUD7), and 1.9L Diesel (XUD9).

Gtib 1.6 Power:

Approximately 105-115 hp (depending on specific market and year).

Gtib 1.9 Power:

Approximately 126-130 hp.

Gtib 1.9 Torque:

Around 160 Nm (118 lb-ft).

Fuel Delivery:

Carburetion (e.g., Weber 36 DCNVA, Solex 34 PICS) on base models and early GTIs, progressing to Bosch L-Jetronic and Motronic fuel injection on later models.

Fuel Type:

Unleaded gasoline (RON 95/98), Diesel.

🔧 Transmission

Manual Transmission:

5-speed manual gearbox (e.g., BE1, MA5) standard on most performance models and common across the range.

Automatic Transmission:

3-speed or 4-speed automatic transmission available on some non-GTI models.

Gear Ratios:

Specific gear ratios are detailed within the manual for various engine and transmission combinations.

Clutch Type:

Hydraulically operated dry single-plate clutch.

📐 Dimensions

Length:

Approx. 3700 mm (Hatchback)

Width:

Approx. 1620 mm (Hatchback)

Height:

Approx. 1360 mm (Hatchback)

Wheelbase:

Approx. 2385 mm

Curb Weight:

Varies significantly by model, ranging from approx. 800 kg (base models) to 950 kg (GTI models).

🛡️ Safety Features

Crash Test Results:

Limited official crash test data publicly available for this era and region, but generally considered robust for its class. Euro NCAP was not established in its current form during the early production years.

Braking System Type:

Front: Ventilated discs; Rear: Drums (standard models), Discs (GTI models).

Seat Belts:

Three-point seat belts front, two-point rear (later models often had three-point rear).

Body Construction:

Monocoque body with integrated safety cage and crumple zones.

💡 Technology Features

Audio System:

Basic radio and cassette player systems common, with speaker placement in front doors and rear parcel shelf. Aftermarket upgrades are prevalent.

ABS:

Optional on some models, standard on later performance variants.

Power Steering:

Standard on most models from mid-production onwards, optional on earlier base variants.

Connectivity Features:

Limited to basic power accessory sockets; no advanced connectivity features like Bluetooth or USB were factory fitted.

🔧 Maintenance

Oil Change Interval:

Typically every 7,500 - 10,000 miles (12,000 - 16,000 km) or 12 months, depending on driving conditions. Consult manual for precise intervals.

Timing Belt Replacement:

Crucial service. Generally recommended every 60,000 miles (100,000 km) or 5 years for petrol engines. Diesel engines may have slightly different intervals. Critical to follow manual recommendations to avoid catastrophic engine damage.

Engine Oil Grade:

API SF/SG or ACEA A1/B1. Viscosity often 10W-40 or 15W-50, depending on climate. Check manual for exact specification.

Coolant:

Ethylene glycol based antifreeze/coolant, typically 50/50 mix with distilled water. Colour may vary by manufacturer, but typically green or blue.

Brake Fluid:

DOT 3 or DOT 4 brake fluid.

Transmission Fluid:

Manual: SAE 75W-80 or 75W-90 GL-4 gear oil. Automatic: ATF Dexron II or equivalent.

Rust:

Common rust points include wheel arches, sills, rear valence, tailgate, and front strut mounts. Regular inspection and treatment are vital.

Electrical Gremlins:

Aging wiring looms, corroded connectors, and failing relays can cause intermittent electrical issues, particularly with lighting and ignition.

Suspension Wear:

Worn ball joints, tie rod ends, and control arm bushings are common, leading to sloppy steering and handling. Struts and shock absorbers may also require replacement.

Engine Mounts:

Degraded engine and gearbox mounts can cause excessive vibration and clunking during acceleration and deceleration.

Gearbox Synchromesh:

Wear in synchromesh rings can lead to notchy gear changes, especially in third and fifth gears on manual transmissions.

📚 Vehicle History

Peugeot History:

Peugeot has a long history of producing practical and often sporting small cars, building on the success of models like the 204 and 304.

Design Philosophy:

The 205 was designed to be a modern, aerodynamic, and fun-to-drive hatchback, intended to revitalize Peugeot's small car offerings. Pininfarina was involved in the design.

Iconic Variants:

The 205 GTI, particularly the 1.6 and 1.9 litre versions, became icons of the 'hot hatch' era, celebrated for their sharp handling and responsive engines.

Production Period:

1983-1994 (mainstream models), with some variants continuing production until 1995.

Manufacturing Locations:

Primarily France (e.g., Mulhouse, Poissy) and also the UK (Ryton) and Finland.

🏆 Awards & Recognition

Car Of The Year Nominations:

The 205 was a significant contender in European car of the year awards upon its release.

Gti Reputation:

The 205 GTI consistently ranked highly in 'hot hatch' shootouts and remains a sought-after classic for its driving dynamics.