Peugeot 205. Manual — part 33

28 Connect the timing light to No 1 cylinder
spark plug lead (No 1 cylinder is at the
transmission end of the engine) as described
in the timing light manufacturer’s instructions.
29 Start the engine, allowing it to idle at the
specified speed, and point the timing light at
the transmission housing aperture. The
flywheel timing mark should be aligned with
the appropriate notch on the timing plate. The
numbers on the plate indicate degrees Before
Top Dead Centre (BTDC).
30 If adjustment is necessary, slacken the
two distributor mounting nuts, then slowly
rotate the distributor body as required until
the flywheel mark and the timing plate notch
are brought into alignment. Once the marks
are correctly aligned, hold the distributor
stationary and tighten its mounting nuts.
Recheck that the timing marks are still
correctly aligned and, if necessary, repeat the
adjustment procedure.
31 When the timing is correctly set, increase
the engine speed, and check that the flywheel
mark advances to beyond the beginning of
the timing plate reference marks, returning to
the specified mark when the engine is allowed
to idle. This shows that the centrifugal

advance mechanism is functioning.
Reconnect the vacuum hose to the
distributor, and repeat the check. The rate of
advance should significantly increase if the
vacuum diaphragm is functioning correctly.
32 When the ignition timing is correct, stop
the engine and disconnect the timing light.

9

TDC sensor - removal and
refitting

2

Removal

1 Depending on engine type, the TDC sensor
is for use with the diagnostic socket located
on the clutch housing, or for the provision of
information on crankshaft position to the
engine management system ECU. When used
in conjunction with the diagnostic socket, a
special instrument and adapter are required
and therefore it will normally be used only by a
Peugeot garage.
2 To remove the sensor, unscrew the
mounting screw or release the clamp as
applicable.

3 Where the sensor forms part of the
diagnostic socket assembly, if it is to be
completely removed, the socket must be
unclipped from its bracket and the remaining
wiring and earth leads disconnected.

Refitting

4 Refitting is a reversal of removal, but the
adjustment procedure for new and used
sensors differs. New sensors have three
extensions on the inner face and the unit
should be inserted through the clamp until the
extensions just touch the flywheel. The clamp
screw is then tightened and clearance is
provided as the flywheel rotates and wears
the ends of the extensions. This method
should not be used when refitting a used
sensor. In this case, cut off the extensions
completely then temporarily insert the sensor
until it touches the flywheel, remove it and
reposition it in the clamp 1.0 mm further out.

Ignition system 5B•7

5B

5B•8

Notes

9

Chapter 9
Braking system

System type:

Footbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dual-circuit hydraulic with servo assistance on all non-basic models.
Anti-lock braking (ABS) optional on certain later models.

Handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical by cables to rear brakes

Front brakes

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Solid or ventilated disc, with single piston sliding calipers

Brake pad minimum lining thickness . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.0 mm

Disc diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

247 mm

Disc thickness:

New:

Non-ventilated disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.0 mm

Ventilated disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20.4 mm

Minimum after resurfacing:

Non-ventilated disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.5 mm

Ventilated disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18.9 mm

Maximum disc run out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.07 mm

Rear drum brakes

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Self-adjusting drum with leading and trailing shoes

Brake shoe minimum lining thickness . . . . . . . . . . . . . . . . . . . . . . . . . .

1.0 mm

Drum internal diameter:

New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

180.0 mm

Maximum after resurfacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

181.0 mm

Drum out-of-round (maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.10 mm

Rear disc brakes

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disc, with single piston sliding calipers

Brake pad minimum lining thickness . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.0 mm

Disc diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

247 mm

Disc thickness:

New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.0 mm

Minimum after resurfacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.0 mm

Maximum disc run out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.07 mm

Anti-lock braking system (ABS) - general information . . . . . . . . . . . . 19
Anti-lock braking system (ABS) components - removal and refitting 20
Brake disc - inspection, removal and refitting . . . . . . . . . . . . . . . . . . 9
Brake fluid level check . . . . . . . . . . . . . . . . . . . . .See “Weekly checks”
Brake fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Brake pad wear check . . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Brake pedal - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Front brake caliper - removal, overhaul and refitting . . . . . . . . . . . . . 7
Front brake pads - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Handbrake - adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Handbrake cables - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Handbrake lever - removal and refitting . . . . . . . . . . . . . . . . . . . . . . 18
Hydraulic pipes and hoses - renewal . . . . . . . . . . . . . . . . . . . . . . . . 3

Hydraulic system - bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Master cylinder - removal, overhaul and refitting . . . . . . . . . . . . . . . 12
Rear brake caliper (1.9 GTI models) - removal, overhaul

and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Rear brake compensator (GTI models) - general information, removal

and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Rear brake hub/drum - removal, inspection and refitting . . . . . . . . . 11
Rear brake pads (1.9 GTI models) - renewal . . . . . . . . . . . . . . . . . . . 6
Rear brake shoes - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rear brake shoe wear check . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Rear wheel cylinder - removal, overhaul and refitting . . . . . . . . . . . . 10
Underbody and fuel/brake line check . . . . . . . . . . . . . . .See Chapter 1
Vacuum servo unit - testing, removal and refitting . . . . . . . . . . . . . . 14

9•1

Specifications

Contents

Easy, suitable for
novice with little
experience

Fairly easy, suitable
for beginner with
some experience

Fairly difficult,
suitable for competent
DIY mechanic

Difficult, suitable for
experienced DIY
mechanic

Very difficult,
suitable for expert DIY
or professional

Degrees of difficulty

5

4

3

2

1

Torque wrench settings

Nm

lbf ft

Girling front caliper mounting bolts:

All models except 1.9 GTI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

97

72

1.9 GTI models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

100

74

Girling front caliper guide bolts (1.9 GTI models) . . . . . . . . . . . . . . . . . .

35

26

DBA Bendix front caliper mounting bolts . . . . . . . . . . . . . . . . . . . . . . . .

120

89

Rear caliper mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

120

89

Rear backplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37

27

Rear hub nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215

159

1

General information

The braking system is of hydraulic type with

the front disc brakes and rear drum brakes on
all except 1.9 GTI models. On these vehicles
disc brakes are also fitted at the rear. On all
models, the handbrake is cable-operated on
the rear wheels.

The hydraulic system is split into two

circuits, so that in the event of failure of one
circuit, the other will still provide adequate
braking power (although pedal travel and
effort may increase). The hydraulic circuits are
split either diagonally or front-to-rear
according to model. In the diagonally split
system, each hydraulic circuit supplies one
front, and one diagonally opposite rear brake.
In the front-to-rear arrangement, one circuit
serves the front brakes and the other circuit
the rear brakes.

A compensating valve (or valves) reduces

the hydraulic pressure to the rear brakes
under heavy applications of the brake pedal in
order to prevent rear wheel lock-up.

A vacuum servo unit is fitted to all

non-basic models.

From 1991, the Bendix anti-lock braking

system (ABS) is available as an option on
certain models and is described in further
detail in Section 19.
Note: When servicing any part of the system,
work carefully and methodically; also observe
scrupulous cleanliness when overhauling any
part of the hydraulic system. Always renew
components (in axle sets, where applicable) if
in doubt about their condition, and use only
genuine Peugeot replacement parts, or at
least those of known good quality. Note the
warnings given in “Safety first” and at relevant
points in this Chapter concerning the dangers
of asbestos dust and hydraulic fluid.

2

Hydraulic system - bleeding

2

Warning: Hydraulic fluid is
poisonous; wash off immediately
and thoroughly in the case of
skin contact, and seek

immediate medical advice if any fluid is
swallowed or gets into the eyes. Certain
types of hydraulic fluid are inflammable,

and may ignite when allowed into contact
with hot components; when servicing any
hydraulic system, it is safest to assume that
the fluid IS inflammable, and to take
precautions against the risk of fire as
though it is petrol that is being handled.
Hydraulic fluid is also an effective paint
stripper, and will attack plastics; if any is
spilt, it should be washed off immediately,
using copious quantities of clean water.
Finally, it is hygroscopic (it absorbs
moisture from the air). The more moisture
is absorbed by the fluid, the lower its
boiling point becomes, leading to a
dangerous loss of braking under hard use.
Old fluid may be contaminated and unfit for
further use. When topping-up or renewing
the fluid, always use the recommended
type, and ensure that it comes from a
freshly-opened sealed container.

General

1 The correct functioning of the brake
hydraulic system is only possible after
removing all air from the components and
circuit; this is achieved by bleeding the
system.
2 During the bleeding procedure, add only
clean, fresh hydraulic fluid of the specified
type; never re-use fluid that has already been
bled from the system. Ensure that sufficient
fluid is available before starting work.
3 If there is any possibility of incorrect fluid
being used in the system, the brake lines and
components must be completely flushed with
uncontaminated fluid and new seals fitted to
the components.
4 If brake fluid has been lost from the master
cylinder due to a leak in the system, ensure
that the cause is traced and rectified before
proceeding further.
5 Park the car on level ground, switch off the
ignition and select first gear (manual
transmission) or Park (automatic transmission)
then chock the wheels and release the
handbrake.
6 Check that all pipes and hoses are secure,
unions tight, and bleed screws closed.
Remove the dust caps and clean any dirt from
around the bleed screws.
7 Unscrew the master cylinder reservoir cap,
and top-up the reservoir to the “MAX” level
line. Refit the cap loosely, and remember to
maintain the fluid level at least above the
“MIN” level line throughout the procedure,
otherwise there is a risk of further air entering
the system.

8 There are a number of one-man, do-it-
yourself, brake bleeding kits currently
available from motor accessory shops. It is
recommended that one of these kits is used
wherever possible, as they greatly simplify the
bleeding operation, and also reduce the risk
of expelled air and fluid being drawn back into
the system. If such a kit is not available, the
basic (two-man) method must be used, which
is described in detail below.
9 If a kit is to be used, prepare the car as
described previously, and follow the kit
manufacturer’s instructions, as the procedure
may vary slightly according to the type being
used; generally, they are as outlined below in
the relevant sub-section.
10 Whichever method is used, the same
sequence must be followed (paragraphs 11
and 12) to ensure the removal of all air from
the system.

Bleeding sequence

11 If the hydraulic system has only been
partially disconnected and suitable precautions
were taken to minimise fluid loss, it should only
be necessary to bleed that part of the system
(ie the primary or secondary circuit).
12 If the complete system is to be bled, then
it should be done in the following sequence:

Non-ABS models:

Diagonally split system - all models except 1.6
GTI:

RH rear wheel
LH front wheel
LH rear wheel
RH front wheel

Front-to-rear split system - 1.6 GTI models:

LH rear wheel and inertia compensator
RH rear wheel
LH front wheel
RH front wheel

ABS models:

Note: Before carrying out any bleeding, the
battery negative lead must be disconnected,
and the brown three-way, brown five-way and
green five-way wiring connectors must be
disconnected from the regulator unit to
prevent the possibility of air entering the
system. The connectors must not be
reconnected until the hydraulic system has
been bled.

LH rear wheel
RH rear wheel
LH front wheel
RH front wheel
ABS regulator unit (see illustration)

9•2 Braking system