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Chapter 4 Part B: Fuel/exhaust systems - single-point fuel injection ...

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4B•1<strong>Chapter</strong> 4 <strong>Part</strong> B: <strong>Fuel</strong>/<strong>exhaust</strong> <strong>systems</strong> -<strong>single</strong>-<strong>point</strong> <strong>fuel</strong> <strong>injection</strong> modelsContentsAccelerator cable - removal, refitting and adjusting . . . . . . . . . . . . . . .4Accelerator pedal - removal and refitting . . . . . . . . . . . . . . . . . . . . . . .5Air cleaner air temperature control system -general information and component renewal . . . . . . . . . . . . . . . . . .3Air cleaner assembly and inlet ducts - removal and refitting . . . . . . . .2Air cleaner filter element renewal . . . . . . . . . . . . . . . . . .See <strong>Chapter</strong> 1Bosch Mono<strong>point</strong> system components - removal and refitting . . . . .15Exhaust manifold - removal and refitting . . . . . . . . . . . . . . . . . . . . . .18Exhaust system check . . . . . . . . . . . . . . . . . . . . . . . . . . .See <strong>Chapter</strong> 1Exhaust system - general information, removal and refitting . . . . . . .19Fenix system components - removal and refitting . . . . . . . . . . . . . . .14<strong>Fuel</strong> filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See <strong>Chapter</strong> 1Degrees of difficulty<strong>Fuel</strong> gauge sender unit - removal and refitting . . . . . . . . . . . . . . . . . .10<strong>Fuel</strong> <strong>injection</strong> system - depressurisation . . . . . . . . . . . . . . . . . . . . . . .8<strong>Fuel</strong> <strong>injection</strong> <strong>systems</strong> - general information . . . . . . . . . . . . . . . . . . . .7<strong>Fuel</strong> <strong>injection</strong> system - testing and adjustment . . . . . . . . . . . . . . . . .13<strong>Fuel</strong> pump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . .9<strong>Fuel</strong> tank - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11General information and precautions . . . . . . . . . . . . . . . . . . . . . . . . . .1Idle speed and mixture adjustment . . . . . . . . . . . . . . . . .See <strong>Chapter</strong> 1Inlet manifold - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .17Magneti Marelli system components - removal and refitting . . . . . . .16Throttle body - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .12Unleaded petrol - general information and usage . . . . . . . . . . . . . . . .6Easy, suitable fornovice with littleexperienceFairly easy, suitablefor beginner withsome experienceFairly difficult,suitable for competentDIY mechanicDifficult, suitable forexperienced DIYmechanicVery difficult,suitable for expertDIY or professionalSpecificationsSystem typeXU5 (BDZ and BDY) engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .XU5 (BDY) engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TU3 (KDX) and XU9 (DDZ) engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TU3 (KDX) engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Magneti Marelli G5 <strong>single</strong>-<strong>point</strong>Magneti Marelli G6 <strong>single</strong>-<strong>point</strong>Solex Fenix 1B <strong>single</strong>-<strong>point</strong>Bosch Monotronic MA3.0 <strong>single</strong>-<strong>point</strong><strong>Fuel</strong> pumpType . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric, external (early models) or internal (later models)Pump delivery pressure:Fenix 1B, MM G5 and MM G6 <strong>systems</strong> . . . . . . . . . . . . . . . . . . . . . . . 0.7 to 0.8 barsBosch MA3.0 system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 ± 0.1 barsPump delivery:Fenix 1B and Bosch MA3.0 <strong>systems</strong> . . . . . . . . . . . . . . . . . . . . . . . . . 370 cc per 15 secondsMM G5 and G6 <strong>systems</strong> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360 cc per 15 seconds<strong>Fuel</strong> system dataSpecified idle speed (not adjustable) . . . . . . . . . . . . . . . . . . . . . . . . . . . 850 ± 50 rpmIdle mixture CO content* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Less than 0.5%*Mixture is controlled by the electronic control unit, and cannot be adjusted.Recommended <strong>fuel</strong>Minimum octane rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95 RON unleaded (UK unleaded premium). Leaded <strong>fuel</strong> must not beused on models with a catalytic converter4BTorque wrench settings Nm lbf ftInlet manifold nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6Exhaust manifold nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 12Exhaust system fasteners:Front pipe-to-manifold nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 22Front pipe mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 26Front pipe-to-catalytic converter nuts . . . . . . . . . . . . . . . . . . . . . . . . 10 7Clamping ring nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15


4B•2 <strong>Fuel</strong>/<strong>exhaust</strong> <strong>systems</strong> - <strong>single</strong>-<strong>point</strong> <strong>fuel</strong> <strong>injection</strong> models1 General information andprecautionsThe <strong>fuel</strong> system consists of a <strong>fuel</strong> tank(which is mounted under the rear of the car,with an electric <strong>fuel</strong> pump immersed in it), a<strong>fuel</strong> filter, <strong>fuel</strong> feed and return lines, and thethrottle body assembly (which incorporatesthe <strong>single</strong> <strong>fuel</strong> injector and the <strong>fuel</strong> pressureregulator). In addition, there is an ElectronicControl Unit (ECU) and various sensors,electrical components and related wiring. Theair cleaner contains a disposable paper filterelement, and incorporates a flap valve airtemperature control system. This allows coldair from the outside of the car and warm airfrom around the <strong>exhaust</strong> manifold to enter theair cleaner in the correct proportions.Refer to Section 7 for further information onthe operation of each <strong>fuel</strong> <strong>injection</strong> system,and to Section 18 for information on the<strong>exhaust</strong> system.Throughout <strong>Part</strong> B, it is occasionallynecessary to identify vehicles by their enginecodes rather than by engine capacity. Refer tothe relevant <strong>Part</strong> of <strong>Chapter</strong> 2 for furtherinformation on engine code identification.Warning: Many of theprocedures in this <strong>Chapter</strong>require the removal of <strong>fuel</strong> linesand connections, which mayresult in some <strong>fuel</strong> spillage. Beforecarrying out any operation on the <strong>fuel</strong>system, refer to the precautions given in“Safety first!” at the beginning of thismanual, and follow them implicitly. Petrolis a highly dangerous and volatile liquid,and the precautions necessary whenhandling it cannot be overstressed.Note: Residual pressure will remain in the<strong>fuel</strong> lines long after the vehicle was last used.When disconnecting any <strong>fuel</strong> line, firstdepressurise the <strong>fuel</strong> system as described inSection 8.2 Air cleaner assembly andinlet ducts - removal and 2refittingRefer to <strong>Chapter</strong> 4A, Section 2, substituting“throttle body” for all references to thecarburettor.3 Air cleaner air temperaturecontrol system - information 2and component renewalRefer to <strong>Chapter</strong> 4A, Section 3, substituting“throttle body” for all references to thecarburettor.4 Accelerator cable - removal,refitting and adjustment 2Note: For automatic transmission modelsrefer to <strong>Chapter</strong> 7B.Removal and refitting1 Refer to <strong>Chapter</strong> 4A, Section 7 substituting“throttle body” for all references to thecarburettor. Adjust the cable as describedbelow.Adjustment2 Remove the spring clip from the acceleratorouter cable then, ensuring that the throttlecam is fully against its stop, gently pull thecable out of its grommet until all free play isremoved from the inner cable.3 With the cable held in this position, ensurethat the flat washer is pressed securelyagainst the grommet, then fit the spring clip tothe third outer cable groove visible in front ofthe rubber grommet and washer (seeillustration). This will leave a fair amount offreeplay in the inner cable which is necessaryto ensure correct operation of the idle controlstepper motor (see Section 14).4.3 Adjust the accelerator cable asdescribed in text4 Have an assistant depress the acceleratorpedal and check that the throttle cam opensfully and returns smoothly to its stop.5 Accelerator pedal -removal and refitting 2Refer to <strong>Chapter</strong> 4A, Section 8.6 Unleaded petrol - generalinformation and usageNote: The information given in this <strong>Chapter</strong> iscorrect at the time of writing. If updatedinformation is thought to be required, checkwith a Peugeot dealer. If travelling abroad,consult one of the motoring organisations (or asimilar authority) for advice on the <strong>fuel</strong>available.The <strong>fuel</strong> recommended by Peugeot is givenin the Specifications Section of this <strong>Chapter</strong>,followed by the equivalent petrol currently onsale in the UK.All Peugeot 405 <strong>single</strong>-<strong>point</strong> <strong>injection</strong>models are designed to run on <strong>fuel</strong> with aminimum octane rating of 95 (RON). Allmodels are equipped with catalyticconverters, and therefore must be run onunleaded <strong>fuel</strong> only. Under no circumstancesshould leaded (UK “4-star”) <strong>fuel</strong> be used, asthis may damage the catalytic converter.Super unleaded petrol (98 octane) can alsobe used in all models if wished, though thereis no advantage in doing so.7 <strong>Fuel</strong> <strong>injection</strong> <strong>systems</strong> -general informationNote: The <strong>fuel</strong> <strong>injection</strong> ECU is of the “selflearning”type, meaning that as it operates, italso monitors and stores the settings whichgive optimum engine performance under alloperating conditions. When the battery isdisconnected, these settings are lost and theECU reverts to the base settings programmedinto its memory at the factory. On restarting,this may lead to the engine running/idlingroughly for a short while, until the ECU has relearnedthe optimum settings. This process isbest accomplished by taking the vehicle on aroad test (for approximately 15 minutes),covering all engine speeds and loads,concentrating mainly in the 2500 to 3500 rpmregion.Fenix 1B system1 The Fenix 1B system is an integrated<strong>single</strong>-<strong>point</strong> <strong>fuel</strong> <strong>injection</strong>/ignition system.Using inputs from various sensors, theelectronic control unit computes the optimum<strong>fuel</strong> injector pulse duration, and ignitionadvance setting, to suit the prevailing engineoperating conditions.2 The electronic control unit receives signalsfrom the following sensors.a) Engine speed/position sensor.b) Manifold absolute pressure (MAP) sensor.c) Inlet air temperature sensor.d) Throttle position sensor.e) Coolant temperature sensor.f) Oxygen sensor.3 The <strong>fuel</strong> <strong>injection</strong> unit houses the <strong>fuel</strong>injector, the <strong>fuel</strong> pressure regulator, thethrottle position switch, and the idle speedcontrol valve. The <strong>single</strong> <strong>fuel</strong> injector injects<strong>fuel</strong> upstream of the throttle valve.4 Idle speed is controlled by the electroniccontrol unit, via the idle speed control valve.5 The oxygen sensor allows the electroniccontrol unit to control the air/<strong>fuel</strong> mixturewithin very fine limits, to enable the use of acatalytic converter.6 All the information supplied to theelectronic control unit is computed andcompared with pre-set values stored in the


<strong>Fuel</strong>/<strong>exhaust</strong> <strong>systems</strong> - <strong>single</strong>-<strong>point</strong> <strong>fuel</strong> <strong>injection</strong> models 4B•3module memory, to determine the requiredperiod of <strong>injection</strong>.7 The electronic control unit constantly variesthe <strong>fuel</strong> mixture, engine idle speed, andignition timing to provide optimum engineefficiency under all operating conditions, andto reduce <strong>exhaust</strong> gas emissions. The mixturestrength is accurately controlled to maintain itwithin the operating limits of the catalyticconverter.Bosch Mono<strong>point</strong> MA3.0 system8 The Bosch Mono<strong>point</strong> MA3.0 enginemanagement (<strong>fuel</strong> <strong>injection</strong>/ignition) systemincorporates a closed-loop catalytic converterand an evaporative emission control system,and complies with the latest emission controlstandards. The system operates as follows.9 The <strong>fuel</strong> pump, immersed in the <strong>fuel</strong> tank,pumps <strong>fuel</strong> from the <strong>fuel</strong> tank to the <strong>fuel</strong>injector, via a filter mounted underneath therear of the vehicle. <strong>Fuel</strong> supply pressure iscontrolled by the pressure regulator in thethrottle body assembly. The regulatoroperates by allowing excess <strong>fuel</strong> to return tothe tank.10 The electrical control system consists ofthe ECU, along with the following sensors.a) Throttle potentiometer - informs the ECUof the throttle position, and the rate ofthrottle opening or closing.b) Coolant temperature sensor - informs theECU of engine temperature.c) Inlet air temperature sensor - informs theECU of the temperature of the air passingthrough the throttle body.d) Lambda sensor - informs the ECU of theoxygen content of the <strong>exhaust</strong> gases(explained in <strong>Part</strong> D of this <strong>Chapter</strong>).e) Microswitch (built into the idle speedstepper motor) - informs the ECU whenthe throttle valve is closed (ie when theaccelerator pedal is released).f) Crankshaft sensor - informs the ECU ofengine speed and crankshaft positiong) Vehicle speed sensor (fitted to thegearbox) - informs the ECU of road speed.11 All the above information is analysed bythe ECU and, based on this, the ECUdetermines the appropriate ignition and<strong>fuel</strong>ling requirements for the engine. The ECUcontrols the <strong>fuel</strong> injector by varying its pulsewidth - the length of time the injector is heldopen - to provide a richer or weaker mixture,as appropriate. The mixture is constantlyvaried by the ECU, to provide the best settingfor cranking, starting (with either a hot or coldengine), warm-up, idle, cruising, andacceleration. Refer to <strong>Chapter</strong> 5 for furtherinformation on the ignition system.12 The ECU also has full control over theengine idle speed, via a stepper motor whichis fitted to the throttle body. The motorpushrod rests against a cam on the throttlevalve spindle. When the throttle valve isclosed, the ECU uses the motor to vary theopening of the throttle valve and so controlsthe idle speed.13 The ECU also controls the <strong>exhaust</strong> andevaporative emission control <strong>systems</strong>, whichare described in <strong>Part</strong> D of this <strong>Chapter</strong>.14 If there is an error in any of the readingsobtained from either the coolant temperaturesensor, the inlet air temperature sensor or thelambda sensor, the ECU enters its back-upmode. In this event, the ECU ignores theabnormal sensor signal, and assumes a preprogrammedvalue which will allow the engineto continue running (albeit at reducedefficiency). If the ECU enters this back-upmode, the warning light on the instrumentpanel will come on, and the relevant faultcode will be stored in the ECU memory.15 If the warning light comes on, the vehicleshould be taken to a Peugeot dealer at theearliest opportunity. A complete test of theengine management system can then becarried out, using a special electronicdiagnostic test unit which is simply pluggedinto the system’s diagnostic connector.Magneti Marelli G5and G6 <strong>systems</strong>16 A Magneti Marelli engine management(<strong>fuel</strong> <strong>injection</strong>/ignition) system is fitted to1580 cc XU5 engines.17 The <strong>fuel</strong> <strong>injection</strong> side of the systemoperates as described in the followingparagraphs. Refer to <strong>Chapter</strong> 5 for informationon the ignition side of the system.18 The <strong>fuel</strong> pump, immersed in the <strong>fuel</strong> tank,pumps <strong>fuel</strong> from the <strong>fuel</strong> tank to the <strong>fuel</strong>injector, via a filter. <strong>Fuel</strong> supply pressure iscontrolled by the pressure regulator in thethrottle body assembly. The regulatoroperates by allowing excess <strong>fuel</strong> to return tothe tank. To reduce emissions and to improvedriveability when the engine is cold, enginecoolant is passed through the manifold andaround the throttle body assembly.19 The electrical control system consists ofthe ECU, along with the following sensors.a) Manifold absolute pressure (MAP) sensor- informs the ECU of the load on theengine (expressed in terms of inletmanifold vacuum).b) Crankshaft sensor - informs the ECU ofthe crankshaft position and engine speed.c) Throttle potentiometer - informs the ECUof the throttle position, and the rate ofthrottle opening/closing.d) Coolant temperature sensor - informs theECU of the engine temperature.e) <strong>Fuel</strong>/air mixture temperature sensor -informs the ECU of the <strong>fuel</strong>/air mixturecharge temperature entering the engine.f) Lambda (oxygen) sensor - informs theECU of the oxygen content of the <strong>exhaust</strong>gases (explained in greater detail in <strong>Part</strong> Dof this <strong>Chapter</strong>).20 In addition, the ECU senses batteryvoltage (adjusting the injector pulse width tosuit, and using the stepper motor to increasethe idle speed and, therefore, the alternatoroutput if the voltage is too low). Short-circuitprotection and diagnostic capabilities areincorporated into the ECU, and it can bothreceive and transmit information via theengine management circuit diagnosticconnector, thus permitting engine diagnosisand tuning by special diagnostic equipment.21 All the above signals are compared by theECU, using digital techniques, with set valuespre-programmed (mapped) into its memory.Based on this information, the ECU selectsthe response appropriate to those values andcontrols the ignition HT coil (see <strong>Chapter</strong> 5),and the <strong>fuel</strong> injector (varying its pulse width -the length of time the injector is held open - toprovide a richer or weaker mixture, asappropriate). The mixture, idle speed andignition timing are constantly varied by theECU, to provide the best settings for cranking,starting (with either a hot or cold engine),warm-up, idle, cruising and acceleration.22 The ECU regulates the engine idle speedvia a stepper motor which is fitted to thethrottle body. The motor has a pushrodcontrolling the opening of an air passagewhich bypasses the throttle valve. When thethrottle valve is closed, the ECU controls themovement of the motor pushrod, whichregulates the amount of air which flowsthrough the throttle body passage, and socontrols the idle speed. The bypass passageis also used as an additional air supply duringcold starting.23 The ECU also controls the <strong>exhaust</strong> andevaporative emission control <strong>systems</strong>, whichare described in <strong>Part</strong> D of this <strong>Chapter</strong>.24 If there is an error in any of the readingsobtained from any of the engine managementcircuit sensors, the ECU enters its back-upmode. In this event, the ECU ignores theabnormal sensor signal, and assumes a preprogrammedvalue which will allow the engineto continue running (albeit at reducedefficiency). On entering this back-up mode,the engine management warning light in theinstrument panel will come on, informing thedriver of the fault, and the relevant fault codewill be stored in the ECU memory.25 If the warning light comes on, the vehicleshould be taken to a Peugeot dealer at theearliest opportunity. A complete test of theengine management system can then becarried out, using a special electronicdiagnostic test unit which is simply pluggedinto the system’s diagnostic connector.8 <strong>Fuel</strong> <strong>injection</strong> system -depressurisation2Note: Refer to the warning note in Section 1before proceeding.Warning: The followingprocedure will merely relievethe pressure in the <strong>fuel</strong> system -remember that <strong>fuel</strong> will still bepresent in the system components, andtake precautions accordingly beforedisconnecting any of them.4B


4B•4 <strong>Fuel</strong>/<strong>exhaust</strong> <strong>systems</strong> - <strong>single</strong>-<strong>point</strong> <strong>fuel</strong> <strong>injection</strong> models9.4 <strong>Fuel</strong> pump showing electricalconnections (A) and <strong>fuel</strong> hoses (B)1 The <strong>fuel</strong> system referred to in this Section isdefined as the tank-mounted <strong>fuel</strong> pump, the<strong>fuel</strong> filter, the <strong>fuel</strong> injector and the pressureregulator in the injector housing, and themetal pipes and flexible hoses of the <strong>fuel</strong> linesbetween these components. All these contain<strong>fuel</strong> which will be under pressure while theengine is running, and/or while the ignition isswitched on. The pressure will remain forsome time after the ignition has beenswitched off, and it must be relieved in acontrolled fashion when any of thesecomponents are disturbed for servicing work.2 Disconnect the battery negative terminal.3 Place a suitable container beneath theconnection or union to be disconnected, andhave a large rag ready to soak up anyescaping <strong>fuel</strong> not being caught by thecontainer.4 Slowly loosen the connection or union nutto avoid a sudden release of pressure, andposition the rag around the connection, tocatch any <strong>fuel</strong> spray which may be expelled.Once the pressure is released, disconnect the<strong>fuel</strong> line. Plug the pipe ends, to minimise <strong>fuel</strong>loss and prevent the entry of dirt into the <strong>fuel</strong>system.5 An alternative method of depressurising the<strong>fuel</strong> system is to remove either the <strong>fuel</strong> pumpfuse or the <strong>fuel</strong> pump relay and start theengine. Allow the engine to idle until it stops.Turn the engine over on the starter once ortwice to ensure that all pressure is released,then switch off the ignition. Always disconnectthe battery negative lead before carrying outwork on the <strong>fuel</strong> system, and do not forget torefit the fuse or relay when work is complete.9 <strong>Fuel</strong> pump -removal and refitting 29.9 Unplug the wiring connector thenrelease the <strong>fuel</strong> feed and return hoses(arrowed) from the <strong>fuel</strong> pump2 Disconnect the battery negative lead.3 Chock the front wheels then jack up therear of the vehicle and support on axle stands(see “Jacking and Vehicle Support”).4 Disconnect the electrical connections onthe pump (see illustration).5 Loosen the clips and disconnect the inletand outlet <strong>fuel</strong> hoses.6 Cut through the plastic cable-tie and slidethe pump from the rubber mounting straps.Internal mounted7 For access to the <strong>fuel</strong> pump, tilt or removethe rear seat as described in <strong>Chapter</strong> 11.8 Using a screwdriver, carefully prise theplastic access cover from the floor to exposethe <strong>fuel</strong> pump. The pump is located under theright-hand cover.9 Disconnect the wiring connector from the<strong>fuel</strong> pump, and tape the connector to thevehicle body, to prevent it from disappearingbehind the tank (see illustration).10 Mark the hoses for identificationpurposes, then slacken the feed and returnhose retaining clips. Where the crimped-typePeugeot hose clips are fitted, cut the clips anddiscard them; use standard worm-drive hoseclips on refitting. Disconnect both hoses fromthe top of the pump, and plug the hose ends.11 Noting the alignment marks on the tank,pump cover and the locking ring, unscrew thering and remove it from the tank (seeillustration). This is best accomplished byusing a screwdriver on the raised ribs of thelocking ring. Carefully tap the screwdriver to9.11 Unscrew the locking ring . . .turn the ring anti-clockwise until it can beunscrewed by hand.12 Displace the pump cover, then reach intothe tank and unclip the pump from the tankbase. Lift the <strong>fuel</strong> pump assembly out of the<strong>fuel</strong> tank, taking great care not to damage thefilter, or to spill <strong>fuel</strong> onto the interior of thevehicle. Recover the rubber sealing ring anddiscard it - a new one must be used onrefitting (see illustrations).13 Note that the <strong>fuel</strong> pump is only availableas a complete assembly - no components areavailable separately.RefittingExternal mounted14 Slide the pump into the rubber mountingstraps and secure with a new plastic cable-tie.15 Reconnect the <strong>fuel</strong> inlet and outlet hoses.16 Reconnect the electrical connections.17 Lower the vehicle to the ground andreconnect the battery negative lead.18 Start the engine and check for leaks.Internal mounted19 Ensure that the <strong>fuel</strong> pump pick-up filter isclean and free of debris. Fit the new sealingring to the top of the <strong>fuel</strong> tank.20 Carefully manoeuvre the pump assemblyinto the <strong>fuel</strong> tank, and clip it into position inthe base of the tank.21 Align the mark on the <strong>fuel</strong> pump coverwith the centre of the three alignment markson the <strong>fuel</strong> tank, then refit the locking ring.Securely tighten the locking ring, then checkNote: Refer to the warning note in Section 1before proceeding. The <strong>fuel</strong> pump is mountedeither on the outside of the <strong>fuel</strong> tank (external)or on the inside of the <strong>fuel</strong> tank (internal)according to model.RemovalExternal mounted1 Depressurise the <strong>fuel</strong> system (Section 8).9.12a . . . then lift outthe <strong>fuel</strong> pump . . .9.12b . . . and recover therubber sealing ring


<strong>Fuel</strong>/<strong>exhaust</strong> <strong>systems</strong> - <strong>single</strong>-<strong>point</strong> <strong>fuel</strong> <strong>injection</strong> models 4B•59.21 On refitting tighten the locking ringuntil it is correctly aligned with the <strong>fuel</strong>tank mark (arrowed)that the locking ring, pump cover and tankmarks are all correctly aligned (seeillustration).22 Reconnect the feed and return hoses tothe top of the <strong>fuel</strong> pump, using the marksmade on removal to ensure that they arecorrectly reconnected, and securely tightentheir retaining clips.23 Reconnect the pump wiring connector.24 Reconnect the battery negative terminaland start the engine. Check the <strong>fuel</strong> pumpfeed and return hoses unions for signs ofleakage.25 If all is well, refit the plastic access cover.Tilt or refit the rear seat as described in<strong>Chapter</strong> 11 (as applicable).10 <strong>Fuel</strong> gauge sender unit -removal and refitting 310.1 Removing the <strong>fuel</strong> gauge sender unitnecessary to disconnect the wiring connectorfrom the internal <strong>fuel</strong> pump before loweringthe tank out of position.12 Throttle body -removal and refitting 3Note: Refer to the warning note in Section 1before proceeding.Removal1 Disconnect the battery negative terminal.2 Remove the air cleaner housing-to-throttlebody duct, using the information given inSection 2 (see illustration).3 Depress the retaining clips and disconnectthe wiring connectors from the throttlepotentiometer, the idle control stepper motor(where fitted), and the injector wiring loomconnector which is situated on the side of thethrottle body (see illustrations).4 Bearing in mind the information in Section 8about depressurising the <strong>fuel</strong> system, releasethe retaining clips and disconnect the <strong>fuel</strong>feed and return hoses from the throttle bodyassembly. If the original crimped-typePeugeot clips are still fitted, cut the clips anddiscard them; use standard worm-drive hoseclips on refitting (see illustration).5 Disconnect the accelerator inner cable fromthe throttle cam, then withdraw the outercable from the mounting bracket, along withits flat washer and spring clip.6 Disconnect the idle control auxiliary airvalve and/or purge valve hose from thethrottle body (as applicable).7 Slacken and remove the bolts securing thethrottle body assembly to the inlet manifold,then remove the assembly along with itsgasket (see illustration).8 If necessary, with the throttle bodyremoved, undo the retaining screws andseparate the upper and lower sections, notingthe gasket which is fitted between the two.Refitting9 Refitting is a reverse of the removalprocedure, bearing in mind the following<strong>point</strong>s:a) Where applicable, ensure that the matingsurfaces of the upper and lower throttlebody sections are clean and dry. Fit a newgasket and reassemble the two sections,tightening the retaining screws securely.Refer to <strong>Chapter</strong> 4A, Section 5, noting thatthere where the <strong>fuel</strong> pump is mountedexternally there are no <strong>fuel</strong> pipe connectionsto the sender unit (see illustration).11 <strong>Fuel</strong> tank -removal and refitting 34BRefer to <strong>Chapter</strong> 4A, Section 6, noting thatit will be necessary to depressurise the <strong>fuel</strong>system before the feed and return hoses aredisconnected (see Section 8). It will also be12.2 Air cleaner housing-to-throttle bodyduct (Magneti Marelli <strong>fuel</strong> <strong>injection</strong> system)12.3a Disconnect the wiring connectorsfrom the throttle potentiometer . . .12.3b . . . the injector wiring loomconnector and the stepper motor12.4 <strong>Fuel</strong> feed and return hoseconnections (arrowed) - later model shown12.7 Throttle body retaining screws(arrowed) on the Bosch Mono<strong>point</strong> system


4B•6 <strong>Fuel</strong>/<strong>exhaust</strong> <strong>systems</strong> - <strong>single</strong>-<strong>point</strong> <strong>fuel</strong> <strong>injection</strong> modelsb) Ensure that the mating surfaces of themanifold and throttle body are clean anddry, then fit a new gasket. Securelytighten the throttle body retaining bolts.c) Ensure that all hoses are correctlyreconnected and, where necessary, thattheir retaining clips are securelytightened.d) On completion, adjust the acceleratorcable using the information given inSection 4.13 <strong>Fuel</strong> <strong>injection</strong> system -testing and adjustment3Testing1 If a fault appears in the <strong>fuel</strong> <strong>injection</strong>system, first ensure that all the system wiringconnectors are securely connected and freeof corrosion. Ensure that the fault is not due topoor maintenance; ie, check that the aircleaner filter element is clean, the spark plugsare in good condition and correctly gapped,the valve clearances are correctly adjusted,the cylinder compression pressures arecorrect, the ignition timing is correct, and thatthe engine breather hoses are clear andundamaged, referring to <strong>Chapter</strong>s 1, 2 and 5for further information.2 If these checks fail to reveal the cause ofthe problem, the vehicle should be taken to aPeugeot dealer for testing. A wiring blockconnector is incorporated in the enginemanagement circuit, into which a specialelectronic diagnostic tester can be plugged.The connector is clipped to the rear of theECU mounting box. The tester will locate thefault quickly and simply, alleviating the needto test all the system components individually,which is a time-consuming operation that alsocarries a risk of damaging the ECU.Adjustment3 Experienced home mechanics with aconsiderable amount of skill and equipment(including a tachometer and an accuratelycalibrated <strong>exhaust</strong> gas analyser) may be ableto check the <strong>exhaust</strong> CO level and the idlespeed. However, if these are found to be inneed of adjustment, the car must be taken toa Peugeot dealer for further testing.4 On the Fenix and Bosch <strong>systems</strong>, noadjustment is possible. Should the idle speedor <strong>exhaust</strong> gas CO level be incorrect, then afault must be present in the <strong>fuel</strong> <strong>injection</strong>system.5 On the Magneti Marelli system, it ispossible to adjust the mixture setting (<strong>exhaust</strong>gas CO level) and ignition timing. However,adjustments can be made only by reprogrammingthe ECU, using specialdiagnostic equipment connected to thesystem via the diagnostic connector.14 Fenix system components -removal and refitting3Throttle position sensor1 Disconnect the battery negative lead, thendisconnect the wiring plug from the sensor.2 Remove the two securing screws, thencarefully withdraw the sensor from the <strong>fuel</strong><strong>injection</strong> unit.3 Refitting is a reversal of removal. Noadjustment of the sensor is possible. A selfadjustingsystem is incorporated in theelectronic control unit.<strong>Fuel</strong> injectorNote: Refer to the warning note in Section 1before proceeding. If a faulty injector issuspected, before condemning the injector, itis worth trying the effect of one of theproprietary injector-cleaning treatments.4 Depressurise the <strong>fuel</strong> system with referenceto Section 85 Disconnect the battery negative lead.6 Unscrew the two securing nuts, andremove the air box from the top of the throttlehousing.7 Release the securing clip and disconnectthe injector wiring plug.8 Remove the screw securing the injectorretaining plate to the top of the <strong>fuel</strong> <strong>injection</strong>unit, lift off the retainer, then withdraw theinjector.9 Recover and discard the injector sealingrings (check to ensure that new sealing ringscan be obtained before discarding the oldones).10 Refitting is a reversal of removal, bearingin mind the following <strong>point</strong>s.a) Always renew both sealing rings, andapply a smear of grease to each to easeinjector refitting.b) Refit the injector so that its wiringterminals <strong>point</strong> towards the front of thevehicle, and locate the edge of theretainer securely in the groove at the topof the injector.c) Before refitting the injector securingscrew, apply a few drops of locking fluidto the threads.d) On completion, switch on the ignition andcheck carefully for signs of <strong>fuel</strong> leaks; ifany signs of leakage are detected, theproblem must be rectified before theengine is started.Idle speed control valve11 Disconnect the battery negative lead, thenrelease the securing clip, and disconnect thewiring plug from the valve.12 Loosen the clamps, and disconnect thetwo air hoses from the base of the valve,noting their locations in relation to the flowdirection arrow marked on the valve body.13 Loosen the two clamp nuts or bolts (asapplicable), then withdraw the valve (it may benecessary to remove the clamp completely, toprovide sufficient clearance to remove thevalve).14 Refitting is a reversal of removal, ensuringthat the valve is positioned correctly, with theair hoses connected as noted before removal.<strong>Fuel</strong> pressure regulator15 The <strong>fuel</strong> pressure regulator (consisting ofa valve operated by a spring-loadeddiaphragm and a metal cover) is secured byfour screws to the top of the throttle housing.Although the unit can be dismantled forcleaning, if required (once the air box hasbeen removed for access), it should not bedisturbed unless absolutely necessary.16 At the time of writing, it was not clearwhether the pressure regulator componentswere available separately from the completethrottle housing.17 Always depressurise the <strong>fuel</strong> systembefore disturbing any components. If theregulator cover is removed, note itsorientation on the throttle housing beforeremoval, to ensure correct refitting.Inlet air temperature sensor18 The sensor is screwed into the top of theinlet manifold.19 Disconnect the battery negative lead.20 Release the securing clip, and disconnectthe wiring plug from the sensor.21 Unscrew the sensor and withdraw it.22 Refitting is a reversal of removal.Manifold absolute pressure(MAP) sensor23 The sensor is mounted on the body frontpanel.24 Disconnect the battery negative lead, thenrelease the securing clip and disconnect thewiring plug from the sensor.25 Disconnect the vacuum hose from thesensor.26 Unscrew the two securing nuts, or bolts(as applicable), then withdraw the sensor fromthe body front panel.27 Refitting is a reversal of removal.Coolant temperature sensor28 Disconnect the electrical plug from thesensor on the water housing.29 Drain the cooling system as described in<strong>Chapter</strong> 1.30 Unscrew the sensor from the waterhousing.31 Refit in the reverse order using a newsealing washer, then top-up and bleed thecooling system with reference to <strong>Chapter</strong> 1.Engine speed/position sensor32 Disconnect the wiring lead and release itfrom the clips.33 Unscrew the bolt and withdraw the sensorfrom the engine.34 Refitting is a reversal of removal. It is notpossible to adjust the position of the sensor.


<strong>Fuel</strong>/<strong>exhaust</strong> <strong>systems</strong> - <strong>single</strong>-<strong>point</strong> <strong>fuel</strong> <strong>injection</strong> models 4B•715.3a Undo the injector cap screw, notingthe use of rag to catch <strong>fuel</strong> spray . . .15.3b . . . then lift off the cap and withdrawthe injector15.3c On refitting, ensure cap terminalsare aligned with injector pins (arrowed)15 Bosch Mono<strong>point</strong> systemcomponents - removal andrefitting3Note: Check the availability of individualcomponents with your Peugeot dealer beforedismantling.<strong>Fuel</strong> injectorNote: Refer to the warning note in Section 1before proceeding. If a faulty injector issuspected, before condemning the injector, itis worth trying the effect of one of theproprietary injector-cleaning treatments.1 Remove the inlet air temperature sensor asdescribed later in this Section.2 Lift out the injector and recover its lowersealing ring.3 Refitting is a reversal of the removalprocedure ensuring that the injector sealingring(s) and injector cap O-ring are in goodcondition. When refitting the injector capensure that the injector pins are aligned withthe cap terminals, the terminals are marked “+”and “-” for identification (see illustrations).8 Refitting is a reverse of the removalprocedure, ensuring that the diaphragm andcover are fitted the correct way round, andthat the retaining screws are securelytightened.Idle control stepper motor9 Disconnect the battery negative terminal.10 Depress the retaining clip and disconnectthe wiring connector from the idle controlstepper motor.11 Undo the retaining screws and removethe motor from the front of the throttle body(see illustration).12 Refitting is a reverse of the removalprocedure, ensuring that the motor retainingscrews are securely tightened.Throttle potentiometer13 The throttle potentiometer is a sealed unit,and under no circumstances should it bedisturbed. For this reason, on some models, itis secured to the throttle body assembly bytamperproof screws. If the throttlepotentiometer is faulty, the complete throttlebody assembly must be renewed - refer toyour Peugeot dealer for the latest information.Inlet air temperature sensorNote: Refer to the warning note in Section 1before proceeding.14 The inlet air temperature sensor is anintegral part of the throttle body injector cap.To remove the cap, first disconnect thebattery negative terminal, then remove the aircleaner-to-throttle body duct using theinformation given in Section 2.15 Undo the three retaining screws andremove the circular plastic ring from the top ofthe throttle body and recover its sealing ring(see illustrations).16 Depress the retaining clip and disconnect4B<strong>Fuel</strong> pressure regulatorNote: Refer to the warning note in Section 1before proceeding. At the time of writing, the<strong>fuel</strong> pressure regulator assembly was notavailable separately from the throttle bodyassembly. Refer to a Peugeot dealer for thelatest information. Although the unit can bedismantled for cleaning, if required, it shouldnot be disturbed unless absolutely necessary.4 Disconnect the battery negative terminal.5 Remove the air cleaner-to-throttle bodyduct, using the information given in Section 2.6 Using a marker pen, make alignment marksbetween the regulator cover and throttlebody, then slacken and remove the coverscrews (see illustration). As the screws areslackened, place a clean rag over the cover tocatch any <strong>fuel</strong> spray which may be released.7 Lift off the cover, then remove the springand withdraw the diaphragm, noting itscorrect fitted orientation. Remove all traces ofdirt and examine the diaphragm for signs ofsplitting. If damage is found, it will probablybe necessary to renew the throttle bodyassembly.15.6 <strong>Fuel</strong> pressure regulatorretaining screws (arrowed)15.15a Undo the three retaining screws(arrowed) . . .15.11 Idle control stepper motorretaining screws (arrowed)15.15b . . . then lift off the plastic ring andrecover the sealing ring


4B•8 <strong>Fuel</strong>/<strong>exhaust</strong> <strong>systems</strong> - <strong>single</strong>-<strong>point</strong> <strong>fuel</strong> <strong>injection</strong> models15.16 Disconnecting the injector wiringconnector. Injector screw is arrowedthe wiring connector from the injector wiringconnector (see illustration).17 Undo the injector cap retaining screw,then lift off the cap and recover the gasketand/or sealing ring (as applicable). Note thatas the cap screw is slackened, place a ragover the injector to catch any <strong>fuel</strong> spray whichmay be released.18 Refitting is a reversal of the removalprocedure ensuring that the injector capgasket and/or O-ring is in good condition.Take care to ensure that the cap terminals arecorrectly aligned with the injector pins andsecurely tighten the cap retaining screw.Coolant temperature sensor19 Refer to <strong>Chapter</strong> 3.Electronic control unit (ECU)20 The ECU is located in the plastic boxwhich is mounted onto the rear of the batterymounting tray.21 To remove the ECU, first disconnect thebattery.22 Unclip the cover from the box, then lift theretaining clip and disconnect the wiringconnector from the ECU.23 Undo the retaining nut and release therelay unit from the rear of the ECU box.24 Undo the retaining screws and removethe ECU and box assembly from the batterytray. If necessary, undo the retaining screwsand separate the ECU and box.25 Refitting is a reverse of the removalprocedure ensuring that the wiring connectoris securely reconnected.<strong>Fuel</strong> <strong>injection</strong> system relay unit26 The relay unit is mounted onto the rear ofthe ECU plastic box which is situated directlybehind the battery.27 To remove the relay unit, first disconnectthe battery.28 Undo the retaining nut, then disconnectthe wiring connector and remove the relay unitfrom the vehicle.29 Refitting is the reverse of removal,ensuring that the relay unit is securely clippedin position.Crankshaft sensor30 The crankshaft sensor is situated on thefront face of the transmission (clutch) housing.31 To remove the sensor, first disconnect thebattery negative terminal.32 Trace the wiring back from the sensor tothe wiring connector, and disconnect it fromthe main harness.33 Prise out the rubber grommet, then undothe retaining bolt and withdraw the sensorfrom the transmission.34 Refitting is a reverse of the removalprocedure. Ensure that the sensor retainingbolt is securely tightened, and that thegrommet is correctly seated in thetransmission housing.Vehicle speed sensor35 The vehicle speed sensor is an integralpart of the speedometer drive housing. Referto <strong>Chapter</strong> 7A, Section 7 for removal andrefitting details.16 Magneti Marelli systemcomponents - removal and 3refittingNote: Check the availability of individualcomponents with your Peugeot dealer beforedismantling.<strong>Fuel</strong> injectorNote: Refer to the warning note in Section 1before proceeding.Note: If a faulty injector is suspected, beforecondemning the injector, it is worth trying theeffect of one of the proprietary injectorcleaningtreatments. If this fails, the vehicleshould be taken to a Peugeot dealer fortesting using the appropriate specialistequipment. At the time of writing, it appearsthat neither the <strong>fuel</strong> injector nor its seals areavailable separately and, if faulty, thecomplete upper throttle body assembly mustbe renewed. Refer to your Peugeot dealer forfurther information on parts availability.1 Disconnect the battery negative terminal.2 Remove the air cleaner-to-throttle bodyduct using the information given in Section 2.3 Release the retaining tangs and disconnectthe injector wiring connector (seeillustration).4 Undo the retaining screw, then remove theretaining clip and lift the injector out of the16.3 Injector wiring connector (arrowed)housing, noting its sealing ring. Note that asthe screw is slackened, place a rag over theinjector to catch any <strong>fuel</strong> spray which may bereleased.5 Refitting is a reverse of the removalprocedure ensuring that the injector sealingring is in good condition.<strong>Fuel</strong> pressure regulatorNote: Refer to the warning note at the start ofthis Section before proceeding.Note: At the time of writing, it appears that the<strong>fuel</strong> pressure regulator is not availableseparately. If the <strong>fuel</strong> pressure regulatorassembly is faulty, the complete upper throttlebody assembly must be renewed. Refer to aPeugeot dealer for further information on partsavailability. Although the unit can bedismantled for cleaning, if required, it shouldnot be disturbed unless absolutely necessary.6 Disconnect the battery negative terminal.7 Remove the air cleaner-to-throttle bodyduct using the information given in Section 2.8 Using a suitable marker pen, makealignment marks between the regulator coverand throttle body, then undo the four retainingscrews. Note that as the screws areslackened, place a rag over the cover to catchany <strong>fuel</strong> spray which may be released.9 Lift off the cover, then remove the springand withdraw the diaphragm whilst noting itscorrect fitted orientation. Remove all traces ofdirt and examine the diaphragm for splitting. Ifdamage is found, it will be necessary to renewthe complete upper throttle body assembly asdescribed earlier in this Section.10 Refitting is a reverse of the removalprocedure ensuring that the diaphragm andcover are fitted the correct way around andthe retaining screws are securely tightened.Idle control stepper motor11 Disconnect the battery negative terminal.12 To remove the stepper motor, depress theretaining tabs and disconnect the wiringconnector. Undo the two retaining screws andwithdraw the motor from the side of thethrottle body assembly.13 Refitting is a reverse of removal.Throttle potentiometer14 Disconnect the battery negative terminal,then depress the retaining tabs anddisconnect the wiring connect from thethrottle potentiometer (see illustration).15 Undo the two retaining screws andremove the throttle potentiometer from theside of the throttle body assembly.16 Refitting is a reversal of the removalprocedure ensuring that the throttlepotentiometer tang is correctly engaged withthe throttle spindle.Inlet air temperature sensor17 The inlet air temperature sensor isscrewed into the underside of the upperthrottle body where it is situated on the lefthandside of the <strong>fuel</strong> injector.


<strong>Fuel</strong>/<strong>exhaust</strong> <strong>systems</strong> - <strong>single</strong>-<strong>point</strong> <strong>fuel</strong> <strong>injection</strong> models 4B•916.14 Throttle potentiometer wiringconnector (arrowed)18 To remove the sensor, first disconnect thebattery negative terminal.19 Disconnect the wiring connector, thenundo the retaining screw and remove the inletair temperature sensor from the throttle body.Note: The sensor retaining screw is verydifficult to reach. If it proves impossible tounscrew, the throttle body will have to beremoved to permit sensor removal.20 Refitting is a reverse of removal.Manifold absolute pressure(MAP) sensor21 The MAP sensor is mounted onto abracket which is situated on the enginecompartment bulkhead, behind the throttlebody.22 To remove the sensor, first disconnect thebattery negative terminal.23 Slacken and remove the three retainingbolts, then free the MAP sensor from thebracket. Disconnect the wiring connector andvacuum hose and remove the sensor from theengine compartment.24 Refitting is a reversal of the removalprocedure.Coolant temperature sensor25 Refer to <strong>Chapter</strong> 3.Crankshaft sensor26 Refer to Section 14.Electronic control unit (ECU)27 Refer to Section 14.<strong>Fuel</strong> <strong>injection</strong> system relay unit28 Refer to Section 14.Throttle body heating element29 The throttle body heating element issituated in the front of the throttle body.30 To remove the element, first disconnectthe battery negative terminal.31 Remove the air cleaner housing-tothrottlebody duct using the information givenin Section 2.32 Disconnect the wiring connectors fromthe inlet air temperature sensor and theinjector. Also disconnect the main wiringconnector from the throttle body and free theconnector from its mounting bracket.33 Undo the retaining screws and free theaccelerator mounting bracket from the throttlebody. As the bracket is released, recover thespring from the front of the heating element.34 Ease the heating element out from thethrottle housing and remove it along with thewiring connector and wiring harness. Examinethe O-ring for signs of damage ordeterioration and renew if necessary.35 Refitting is a reversal of removal; wherenecessary, use a new O-ring.17 Inlet manifold -removal and refitting3Removal1 Remove the throttle body (Section 12).2 Drain the cooling system (see <strong>Chapter</strong> 1).3 Slacken the retaining clip and disconnectthe coolant hose(s) from the manifold.4 Slacken the retaining clip and disconnectthe vacuum servo unit hose from the left-handside of the manifold.5 Make a final check that all the necessaryvacuum/breather hoses have beendisconnected from the manifold.6 Unscrew the retaining nuts, thenmanoeuvre the manifold away from the headand out of the engine compartment. Note thatthere is no manifold gasket.Refitting7 Refitting is the reverse of the removalprocedure, noting the following <strong>point</strong>s:a) Ensure that the manifold and cylinderhead mating surfaces are clean and dry,and apply a thin coating of suitablesealing compound to the manifold matingsurface. Refit the manifold and tighten itsretaining nuts to the specified torque.b) Ensure that all relevant hoses arereconnected to their original positions andsecurely held (where necessary) by theirretaining clips.c) Refit the throttle body as described inSection 12.d) On completion, refill the cooling systemas described in <strong>Chapter</strong> 1.18 Exhaust manifold -removal and refitting3Removal1 Refer to <strong>Chapter</strong> 4A, Section 15, noting thatthe lambda (oxygen) sensor wiring connectorsshould be disconnected. Alternatively, caremust be taken to support the front pipe, toavoid any strain being placed on the sensorwiring.Refitting2 Refitting is the reverse of the removalprocedure, noting the following <strong>point</strong>s:a) Examine all the <strong>exhaust</strong> manifold studs forsigns of damage and corrosion; removeall traces of corrosion, and repair orrenew any damaged studs.b) Ensure that the manifold and cylinderhead sealing faces are clean and flat, andfit the new manifold gaskets. Tighten themanifold retaining nuts to the specifiedtorque.c) Reconnect the front pipe to the manifold.19 Exhaust system -general information, removal3and refittingRefer to <strong>Chapter</strong> 4A, Section 16, howevernote that it will be necessary to disconnectthe lambda (oxygen) sensor wiring connectorsin order to remove the front pipe/completesystem. On refitting, ensure that the sensorwiring is retained by all the relevant retainingclips so that it is in no danger of contactingthe hot <strong>exhaust</strong>/engine.4B

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