Peugeot 205. Manual - part 54

REF•14

Fault finding

Engine (continued)

Engine misfires throughout the driving speed
range

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Fuel filter choked - fuel-injected models (Chapter 1).

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Fuel pump faulty, or delivery pressure low (Chapter 4A, 4B or 4C).

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Fuel tank vent blocked, or fuel pipes restricted (Chapter 4A, 4B 
or 4C).

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Vacuum leak at the carburettor/throttle body, inlet manifold or
associated hoses (Chapter 4A, 4B or 4C).

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Worn, faulty or incorrectly-gapped spark plugs (Chapter 1).

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Faulty spark plug HT leads (Chapter 1).

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Distributor cap cracked or tracking internally (where applicable)
(Chapter 1).

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Faulty ignition coil or ignition module (Chapter 5B).

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Uneven or low cylinder compressions (Chapter 2A, 2B or 2C).

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Blocked carburettor jet(s) or internal passages - carburettor
models (Chapter 4A).

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Blocked injector/fuel injection system fault - fuel-injected models
(Chapter 4B or 4C).

Engine hesitates on acceleration

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Worn, faulty or incorrectly-gapped spark plugs (Chapter 1).

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Vacuum leak at the carburettor/throttle body, inlet manifold or
associated hoses (Chapter 4A, 4B or 4C).

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Blocked carburettor jet(s) or internal passages - carburettor
models (Chapter 4A).

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Blocked injector/fuel injection system fault - fuel-injected 
(Chapter 4B or 4C).

Engine stalls

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Vacuum leak at the carburettor/throttle body, inlet manifold or
associated hoses (Chapter 4A, 4B or 4C).

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Fuel filter choked - fuel-injected models (Chapter 1).

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Fuel pump faulty, or delivery pressure low (Chapter 4A, 4B or 4C).

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Fuel tank vent blocked, or fuel pipes restricted (Chapter 4A, 4B, 4C
or 4D).

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Blocked carburettor jet(s) or internal passages - carburettor
models (Chapter 4A).

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Blocked injector/fuel injection system fault - fuel-injected models
(Chapter 4B or 4C).

Engine lacks power

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Timing chain or belt incorrectly fitted or tensioned (Chapter 2A, 2B
or 2C).

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Fuel filter choked - fuel-injected models (Chapter 1).

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Fuel pump faulty, or delivery pressure low (Chapter 4A, 4B, or 4C).

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Uneven or low cylinder compressions (Chapter 2A, 2B or 2C).

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Worn, faulty or incorrectly-gapped spark plugs (Chapter 1).

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Vacuum leak at the carburettor/throttle body, inlet manifold or
associated hoses (Chapter 4A, 4B or 4C).

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Blocked carburettor jet(s) or internal passages - carburettor
models (Chapter 4A).

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Blocked injector/fuel injection system fault - fuel-injected models
(Chapter 4B or 4C).

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Brakes binding (Chapters 1 and 9).

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Clutch slipping (Chapter 6).

Engine backfires

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Timing chain or belt incorrectly fitted or tensioned (Chapter 2A, 2B
or 2C).

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Vacuum leak at the carburettor/throttle body, inlet manifold or
associated hoses (Chapter 4A, 4B or 4C).

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Blocked carburettor jet(s) or internal passages - carburettor
models (Chapter 4A).

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Blocked injector/fuel injection system fault - fuel-injected models
(Chapter 4B or 4C).

Oil pressure warning light illuminated with engine
running

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Low oil level, or incorrect oil grade (Chapter 1).

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Faulty oil pressure warning light switch (Chapter 5A).

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Worn engine bearings and/or oil pump (Chapter 2D).

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High engine operating temperature (Chapter 3).

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Oil pressure relief valve defective (Chapter 2A, 2B or 2C).

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Oil pick-up strainer clogged (Chapter 2A, 2B or 2C).

Engine runs-on after switching off

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Excessive carbon build-up in engine (Chapter 2D).

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High engine operating temperature (Chapter 3).

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Faulty fuel cut-off solenoid - carburettor models (Chapter 4A).

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Fuel injection system fault - fuel-injected models (Chapter 4B 
or 4C).

Engine noises

Pre-ignition (pinking) or knocking during acceleration or
under load

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Ignition timing incorrect/ignition system fault (Chapters 1 and 5B).

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Incorrect grade of spark plug (Chapter 1).

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Incorrect grade of fuel (Chapter 1).

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Vacuum leak at the carburettor/throttle body, inlet manifold or
associated hoses (Chapter 4A, 4B or 4C).

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Excessive carbon build-up in engine (Chapter 2D).

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Blocked carburettor jet(s) or internal passages - carburettor
models (Chapter 4A).

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Blocked injector/fuel injection system fault - fuel-injected models
(Chapter 4B or 4C).

Whistling or wheezing noises

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Leaking inlet manifold or carburettor/throttle body gasket
(Chapter 4A, 4B or 4C).

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Leaking exhaust manifold gasket or pipe-to-manifold joint
(Chapter 4A, 4B, 4C or 4D).

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Leaking vacuum hose (Chapters 4A, 4B, 4C, 4D, 5B and 9).

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Blowing cylinder head gasket (Chapter 2A, 2B and 2C).

Tapping or rattling noises

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Worn valve gear or camshaft (Chapter 2A, 2B or 2C).

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Ancillary component fault (coolant pump, alternator, etc) 
(Chapters 3, 5A, etc).

Knocking or thumping noises

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Worn big-end bearings (regular heavy knocking, perhaps less
under load) (Chapter 2D).

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Worn main bearings (rumbling and knocking, perhaps worsening
under load) (Chapter 2D).

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Piston slap (most noticeable when cold) (Chapter 2D).

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Ancillary component fault (coolant pump, alternator, etc) 
(Chapters 3, 5A, etc).

Fault finding

REF•15

REF

2 Cooling system

3 Fuel and exhaust systems

Overheating

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Insufficient coolant in system (“Weekly checks” ).

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Thermostat faulty (Chapter 3).

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Radiator core blocked, or grille restricted (Chapter 3).

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Electric cooling fan or thermoswitch faulty (Chapter 3).

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Pressure cap faulty (Chapter 3).

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Ignition timing incorrect/ignition system fault (Chapters 1 and 5B).

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Inaccurate temperature gauge sender unit (Chapter 3).

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Airlock in cooling system (Chapter 1).

Overcooling

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Thermostat faulty (Chapter 3).

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Inaccurate temperature gauge sender unit (Chapter 3).

External coolant leakage

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Deteriorated or damaged hoses or hose clips (Chapter 1).

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Radiator core or heater matrix leaking (Chapter 3).

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Pressure cap faulty (Chapter 3).

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Coolant pump seal leaking (Chapter 3).

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Boiling due to overheating (Chapter 3).

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Core plug leaking (Chapter 2D).

Internal coolant leakage

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Leaking cylinder head gasket (Chapter 2A, 2B or 2C).

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Cracked cylinder head or cylinder bore (Chapter 2A, 2B, 2C 
or 2D).

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Leaking cylinder liner base seal (Chapter 2D)

Corrosion

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Infrequent draining and flushing (Chapter 1).

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Incorrect coolant mixture or inappropriate coolant type 
(Chapter 1).

Excessive fuel consumption

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Air filter element dirty or clogged (Chapter 1).

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Choke cable incorrectly adjusted, or choke sticking - carburettor
models (Chapter 4A).

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Fuel injection system fault - fuel-injected models (Chapter 4B 
or 4C).

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Ignition timing incorrect/ignition system fault (Chapters 1 and 5B).

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Tyres under-inflated (“Weekly checks” ).

Fuel leakage and/or fuel odour

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Damaged or corroded fuel tank, pipes or connections 
(Chapter 4A, 4B, 4C or 4D).

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Carburettor float chamber flooding (float height incorrect) -
carburettor models (Chapter 4A).

Excessive noise or fumes from exhaust system

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Leaking exhaust system or manifold joints (Chapters 1 and 4D).

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Leaking, corroded or damaged silencers or pipe (Chapters 1 
and 4D).

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Broken mountings causing body or suspension contact 
(Chapter 1).

4 Clutch

Pedal travels to floor - no pressure or very little
resistance

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Broken clutch cable (Chapter 6).

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Incorrect clutch pedal stroke adjustment (Chapter 1).

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Broken clutch release bearing or fork (Chapter 6).

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Broken diaphragm spring in clutch pressure plate (Chapter 6).

Clutch fails to disengage (unable to select gears).

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Incorrect clutch pedal stroke adjustment (Chapter 1).

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Clutch plate sticking on transmission input shaft splines 
(Chapter 6).

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Clutch plate sticking to flywheel or pressure plate (Chapter 6).

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Faulty pressure plate assembly (Chapter 6).

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Clutch release mechanism worn or incorrectly assembled 
(Chapter 6).

Clutch slips (engine speed increases, with no
increase in vehicle speed).

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Incorrect clutch pedal stroke adjustment (Chapter 1).

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Clutch plate linings excessively worn (Chapter 6).

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Clutch plate linings contaminated with oil or grease (Chapter 6).

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Faulty pressure plate or weak diaphragm spring (Chapter 6).

Judder as clutch is engaged

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Clutch plate linings contaminated with oil or grease (Chapter 6).

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Clutch plate linings excessively worn (Chapter 6).

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Clutch cable sticking or frayed (Chapter 6).

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Faulty or distorted pressure plate or diaphragm spring (Chapter 6).

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Worn or loose engine or transmission mountings (Chapter 2A, 2B
or 2C).

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Clutch plate hub or transmission input shaft splines worn 
(Chapter 6).

Noise when depressing or releasing clutch pedal

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Worn clutch release bearing (Chapter 6).

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Worn or dry clutch pedal bushes (Chapter 6).

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Faulty pressure plate assembly (Chapter 6).

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Pressure plate diaphragm spring broken (Chapter 6).

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Broken clutch plate cushioning springs (Chapter 6).

REF•16

Fault finding

7 Driveshafts

Clicking or knocking noise on turns (at slow speed
on full-lock)

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Lack of constant velocity joint lubricant, possibly due to damaged
bellows (Chapter 8).

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Worn outer constant velocity joint (Chapter 8).

Vibration when accelerating or decelerating

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Worn inner constant velocity joint (Chapter 8).

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Bent or distorted driveshaft (Chapter 8).

6 Automatic transmission

Note: Due to the complexity of the automatic transmission, it is difficult
for the home mechanic to properly diagnose and service this unit. For
problems other than the following, the vehicle should be taken to a
dealer service department or automatic transmission specialist. Do not
be too hasty in removing the transmission if a fault is suspected, as
most of the testing is carried out with the unit still fitted.

Fluid leakage

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Automatic transmission fluid is usually dark in colour. Fluid leaks

should not be confused with engine oil, which can easily be blown onto
the transmission by airflow.

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To determine the source of a leak, first remove all built-up dirt and

grime from the transmission housing and surrounding areas using a
degreasing agent, or by steam-cleaning. Drive the vehicle at low
speed, so airflow will not blow the leak far from its source. Raise and
support the vehicle, and determine where the leak is coming from. The
following are common areas of leakage:

a) Fluid pan or “sump” (Chapter 1 and 7B).
b) Dipstick tube (Chapter 1 and 7B).
c) Transmission-to-fluid cooler pipes/unions (Chapter 7B).

Transmission fluid brown, or has burned smell

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Transmission fluid level low, or fluid in need of renewal 
(Chapter 1).

General gear selection problems

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Chapter 7B deals with checking and adjusting the selector cable

on automatic transmissions. The following are common problems
which may be caused by a poorly-adjusted cable:

a) Engine starting in gears other than Park or Neutral.
b) Indicator panel indicating a gear other than the one actually being

used.

c) Vehicle moves when in Park or Neutral.
d) Poor gear shift quality or erratic gear changes.

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Refer to Chapter 7B for the selector cable adjustment procedure.

Transmission will not downshift (kickdown) with
accelerator pedal fully depressed

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Low transmission fluid level (Chapter 1).

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Incorrect selector cable adjustment (Chapter 7B).

Engine will not start in any gear, or starts in gears
other than Park or Neutral

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Incorrect starter/inhibitor switch adjustment (Chapter 7B).

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Incorrect selector cable adjustment (Chapter 7B).

Transmission slips, shifts roughly, is noisy, or has
no drive in forward or reverse gears

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There are many probable causes for the above problems, but the

home mechanic should be concerned with only one possibility - fluid
level. Before taking the vehicle to a dealer or transmission specialist,
check the fluid level and condition of the fluid as described in Chapter 1.
Correct the fluid level as necessary, or change the fluid and filter if
needed. If the problem persists, professional help will be necessary.

5 Manual transmission

Noisy in neutral with engine running

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Input shaft bearings worn (noise apparent with clutch pedal
released, but not when depressed) (Chapter 7A).*

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Clutch release bearing worn (noise apparent with clutch pedal
depressed, possibly less when released) (Chapter 6).

Noisy in one particular gear

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Worn, damaged or chipped gear teeth (Chapter 7A).*

Difficulty engaging gears

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Clutch fault (Chapter 6).

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Worn or damaged gear linkage (Chapter 7A).

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Incorrectly-adjusted gear linkage (Chapter 7A).

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Worn synchroniser units (Chapter 7A).*

Jumps out of gear

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Worn or damaged gear linkage (Chapter 7A).

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Incorrectly-adjusted gear linkage (Chapter 7A).

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Worn synchroniser units (Chapter 7A).*

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Worn selector forks (Chapter 7A).*

Vibration

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Lack of oil (Chapter 1).

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Worn bearings (Chapter 7A).*

Lubricant leaks

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Leaking differential output (driveshaft) oil seal (Chapter 7A).

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Leaking housing joint (Chapter 7A).*

*Although the corrective action necessary to remedy the symptoms
described is beyond the scope of the home mechanic, the above
information should be helpful in isolating the cause of the condition, so
that the owner can communicate clearly with a professional mechanic.

Fault finding

REF•17

REF

9 Suspension and steering

Note: Before diagnosing suspension or steering faults, be sure that the
trouble is not due to incorrect tyre pressures, mixtures of tyre types, or
binding brakes.

Vehicle pulls to one side

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Defective tyre (“Weekly checks” ).

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Excessive wear in suspension or steering components (Chapters 1
and 10).

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Incorrect front wheel alignment (Chapter 10).

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Accident damage to steering or suspension components 
(Chapter 1).

Wheel wobble and vibration

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Front roadwheels out of balance (vibration felt mainly through the
steering wheel) (Chapters 1 and 10).

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Rear roadwheels out of balance (vibration felt throughout the
vehicle) (Chapters 1 and 10).

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Roadwheels damaged or distorted (Chapters 1 and 10).

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Defective tyre (“Weekly checks” ).

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Worn steering or suspension joints, bushes or components
(Chapters 1 and 10).

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Wheel bolts loose (Chapters 1 and 10).

Excessive pitching and/or rolling around corners,
or during braking

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Defective shock absorbers (Chapters 1 and 10).

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Broken or weak spring and/or suspension component (Chapters 1
and 10).

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Worn or damaged anti-roll bar or mountings (Chapter 10).

Wandering or general instability

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Incorrect front wheel alignment (Chapter 10).

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Worn steering or suspension joints, bushes or components
(Chapters 1 and 10).

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Roadwheels out of balance (Chapters 1 and 10).

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Defective tyre (“Weekly checks” ).

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Wheel bolts loose (Chapters 1 and 10).

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Defective shock absorbers (Chapters 1 and 10).

Excessively-stiff steering

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Lack of steering gear lubricant (Chapter 10).

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Seized track rod end balljoint or suspension balljoint (Chapters 1
and 10).

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Broken or incorrectly-adjusted auxiliary drivebelt - power steering
(Chapter 1).

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Incorrect front wheel alignment (Chapter 10).

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Steering rack or column bent or damaged (Chapter 10).

8 Braking system

Note: Before assuming that a brake problem exists, make sure that the
tyres are in good condition and correctly inflated, that the front wheel
alignment is correct, and that the vehicle is not loaded with weight in an
unequal manner. Apart from checking the condition of all pipe and
hose connections, any faults occurring on the anti-lock braking system
should be referred to a Peugeot dealer for diagnosis.

Vehicle pulls to one side under braking

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Worn, defective, damaged or contaminated brake pads/shoes on
one side (Chapters 1 and 9).

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Seized or partially-seized front brake caliper/wheel cylinder piston
(Chapters 1 and 9).

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A mixture of brake pad/shoe lining materials fitted between sides
(Chapters 1 and 9).

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Brake caliper or backplate mounting bolts loose (Chapter 9).

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Worn or damaged steering or suspension components 
(Chapters 1 and 10).

Noise (grinding or high-pitched squeal) when
brakes applied

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Brake pad or shoe friction lining material worn down to metal
backing (Chapters 1 and 9).

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Excessive corrosion of brake disc or drum. (May be apparent after
the vehicle has been standing for some time (Chapters 1 and 9).

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Foreign object (stone chipping, etc) trapped between brake disc
and shield (Chapters 1 and 9).

Excessive brake pedal travel

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Inoperative rear brake self-adjust mechanism - drum brakes
(Chapter 9).

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Faulty master cylinder (Chapter 9).

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Air in hydraulic system (Chapters 1 and 9).

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Faulty vacuum servo unit (Chapter 9).

Brake pedal feels spongy when depressed

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Air in hydraulic system (Chapters 1 and 9).

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Deteriorated flexible rubber brake hoses (Chapters 1 and 9).

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Master cylinder mounting nuts loose (Chapter 9).

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Faulty master cylinder (Chapter 9).

Excessive brake pedal effort required to stop
vehicle

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Faulty vacuum servo unit (Chapter 9).

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Disconnected, damaged or insecure brake servo vacuum hose
(Chapter 9).

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Primary or secondary hydraulic circuit failure (Chapter 9).

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Seized brake caliper or wheel cylinder piston(s) (Chapter 9).

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Brake pads or brake shoes incorrectly fitted (Chapters 1 and 9).

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Incorrect grade of brake pads or brake shoes fitted (Chapters 1
and 9).

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Brake pads or brake shoe linings contaminated (Chapters 1 
and 9).

Judder felt through brake pedal or steering wheel
when braking

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Excessive run-out or distortion of discs/drums (Chapters 1 and 9).

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Brake pad or brake shoe linings worn (Chapters 1 and 9).

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Brake caliper or brake backplate mounting bolts loose (Chapter 9).

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Wear in suspension or steering components or mountings
(Chapters 1 and 10).

Brakes binding

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Seized brake caliper or wheel cylinder piston(s) (Chapter 9).

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Incorrectly-adjusted handbrake mechanism (Chapter 9).

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Faulty master cylinder (Chapter 9).

Rear wheels locking under normal braking

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Rear brake shoe linings contaminated (Chapters 1 and 9).

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Faulty brake pressure regulator (Chapter 9).