Chapter 1 Routine maintenance and servicing

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1•14 12 000 Mile / 12 Month Service 10.27 Mixture (CO) adjustment screw (2) on the Bosch MP3.1 fuel injection system 26 The idle mixture (exhaust gas CO level) is set at the factory, and should require no further adjustment. If, due to a change in engine characteristics (carbon build-up, bore wear etc) or after a major overhaul, the mixture becomes incorrect, it can be reset. Note, however, that an exhaust gas analyser (CO meter) will be required to check the mixture, and to set it with the necessary standard of accuracy. If this is not available, the car must be taken to a Peugeot dealer for the work to be carried out. 27 Follow the exhaust gas analyser manufacturer’s instructions to check the exhaust gas CO level. If adjustment is required, it is made via mixture adjustment screw (see illustration). The screw may be covered with a tamperproof plug to prevent unnecessary adjustment. To gain access to the screw, use a sharp instrument to hook out the plug. 28 Turn the screw clockwise to increase and anti-clockwise to decrease CO content until the specified CO level is obtained. 29 When adjustments are complete, disconnect any test equipment, and fit a new tamperproof plug to the mixture adjustment screw. Bosch Motronic M1.3 fuel injection system 30 The idle speed is only adjustable on the XU9JA/Z engine - on other engines it is controlled by the ECU and idle speed control valve. 31 Ensure that all electrical loads are switched off. If the car does not have a tachometer, connect one following its manufacturer’s instructions. Note the idle speed, and compare it with that specified. 32 Turn the idle speed adjustment screw to obtain the specified idle speed (see illustration). 33 The idle mixture (CO) is only adjustable on the XU9J4/K engine - on other engines it is controlled by the ECU. 34 The idle mixture (exhaust gas CO level) is set at the factory, and should require no further adjustment. If, due to a change in engine characteristics (carbon build-up, bore wear etc) or after a major overhaul, the mixture becomes incorrect, it can be reset. Note, however, that an exhaust gas analyser 10.32 Idle speed adjustment screw (7) on the Bosch Motronic M1.3 injection system (CO meter) will be required to check the mixture, and to set it with the necessary standard of accuracy. If this is not available, the car must be taken to a Peugeot dealer for the work to be carried out. 35 Follow the exhaust gas analyser manufacturer’s instructions to check the exhaust gas CO level. If adjustment is required, it is made via mixture adjustment screw located on top of the airflow meter assembly (see illustration). The screw may be covered with a tamperproof plug to prevent unnecessary adjustment. To gain access to the screw, use a sharp instrument to hook out the plug. 36 Turn the screw clockwise to increase and anti-clockwise to decrease CO content until the specified CO level is obtained. All other fuel injection systems 37 Experienced home mechanics, with a considerable amount of skill and equipment (including a tachometer and an accurate exhaust gas analyser) may be able to check the exhaust CO level and the idle speed. However, if these are found to be in need of adjustment, the car must be taken to a suitably-equipped Peugeot dealer. 38 On models with a Magneti Marelli engine management (fuel injection/ignition) system, adjustment of the mixture setting (exhaust gas CO level) is possible, but adjustments can only be made by reprogramming the engine management ECU using special electronic test equipment which is connected to the diagnostic connector (see Chapter 4). 39 On all other vehicles, adjustments are not possible. If the idle speed or the exhaust gas CO level is incorrect, there must be a fault in the engine management system, and the vehicle should be taken to a Peugeot dealer for testing (see Chapter 4). 11 Spark plug renewal 2 Note: On models from 1994, the maker’s specified interval for this procedure is 18 000 miles (30 000 km). 1 The correct functioning of the spark plugs is vital for the correct running and efficiency of 10.35 Mixture adjustment screw (5) on the Bosch Motronic M1.3 fuel injection system the engine. It is essential that the plugs fitted are appropriate for the engine (the suitable type is specified at the beginning of this Chapter). If this type is used, and the engine is in good condition, the spark plugs should not need attention between scheduled replacement intervals. Spark plug cleaning is rarely necessary, and should not be attempted unless specialised equipment is available, as damage can easily be caused to the firing ends. 2 On 16-valve models, to gain access to the spark plugs, the access cover fitted over the centre of the cylinder head must first be removed. Undo the eight bolts, noting the position of the wiring retaining clip, and remove the cover (see illustration). 3 On other models, to improve access to some of the plugs, it may be necessary to remove the air inlet duct (refer to Chapter 4 for further information). 4 On 1998 cc 16-valve models, pull the HT coils off the spark plugs. If necessary, to remove the possibility of the HT coils being connected to the wrong spark plugs on refitting, mark the coils 1 to 4 (No 1 cylinder is at the transmission end of the engine). 5 On all other models, if the marks on the original-equipment spark plug (HT) leads cannot be seen, mark the leads 1 to 4, corresponding to the cylinder the lead serves (No 1 cylinder is at the transmission end of the engine). Pull the leads from the plugs by gripping the end fitting, not the lead, otherwise the lead connection may be fractured (see illustration). 11.2 On 16-valve models undo the eight bolts (arrowed) and remove the access cover to reach the spark plugs
12 000 Mile / 12 Month Service 1•15 11.5 Pulling the HT leads from the spark plugs 11.7 Tools required for spark plug removal, gap adjustment and refitting 11.12 Measuring the spark plug gap with a feeler blade 6 It is advisable to remove the dirt from the spark plug recesses, using a clean brush, vacuum cleaner or compressed air before removing the plugs, to prevent dirt dropping into the cylinders. 7 Unscrew the plugs using a spark plug spanner, suitable box spanner, or a deep socket and extension bar (see illustration). Keep the socket aligned with the spark plug - if it is forcibly moved to one side, the ceramic insulator may be broken off. As each plug is removed, examine it as follows. 8 Examination of the spark plugs will give a good indication of the condition of the engine. If the insulator nose of the spark plug is clean and white, with no deposits, this is indicative of a weak mixture or too hot a plug (a hot plug transfers heat away from the electrode slowly, a cold plug transfers heat away quickly). 9 If the tip and insulator nose are covered with hard black-looking deposits, then this is indicative that the mixture is too rich. Should the plug be black and oily, then it is likely that the engine is fairly worn, as well as the mixture being too rich. 10 If the insulator nose is covered with light tan to greyish-brown deposits, then the mixture is correct, and it is likely that the engine is in good condition. 11 The spark plug electrode gap is of considerable importance as, if it is too large or too small, the size of the spark and its efficiency will be seriously impaired. The gap should be set to the value given in the Specifications at the beginning of this Chapter. 12 To set the gap, measure it with a feeler blade, then bend the outer plug electrode until the correct gap is achieved (see illustration). The centre electrode should never be bent, as this may crack the insulator and cause plug failure, if nothing worse. If using feeler blades, the gap is correct when the appropriate-size blade is a firm, sliding fit. 13 Special spark plug electrode gap adjusting tools are available from most motor accessory shops, or from some spark plug manufacturers. 14 Before fitting the spark plugs, check that the threaded connector sleeves (on top of the plug) are tight, and that the plug exterior surfaces and threads are clean. It is very often difficult to insert spark plugs into their holes without cross-threading them. To avoid this possibility, fit a short length of hose over the end of the spark plug (see Haynes Hint). 15 Remove the rubber hose (if used), and tighten the plug to the specified torque (see “Specifications”) using the spark plug socket and a torque wrench. Refit the remaining plugs in the same way. 16 Connect the HT leads in the correct order, and refit any components removed for access. On 1998 cc 16-valve models, connect the HT coils in their correct order. 12 Clutch adjustment check and control mechanism 2 lubrication 2 The clutch itself should function correctly, with no trace of slip or drag. 3 Where possible, adjust the clutch cable if necessary, as described in Chapter 6. 4 If excessive effort is required to operate the clutch, check first that the cable is correctly routed and undamaged. Remove the pedal, and make sure that its pivot is properly greased. Refer to Chapter 6 for further information. 13 Driveshaft gaiter check 1 Note: On models from 1994, the maker’s specified interval for this procedure is 9000 miles (15 000 km) or 12 months. With the vehicle raised and securely supported on stands, turn the steering onto full lock, then slowly rotate the roadwheel. Inspect the condition of the outer constant velocity (CV) joint rubber gaiters, while squeezing the gaiters to open out the folds (see illustration). Check for signs of cracking, splits, or deterioration of the rubber, which may allow the grease to escape, and lead to water and grit entry into the joint. Also check the security and condition of the retaining clips. Repeat these checks on the inner CV joints. If any damage or deterioration is found, the gaiters should be renewed without delay as described in Chapter 8. At the same time, check the general condition of the CV joints themselves, by first holding the driveshaft and attempting to rotate 1 It is often difficult to insert spark plugs into their holes without cross-threading them. To avoid this possibility, fit a short length of 5/16 inch internal diameter rubber hose over the end of the spark plug. The flexible hose acts as a universal joint to help align the plug with the plug hole. Should the plug begin to cross-thread, the hose will slip on the spark plug, preventing thread damage to the cylinder head. Note: On models from 1994, the maker’s specified interval for this procedure is 9000 miles (15 000 km) or 12 months for clutch adjustment, and 18 000 miles (30 000 km) for lubrication. 1 Check that the clutch pedal moves smoothly and easily through its full travel. 13.1 Check the condition of the driveshaft gaiters (arrowed)
Page 1 and 2: Chapter 1 Routine maintenance and s
Page 3 and 4: Maintenance schedule - models up to
Page 5 and 6: Underbonnet view of a 1580 cc carbu
Page 7 and 8: Front underbody view of a 1905 cc e
Page 9 and 10: 6000 Mile / 6 Month Service 1•9 A
Page 11 and 12: 6000 Mile / 6 Month Service 1•11
Page 13: 12 000 Mile / 12 Month Service 1•
Page 17 and 18: 18 000 Mile / 18 Month Service 18 0
Page 19 and 20: 24 000 Mile / 2 Year Service 1•19
Page 21 and 22: 24 000 Mile / 2 Year Service 1•21
Page 23: 36 000 Mile / 3 Year Service 1•23

Chapter 1 Routine maintenance and servicing

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