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Peugeot 205 GTI 1.9 - Box 20
BOX 20 - Kits 77-78-79-80
Kit 77
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The parts of kit 77
- 77A Tailgate deco panel
- 77B Tailgate lock
- 77C Lock button
- 77D Tailgate glass with heater
- AP M 1,7 x 4 mm (x 4)
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Step 1
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Fit 77A Tailgate deco panel to 76A Tailgate frame and fix with two AP screws.
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77A Tailgate panel is attached to 76A Tailgate.
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Assembly drawings
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General view
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Kit 78
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The parts of kit 78
- 78A Tailgate inner panel
- 78B Rear wiper arm
- 78C Rear wiper blade
- AM M 1,7 x 3 mm (x 8)
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Step 2
Fit 78A Tailgate inner panel to 76A Tailgate frame with 77D Tailgate glass in between.
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Fix 78A Tailgate inner panel to 76A Tailgate with eight AM screws.
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Fit 78C Rear wiper blade to 78B Rear wiper arm.
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Fit 78B Rear wiper arm to 76A Tailgate.
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78B Rear wiper arm is attached to 76A Tailgate.
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Assembly drawings
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General view
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Kit 79
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The parts of kit 79
- 79A Tailgate spoiler
- 79B Bracket ( x2 )
- 79C Tailgate strut piston ( x2 )
- 79D Tailgate strut cylinder ( x2 )
- 79E Tailgate hinge clamp ( x2 )
- 79F Rear shelf support rope ( x2 )
- AM M 1,7 x 3 mm (x 3)
- BM M 2,0 x 4 mm (x 5)
- CM M 1,7 x 4 mm (x 3)
- DP M 1,7 x 3 mm (x 5)
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Step 3
Fit 79A Tailgate spoiler to 76A Tailgate and fix it to 77D Tailgate glass with two DP screws.
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Fit DP screw to upper right corner of 78A Tailgate inner panel , leaving space under screw head to loop over and tie to knot first 79F Rear shelf support rope ( lower illustrations )
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Fit DP screw to upper left corner of 78A Tailgate inner panel , leaving space under screw head to loop over and tie to knot second 79F Rear shelf support rope (lower illustrations )
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Make two assemblies of 79C Tailgate strut piston fitted to shorter tab of 79B Bracket and fixed with AM screw.
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Fit 79B Bracket by its longer tab to 76A Tailgate frame right side and fix with CM screw.
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Fit 79B Bracket by its longer tab to 76A Tailgate frame left side and fix with CM screw.
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Preassembled Tailgate.
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Fit 76A Tailgate to 64A Body frame rear opening , fitting 76B Left and 76C Right tailgate hinge axles into respective grooves in 64A Body frame inner ceiling edge ( lower illustrations ).
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Fit 79E Tailgate hinge clamps over 76B Left and 76C Right tailgate hinge axles and fix them with four BM screws ( don’t tighten too much BM screws at this moment ). With closed Tailgate , tighten two AM screws
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Check opening and closing of 64A Tailgate . Adjust tension of four BM screws ( previous illustration ) if needed for smooth work of hinges.
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Assembly drawings
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General view
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Kit 80
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The parts of kit 80
- 80A Ceiling panel
- 80B Assist handle ( x3 )
- 80C Interior lamp cable F
- 80D Tape ( x3 )
- HP M 1,5 x 3 mm (x 7)
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Step 4
One by one , fit three 80B Assist handles to 80A Ceiling lining and fix each one with two HP screws ( lower illustrations )
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Fit 80C Interior lamp LED into 80A Ceiling lining socket ( red arrow ) , check it showing on the opposite side ( lower illustrations )
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Lead 80C Interior lamp cable F along the groove on 80A Ceiling lining and fix with three 80D tape pieces.
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Assembly drawings
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General view
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