Peugeot 205 GTI 1.9 - Box 2

Fit 5G Bracket to 5E rear cover and fix with two BM screws.

Fit 5A Oil sump to 5D Bottom Gearbox housing and fix with two BM screws. Fit 5G Bracket to 5D Bottom Gearbox housing and fix with BM screw.

Fit 5F Top Gearbox housing to 5D Bottom Gearbox housing and fix with two BM screws.

Fit 5H Mount plate to 5E Rear cover and fix with BM screw.

Fit 6D Ignition distributor 1 to 6B Cylinder head cover and fix with AP screw. Fit 6E Ignition distributor 2 to 6D Ignition distributor 1 and fix with AP screw.

Fit 6G Distributor cap and 6F Vacuum Advance distributor to 6E Ignition distributor 2. Fit 6I Exhaust manifold to 6A Cylinder head and fix with two AP screws.

Fit 6B Cylinder head cover to 6A Cylinder head and fix with two AP screws. Fit 6L Ignition distributor 3 to 6H Thermostat housing and fix with AP screw.

Fit 6H Thermostat housing to 6A Cylinder head and fix with two CM screws. Fit 6K Lead guides to 6D Ignition distributor 1 and 6E Ignition distributor 2 respectively.

Connect one end of 6J High tension lead to pointed 6A Spark Plug and the other end to pointed 6G Distributor cap contact. Fit loose stretch of 6J High tension lead to lowest slots of 6K Lead guides. Connect one end of 6J High tension lead to pointed 6A Spark Plug and the other end to pointed 6G Distributor cap contact. Fit loose stretch of 6J High tension lead to next higher slot of 6K Lead guides.

Connect one end of 6J High tension lead to pointed 6A Spark Plug and the other end to pointed 6G Distributor cap contact. Fit loose stretch of 6J High tension lead to next higher slot of 6K Lead guides. Connect one end of 6J High tension lead to pointed 6A Spark Plug and the other end to pointed 6G Distributor cap contact. Fit loose stretch of 6J High tension lead to highest slots of 6K Lead guides.

Connect the oil breather hose 6C to the nozzle on the cylinder head cover 6B.

Fit 7C Vacuum hose and 7D Oil breather hose to 7B Oil filler housing. Fit 7G Fuel pressure regulator to 7E Fuel injection feed rail. Fit 7E Fuel injection feed rail to 7A Intake manifold.

Fit 7F Gas hose bracket to 7E Fuel injection feed rail. Fit 7C Vacuum hose to 7G Fuel pressure regulator and 7A Intake manifold nozzles.

Fit four 7H Fuel injectors to 6A Cylinder head.

Start fitting 7A Intake manifold to 6A Cylinder head. At the same time ( continued on next page) aim four 7H Fuel injectors to enter in their respective sockets on 7E Fuel injection feed rail.

Fix connected 7A Intake manifold and 6A Cylinder head with two BM screws.

Fit 8C Oil filter to 8A Left Engine block with 8B Oil Cooler in between , and fix with AP screw. Fit 8A Left Engine block to 6A Cylinder head and fix with two BM screws.

Fit 8F Right Engine block to 5B Bracket and fix with two BM screws. Fit together 8F Right and 8A Left Engine blocks and fix with two BM screws.

Fit 8G Drive shaft extension to 5F Top Gearbox housing socket and 8F Right Engine block and fix with AM screw. Fit 8H Oil dipstick to the socket in 8F Right Engine block. Fit 8I Heater pipe to the nozzle of 8F Right Engine block. 

Fit two 8D Oil hoses to both 8B Oil cooler nozzles. Fit 8E Starter motor to 8A Left Engine block.

Pass 6C Oil breather hose via 7A Intake manifold V-shape passage , leading it down to fit on 7B Oil filler housing lower side nozzle . Fit 7B Oil filler housing to the socket of 8A Left Engine block.

Pass 7D Oil breather hose via 7A Intake manifold V-shape passage , leading it down to fit on 8A Left Engine block nozzle ( illustration below ).