Peugeot 205. Manual - part 27

Inlet air temperature sensor

22 The sensor is screwed into the top of the
inlet manifold.
23 Disconnect the battery negative lead.
24 Release the securing clip, and disconnect
the wiring plug from the sensor.
25 Unscrew the sensor and withdraw it.
26 Refitting is a reversal of removal.

Throttle body

Note: Refer to the warning note in Section 1
before proceeding.
27 Disconnect the battery negative lead.
28 Remove the air inlet trunking from the top
of the throttle body.
29 Disconnect the throttle cable (see Sec-
tion 3).
30 Release the securing clips, then
disconnect the wiring plugs from the fuel
injector (remove the rubber throttle
body/trunking seals to release the wiring),
throttle switch, and the idle speed control
motor (MMFD G6 system only).
31 Disconnect the fuel hoses from the unions
on the throttle body, labelling the hoses to
ensure correct refitting. Plug the open ends of
the hoses, to prevent dirt ingress and further
loss of fuel.
32 Disconnect the vacuum pipes and hoses
from the throttle body unions. Label the hoses
so that they can be correctly reconnected.
33 Unscrew the studs securing the throttle
body to the inlet manifold, and withdraw the
assembly. Recover and discard the gasket.
34 If desired, the two halves of the throttle

body (upper and lower) can be separated by
removing the securing screws. Note that in
this case, a new gasket must be used on
reassembly.
35 Refitting is a reversal of removal, bearing
in mind the following points.

a) Renew all disturbed gaskets and seals,

and use suitable thread locking
compound where necessary.

b) Check the throttle cable operation and

adjustment (Section 3).

c) Ensure that all vacuum hoses and pipes

are correctly reconnected as noted before
removal.

d) When reconnecting the manifold absolute

pressure sensor hose, ensure that it is
routed so that it falls steadily from the
sensor to the throttle body. This is
necessary to prevent any fuel droplets
from entering the sensor (no fuel vapour
trap is fitted), allowing them to drain into
the throttle body instead.

e) Ensure that the fuel hoses are correctly

reconnected, as noted before removal.

f) On completion, switch on the ignition,

and check carefully for signs of fuel
leakage from all disturbed unions. If any
signs of leakage are detected the problem
must be rectified before the engine is
started.

Manifold absolute pressure
sensor

36 Disconnect the battery negative lead.
37 Release the securing clip, and disconnect

the wiring plug from the idle speed control
motor (MMFD G6 systems only).
38 Slacken the clamp (if fitted), and
disconnect the vacuum hose from the sensor.
39 Remove the securing screws and
withdraw the sensor, complete with bracket,
from the body front panel (or wing panel, as
applicable).
40 Refitting is a reversal of removal, but note
the following. When reconnecting the vacuum
hose to the sensor ensure that the hose is
routed so that it falls steadily from the sensor
to the throttle body. This is necessary to
prevent any fuel droplets from entering the
sensor (no fuel vapour trap is fitted), allowing
them to drain into the throttle body instead.

Coolant temperature sensor

Refer to Chapter 3, Section 7.

Electronic control unit (ECU)

Refer to Section 11, paragraphs 29 to 34.

Fuel injection system fuses and
relays

Refer to Section 11, paragraphs 35 to 37.

13 Inlet manifold - removal and

refitting

The procedure is essentially as described in

Part A, Section 11, but remove the throttle
body as described in Section 11 or 12 of this
Part and ignore any references to carburettor.

Fuel system - single-point fuel injection engines 4B•7

4B•8

Notes

Chapter 4 Part C:
Fuel system - multi-point fuel injection engines

General

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

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

System application:

XU5J, XU5JA, XU5JA/K, XU51C/K, XU9JA, XU9JA/K . . . . . . . . . . . .

Bosch LE2-Jetronic

XU9J1/Z, XU9J1/L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bosch LU2-Jetronic

XU9JA/Z, XU9JA/L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bosch Motronic M1.3

Fuel system data

Regulated fuel pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9 to 3.1 bar

Fuel pump delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

540 cc/15 sec

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

900 ± 50 rpm

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

1.0 to 2.0 %

*Adjustable on LE2-Jetronic system only - controlled by ECU on all other systems

Recommended fuel

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

95 RON unleaded or 97/98 RON unleaded*

* Note: The XU9JA engine should not be operated on 95 RON unleaded petrol

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 - checks and adjustment  . . . . . . . . . . . . . . . . 10
Fuel injection system components - removal and refitting  . . . . . . . . 11
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
Idle speed and mixture adjustment  . . . . . . . . . . . . . . . . .See Chapter 1
Inlet manifold - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . 12
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

4C•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

General information and
precautions

General information

The fuel supply 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. The fuel
pump supplies fuel to the fuel rail, which acts
as a reservoir for the four fuel injectors which
inject fuel into the inlet tracts. The fuel filter
incorporated in the feed line from the pump to
the fuel rail ensures that the fuel supplied to
the injectors is clean.

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.

Air cleaner assembly -
removal and refitting

Removal

1 Disconnect the inlet and outlet ducts.
2 Unscrew the mounting bolts and lift the air
cleaner from the engine.

Refitting

3 Refitting is a reversal of removal.

Throttle cable - removal,
refitting and adjustment

Removal

1 Extract the spring clip from the adjustment
ferrule located beneath the inlet manifold.
Release the cable end fitting from the linkage
the outer cable from the support bracket.
2 Working inside the car, disconnect the
cable end fitting from the top of the
accelerator pedal arm.
3 Withdraw the throttle cable through the
bulkhead grommet.

Refitting and adjustment

4 Refitting is a reversal of removal, but adjust
the cable as follows.
5 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.
6 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.
7 Have an assistant depress the accelerator
pedal and check that the throttle cam opens
fully and returns smoothly to its stop.

Fuel system -
depressurisation

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 injectors, the fuel rail and
the pressure regulator, 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 must be relieved in a
controlled fashion when any of these
components are disturbed for servicing work.
2 Disconnect the battery negative lead.
3 Where possible, place a container beneath
the connection/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.

Fuel pump - removal and
refitting

Refer to Part B, Section 5.

Fuel gauge sender unit -
removal and refitting

Refer to Part A, Section 6.

Fuel tank - removal and
refitting

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 which is
located inside the tank. It will also be
necessary to disconnect the wiring connector
from the fuel pump before lowering the tank
out of position.

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.

1 With the exception of the XU9JA engine
(fitted to 1.9 GTI models without a catalytic
converter), all engines can be operated on 95
RON unleaded petrol. The XU9JA engine
should not be operated on 95 RON unleaded
petrol.
2 No adjustments to the ignition timing are
necessary in order to operate engines on 95
RON unleaded petrol, with the exception of
the XU5J and XU5JA engines, which must
both have the ignition timing retarded by 2°.
Refer to Chapter 5B for details of ignition
timing adjustment.
3 Do not operate an engine equipped with a
catalytic converter on leaded petrol. If a
catalytic converter is fitted, unleaded petrol
must be used at all times.

Engine

Code

Retard ignition by

XU5J

180A

2° (95 or 97/98 RON
unleaded)

XU5JA

B6D

2° (95 or 97/98 RON
unleaded)

XU5JA/K

B6E