Peugeot 205. Manual - part 28

 

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Peugeot 205. Manual - part 28

 

 

Bosch Motronic M1.3 system

The Bosch Motronic fuel injection system is

designed to meet stringent emission control
legislation whilst still providing excellent
engine performance and fuel economy. The
system is under the overall control of the
Motronic M1.3 engine management system,
which also controls the ignition timing.

The principle of operation of the system is

similar to that described above for the
LE2-Jetronic system, noting the following
differences.

a) A double-barrel throttle housing is used

with two throttle valves operating
simultaneously.

b) An oxygen sensor Is fitted to the exhaust

system which allows fine mixture
adjustment to enable the use of a catalytic
converter.

c) A TDC sensor is used to provide the ECU

with information on crankshaft speed and
position.

10 Fuel injection system -

checks and adjustment

3

General information

If a fault appears in the fuel injection
system, first ensure that all the system wiring
connectors are securely connected and free
of corrosion. Ensure that the fault is not due to
poor maintenance; ie, check that the air
cleaner filter element is clean, the spark plugs
are in good condition and correctly gapped,
the valve clearances are correctly adjusted,
the cylinder compression pressures are
correct, the ignition timing is correct (where
adjustable), and that the engine breather
hoses are clear and undamaged, referring to
Chapters 1, 2 and 5 for further information.
If these checks fail to reveal the cause of
the problem, carry out the checks and

adjustments described in the following sub-
sections which represent the limit of work that
can be done without sophisticated test
equipment. If problems still exist, the vehicle
should be taken to a suitably-equipped
Peugeot dealer for testing. A wiring block
connector is incorporated in the engine
management circuit, into which a special
electronic diagnostic tester can be plugged.
The tester will locate the fault quickly and
simply, alleviating the need to test all the
system components individually, which is a
time-consuming operation that also carries a
risk of damaging the ECU.

Checks and adjustment

Idle speed and mixture CO content

Refer to Chapter 1.

Throttle initial position - LE2-Jetronic
system

Run the engine to normal operating
temperature - indicated when the electric
cooling fan has cut in and out twice. The
ignition timing must be correctly adjusted, as
described in Chapter 5B.
Connect a vacuum gauge to the test point
in the distributor vacuum advance line (see
illustration)
.
Check that the throttle movement is
smooth.
With the engine stopped turn the air screw
fully in (see illustration).
Prise the tamperproof cap from the throttle
stop screw (see illustration).
Unscrew the throttle stop screw then
retighten it until it just touches the throttle
lever. Tighten the screw a further four
complete turns.
10 Start the engine and allow it to idle. Turn
the throttle stop screw to obtain an idle speed
of 650 rpm (XU5J engines) or 600 rpm (XU5JA
and XU9JA engines). Check that the vacuum
reading shown on the gauge does not exceed
50 mm Hg (65 mbar) and if necessary adjust
the throttle stop screw.
11 Now turn the air screw in the throttle
housing as necessary to obtain the specified
idling speed.
12 Stop the engine and adjust the throttle
switch, as described below.

Throttle initial position - LU2-Jetronic
and Motronic M1.3 systems 

13 The throttle initial position is set in
production, and will not normally require
adjustment unless the throttle housing has
been tampered with. Adjustment should be
entrusted to a Peugeot dealer.

Throttle switch - LE2-Jetronic system

14 Pull the connector from the throttle switch
(see illustration).
15 Connect a voltmeter between the middle
terminal on the connector and earth.
16 Pull the connector from the ignition
amplifier (see Chapter 5B), then operate the
starter motor and check that there is a reading
of at least 9 volts.
17 Disconnect the air hose from the throttle
housing.
18 On all engines except XU5JA and XU9JA,
position a 0.30 mm feeler blade between the
throttle stop screw and the throttle lever.
19 Loosen the two throttle switch screws.
20 Connect an ohmmeter between terminals
18 and 2 on the throttle switch, then rotate the
switch until the internal contacts close and the
reading is zero ohms. Tighten the screws with
the switch in this position.
21 Remove the feeler blade (where
applicable) and on all engines, insert in its
place a 0.70 mm feeler blade. The internal
contacts should now be separated and the
reading on the ohmmeter infinity. If not, repeat
the procedure in paragraph 19.
22 Remove the feeler blade.

Fuel system - multi-point fuel injection engines  4C•3

4C

10.8  Prise the tamperproof cap from the

throttle stop screw (arrowed) and adjust as

described in text

10.14  Removing the throttle switch

connector

10.5  To check the throttle initial position,

connect a vacuum gauge to the 

test point (1)

10.7  Turn the air screw fully in

23 Check the full throttle operation by
connecting an ohmmeter between terminals
18 and 3, then fully opening the throttle so
that dimension X is 4.0 mm (see illustration).
The internal contacts should close and the
ohmmeter reading be zero.
24 If the switch does not operate correctly it
should be renewed.

Throttle switch - LU2-Jetronic and
Motronic M1.3 systems

25 The throttle initial position must be correct
before attempting to adjust the throttle switch.
26 Slacken the throttle switch securing
screws.
27 Turn the switch unit fully clockwise, then
turn it slowly back until the idling contacts are
heard to close.
28 Tighten the securing screws.
29 Pull the wiring from the switch, then
connect an ohmmeter between terminals 2
and 18 in the switch (see illustration). The
ohmmeter should read zero.
30 Operate the throttle linkage, and the
ohmmeter should read infinity.
31 If the readings are not correct, repeat the
procedure described in paragraphs 26 to 30
inclusive.
32 Connect the ohmmeter between switch
terminals 3 and 18. The ohmmeter should
read infinity.
33 Fully open the throttle, and the ohmmeter
should read zero.
34 If the specified readings cannot be
obtained, renew the switch.
35 Reconnect the switch wiring plug on
completion.

11 Fuel injection system

components - removal and
refitting

3

Note: Although some of the components may
differ slightly in detail, the following
procedures are applicable to all three multi-
point fuel injection systems. It is advisable to
check the availability of individual components
with your Peugeot dealer before dismantling.

Fuel injectors

Note: Refer to the warning note in Section 1
before proceeding. Ensure that the working
area is clean before removing the injectors,
and ensure that no dirt is allowed to enter the
system during the procedure. No attempt
should be made to overhaul the injectors. If a
fault or contamination is suspected, seek
specialist advice.
Disconnect the battery negative lead.
Disconnect the wiring plugs from the fuel
injectors, labelling them if necessary to ensure
correct refitting.
Disconnect the vacuum hose from the top
of the fuel pressure regulator.
Unscrew the four bolts securing the fuel rail
to the inlet manifold (two upper bolts, and two
bolts at the right-hand end of the rail), then

carefully lift the rail, complete with pressure
regulator and fuel injectors, from the inlet
manifold, taking care not to strain any of the
hoses or pipes.
To remove a fuel injector from the fuel rail,
carefully remove the metal securing clip, then
pull the injector from the rail. Be prepared for
fuel spillage, and take adequate precautions.
Refitting is a reversal of removal, but fit new
injector O-rings.

Fuel pressure regulator

Note: Refer to the warning note in Section 1
before proceeding. Ensure that the working
area is clean and that no dirt is allowed to
enter the system during the procedure.
For improved access to the lower pressure
regulator securing nut, proceed as described
in paragraphs 3 and 4.
If not already done, disconnect the vacuum
hose from the top of the pressure regulator.
Slacken the hose clip, and disconnect the
fuel return hose from the bottom of the
pressure regulator. Be prepared for fuel
spillage, and take adequate precautions.
10 Unscrew the two bolts securing the
pressure regulator to the fuel rail bracket
assembly, whilst counter holding the nuts.
Note that on some models, a hose bracket is
secured by the upper bolt.

11 Pull the regulator from the end of the fuel
rail, and recover the O-ring.
12 Refitting is a reversal of removal, but use a
new O-ring when refitting the pressure
regulator to the fuel rail, and where applicable,
use new injector O-rings.

Throttle position switch

13 Disconnect the battery negative lead.
14 Release the securing clip and disconnect
the wiring plug from the switch.
15 Remove the two securing screws, then
withdraw the switch from the throttle body.
16 Refitting is a reversal of removal, but on
completion, adjust the switch as described in
Section 10.

Throttle housing

17 Disconnect the battery negative lead.
18 Release the securing clip, and disconnect
the wiring plug from the throttle position
switch.
19 Loosen the securing clamp, and
disconnect the air trunking from the front of
the throttle housing.
20 Disconnect the throttle cable, with
reference to Section 3.
21 Disconnect the vacuum and/or breather
hoses from the throttle housing, noting their
locations to ensure correct refitting.
22 Unscrew the three throttle housing
securing nuts, and recover the washers.
Remove the throttle cable bracket from the
top throttle housing securing stud, noting its
orientation.
23 Withdraw the throttle housing from the
inlet manifold.
24 Refitting is a reversal of removal, bearing
in mind the following points.

a) Ensure that the vacuum and/or breather

hoses are correctly reconnected, as noted
before removal.

b) After refitting the throttle housing, check

the adjustment of the throttle cable, as
described in Section 3.

c) On completion, if any work has been

carried out on the housing, check the
adjustment of the throttle switch, as
described in Section 10.

Supplementary air (cold start)
device

25 Remove the battery as described in
Chapter 5A.
26 Disconnect the air hoses then unbolt the
airflow sensor and bracket. Disconnect the
wiring.
27 Unscrew the supplementary air device
bracket nuts and disconnect the wiring.
28 Tilt the assembly and coolant outlet
housing (without disconnecting the coolant
hoses) and remove the concealed mounting
bolt.
29 Disconnect the air hoses, then remove the
remaining mounting bolt and withdraw the
unit.
30 Refitting is a reversal of removal.

4C•4 Fuel system - multi-point fuel injection engines

10.23  Full throttle dimension “X”

4

Throttle lever

7

Throttle housing
X = 4.0 mm

10.29  Throttle switch terminal

identification - LU2-Jetronic and Motronic

M1.3 systems

Coolant temperature sensor

31 Refer to Chapter 3, Section 7.

Electronic control unit (ECU)

32 Refer to Part B, Section 11.

Fuel injection system fuses and
relays

33 Refer to Part B, Section 11.

12 Inlet manifold - removal and

refitting

3

Note: The following procedure is applicable to
all three multi-point fuel injection systems, but
slight differences in component layout may be
encountered.

Removal

Disconnect the battery negative lead.
Slacken the retaining clip, then disconnect
the inlet duct from the throttle housing and
recover the sealing ring.

Disconnect the throttle inner cable from the
throttle cam, then withdraw the outer cable
from the mounting bracket, along with its flat
washer and spring clip.
Depress the retaining clip and disconnect
the wiring connector from the throttle position
switch.
Release the retaining clips (where fitted)
and disconnect all the relevant vacuum and
breather hoses from the manifold. Make
identification marks on the hoses to ensure
that they are connected correctly on refitting.
Bearing in mind the information given in
Section 4, slacken the retaining clips and
disconnect the fuel feed and return hoses
from the fuel rail.
Depress the retaining tangs and disconnect
the wiring connectors from the four injectors.
Free the wiring from any relevant retaining
clips and position it clear of the manifold.
Where necessary, undo the retaining bolts
and remove the support bracket from the
underside of the manifold.
Undo the manifold retaining nuts and
withdraw the manifold from the engine

compartment. Recover the four manifold seals
and discard them; new ones must be used on
refitting.

Refitting

10 Refitting is a reverse of the relevant
removal procedure, noting the following
points:

a) Ensure that the manifold and cylinder

head mating surfaces are clean and dry,
then locate the new seals in their recesses
in the manifold.

b) Ensure that all relevant hoses are

reconnected to their original positions and
are securely held (where necessary) by
the retaining clips.

c) Adjust the throttle cable as described in

Section 3.

Fuel system - multi-point fuel injection engines  4C•5

4C

4C•6

Notes

 

 

 

 

 

 

 

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