Peugeot 205 GTI 1.9 - Box 11

Kit 41

Parts of kit

41A Exhaust front pipe
41B Exhaust mid pipe
41C Catalytic converter bottom
41D Catalytic converter top
41E Speaker with cable C (red - green)
41F Speaker bracket
41G Cable D ( gray - white )
41H Cable E ( gray - white )
41I Cable K ( red - black )
AP M 1,7 x 4 mm (x 3)
BM M 2,0 x 4 mm (x 4)

41A Exhaust front pipe41B Exhaust mid pipe41C Catalytic converter bottom41D Catalytic converter top41E Speaker with cable C (red - green)41F Speaker bracket41G Cable D ( gray - white )41H Cable E ( gray - white )41I Cable K ( red - black )AP M 1,7 x 4 mm (x 3)BM M 2,0 x 4 mm (x 4)

Step 1

Minding red circled markings and green arrow direction engravings alignment , fit 41A front ( 1 ) and 41B mid ( 2 ) Exhaust pipes to 41D Catalytic converter top nests , and then cover and fix to 41C Catalytic converter bottom with two AP screws ( bottom illustrations ).

Pre assembled Catalytic converter and Exhaust pipes.

Fit 41E Speaker with cable C ( red - green ) to the nest on 23A Firewall and secure it with three BM screws through 41F Speaker bracket.

Fit 41E Speaker with cable C ( red - green ) fitted to 23A Firewall.

Assembly drawings

General view

Kit 42

Parts of kit

42A Exhaust silencer top
42B Exhaust exit pipe
42C Exhaust silencer bottom
42D Exhaust silencer clip
42E Exhaust mount
42F Replacement decal ( x2 , one spare )
AP M 1,7 x 4 mm (x 5)
CM M 1,7 x 4 mm (x 2)

42A Exhaust silencer top42B Exhaust exit pipe42C Exhaust silencer bottom42D Exhaust silencer clip42E Exhaust mount42F Replacement decal ( x2 , one spare ) AP M 1,7 x 4 mm (x 5)CM M 1,7 x 4 mm (x 2)

Step 2

Minding red circled markings and green arrow direction engravings alignment , fit 41B Exhaust mid pipe ( 3 ) and 42B Exhaust exit pipe ( 4 ) to 42A Exhaust silencer top nests , and fix each one with AP screw.

Align 42A Exhaust silencer top to 42C Exhaust silencer bottom following engraved arrows pointed by green arrow.

Fix 42A Exhaust silencer top to 42C Exhaust silencer bottom with two AP screws.

Assembled Exhaust line

Fit 42E Exhaust mount to 30A Chassis rear section and fix with CM screw ( top and bottom illustrations ).

Fit 42F Replacement decal in water for 15 seconds , and gently slide it off backing paper , using pincers , to replace ( new on top of olad one ) existing decal on 10A Front wheel left arc frame ( top and bottom illustrations ).

Assembly drawings

General view

Kit 43

Parts of kit

43A Right side fuel tank
43B Fuel return pipe
43C Jack stands ( x4 )
43D Lock nut
43E Lock nut keeper
43F Battery compartment
AP M 1,7 x 4 mm (x 5)
BM M 2,0 x 4 mm (x 3)
JP M 1,7 x 4 mm (tête plate x 3)
Touch up paint

43A Right side fuel tank43B Fuel return pipe43C Jack stands ( x4 )43D Lock nut43E Lock nut keeper43F Battery compartmentAP M 1,7 x 4 mm (x 5)BM M 2,0 x 4 mm (x 3)JP M 1,7 x 4 mm (tête plate x 3)Touch up paint

Step 3

Pass one end of 43B Fuel return pipe down into blue circled area between 24A Coolant bottle and 26A Air filter housing.

Turn chassis over and continue to lead 43B Fuel return pipe vis three 23B Clamps leaving the end loose.

43B Fuel return pipe fit along chassis panel . Note 11I Fuel feed pipe loose end to be used in further assembly.

Turn the chassis back on wheels , and fit 43B Fuel return pipe to 7E Fuel injection rail stub-pipe.

43B Fuel return pipe fitted to 7E Fuel injection rail stub-pipe.

Fit 43D Lock nut to 43A Right side fuel tank niche and secure it with 43E Lock nut keeper and two JP screws.

Fit 43F Battery compartment switch to 43A Right side fuel tank on two guides ( green arrows ) and fix with two AP screws ( blue arrows ) . Fit 43F Battery compartment main body into 43A Right side fuel tank and fix it with two AP screws ( red arrows ).

Fit 43A Right side fuel tank to the niche on 22A Chassis panel and fix with two BM screws ( bottom illustrations ).

Fit 11I Fuel feed pipe loose end to the hole on 43A Right side fuel tank ( blue arrow ) . Fit 43B Fuel return pipe loose end to the hole on 43A Right side fuel tank ( green arrow ). Test fit and nip off extra lengths of pipes to minimize bulging.

Assembly drawings

General view

Kit 44

Parts of kit

44A Left side fuel tank
44B Heatshield
44C Brake line clamp
44D Battery cover
44E Battery cover lock
44F Washer
44G Pop up sring
44H Circuit board
44I Saloon lamp cable H ( green - red )
44J Rear lights cable F ( blue - white )
AP M 1,7 x 4 mm (x 5)

44A Left side fuel tank44B Heatshield44C Brake line clamp44D Battery cover44E Battery cover lock44F Washer44G Pop up sring44H Circuit board44I Saloon lamp cable H ( green - red )44J Rear lights cable F ( blue - white )AP M 1,7 x 4 mm (x 5)

Step 4

Fit 44H Circuit board into 44A Left side fuel tank and fix with four AP screws . ( note the mutual orientation of parts on lower illustration)

Refer to this illustration throught the assembly process . 44H Circuit board nests to be used in assembly , are pointed by red arrows with respective letter codes .

Fit 41E Speaker cable C ( red - green ) plug into square opening in 22A Chassis panel ( red arrow ) , then lead and plug it to Nest C of 44H Circuit board , on the bottom side of chassis ( upper and lower illustrations ).

Plug 43F Battery compartment cable A ( red - black ) to Nest A of 44H Circuit board as shown next.

43F Battery compartment cable A ( red - black ) plugged into Nest A of 44H Circuit board.

Fit one by one , 44I Saloon lamp cable H ( green - red ) , 44J Rear lights cable F ( blue - white ) and 41G cable D ( gray - white ) plugs into square opening in 22A Chassis panel , then lead and plug them to Nests H ,F , D respectively of 44H Circuit board , on the bottom side of chassis ( upper and lower illustrations ).

Fit one by one , 41I Cable K ( black - red ) and 41H cable E ( gray - white ) plugs into square opening in 22A Chassis panel ( red arrows ) , then lead and plug them to Nests K and E respectively of 44H Circuit board , on the bottom side of chassis ( upper and lower illustrations ).

Fit 44E Battery cover lock screw through 44D Battery cover.

Fit one by one , 44G Pop up spring and 44F Washer on 44E Battery cover lock screw.

44G Pop up spring and 44F Washer fitted to 44E Battery cover lock screw.

Fit 44D Battery cover to 43A Right side fuel tank and fix 44E Battery cover lock with screwdriver.

With 44D Battery cover in place , you may turn over ( blue arrow ) 44A Left side fuel tank over to better protect attached cables when putting chassis back on wheels , to keep it for later assembly stages.