MODIFICATIONS POSSIBLE WITH THE 205 XS
(TU3S engine)

 

Disclaimer: I am not a mechanic nor in any way affiliated with the motor industry. I am purely a hobbyist. Please do not rely on the information here when pursuing any modifications as it is for reference only; always seek professional advice from a specialist beforehand if you are unsure of any modification. I do not accept liability for any actions taken following the viewing of these pages.

BODY


The body shell of the XS isn't too different to that of a GTi, it has a front splitter with built-in driving/fog lamps which are a feature of the sportier pugs (These often go rusty but are easily replaced by the same or even circular long-range driving lamps). This is accompanied by a rear plastic valance, in bodycolour (lower models just have a black piece sloping under the bumpers). Their is an option when purchased to have a small black rear tailgate spoiler, which came as standard on GTi models. This can be purchased in many places as well as a fairly attractive mid-spoiler. These are usually advertised for all 205 models as the tailgates are the same design. The top spoiler can also be purchased as a larger version, often as part of a full bodykit.
The dark plastic wheelarches and side mouldings from the 205 GTi models don't easily transfer to an XS. It is possible to buy a kit to fit an XS. The plastic just pops off with studs lined around the arches and down the sides. The two plastic pieces on the rear pillar come off the same way, with two or three studs holding them in. The XS has a chrome strip running along the middle of the bumpers which can also be replaced easily with the red stripe found on GTis.
Some bodykits include nice looking sideskirts, the Zender ones are decent, the ones with Guttman bodykits can make the car resemble the award winning Turbo 16. Don't forget also, to check out the 205 bodykits available from Dimma
Another feature of the XS (and GT and XT) is plastic transfer stickers advertising the 205 type on the front wings just underneath the side repeater lights (these can be replaced also, with oval repeaters if preferred). These can probably be quite easily removed (my XS doesn't have them) if so desired. They come in several different colours, including red and yellow in accordance with the factory body colour.
Single wiper conversions are not impossible at the front, as are twin headlamp conversions. Another great looking mod is to change the standard yellow indicators for clear ones for around £25 a pair. Tim at Magnatec (Ad Hoc Clear Lens Solutions) is currently working on rolling out clear rear light clusters which are liable to retail at a maximum of £70. See the picture below and if you like what you see you can e-mail Tim to show your interest and get updates on the latest developments...



Clear rear light clusters for the 205 which should be available soon...


Again, the similarity to GTis makes finding the parts for this job easy. The front grille, with the Peugeot badge in the centre can also be replaced, by quite easily lifting it out and sliding, say, a Guttman grille in it's place.

Also, the rear pillar pieces can be replaced too (those plain grey ridged plastic pieces) with special '205 XS' badges available for just under £40 as a set from Peter Maiden Components or Online Auto Sport. These are easily replaced, the larger pieces are held in by three spikes, which are prone to breaking, but can be carefully pulled out and new badges pushed in, maybe with the help of some strong glue.
The modifications for the front splitter/spoiler are various and can include a wide range of personal customizations.
The wing mirrors in later models are more rectangular, those in earlier models are more rounded. They are the same colour as the bumpers (grey or black). If desired the car can have it's plastic parts sprayed to match the bodycolour as with any other car, though I've been told it's not an easy job at all.


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ENGINE


The engine as mentioned on the main page is basically the same as the Citroen AX GT and many of the mods can be applied as for that car (Many performance parts come available for 205 GTis and Citroen AX GTs, but rarely the 205 XS, the car-mixture of the XS makes things much easier!)
OK, the carburettor is a twin-choke Solex. The best option for any standard car is just to get this properly tuned up. If you want speed, remember to really put your foot down and the second choke will help out. If you wish to replace the carb then it is possible to replace it with the twin side-draught carbs and inlet manifold from an early MG Maestro if you can find one as this is an easy 15bhp gain, contact On-Line AutoSport for further details. If the desire is to have fuel injection then go for a GTi. Needless to say many mods favour injection cars (ECUs, chips etc.).
The air intake in an engine is very important. The combustion process requires quite a large amount of outside cold air to be mixed with the fuel in combustion and so increasing the flow of air into and out of the engine is a crucial factor in improving performance.

The best and most convenient mod is to get a K & N bolt-on filter kit (see the 205 Links page), this includes the actual filter unit and modified jets for the carb to accompany the increased airflow. Together they are said to add up to 5bhp (NB Some insurance companies, like mine, forbid such engine modifications and it may invalidate your insurance in the case of a claim - always check first).
The extra bhp may or may not be greatly noticed, though with a performance exhaust the induction noise of the filter may be well amplified for greater effect.

Alternatively, you could invest in a replacement filter element that replaces the standard paper filter but is cleanable and allows the easier passage of air into the system. It is a basic, easy idea and may be almost as effective as a bolt-on filter. They just go in place of the normal filter, with no modifications or difficulty and cost about £30+. You could also try pepperpotting the air cleaner housing as this can allow easier air intake to the filter element by bypassing the air intake that runs towards the front of the engine. K & N kits allow much more efficient intake as they bolt onto the carb and the element is more exposed. They also help remove some of the clutter around the engine, such as the filter housing.

Another modification for increased airflow into the engine may be to modify the front of the car to allow more air to pass into the engine bay. This could be done with a modified grille or by simply relocating the numberplate. Even more extreme may be the inclusion of bonnet vents, though this would probably be a bit too far for most 205 XSs and could lead to other problems regarding the location of the vent.
Performance spark plugs are available for the XS too. A strange point being that the 205 1.9 GTi and the XS are the two models which share the same spark plugs. Peugeot recommends single or double copper Champion plugs (C7YCX and RC7YCC). NGK will also suffice. Bosch Super 4s are worth a try, though Splitfires have now got themselves a bad reputation. Performance plugs and leads are wasted on a standard engine. The most expensive ones are best used in uprated engines. There is unlikely to be any noticeable improvement if you put £20 performance plugs in a standard XS engine. The same goes for HT leads. Peugeot ignition leads are made by Motorquip and are 8mm, silicone leads. Performance leads are available, such as 'splitfire' and 'mega-leads'. Also not to be forgotten are performance ignition coils and distributors, which are a good idea to compliment performance plugs and leads.
Other engine mods are likely to be quite a bit more expensive, such as modified cams, lightened flywheels and modified cylinder heads. Kits are available which include such modifications with some good power increases from Peter Maiden, though can cost as much as £570. Peugeot engines are already very finely made for high bhp figures, so this isn't too often necessary (the engine, being small anyway would be quite limited in potential, so heavy engine modifications are best undertaken on a GTi or Mi16 conversion).
Performance steel exhausts suitable for the 205 XS are widely available from companies such as Magnex, Mongoose and Jetex and can make pleasing sounds when a K & N kit is also fitted. These can also help with a gain of a few bhp. Single pipe exhausts shouldn't be a problem with the rear valance as it does have some allowance for a wider pipe, though twin pipes would require some modification.

The exhaust system could range from just the backbox for as little as £55 to a full system including the manifold. The backbox will be the best choice for those on a budget who desire the noises from the removal of the silencer. The full system will greatly enhance the flow of exhaust gases and have more effect on engine performance. I'm not too sure if AX GT exhaust systems are the same, as a smaller car, they may be quite different, best to check with suppliers, although there are a couple of systems specifically for the XS on the market including twin pipes!

On the front of actual engine conversions, this is quite an unexplored topic but conversion to a GTi engine or even a Mi16 (160bhp from a 405) or Cosworth engine, can be done as the XS has many similarities with the GTis which often have engine conversions done. If a 205 XS was converted to house a bigger engine, thought must be given to uprating the suspension and brake components to handle more power. The brakes and suspension of an XS isn't quite as adapted to that of GTis to handle big and fast engines. Conversions to bigger engines in an XS will probably set you back a couple of grand to include the cost of replacing the suspension and braking components. A few projects involving engine transplants in 205 XSs have been undertaken but I shall not go into any detail on these here. If you're intertested in doing this, a good person to speak to would be Colin at Pug Performance. You could also try contacting Evolution Motorsport or Ecosse for information on further possibilities.
Turbocharging a 205 XS would be difficult and involve altering cylinder compressions and numerous other adjustments, being a very time consuming and difficult exercise, although Turbo Technics used to convert GTis. There has been suggestion of an AX GT with a TT badge, so there may have been some chance of them doing it to this engine. At the time of writing they are only really interested in supercharging the Lotus Elise.

Another possibility as a small modification (which I've been informed doesn't require informing the insurance company) is the Ecotek CB-26P. It stands for 'Clean Burn 2.6L (max. engine size for one device) and P for Petrol-only). It can be fitted to an XS by cutting the braided pipe that runs from the manifold to the brake servo and next to the under the air cleaner cover, next to the carburettor. The device is place in this pipe and it injects a small amount of turbulent air into the manifold to agitate the fuel/air mixture and aid the combustion process. In a way this is like a miniature turbocharger. Many tests have been run on it and it was highly commended by Revs magazine. It improves economy, emissions and performance and at £44 sounds like value for money! Read the info on the Ecotek website for testimonials and more details.

Alternatively, the Turbo Zet is a new device that works from the ignition coil and works similar in some ways to a turbocharger, except it is easier to install and uses two fans to blow extra air into the engine. They cost just under £400, whether they would work on an XS or not I don't know; call 0208 800 3355 for more details.


One thing many people don't realise is that an XS could be made faster than a 1.9GTi with a good filter & exhaust system, twin Weber 45s, race cam and a modified cylinder head. 120bhp is quite possible to reach and with such a light engine, you'll have a car that'll outperform any standard GTi easily, perhaps also some modified ones!
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GEARBOX & TRANSMISSION


The 5 speed gearbox of the 205 XS has a very low gearing. This is to ensure that as much power as possible is put into each gear. It is very much the secret to the 10 second 0-60 times of the XS compared with other cars with higher bhp figures. If you were to keep an XS gearbox and get a 1.9GTi engine, it would potentially be faster 0-60 than a standard GTi. The XS transmission is generally very good, except at high speeds when you're doing about 4000 rpm at about 75 mph in 5th. 4th and 5th gears on this model aren't that different. The best gear for hard accelerating in the XS is 2nd as you can often really feel the 2nd choke kick in at high revs after running at around 3000 rpm, then flooring it.
The clutch of a 205 XS is generally very standard and not known to be very sporty at all. Sports clutches are available for the AX GT for as little as £65 from Power Zone Motorsport (Tel: 01282 724427). A quick-shift conversion is available for 205 GTis for £83 from Demon Tweeks, which may make the quick gear changes for a good 0-60 much easier. The 205 GTi quickshift kits from most places though are not compatible with the XS. Pug Performance is working on an XS quickshift kit, so it's worth trying there for one (£35). Apart from that, best thing is practice your clutch control and get down to the gym. Generally an XS shoots off in 2nd, when other cars are still changing up. Rapid gear changes are the key to the performance of an XS.
The MA transmission in the XS was of such a successful design it was used in newer sporty Peugeot models as well.
Another advantage of it is that it can be detached and removed from the car without having to remove the engine as well.
 

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WHEELS

 

A very important aspect of modifying any car. The 205 range came with various wheel types and sizes. The lower models (XR, XE, GL etc.) all generally had plain steel wheels (middle in above picture), which were black and usually covered by wheel-trims. The sportier, non-GTi cars (XS, GT, XT, SR, DTurbo) had fairly attractively patterned steel wheels (right in picture). These could pass off for alloys to some people (can look quite good when resprayed in certain colours), but cheap ones at that. These were 5.5B X 13 in size with 165 70R 13 tyres, though alloy wheels were available as an option. The alloys aren't anything spectacular, being like round plates with holes round the edge (left in picture). They are the same size as the steel wheels.
To upgrade from standard XS wheels or alloys is easy. The wheelarches are big enough to accommodate 1.6GTi alloys (below).


These are 5.5J X 14 in size with 185 60HR 14 tyres. Changing to 1.6GTi alloys will also provide a significant improvement in the car's handling and are generally more attractive.


1.9GTi alloys (in above picture) are 15" in size and if fitted, may cause problems with rubbing when people are in the back. There are ways round this, by cutting away the rear valance or replacing it with the GTi rear valance or rolling arches out and so on. Best way to alleviate these problems is to ask people who have (try Tim's Pug Bulletin Board)
Also to note about wheels, they are of the 4 stud type (in contrast with the AX GT which is 3 stud). The chrome nuts which come as standard with 205 alloys are specially made for these wheels. They are only available through Peugeot and cost around £5 each. The reason being is the inner part of the head of the nut is flat rather than more conical as with most other cars. These means they cannot be effectively used with other non-Peugeot alloys. Also to mention that 1.9 GTis can handle wheels up to 17 inches in size, this isn't recommended for a standard XS as the wheelarches of the 1.9GTi are built for larger wheels.


Other alloys are available for Peugeots and a fairly comprehensive alloy wheel brochure is available free from most Peugeot dealers.


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INTERIOR


Inside the XS, there is a fairly comprehensive dashboard layout, including a locking glovebox, 3 sets of air vents, a recession just above the glovebox and a centre console and driving instruments very much the same as the later 205 models. The centre console, working up from the gear stick, has a small covered compartment, Phillips stereo, ashtray and lighter plug, digital clock, hazard lights, rear window de-mister and fog light buttons, heater controls, air vents and coin box. If so desired, these can be painted over in any preferred colours, to maybe match body colour. Various style gear knobs are available as for any car and handbrake levers also.
The glovebox is not at all spacious and is of an odd design inside making it awkward to try and put any sorts of large or rigid objects in.
The driving instruments display is very much the standard sort as supplied with the other non-GTi sporty Peugeots. Lower models may have a clock within the display. The two main dials on the XS are the speedometer and rev counter as normal, though the four smaller dials are different in a XS to a GTi, as only one actually has a needle indicator, the others are just icons with small orange lights that appear if there's a problem. There are dials for both engine temperature and the fuel gauge, whereas the GTi has them for the others too. One of the
warning lights (heater coil for fuel tank) are for diesels only. The only real modification possible might be a change to white-faced dials or to the instrument display of a GTi, although be aware that the needle indicators are unlikely to function due to the different wiring arrangement of the XS (but the lights still would).
The steering wheel is similar to that of a GTi though has a Peugeot logo in the centre instead. This can easily be replaced by a sports wheel (inc. snap-off types) like those by Momo.
The door panels are plain grey and cover the entire door. They have a single red stripe running across near the top. The only modifications necessary for these may be for ICE upgrades or if it is desired to modify the interior to resemble that of a GTi or other car (they are easily removed, by unscrewing the handles etc., pulling off the window handle (unless electric is fitted) and pulling it off the studs around the edge as normal).



The seats are sports seats (see above picture), which are trimmed in Stratos tweed, with stripes going up the seat rather than across it as they do in the 1.6GTi. If preferred, it is possible to replace the XS interior trim and seats with those from a 1.9GTi (half leather seats) or even other Peugeot models if desired.
Also not to be forgotten, the carpet, which is plain grey, though can be swapped quite easily for the red carpet of a GTi. GTi carmats are also available which can compliment and protect the bright red GTi carpet.
 Also to note is the changes in the colour of the interior plastic in 205s. Early models had light grey plastic, followed by dark grey, then some had black. GTis had black plastic in the later cars which may be preferred as a nice contrast if red GTi carpet is fitted. The fan controls can also be replaced by similar controls including nice chrome ones if preferred (see below). These are available from Ecosse.


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ICE


OK, the 205 XS, as with all the sportier 205s (apart from the Cabriolets) comes fitted as standard with a 4-speaker stereo system and a digital Phillips radio cassette player. The front speakers are located behind square grilles in the door panels at the front (see pictures below).



The direction of sound from these tends to go into the side of the dashboard!


At the back, the speakers in the rear pillars are behind rectangular grilles (see above) which unlike the screw-in front ones, need to be prised out with a screwdriver or similar. Bear in mind also, that it helps to move the rear belts out the way when doing this. The direction of sound from these travels across the parcel shelf and doesn't deafen rear passengers too much.
The factory-fitted speakers are all 5 1/4" (13cm) in diameter and are usually dual cone, though two way coaxials may have been fitted. Removing one, it is likely to say either 205/305 or 205/309 on the red sticker on the back.
Custom fit speakers are readily available from companies like Sony and Pioneer from most good ICE shops. If you desire to make use of the factory fitted space and not cut away any of the interior, then these are your best option. The ones at the front are very easy to remove with a Phillips crosshead screwdriver and the wires at the back cut and new spade connectors fitted for new speakers (or for custom fit, just unplug them then plug on to the new speakers-very easy!). It's always a good idea to ensure positive and negative are correctly identified. Getting them the wrong way round won't damage the speaker, but they'll be out of phase and the stereo effect won't be so good especially with high power, as with using an amp. 13cm custom fit speakers are available as dual cone (cheapest), 2 way coaxial and 3 way coaxial (most expensive). Dual cone just involves a smaller cone acting as a cheap tweeter for the higher sounds. The standard speakers are black paper cone and an upgrade to a PMPP water resistant cone may make a difference. 2 ways are fairly common and are composed of a midrange or woofer, and tweeter. 3 ways are the best as they include a woofer cone, midrange in the centre, with a tweeter attached to one side. This creates a better range in sound, though the midrange and tweeter in the centre can obscure some of the bass. For this reason many people prefer component speakers. Check out the Sony or Pioneer websites for more speaker info and to see some of the custom-fit speakers on offer. The standard grilles should fit back over replacement speakers without hassle. Check that the plastic doesn't touch the speaker, otherwise vibration will result. If it does touch, try gently bending the grille plastic out a bit (maybe with the help of some foam pieces between the edge of the cone and the grille). If it breaks, new ones cost around £8 from a Peugeot dealer.

The best idea said to be used for the front of a 205 is a component set-up; midrange speakers in the factory-fitted positions and tweeters either on the ends of the dashboard or in the mirror covers as mentioned below.
The rear speakers are not so easy, they have a much more limited depth in their factory positions and replacements are few and far between. If these positions are to be kept, it's best keeping the standard speakers.
Tweeters can be quite easily fitted in the plastic piece where the wing mirror controls are (see below). This helps create better imaging in the car, though some might say the treble can be a bit too much.



Also, these sorts of mods are good if you intend to sell the car on, so you can refit the old system easily and replace the old panels quite cheaply.
The rear parcel shelf is amenable for fitting a pair of 6X9s or even subwoofers. Boot space is adequate for a bass box if desired. There is also space under the two front seats which may be ok for a small amp or 6 disk or other slim CD or MD changer. Only problem being it might get kicked when passengers get in the back. The panels at the back under the windows can also be removed, to put in woofer cones or possibly a very compact CD changer.
The slot for a head unit is of standard size, that suits most stereos on the market. It's in quite a low position though, which can prove awkward. With some expertise it is possible to move it to where the top vents are, though this isn't at all easy.


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SUSPENSION & BRAKES


The suspension of the XS is similar to the GTis, including Macpherson struts and anti-roll bars, though it has track control arms rather than wishbones. Any modifications available for GTis may also be suitable for an XS. Things such as competition shocks, lowering springs and performance bushes. Lowering shouldn't prove too difficult an operation but simply cutting the old springs isn't recommended. The shocks absorbers are fitted at an angle away from the body, which enables the pedals inside to be more spread out, rather than having the intruding wheelarches typical of most other cars. In lowering the car, the torsion bar must also be adjusted.
XS brakes are 9.7in diameter solid discs at the front and 7.1in diameter drums at the back. It may be possible to fit vented discs to the front as in the GTi models. This would require more than just changing the discs as the hubs on GTis are different too. I haven't heard of any anyone changing the rear drums to discs as in the 1.9GTi, for what it may be worth. Also to be noted on the point of brakes is that two types of brake are fitted, Bendix and Girling. It is definitely worth knowing what sort you have, for buying shoes and pads etc. It's quite easy to check, just remove the front wheels and look at the calipers. 'Lucas' will mean they are Girling. Bendix are possibly more common though. There are no known differences in performance between the two makes. Pads can be changed for such makes as EBC, with Greenstuff pads coming highly recommended for improved stopping power and up to 80% less brake dust (a real eyesore on alloys!).
Also to look out for is a sensor wire which rests along side the pad and lights a warning light on the dashboard when it comes into contact with the disc. This completes a circuit and indicates the pads need renewing. That light is a small orange light with a circle and two brackets either side. This wire often gets damaged by turning the steering wheel and this is quite normal. Often these systems get so knackered they fail to work, so shouldn't be relied upon.


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WINDOWS

The 205 XS windows have a brown tint as standard, which helps with security and to a small amount with sun deflection. This should be remembered when replacing any XS windows. This tinting can be increased and darkened by window tinting specialists if required. The rear windows are easily opened from the inside, as with most 205 models. Electric windows is an option on later XS models as is a sunroof. Remember that having a sunroof reduces headroom, so always consider that when purchasing cars if you're really tall, like me. The commonest 205 sunroof is the sliding variety, rather than with two sections which lift up. For extra security, anti-smash film is available, though isn't cheap.


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 SECURITY

The 205 XS as with all the 205s of the time, wasn't the most secure of 80s hatchbacks. The locks are good but shouldn't be relied upon at all, especially with a good stereo system or expensive mods. CAT 1 Immobilisers are fitted as easily as to any car and cost around £80 and will help stop someone running off with your car, though won't do anything to stop them taking what's inside. These may be required by some insurance companies and at the same note, if you have a Thatcham approved alarm or immobiliser fitted (with certificate) always let your insurance company know as it can give good discounts on premiums. Steering locks are also a good deterrent (including the Taser, which electrocutes thieves with 50,000 volts and is said to be legal in the UK!). If you really love your car, get a proper alarm/immobiliser system fitted. An alarm may range from a basic one that just has perimeter sensors (that trigger when a door is opened) or totally secure virtually every aspect of the car. For an alarm to react to a window breaking it'll need to have ultrasonics or glass-break sensors (or microwave sensors for soft-tops). Ultrasonics react to movement and are usually quite good at sensing if a window is open (or missing!), glass-break sensors react to the sound of glass breaking. Alarm systems will often include central locking control (if c/l is fitted already) and some even have total closure, for cars with electric windows and/or sunroof, which close any windows left open when arming the car. Another option available are shock sensors or tilt sensors. If these are fitted they must be correctly adjusted or else much aggravation will ensue and you'll fall out with your neighbours big time! Tilt sensors secure theft of wheels, and have a small device (with a ball bearing or liquid in I think) that triggers when the car is lifted from any angle (as if being jacked up). Bad cases may trigger if a car is parked on a slope! Shock sensors react to impact against the car, if someone pushes it, sits on it or hits it. If badly adjusted these can trigger in strong winds or if a football hits the car or something. Ultrasonics can also react to an insect inside the car if incorrectly adjusted, which can be just as annoying.

Immobilisers work by cutting off the fuel pump (if electronic) or ignition coil, or sometimes the starter motor, or even several circuits.

Further theft prevention (well the best method of finding your car again if it is nicked!) is with a Tracker. A small device hidden somewhere in the car that reports to a call centre when the car is stolen and the car can then be traced. These aren't that cheap either.


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OVERALL MOD ADVICE

The range of styles and modifications for any car is as varied as individual taste and is virtually limitless. I cannot cover every Peugeot mod ever done, but just provide a brief account of some of what is out there and provide some idea on how things can be done or where to go. I hope you find this information of some use, anything else that you think should be included here, please e-mail me. Many thanks for visiting this site and happy modding!


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