Peugeot 205. Manual - part 25

Choke opening setting

38 This adjustment can be made with the
carburettor removed using a vacuum pump,
or with the carburettor fitted and the engine
running.
39 Turn the choke lever so that the choke is
fully closed (see illustration).
40 With the engine running or vacuum
applied, check that the gap between the lower
edge of the choke valve and the barrel is 3.25
mm. Use a twist drill to make the check, and if
adjustment is necessary, turn the screw
located in the end of the vacuum capsule.

Weber 36 TLC adjustments

Idle speed and mixture

41 Refer to Chapter 1.

Float level

42 To check the float level, hold the cover
vertically with the gasket in place. Check that
the dimension is as specified (see
illustration), and if necessary bend the
tongue on the float arm to correct it.

Choke opening after starting

43 To adjust the cold start device choke
opening after starting, Peugeot tool No 0.145G
is essential. The carburettor must be fitted and
the engine must be at normal operating
temperature and idling at the specified idle
speed (the cooling fan should have cut in and
out at least twice). The air cleaner hose and
the cold start device cover must be removed,
and the transmission selector lever should be
in the Park (P) position.

44 Fit the tool, then slacken the locknut and
turn the adjusting screw to bring the end of
the cam just into contact with the peg on the
tool (see illustration).
45 Using a 9.5 mm twist drill, check that the
choke flap has opened by 9.5 mm - if not,
adjust by means of the adjusting screw (see
illustration).
46 Disconnect and plug the diaphragm
vacuum hose, and using a 5.5 mm twist drill,

check that the choke flap has opened by 5.5
mm if not, loosen the clamp screw then hold
the roller against the top of the cam, and
adjust the lever until the drill will just pass (see
illustration). Tighten the screw and reconnect
the hose on completion.

Positive throttle opening

47 With the choke opening after starting
adjusted as described previously, press the
roller to open the choke flap and check that
the engine speed is 2000 rpm with the cooling
fan stopped. If necessary, adjust the screw to
obtain the specified speed (see illustration).
48 To adjust the choke cam, Peugeot tool No
0.145G must again be used. Fit the tool,
loosen the locknut, and adjust the screw until
the cam contacts peg (see illustration).
Tighten the locknut on completion.
49 With the adjustments completed, stop the
engine and refit the cold start device cover
and the air cleaner hose.

Weber 32 IBS 15, 32 IBSH 16/17
and 34 TLP 3 adjustments

Idle speed and mixture

50 Refer to Chapter 1.

Fast idle setting

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

Fuel system - carburettor engines  4A•9

4A

10.47 Positive throttle opening adjustment on the 

Weber 36 TLC carburettor

1 Roller

2 Adjusting screw

10.48  Choke cam adjustment on the Weber 36 TLC carburettor

1 Hole
2 Roller
3 Adjusting screw

4 Cam
5 Peg on special tool
6 Locknut

10.52  Fast idle adjustment on 

Weber IBS, IBSH and TLP carburettors

1

Choke lever fully on

2

Adjustment screw
a = 0.8 mm

Throttle damper

53 Refer to the procedures contained in
paragraphs 29 and 30 

Additional adjustments

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

11 Inlet manifold - removal and

refitting

3

Removal

1 Disconnect the battery negative lead.
2 Drain the cooling system as described in
Chapter 1.

3 Remove the air cleaner assembly and
carburettor(s) as described in Sections 2 and 9.
4 Where applicable, disconnect the brake
servo vacuum hose from the manifold (see
illustration).
5 Disconnect the coolant hoses from the
manifold together with any cable clips and
support brackets.
6 Unbolt the manifold, releasing any
additional attachments as necessary and
remove it from the cylinder head (see
illustration). Where fitted, recover the gasket
or seals.

Refitting

7 Refitting is a reversal of removal, bearing in
mind the following points:

a) Ensure that the manifold and cylinder

head mating faces are perfectly clean and

use a new gasket or seals on models so
equipped. On TU engines apply a thin
coating of suitable sealing compound to
the manifold mating face before fitting -
no gasket is used on these engines.

b) Ensure that all hoses are reconnected to

their original positions and are securely
held by their retaining clips.

c) Refit the carburettor(s) and air cleaner

assembly as described in Sections 9
and 2.

d) On completion, refill the cooling system

as described in Chapter 1.

4A•10 Fuel system - carburettor engines

11.4  Disconnecting the brake servo vacuum hose at the inlet

manifold - TU series engine shown

11.6  Unscrewing the inlet manifold retaining nuts - 

TU series engine shown

4B

Chapter 4  Part B:
Fuel system - single-point fuel injection engines

General

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

Rear-mounted fuel tank, electric fuel pump, single-point fuel injection
system

System application:

TU1M/Z, TU3M/Z and TU3FM/L engines.  . . . . . . . . . . . . . . . . . . . . .

Bosch Mono-Jetronic A2.2

XU5M2/Z engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MMFD Mono-point G5

TU1M/L, XU5M3/Z and XU5M3/L engines  . . . . . . . . . . . . . . . . . . . . .

MMFD Mono-point G6

Fuel system data

Idling speed*  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

850 ± 50 rpm

Idle mixture CO content*  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Less than 1.0 %

*Not adjustable, controlled by ECU - data given for reference purposes only

Recommended fuel

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

95 RON unleaded. Leaded fuel must not be used

Air cleaner assembly - removal and refitting  . . . . . . . . . . . . . . . . . . . 2
Air cleaner element renewal  . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Fuel filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Fuel gauge sender unit - removal and refitting  . . . . . . . . . . . . . . . . . 6
Fuel injection system - testing and adjustment  . . . . . . . . . . . . . . . . . 10
Fuel injection systems - general information  . . . . . . . . . . . . . . . . . . . 9
Fuel pump - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel system - depressurisation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel tank - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
General fuel system checks  . . . . . . . . . . . . . . . . . . . . . .See Chapter 1

General information and precautions  . . . . . . . . . . . . . . . . . . . . . . . . 1
Inlet manifold - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . 13
MMFD Mono-point G5 and G6 system components - removal   . . . .

and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Mono-Jetronic A2.2 system components - removal and refitting  . . . 11
Throttle cable - removal, refitting and adjustment . . . . . . . . . . . . . . . 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

4B•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

1

General information and
precautions

General information

The fuel system consists of a fuel tank

(which is mounted under the rear of the car,
with an electric fuel pump immersed in it), a
fuel filter, fuel feed and return lines, and the
throttle body assembly (which incorporates
the single fuel injector and the fuel pressure
regulator). In addition, there is an Electronic
Control Unit (ECU) and various sensors,
electrical components and related wiring. The
air cleaner contains a disposable paper filter
element, and incorporates a flap valve air
temperature control system. This allows cold
air from the outside of the car and warm air
from around the exhaust manifold to enter the
air cleaner in the correct proportions.

Refer to Section 9 for further information on

the operation of each fuel injection system.

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.

Note: Residual pressure will remain in the

fuel lines long after the vehicle was last used.
When disconnecting any fuel line, first
depressurise the fuel system as described in
Section 4.

2

Air cleaner assembly -
removal and refitting

1

Refer to the procedures in Chapter 4A,

Section 2, substituting “throttle body” for all
references to the carburettor.

3

Throttle cable - removal,
refitting and adjustment

2

Removal and refitting

1 Refer to Chapter 4A, Section 3 substituting
“throttle body” for all references to the
carburettor. Adjust the cable as described
below.

Adjustment

2 Remove the spring clip from the adjustment
ferrule then, ensuring that the throttle cam is
fully against its stop, gently pull the cable out
of its grommet until all free play is removed
from the inner cable.
3 With the cable held in this position, ensure
that the flat washer is pressed securely
against the grommet, then fit the spring clip to
the third ferrule groove visible in front of the
rubber grommet and washer (see
illustration). This will leave a fair amount of
freeplay in the inner cable which is necessary
to ensure correct operation of the idle speed
control motor.
4 Have an assistant depress the accelerator
pedal and check that the throttle cam opens
fully and returns smoothly to its stop.

4

Fuel system -
depressurisation

1

Note: Refer to the warning note in Section 1
before proceeding.

Warning: The following
procedure will merely relieve the
pressure in the fuel system -
remember that fuel will still be

present in the system components, and
take precautions accordingly before
disconnecting any of them.
1 The fuel system referred to in this Section is
defined as the tank-mounted fuel pump, the
fuel filter, the fuel injector and the pressure
regulator in the injector housing, and the
metal pipes and flexible hoses of the fuel lines
between these components. All these contain
fuel which will be under pressure while the
engine is running, and/or while the ignition is
switched on. The pressure will remain for
some time after the ignition has been
switched off, and it must be relieved in a
controlled fashion when any of these
components are disturbed for servicing work.
2 Disconnect the battery negative lead.

3 If possible, place a suitable container
beneath the connection or union to be
disconnected, and have a large rag ready to
soak up any escaping fuel not being caught
by the container.
4 Slowly loosen the connection or union nut to
avoid a sudden release of pressure, and
position the rag around the connection, to catch
any fuel spray which may be expelled. Once the
pressure is released, disconnect the fuel line.
Plug the pipe ends, to minimise fuel loss and
prevent the entry of dirt into the fuel system.

5

Fuel pump - removal and
refitting

3

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

Removal

1 Disconnect the battery negative lead.
2 Raise the rear seat cushion.
3 Prise up the right-hand plastic cover from
the floor then disconnect the wiring, and the
fuel supply and return pipes, noting their
location (see illustration).
4 Unscrew the retaining screws and lift the
fuel pump housing from the fuel tank. Note
that in some cases, the hole in the floor may
not be aligned with the pump, in which case
the fuel tank may need to be lowered for
access (refer to Section 7 for details).
5 Release the filter from the bottom of the
housing, then the collar (see illustration).

6 Disconnect the wiring and release the fuel
pump from the upper collar.

Refitting

7 Refitting is a reversal of removal, but fit new
collars and make sure that the wiring
terminals are positioned away from the pump
terminals. Always fit a new gasket between
the pump housing and fuel tank.

6

Fuel gauge sender unit -
removal and refitting

3

Refer to Part A, Section 6.

7

Fuel tank - removal and
refitting

3

Refer to Part A, Section 7, noting that it will

be necessary to depressurise the fuel system
as the feed and return hoses are
disconnected from the fuel pump (see Section
5). It will also be necessary to disconnect the
wiring connector from the fuel pump before
lowering the tank out of position.

4B•2 Fuel system - single-point fuel injection engines

3.3  Adjust the throttle cable as described

in text

5.3  Fuel pump locations and connections

5.5  Fuel pump components

1

Bleed tube

2

Bracket

3

Collar

4

Collar

5

Fuel pump

6

Filter