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Peugeot 205. Manual - part 23

Chapter 4 Part A:
Fuel system - carburettor engines

General

System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear-mounted fuel tank, mechanical or electric fuel pump, single or
twin carburettor

Carburettor

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

Fixed jet, downdraught

Application:

XV8 (954 cc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Solex 32 PBISA

XW7 (1124 cc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Solex 32 PBISA

XY7 (1360 cc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Solex 34 PBISA

XY8 (1360 cc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Solex 35 PBISA 8 or Weber 35 IBSH

XU51C (1580 cc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weber 36 TLC

TU1 (1124 cc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Solex 32 PBISA 16, Weber 32 IBS 15 or Weber 32 IBSH 17

TU3 (1360 cc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weber 34 TLP3

TU3A (1360 cc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Solex 34 PBISA 17

TU3A/K (1360 cc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Solex 34 PBISA 17

TU3S (1360 cc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Solex 32-34 Z2

TU3S/K (1360 cc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Solex 32-34 Z2

TU9 (954 cc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Solex 32 PBISA 16 or Weber 32 IBSH 16

Carburettor data

Calibrations and settings:

XV8

XW7

XY7

Venturi diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 mm

26 mm

Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

120 ± 5

125 ± 5

130 ± 25

Air correction jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

155 ± 20

175 ± 20

160 ± 20

Idling fuel jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 ± 5

42 ± 5

45 ± 5

Acceleration pump injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 ± 5

32 ± 5

40 ± 5

Enriched calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55 ± 20

60 ± 20

75 ± 20

Needle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6 mm

Initial throttle opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20°40’ ± 30’

Idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

650 ± 50 rpm

CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 ± 0.5

Air cleaner assembly - removal and refitting  . . . . . . . . . . . . . . . . . . . 2
Air cleaner element renewal  . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Carburettor - fault diagnosis, overhaul and adjustments  . . . . . . . . . 10
Carburettor - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Choke cable - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel gauge sender unit - removal and refitting  . . . . . . . . . . . . . . . . . 6
Fuel pump - removal, overhaul and refitting  . . . . . . . . . . . . . . . . . . . 5
Fuel tank - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

General fuel system checks  . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
General information and precautions  . . . . . . . . . . . . . . . . . . . . . . . . 1
Idle speed and mixture adjustment  . . . . . . . . . . . . . . . . .See Chapter 1
Inlet manifold - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . 11
Throttle cable - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . 3
Underbody and fuel/brake line check  . . . . . . . . . . . . . . .See Chapter 1
Underbonnet check for fluid leaks and hose condition . .See Chapter 1
Unleaded petrol - general information and usage  . . . . . . . . . . . . . . . 8

4A•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

Carburettor data (continued)

Calibrations and settings:

XY8

XU51C

Solex

Weber

Venturi diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 mm

26 mm

28 mm

Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

145 ± 10

130 ± 5

137/42

Air correction jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

175 ± 10

165 ± 15

150 ± 10

Idling fuel jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 ± 5

45 ± 5

48 ± 1

Emulsion tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F104

F80

Acceleration pump injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 ± 10

45 ± 5

Needle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 mm*

Initial throttle opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15°

Normal idling position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7°45’

Choke opening after starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5 mm ± 0.3

3.25 mm

Float level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.0 mm

28.0 mm

Idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

950 to 1000 rpm**

975 ± 25 rpm

750 rpm

CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.0 ± 0.5

1.5 ± 0.5

*1.2 mm from serial number 5043526
**850 to 900 rpm from serial number 5043526

TU9

Weber

Solex

Venturi diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

122

127.5 ± 2.5

Air correction jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

135

155 ± 10

Emulsion tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F112

Enrichener drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Idling fuel jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 ± 4

Idling air jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

150

135 ± 10

Accelerator pump injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 ± 5

Fuel inlet needle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5

1.6

Float setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.0 mm

Idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

700 rpm

CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5

1.5 ± 0.5

TU1

Weber 32IBS15

Weber 32IBSH17

Solex

Venturi diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

140 ± 5

132

127.5 ± 2.5

Air correction jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

180 ± 15

165

175 ± 10

Emulsion tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F102

F100 EM

Enrichener drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 ± 10

35 ± 5

Idling fuel jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 ± 5

46 ± 4

Idling air jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

170

165 ± 10

Accelerator pump injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 ± 10

40 ± 10

Fuel inlet needle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5

1.6

Float setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.0 mm

Idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

700 rpm

CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.0

1.5 ± 0.5

TU3

TU3A and

TU3S and

TU3A/K

TU3S/K

Venturi diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24/27

Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

132 (127)*

132

117/130

Air correction jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

145

155

145/170 (155/175)*

Emulsion tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F80 (F115)*

27/AZ

Enrichener drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Idling fuel jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 (45)*

44 ± 2

44/80 (44/100)*

Idling air jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

140(130)*

140

190/150

Accelerator pump injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35/35

Fuel inlet needle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5

1.6

1.8

Float setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28.0 mm

Idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

700 rpm

750 rpm

CO% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 ± 0.5

1.0

1.5 ± 0.5

*1988 models onward

Recommended fuel

Minimum octane rating (see text Section 8) . . . . . . . . . . . . . . . . . . . . . .

97 RON leaded or 95 RON unleaded

Torque wrench settings

lbf ft

Carburettor nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4A•2 Fuel system - carburettor engines

General information and
precautions

General information

The fuel system consists of a fuel tank

mounted under the rear of the car, a
mechanical fuel pump, and a single or twin
downdraught carburettor.

On manual transmission and early automatic

transmission models, the fuel pump is
operated by an eccentric on the camshaft, and
is mounted on the rear of the cylinder head. On
automatic transmission models manufactured
from November 1986, an electric fuel pump
submerged in the fuel tank is fitted instead of
the previous mechanical type. The two relays
which supply the pump are located on the side
of the heater. One relay incorporates a safety
feature, in that its primary windings are
short-circuited to earth via the engine oil
pressure switch. When the engine is stationary,
this relay will not operate the fuel pump, but as
soon as the engine is running it will supply
current to the pump. The other relay operates
in conjunction with the starter motor to operate
the fuel pump for starting.

A number of different Solex and Weber

carburettors may be encountered and their
type and engine applications are shown in the
Specifications. All carburettors are of the fixed
jet downdraught type with either manual or
automatic choke arrangements. XY8 engine
models utilise a twin carburettor configuration.

The air cleaner contains a disposable paper

filter element, and on certain models
incorporates a flap valve air temperature
control system; this allows cold air from the
outside of the car, and warm air from the
exhaust manifold, to enter the air cleaner in
the correct proportions.

Precautions

Warning: Petrol is extremely
flammable - great care must be
taken when working on any part
of the fuel system. Do not smoke

or allow any naked flames or uncovered
light bulbs near the work area. Note that
gas powered domestic appliances with pilot
flames, such as heaters, boilers and tumble
dryers, also present a fire hazard - bear this
in mind if you are working in an area where
such appliances are present. Always keep a
suitable fire extinguisher close to the work
area and familiarise yourself with its
operation before starting work. Wear eye
protection when working on fuel systems
and wash off any fuel spilt on bare skin
immediately with soap and water. Note that
fuel vapour is just as dangerous as liquid
fuel; a vessel that has just been emptied of
liquid fuel will still contain vapour and can
be potentially explosive. Petrol is a highly
dangerous and volatile liquid, and the
precautions necessary when handling it
cannot be overstressed.

Many of the operations described in this

Chapter involve the disconnection of fuel
lines, which may cause an amount of fuel

spillage. Before commencing work, refer to
the above Warning and the information in
“Safety first” at the beginning of this
manual.

When working with fuel system

components, pay particular attention to
cleanliness - dirt entering the fuel system
may cause blockages which will lead to
poor running.

Air cleaner assembly -
removal and refitting

Removal

All engines except TU series

1 Disconnect the inlet and warm air hoses.
2 Release the rubber straps from the
mounting brackets (see illustration).
3 Lift the air cleaner from the brackets then
disconnect the outlet hose and where fitted,
the crankcase ventilation hose.
4 If necessary, unbolt the mounting brackets
- noting the location of the diagnostic socket
and cable retaining brackets (see
illustrations).

TU series engines

5 Loosen the screw and release the air
cleaner ducting from the carburettor (see
illustration).
6 Disconnect the crankcase ventilation hose
(see illustrations) from the valve cover and
inlet manifold.

Fuel system - carburettor engines 4A•3

2.6b . . . and inlet manifold

2.6a Disconnect the crankcase ventilation

hose from the valve cover . . .

2.5 On TU series engines, slacken the air

cleaner and release the ducting from the

carburettor

2.4b . . . and cable retaining bracket

2.4a Air cleaner mounting bracket bolt

(arrowed) . . .

2.2 On all engines except TU series,

release the air cleaner rubber straps from

the mounting brackets

7 Release the spring clips, and lift the
element and ducting from the air cleaner body
(see illustrations).
8 Disconnect the fuel pump inlet hose, and
release it from the clip on the ducting.
9 Disconnect the hose from the vacuum
motor (see illustration).
10 Disconnect the inlet and warm air hoses.
11 Remove the special clip, then lift the air
cleaner and ducting from the mounting on the
starter motor.

Refitting

All engines

12 Refitting is a reversal of removal.

Throttle cable - removal and
refitting

Removal

1 The throttle cable is connected to a
spring-loaded reel which pivots on the face of
the cylinder head. On certain models, the reel
then operates the throttle lever on the
carburettor through a plastic balljointed
control rod.
2 Extract the spring clip from the adjustment
ferrule at the cable bracket on the cylinder
head. Release the cable end fitting from the
linkage.
3 Working inside the car, disconnect the
cable end fitting from the top of the

accelerator pedal arm.
4 Release the cable from the engine bracket.
5 Withdraw the throttle cable through the
bulkhead grommet.

Refitting

6 Refitting is a reversal of removal, but adjust
the cable at the ferrule to remove all but the
slightest amount of play. Check that full
throttle can be obtained with the accelerator
pedal fully depressed.

Choke cable - removal and
refitting

Removal

1 Remove the carburettor inlet cowl.
2 Unscrew the pinch bolts and disconnect
the inner and outer cables from the lever and
bracket (see illustration).
3 Release the cable from the clips in the
engine compartment.
4 Working inside the car, disconnect the
warning lamp wiring and detach the cable
from the support bracket.

Refitting

5 Refitting is a reversal of removal, but adjust
the cable at the carburettor end so that, when
the control knob is pushed fully in, the choke
valve plate is fully open.

Fuel pump - removal,
overhaul and refitting

Note: Observe the precautions in Section 1
before working on any component in the fuel
system.

Mechanical fuel pump

Removal

1 Disconnect the battery negative lead.
2 Where necessary for improved access,
remove the air cleaner assembly as described
in Section 2.
3 Disconnect the fuel hoses from the pump.
Plug the inlet hose.
4 Unscrew the pump mounting bolts and lift
the pump away (see illustrations).
5 Remove the gasket.
6 Once the pump is removed on XV, XW and
XY series engines, the pushrod may be
withdrawn.
7 If the pump is to be dismantled, remove the
cover, gasket and filter screen (see
illustrations). Note that dismantling can only
be undertaken on the pump fitted to XV, XW
and XY series engines; The TU series engine
pump is a sealed assembly and no repair or
overhaul is possible.

Overhaul

8 Scribe a mark across the edges of the
upper and lower body flanges and extract the
flange screws.

4A•4 Fuel system - carburettor engines

2.7a Release the spring clips . . .

2.7b . . . and remove the air cleaner

ducting and element from the body

2.9 Disconnect the hose from the vacuum

motor

4.2 Disconnect the choke inner and outer

cables from the lever and bracket - twin

carburettor installation shown

5.4a Removing the fuel pump on TU series

engines . . .

5.4b . . . and XV, XW and XY series

engines

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