Peugeot 205. Manual - part 16

3

Engine/manual transmission
- removal, separation,
reconnection and refitting

4

Removal

Note: The engine can be removed from the car
only as a complete unit with the transmission;
the two are then separated for overhaul.
1 Park the vehicle on firm, level ground.
Chock the rear wheels, then firmly apply the
handbrake. Jack up the front of the vehicle,
and securely support it on axle stands (see
“Jacking and vehicle support”). Remove the
front roadwheels.
2 Set the bonnet in the upright position, and
remove the battery and tray as described in
Chapter 5A.
3 Remove the complete air cleaner assembly
and all inlet ducting, as described in the
relevant Part of Chapter 4.
4 If the engine is to be dismantled, working as
described in Chapter 1, first drain the oil and
remove the oil filter. Clean and refit the drain
plug, tightening it securely.
5 On XU and TU series engines, drain the
transmission oil as described in Chapter 7A.
Refit the drain and filler plugs (as applicable),
and tighten them to their specified torque
settings.
6 Remove the alternator as described in
Chapter 5A.
7 Where applicable, remove the power
steering pump as described in Chapter 10.
Where possible, unbolt the pump and move it
aside without disconnecting the fluid hoses.
8 On models with air conditioning, unbolt the
compressor, and position it clear of the engine.
Support the weight of the compressor by tying
it to the vehicle body, to prevent any excess
strain being placed on the compressor lines
whilst the engine is removed. Do not disconnect
the refrigerant lines from the compressor (refer
to the warnings given in Chapter 3).
9 Drain the cooling system as described in
Chapter 1 then remove the radiator as
described in Chapter 3. Note that it is not
strictly necessary to remove the radiator, but
it does improve clearance, and removes the
risk of damaging the radiator as the engine is
removed. If the radiator is to be left in
position, disconnect the top and bottom
radiator hoses at both ends and remove them
completely. It is also a good idea to place a
sheet of cardboard (or preferably plywood)
between the engine and radiator as protection
against any accidental contact.
10 On carburettor models, carry out the
following operations, using the information
given in the relevant Part of Chapter 4:

a) Disconnect the fuel feed and return hoses.
b) Disconnect the throttle and where

applicable the choke cables from the
carburettor.

c) Where fitted, disconnect the braking

system servo vacuum hose from the inlet
manifold.

d) Disconnect the exhaust system downpipe

from the exhaust manifold and remove
the support brackets or clamps securing it
to the engine or transmission.

11 On fuel injection models, carry out the
following operations, using the information
given in the relevant Part of Chapter 4:

a) Depressurise the fuel system, and

disconnect the fuel feed and return hoses.

b) Disconnect the throttle cable.
c) Disconnect the fuel system wiring

connectors.

d) Disconnect all vacuum hoses from the

inlet manifold.

e) Disconnect the exhaust system downpipe

from the exhaust manifold and remove
the support brackets or clamps securing it
to the engine or transmission.

12 Referring to Chapter 3, release the
retaining clip and disconnect the heater matrix
hoses from their connection on the engine
compartment bulkhead.
13 Working as described in Chapter 6,
disconnect the clutch cable from the
transmission, and position it clear of the
working area.

14 Carry out the following operations, using
the information given in Chapter 7A:

a) Disconnect the gearchange selector

rod/link rods (as applicable) from the
transmission.

b) Disconnect the speedometer cable from

the speedometer drive.

c) Where applicable, release the power

steering pipe from the underside of the
transmission.

d) Disconnect the wiring connector(s) from

the reversing light switch and
speedometer drive (as applicable).

15 Remove both driveshafts as described in
Chapter 8.
16 On some models it will be possible to
remove the engine/transmission complete
with the engine wiring harness left in position.
This saves having to disconnect each
individual wire from its relevant connection
and its retaining clips. Unfortunately this will
not be possible on all models, but where it is,
trace the wiring harness back from the engine
to the wiring connector(s) in the front, left-
hand corner of the engine compartment (see
illustration). Release the locking ring(s) by

Engine removal and overhaul procedures  2D•5

2D

3.16  Typical engine wiring harness connections (XU series fuel injected engine shown)

twisting them anti-clockwise and disconnect
the connectors. Also, where applicable, trace
the harness lead(s) back to the relay box,
situated beside the battery. Unclip the wiring
connector plate from the front of the relay box
cover, then undo the retaining nut and remove
the cover. Lift up the engine harness lead
cover; then undo the nut(s) and release the
lead(s) from the relay box. Check that all the
relevant connectors have been disconnected,
and that the wiring is released from any
relevant clips or ties, so that it is free to be
removed with the engine/transmission. Where
it is not possible to separate the harness at
the main connectors, make careful notes and
disconnect all individual wiring connectors
attached to the engine and transmission.
17 Manoeuvre the engine hoist into position,
and attach it to the lifting brackets bolted to
the engine. Raise the hoist until it is
supporting the weight of the engine.
18 On XU and TU series engines from
underneath the vehicle, slacken and remove
the nuts and bolts securing the rear engine
mounting link to the mounting assembly and
subframe, and remove the link. On all models,
undo the nuts/bolts securing the left-hand
and right-hand engine mounting brackets to
the engine and mountings, and remove the
brackets and mountings as necessary.
19 Make a final check that any components
which would prevent the removal of the
engine/transmission from the car have been
removed or disconnected. Ensure that
components such as the gearchange selector
rod are secured so that they cannot be
damaged on removal.
20 Slowly and methodically lift the
engine/transmission out of the car, ensuring
that nothing is trapped or damaged. Enlist the
help of an assistant during this procedure, as
it will be necessary to tilt the assembly slightly
to clear the body panels.
21 Once the engine is high enough, lift it out
over the front of the body, and lower the unit
to the ground (see illustration).

Separation

22 With the engine/transmission assembly
removed, support the assembly on suitable
blocks of wood, on a workbench (or failing
that, on a clean area of the workshop floor).

XV, XW and XY series engines

23 Unscrew and remove the flywheel
housing-to-engine connecting bolts and nuts.
24 There are thirteen bolts and two nuts
altogether. Note that an engine lifting lug and
earth strap are fitted under some of the bolts.
25 Refer to Chapter 6 and remove the clutch
assembly, ignoring any procedures that have
already been carried out as part of the
engine/transmission removal sequence.
26 Unbolt and remove the flywheel (Chap-
ter 2A), then slacken and remove the retaining
bolts, and remove the starter motor.
27 Unscrew and remove the two bolts and
the nut close to the crankshaft oil seal (see
illustration).
28 Unscrew the engine-to-transmission
flange connecting bolts. Unbolt the right-hand
rear engine mounting.
29 Unscrew and remove the crankshaft
pulley nut. In order to hold the crankshaft
against rotation, temporarily screw in two
bolts into the holes in the flywheel mounting
flange and place a long lever between them.
30 Remove the crankshaft pulley.
31 Remove the rocker cover.
32 Remove the timing chain cover and
extract the fuel pump operating plunger (see
illustration).
33 Unscrew and remove the remaining
connecting bolts and nuts which are located
on the final drive casing side near the
driveshaft oil seals.
34 Using a length of wood, prise the engine
and transmission apart (see illustration).

XU and TU series engines

35 Undo the retaining bolts, and remove the
flywheel lower cover plate (where fitted) from
the transmission.
36 Slacken and remove the retaining bolts,
and remove the starter motor from the
transmission.
37 Ensure that both engine and transmission
are adequately supported, then slacken and
remove the remaining bolts securing the
transmission housing to the engine. Note the
correct fitted positions of each bolt (and the
relevant brackets) as they are removed, to use
as a reference on refitting.
38 Carefully withdraw the transmission from
the engine, ensuring that the weight of the

transmission is not allowed to hang on the
input shaft while it is engaged with the clutch
friction plate.
39 If they are loose, remove the locating
dowels from the engine or transmission, and
keep them in a safe place.

Reconnection

XV, XW and XY series engines

40 If removed, check that the oil pump
pick-up strainer is in position within the
transmission casing.

2D•6 Engine removal and overhaul procedures

3.32  Removing the timing chain cover

3.34  Separating the engine from the

transmission

3.21  Removing the engine and manual

transmission

3.27  Remove the two bolts and nut close

to the crankshaft oil seal - XV, XW and XY

series engines

41 Fit the sump cover to the transmission
using a new gasket. 
42 Tighten the tighten the cover bolts and
drain plug to the specified torque.
43 Fit the protective cover plate to the sump
cover. 
44 Apply jointing compound to the mating
surfaces on the engine and transmission. 
45 On the transmission, locate a new O-ring
seal and check that the locating dowels and
the studs are in position (see illustration). 
46 Offer the transmission to the engine,
screw in the connecting bolts and nuts and
tighten to the specified torque.
47 With the fuel pump operating rod in place,
locate the timing chain cover using a new
gasket. The bolt nearest the coolant pump
pulley must be located in the cover before
offering it up, otherwise the pulley will prevent
the bolt entering its cover hole. Use the
crankshaft pulley to centralise the timing
chain cover and refit the remaining cover
bolts. Note that the coolant hose safety rod
must be fitted under its cover bolts. This rod
prevents the coolant hose being cut by the
rim of the coolant pump pulley should the
hose sag.
48 Tighten the timing chain cover bolts to the
specified torque and then trim the upper ends
of the gasket flush. Fit the rocker cover using
a new gasket. Do not overtighten the securing
bolts. 
49 Tighten the crankshaft pulley nut to the
specified torque.
50 Refit the flywheel (Chapter 2A) and the
clutch and transfer gear assembly (Chapter 6).
51 If they were removed, bolt the engine
mountings to the flywheel housing.
52 Fit the starter motor. Tighten the bolts and
nuts in the following order:

a) Starter drive end flange to flywheel

housing 

b) Brush end bracket to engine crankcase 
c) Brush end bracket to starter motor

XU and TU series engines

53 Apply a smear of high-melting-point
grease (Peugeot recommend the use of
Molykote BR2 plus - available from your
Peugeot dealer) to the splines of the
transmission input shaft. Do not apply too
much, otherwise there is a possibility of the
grease contaminating the clutch friction plate.

54 Ensure that the locating dowels are
correctly positioned in the engine or
transmission.
55 Carefully offer the transmission to the
engine, until the locating dowels are engaged.
Ensure that the weight of the transmission is
not allowed to hang on the input shaft as it is
engaged with the clutch friction disc.
56 Refit the transmission housing-to-engine
bolts, ensuring that all the necessary brackets
are correctly positioned, and tighten them
securely.
57 Refit the starter motor, and securely
tighten its retaining bolts.
58 Where necessary, refit the lower flywheel
cover plate to the transmission, and securely
tighten its retaining bolts.

Refitting

59 Reconnect the hoist and lifting tackle to
the engine lifting brackets. With the aid of an
assistant, lift the assembly over the engine
compartment.
60 The assembly should be tilted as
necessary to clear the surrounding
components, as during removal; lower the
assembly into position in the engine
compartment, manipulating the hoist and
lifting tackle as necessary.
61 With the engine/transmission in position,
and centralised over its mountings, refit the
engine/transmission mountings using a
reverse of the removal operations, but only
tighten the mounting nuts/bolts finger tight at
this stage.
62 Where applicable, from underneath the
vehicle, refit the rear mounting link and install
both its bolts.
63 Rock the engine to settle it on its
mountings, then go around and tighten all the
mounting nuts and bolts to their specified
torque settings. The hoist can then be
detached from the engine and removed.
64 The remainder of the refitting procedure is
a direct reversal of the removal sequence,
noting the following points:

a) Ensure that the wiring loom is correctly

routed and retained by all the relevant
retaining clips; all connectors should be
correctly and securely reconnected.

b) Prior to refitting the driveshafts to the

transmission, renew the driveshaft oil
seals as described in Chapter 7A.

c) Ensure that all coolant hoses are correctly

reconnected, and securely retained by
their retaining clips.

d) Reconnect the clutch cable as described

in Chapter 6.

e) Adjust the choke cable and/or throttle

cable (as applicable) as described in the
relevant Part of Chapter 4.

f) Refill the engine and transmission with the

correct quantity and type of lubricant, as
described in Chapter 1 and 7A.

g) Refill the cooling system as described in

Chapter 1.

4

Engine/automatic transmission
- removal, separation,
reconnection and refitting

4

Removal

Note: The engine can be removed from the
car only as a complete unit with the
transmission; the two are then separated for
overhaul.
1 Carry out the operations described in
paragraphs 1 to 12 of Section 3, noting that
the transmission oil draining procedure is
given in Chapter 1.
2 Carry out the following operations, using
the information given in Chapter 7B:

a) Remove the transmission dipstick tube.
b) Disconnect the wiring from the starter

inhibitor/reversing light switch and the
speedometer drive housing. Release the
earth strap(s) from the top of the
transmission housing.

c) Disconnect the selector cable.
d) Release the power steering pipe from the

transmission.

e) Disconnect the speedometer cable.

3 Remove the engine/transmission as
described in paragraphs 15 to 21 of Section 3.

Separation

4 With the engine/transmission assembly
removed, support the assembly on suitable
blocks of wood, on a workbench (or failing
that, on a clean area of the workshop floor).
5 Detach the kickdown cable from the throttle
cam. Work back along the cable, freeing it
from any retaining clips, and noting its correct
routing.
6 Undo the retaining bolts and remove the
driveplate lower cover plate from the
transmission, to gain access to the torque
converter retaining bolts. Slacken and remove
the visible bolt. Rotate the crankshaft using a
socket and extension bar on the pulley bolt,
and undo the remaining bolts securing the
torque converter to the driveplate as they
become accessible.
7 Slacken and remove the retaining bolts,
and remove the starter motor from the
transmission.
8 To ensure that the torque converter does
not fall out as the transmission is removed,
secure it in position using a length of metal
strip bolted to one of the starter motor bolt
holes.
9 Ensure that both the engine and
transmission are adequately supported, then
slacken and remove the remaining bolts
securing the transmission housing to the
engine. Note the correct fitted positions of
each bolt (and any relevant brackets) as they
are removed, to use as a reference on
refitting.
10 Carefully withdraw the transmission from
the engine. If the locating dowels are a loose
fit in the engine/transmission, remove them
and keep them in a safe place.

Engine removal and overhaul procedures  2D•7

2D

3.45  Locate a new O-ring oil seal on the

transmission casing

Reconnection

11 Ensure that the bush fitted to the centre of
the crankshaft is in good condition. Apply a
little Molykote G1 grease (available from your
Peugeot dealer) to the torque converter
centring pin. Do not apply too much,
otherwise there is a possibility of the grease
contaminating the torque converter.
12 Ensure that the locating dowels are
correctly positioned in the engine or
transmission.
13 Carefully offer the transmission to the
engine, until the locating dowels are engaged.
14 Refit the transmission housing-to-engine
bolts, ensuring that all the necessary brackets
are correctly positioned, and tighten them to
the specified torque setting.
15 Remove the torque converter retaining
strap installed prior to removal. Align the
torque converter threaded holes with the
retaining plate, and refit the three retaining
bolts.
16 Tighten the torque converter retaining
bolts to the specified torque setting, then refit
the driveplate lower cover.
17 Refit the starter motor, and securely
tighten its retaining bolts.

Refitting

18 Refit the engine/transmission to the
vehicle as described in paragraphs 59 to 63 of
Section 3.
19 The remainder of the refitting procedure is
a reversal of the removal sequence, noting the
following points:

a) Ensure that the wiring loom is correctly

routed, and retained by all the relevant
retaining clips; all connectors should be
correctly and securely reconnected.

b) Prior to refitting the driveshafts to the

transmission, renew the driveshaft oil
seals (see Chapter 7).

c) Ensure that all coolant hoses are correctly

reconnected, and securely retained by
their retaining clips.

d) Adjust the selector cable and kickdown

cable as described in Chapter 7B.

e) Adjust the throttle cable as described in

Chapter 4.

f) Refill the engine and transmission with

correct quantity and type of lubricant, as
described in Chapter 1.

g) Refill the cooling system as described in

Chapter 1.

5

Engine overhaul - preliminary
information

It is much easier to dismantle and work on

the engine if it is mounted on a portable
engine stand. These stands can often be hired
from a tool hire shop. Before the engine is
mounted on a stand, the flywheel/driveplate
should be removed so that the stand bolts
can be tightened into the end of the cylinder
block/crankcase.

If a stand is not available, it is possible to

dismantle the engine with it suitably
supported on a sturdy, workbench or on the
floor. Be careful not to tip or drop the engine
when working without a stand.

If you intend to obtain a reconditioned

engine, all ancillaries must be removed first, to
be transferred to the replacement engine (just
as they will if you are doing a complete engine
overhaul yourself). These components include
the following:

a) Alternator mounting brackets.
b) Engine mountings and brackets (Part A, B

or C of this Chapter).

c) The ignition system and HT components

including all sensors, distributor cap and
rotor arm, ignition module, HT leads and
spark plugs (Chapters 1 and 5).

d) Power steering pump and air conditioning

compressor brackets (where fitted).

e) Thermostat and housing, coolant pump,

coolant outlet chamber/elbow (Chapter
3).

f) Dipstick tube.
g) Carburettor/fuel system components

(Chapter 4).

h) All electrical switches and sensors.
i) Inlet and exhaust manifolds (Chapter 4).
j) Oil filter (Chapter 1).
k) Fuel pump - carburettor engines only

(Chapter 4).

l) Flywheel/driveplate (Part A, B or C of this

Chapter).

Note:

When removing the external

components from the engine, pay close
attention to details that may be helpful or
important during refitting. Note the fitting
positions of gaskets, seals, washers, bolts and
other small items.

If you are obtaining a “short” engine

(cylinder block/crankcase, crankshaft, pistons
and connecting rods all assembled), then the
cylinder head, timing chain/belt (together with
tensioner, tensioner and idler pulleys and
covers) sump and oil pump will have to be
removed also.

If a complete overhaul is planned, the

engine can be dismantled in the order given
below, referring to Part A, B or C of this
Chapter unless otherwise stated.

a) Inlet and exhaust manifolds (Chapter 4).
b) Timing chain, sprockets, tensioner and oil

pump - XV, XW and XY series engines.

c) Timing belt, sprockets and tensioner - XU

and TU series engines.

d) Cylinder head.
e) Flywheel/driveplate - XU and TU series

engines.

f) Sump - XU and TU series engines.
g) Oil pump - XU and TU series engines.
h) Piston/connecting rod assemblies

(Section 7).

i) Crankshaft (Section 8).

6

Cylinder head - dismantling,
cleaning, inspection and
reassembly

3

Note: New and reconditioned cylinder heads
are available from the manufacturer, and from
engine overhaul specialists. Be aware that
some specialist tools are required for the
dismantling and inspection procedures, and
new components may not be readily available.
It may therefore be more practical and
economical for the home mechanic to
purchase a reconditioned head, rather than
dismantle, inspect and recondition the original
head.

Dismantling

1 Remove the cylinder head as described in
Part A, B or C of this Chapter (as applicable).
2 If not already done, remove the inlet and
exhaust manifolds with reference to the
relevant Part of Chapter 4.
3 Remove the camshaft, followers and shims
(as applicable) as described in Part A, B or C
of this Chapter.
4 Using a valve spring compressor, compress
each valve spring in turn until the split collets
can be removed. Release the compressor,
and lift off the spring retainer, spring and
spring seat. Using a pair of pliers, carefully
extract the valve stem oil seal from the top of
the guide (see illustrations).
5 If, when the valve spring compressor is
screwed down, the spring retainer refuses to
free and expose the split collets, gently tap
the top of the tool, directly over the retainer,
with a light hammer. This will free the retainer.
6 Withdraw the valve through the combustion
chamber (see illustration).

2D•8 Engine removal and overhaul procedures

6.4a  Compress the valve spring with a

compressor and remove the split collets . . .

6.4b  . . . Release the compressor and

remove the spring retainer . . .