Peugeot 205 GTI 1.9 - Box 7

Fit 25A Brakes master cylinder to 23A Firewall and fix with CP screw.

Fit 25G Clamp to 23A Firewall and fix with AM screw.

Pass 25F Rear right brake line behind 24A Coolant expansion bottle top, through 25G Clip and fit to the pointed nozzle on 25A Brakes master cylinder.

Fit 25E Rear left brake line to the pointed nozzle on 25A Brakes master cylinder.

Detail view.

Fit together 26F and 26G Filter to Flow meter Duct halves and fix them with two AP screws . Fit 26D Air intake Duct half to 26A Air filter Housing half and fix them with AP screw .

Fit 26E Air intake Duct half to 26D Air intake Duct half and fix with three AP screws . Fit 26B Air filter Housing half to 26A Air filter Housing half and fix with AP screw.

Fit 26C Air filter Support to 23A Firewall and fix with two AM screws.

Fit 26B Air filter Housing half to 26C Air filter Support and fix with two AP screws.

Prior to installation of pre assembled 23A Firewall to Engine compartment , and for further assembly convenience , identify : 8I Heater pipe , 24H Coolant hose , 12G and 14G Brake fluid pipes.

Pass 25E Rear left and 25F Rear right brake fluid lines under 22A Chassis panel ( illustration below ) , denoted by green dashed lines . Fit 12G Brake line to 25A Brakes master cylinder nozzle ( blue dashed line and arrow ) . Pass 14G Brake line through 25G Clamp ( blue dashed line and arrow , and refer to illustration below ) . Fit 8I Heater pipe ( see page 6 top image ) to the nozzle on 23A Firewall ( blue arrow , and refer to illustration below )

25E Rear left and 25F Rear right brake fluid lines passed under 22A Chassis panel .

Carefully note that 24B Coolant bottle bottom socket should be connected to 24H Coolant hose , during 23A Firewall final positioning.

Move 23A Firewall to fit to 22A Chassis panel attachment points and two pockets on 10A Front wheel arcs , all pointed by four blue arrows.

Make sure 17G Shaft exits through 23A Firewall as shown below . Fix 23A Firewall to 22A Chassis panel attachment points with two BM screws.

Fit 14G Brake fluid line , passing through 25G Clamp , to 25A Brakes master cylinder.

Pass 25E Rear left and 25F Rear right brake fluid lines through two 23C and three 23B Clamps respectively.

Fit 24G Radiator coolant hose to 21E Radiator Rear panel nozzle ( see image below ).

Fit 24I Engine wiring loom to 7A Intake manifold nozzle.

Fit 27A Air flow meter cap and 27C Air duct to 27B Air flow meter.

Fit 27F Throttle command link and 27E Throttle position sensor to 27D Throttle body.

Fit 27D Throttle body to 27C Air duct.

Connect 26F Air duct to 27B Air flow meter and fix with AP screw.

Fit 26F Air duct to 26A/B Air filter Housing and 27D Throttle body to 7A Intake manifold socket , passing under 26D/E Air duct and 10B Hose.

Fit 7C Vacuum hose to 27D Throttle body nozzle.

Fit 10B Hose to 25C Brakes booster nozzle.

Fit 28B Battery top to 28A Battery and fix with two AP screws.

Fit 28D Positive terminal to 28A Battery through 28B Battery top. Fit 28C Ground terminal to 28A Battery through 28B Battery top and fix with AP screw.

Fit 28A Battery to 28E Battery tray and fix with two AP screws.

Fit 28F Battery cables between 28E Battery tray nozzles and 28D Positive terminal , and 28C Ground terminal respectively.

Connect 11C Washer fluid hose to 28E Battery tray nozzle and then fit the latter to 10A Front wheels arc frame , fixing it with two BM screws . ( bottom images ).

Battery installed into Engine Bay