Peugeot 205. Manual - part 24

 

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Peugeot 205. Manual - part 24

 

 

Remove the upper body.
10 Drive out the operating arm pivot pin,
withdraw the arm and lift out the diaphragm.
11 Obtain a repair kit which will contain a
new diaphragm and the necessary gaskets.
12 If the valves are damaged, reassemble the
pump and obtain a new one complete.
13 If the valves are in good condition, locate
the diaphragm, push the operating arm into
position so that its forked end engages with
the groove in the end of the diaphragm rod,
with the coil springs in position.
14 Fit the pivot pin and stake around the
holes to secure both ends of the pin.
15 Fit the upper body so that the alignment
marks are opposite and then fit the screws
and tighten evenly.
16 Fit the filter screen and cover with gasket.

Refitting

17 Refitting to the cylinder head is a reversal
of removal, but fit a new gasket.

Electric fuel pump

18 Refer to the procedures contained in Part
B, Section 5.

6

Fuel gauge sender unit -
removal and refitting

3

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

Removal

Disconnect the battery negative lead. 
Raise the rear seat cushion.
Remove the circular plastic cover to expose
the sender unit (see illustrations)
Disconnect the electrical lead. 
Using a suitable tool, unscrew the sender
unit mounting plate to release it from the
securing tabs. 
Withdraw the sender unit, taking care not to
damage the float as it passes through the hole
in the tank. 

Refitting

Refitting is a reversal of removal, but use a
new sealing ring if there is any doubt about
the condition of the original one.

7

Fuel tank - removal and
refitting

3

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

Removal

Before the tank can be removed, it must be
drained of as much fuel as possible. To avoid
the dangers and complications of fuel
handling and storage, it is advisable to carry
out this operation with the tank almost empty.
Any fuel remaining can be drained as follows.
Disconnect the battery negative lead.
Using a hand pump or syphon inserted
through the filler neck, remove any remaining
fuel from the bottom of the tank.
Chock the front wheels then jack up the
rear of the car and support it on axle stands
(see “Jacking and vehicle support”).
Either remove the complete exhaust system
or, on later models, release the support band
on the silencer, and lower the system using a
jack under the tailpipe.
Release the handbrake cables from their
fuel tank and other guide sleeves - there is no
need to disconnect the cables.
Unbolt and remove the heat shield.
Disconnect the wiring from the fuel gauge
sender unit.

Unscrew the mounting and safety strap
bolts and nuts, then lower the tank - at the
same time disconnecting the filler, breather
and supply hoses.
10 If the tank is contaminated with sediment
or water, remove the fuel gauge sender unit as
described previously and swill the tank out
with clean fuel. The tank is moulded from a
synthetic material and if damaged, it should
be renewed. However, in certain cases it may
be possible to have small leaks or minor
damage repaired. Seek the advice of a dealer
or suitable specialist concerning tank repair.

Refitting

11 Refitting is a reversal of removal.

8

Unleaded petrol - general
information and usage

Note: The information given in this Chapter is
correct at the time of writing. If updated
information is thought to be required, check
with a Peugeot dealer. If travelling abroad,
consult one of the motoring organisations (or a
similar authority) for advice on the fuel
available.

The fuel recommended by Peugeot is given

in the Specifications Section of this Chapter.

Only the following models may be operated

on unleaded fuel, and where applicable, the
ignition timing must be retarded as shown
with reference to Chapter 5B:

Engine

Code

Retard
ignition by

XY7 from 
engine No 598051 150D

TU9

C1A

None

TU9/K

C1A

None

TU9A

C1A

None

TU1

H1A

None

TU1/K

H1A

None

TU3

K1A

TU3A

K1G

TU3A/K

K1G

TU3S

K2A

TU3S/K

K2A

None

TU3.2/K

K2D

None

XU51C/K

B1F

None

Fuel system - carburettor engines  4A•5

4A

5.7a  Removing the fuel pump cover . . .

5.7b  . . . and filter

6.3a  Remove the circular plastic 

covers . . .

6.3b  . . . for access to the sender unit and

fuel supply and return pipes

9

Carburettor - removal and
refitting

2

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

Removal

Remove the air cleaner assembly, as
described in Section 2.
Unscrew the bolts or nuts and remove the
air inlet duct from the top of the carburettor(s).
Disconnect the throttle cable or ball-jointed
throttle control rod from the carburettor(s)
with reference to Section 3 (see illustration).
Disconnect the choke cable with reference
to Section 4.
Where fitted, remove the short hose which
runs between the oil filler cap and the
carburettor.
Disconnect the wiring connector from the
idle cut-off solenoid as applicable.
Slacken the retaining clip, and disconnect
the fuel feed hose from the carburettor. Place
wads of rag around the union to catch any
spilled fuel, and plug the hose as soon as it is
disconnected, to minimise fuel loss.
Make a note of the correct fitted positions
of all the relevant vacuum pipes and breather
hoses, to ensure that they are correctly
positioned on refitting, then release the
retaining clips (where fitted) and disconnect
them from the carburettor.
Disconnect and plug the carburettor
coolant hose(s). Plug the hoses immediately
to prevent coolant loss.
10 Unscrew the nuts and washers securing
the carburettor(s) to the inlet manifold.
Remove the carburettor assembly from the
car. Remove the insulating spacer and/or
gasket(s). Discard the gasket(s); new ones
must be used on refitting. Plug the inlet
manifold port with a wad of clean cloth, to
prevent the possible entry of foreign matter.

Refitting

11 Refitting is the reverse of the removal
procedure, noting the following points:

a) Ensure that the carburettor and inlet

manifold sealing faces are clean and flat.
Fit a new gasket, and securely tighten the
carburettor retaining nuts.

b) Use the notes made on dismantling to

ensure that all hoses are refitted to their
original positions and, where necessary,
are securely held by their retaining clips.

c) Where the original crimped-type Peugeot

hose clips were fitted, discard them; use
standard worm-drive hose clips when
refitting.

d) Refit and adjust the throttle cable and

choke cable (where applicable) as
described in Sections 3 and 4.

e) Refit the air cleaner assembly as

described in Section 2.

f) Top-up the cooling system as described

in “Weekly checks”.

g) On completion, check and, if necessary,

adjust the idle speed and mixture settings
as described in Chapter 1.

10 Carburettor - fault diagnosis,

overhaul and adjustments

3

Fault diagnosis

If a carburettor fault is suspected, always
check first that the ignition timing is correctly
set, that the spark plugs are in good condition
and correctly gapped, that the throttle and
choke cables are correctly adjusted, and that
the air cleaner filter element is clean; refer to
the relevant Sections of Chapter 1, Chapter 5
or this Chapter. If the engine is running very
roughly, first check the valve clearances as
described in Chapter 1, then check the
compression pressures as described in
Chapter 2.
If careful checking of all the above
produces no improvement, the carburettor
must be removed for cleaning and overhaul.
Prior to overhaul, check the availability of
component parts before starting work; note
that most sealing washers, screws and
gaskets are available in kits, as are some of
the major sub-assemblies. In most cases, it
will be sufficient to dismantle the carburettor
and to clean the jets and passages.

Overhaul

Note: Refer to the warning note in Section 1
before proceeding. The following procedures
are typical for the various carburettors
encountered on 205 models. Refer to the
accompanying illustrations for details of
specific carburettor types and component
locations.
Remove the carburettor from the car as
described in Section 9.
Unscrew the idle cut-off solenoid (where
fitted) from the carburettor body, and remove
it along with its plunger and spring. To test the
solenoid, connect a 12-volt battery to it
(positive terminal to the solenoid terminal,
negative terminal to the solenoid body), and
check that the plunger is retracted fully into
the body. Disconnect the battery, and check
that the plunger is pushed out by spring

pressure. If the valve does not perform as
expected, and cleaning does not improve the
situation, the solenoid valve must be renewed.
Remove the screws and lift off the
carburettor upper body.
Tap out the float pivot pin and remove the
float assembly, needle valve, and float
chamber gasket. Check that the needle valve
anti-vibration ball is free in the valve end, then
examine the needle valve tip and seat for wear
or damage. Examine the float assembly and
pivot pin for signs of wear and damage. The
float assembly must be renewed if it appears
to be leaking - shake the float to detect the
presence of fuel inside.
Unscrew the fuel inlet union and inspect the
fuel filter. Clean the filter housing of debris
and dirt, and renew the filter if it is blocked.
Undo the screws and remove the various
diaphragm covers and diaphragms. Remove
the diaphragm(s) and spring(s), noting which
way around all the parts are fitted. Examine
the diaphragm(s) for signs of damage and
deterioration, and renew if necessary.
10 Unscrew the jets from the upper body and
main body making notes as to their location
and arrangement.
11 Remove the idle mixture adjustment
screw tamperproof cap if fitted. Screw the
screw in until it seats lightly, counting the
exact number of turns required to do this,
then unscrew it. On refitting, screw the screw
in until it seats lightly, then back the screw off
by the number of turns noted on removal, to
return the screw to its original position.
12 Clean the jets, carburettor body
assemblies, float chamber and internal
drillings. An air line may be used to clear the
internal passages once the carburettor is fully
dismantled.
Caution: If high pressure air is directed into
drillings and passages where a diaphragm
is fitted, the diaphragm is likely to be
damaged.

13 Use a straight edge to check all
carburettor body assembly mating surfaces
for distortion.
14 On reassembly renew any worn
components and fit a complete set of new
gaskets and seals. A jet kit and a gasket and
seal kit are available from your Peugeot dealer.
15 Reassembly is a reversal of the
dismantling procedure. Ensure that all jets are
securely locked in position, but take great care
not to overtighten them. Ensure that all mating
surfaces are clean and dry, and that all body
sections are correctly assembled with their
fuel and air passages correctly aligned. Prior
to refitting the carburettor to the car, carry out
all the applicable adjustments, according to
carburettor type as described below.

4A•6 Fuel system - carburettor engines

9.3  Ball-jointed throttle control rod

(arrowed)

Aerosol cans of carburettor
cleaner are widely available
and can prove very useful in
helping to clear internal

passages of stubborn obstructions.

Solex 32 and 34 PBISA
adjustments

Idle speed and mixture

16 Refer to Chapter 1.

Fast idle setting

17 To adjust this accurately it will be
necessary to measure the angular movement
of the throttle valve. The use of a piece of card
with the angle drawn on it will provide the
necessary setting. 
18 Fully close the choke valve then check that
the throttle valve has opened by 20° 40’ ± 30’. 
19 If necessary turn the fast idle adjustment
screw as required.

Solex 35 PBISA 8 adjustments

Idle speed and mixture

20 Refer to Chapter 1.

Initial throttle opening

21 To adjust the initial throttle valve opening,
fully unscrew the adjustment screw then,
using a piece of card as described in
paragraph 17, turn the screw until the valve is
opened by 7° 45’.

Fast idle setting

22 The fast idle setting is only made on the
left-hand carburettor with the reference
number 346. First close the choke valve then
check that the throttle valve has opened by
15º. If not, turn the adjustment screw as
required.

Choke opening after starting

23 To adjust the choke opening after starting,
first close the choke then pull the vacuum
opener rod and, using a suitable twist drill,
check that the gap between the bottom edge
of the throttle valve and the carburettor wall is
2.5 ± 0.3 mm. If not, turn the nut on the end of
the vacuum opener as required.

Solex 32 PBISA 16 adjustments

Idle speed and mixture

24 Refer to Chapter 1.

Fast idle setting

25 With the carburettor removed, invert it
then pull the choke lever fully on.
26 Using a twist drill, check that the gap
between the throttle valve and barrel is 0.8
mm. If not, turn the adjustment screw.

Choke opening after starting

27 Close the choke flap, then fully operate
the pneumatic opener either manually or by
vacuum.
28 Using a twist drill, check that the gap
between the choke flap and barrel is 3.0 mm.
If not, turn the adjusting screw in the end of
the opener.

Throttle damper

29 Certain models may have a throttle
damper assembly, fitted to the carburettor on
a modified throttle cable support bracket, to
prevent engine stalling during gearchanges.

30 The assembly should not require any
adjustment, but if the throttle is held open by
the damper excessively during gearchanges,
adjustment can be made by loosening the
locknut, and altering the position of the
damper in the bracket as necessary. Tighten
the locknut on completion of adjustment.

Solex 32-34 Z2 adjustments

Idle speed and mixture

31 Refer to Chapter 1.

Additional adjustments

32 At the time of writing, not further
information was available relating to any
further adjustment of these carburettors.

Weber 35 IBSH adjustments

Idle speed and mixture

33 Refer to Chapter 1.

Float level

34 Hold the cover vertical with the float arm
touching, but not depressing, the
spring-tensioned ball on the needle valve.
35 Using vernier calipers, measure the
dimension between the float and the fitted
gasket (see illustration). If it is not 9.0 mm,
bend the tongue on the arm as necessary.

Throttle normal idling position

36 This adjustment is made after overhauling
the carburettors, and is necessary to enable
the engine to be started and to prevent the
throttle valve sticking in the closed position.
The idle speed screw must be adjusted to set
the throttle valve 6° open, using a piece of
card as described in paragraph 17.

Fast idle setting

37 With the choke fully closed, the throttle
valve should be open by 14°. Adjust the fast
idle screw on the throttle lever to achieve the
desired setting (see illustration).

Fuel system - carburettor engines  4A•7

4A

10.35  Checking float level dimension “X”

on the Weber 35 IBSH carburettor

1

Gasket

a

Adjustment tongue

10.37  Fast idle adjustment on the

Weber 35 IBSH carburettor

1  Fast idle screw

4A•8 Fuel system - carburettor engines

10.39  Checking the choke opening setting on the 

Weber 35 IBSH carburettor

2 Adjustment screw on vacuum capsule

10.42  Float level setting on the Weber 36 TLC carburettor

1 Gasket

x = 28.0 mm

10.44  Choke opening after starting adjustment on the 

Weber 36 TLC carburettor

1 Locknut
2 Hole
3 Roller

4 Adjusting screw
5 Can
6 Peg on special tool

10.45  Choke opening after starting adjusting screw (1) on the

Weber 36 TLC carburettor

10.46  Choke opening after starting adjustment on the 

Weber 36 TLC carburettor

1 Roller

2 Lever

 

 

 

 

 

 

 

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