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Peugeot 205 GTI 1.9 - Box 6
BOX 6 - Kits 21-22-23-24
Kit 21
The parts of kit 21
- 21A Radiator case
- 21B Rear panel
- 21C Cooling fan
- 21D Cooling fan frame
- 21E Oil radiator
- 21F Coolant hose
- 21G Coolant hose
- 21H Cooling fan motor grid
- AP M 1,7 x 4 mm (x 5)
- DP M 1,7 x 3 mm (x 7)
- EP M 1,7 x 3 x 5 mm (x 2)
- BM M 2,0 x 4 mm (x 3)
Step 1
Fit 21B Cooling fan to 21C Cooling fan frame with EP screw.
Fit 21H Cooling fan motor grid by its three pegs to 21C Cooling fan frame.
Connect 8D Oil hoses to 21D Oil radiator nozzles , and fit the latter to 21A Radiator case.
Fit 21C Cooling fan frame to 21A Radiator case and fix with four AP screws.
Assembly drawings
General view
Kit 22
The parts of kit 22
- 22A Chassis panel
- 22B Pinion shaft support
- AM M 1,7 x 3 mm (x 2)
- BM M 2,0 x 4 mm (x 8)
Step 2
Remove the spacer plank by undoing two screws.
Align 22A Chassis panel to 10A Front wheel arc frame bars . Pass 11I Fuel feed pipe under 22A Chassis panel ( see next illustration ) and leave 12G and 14G Brake fluid pipes on top of 22A Chassis panel.
Lead out 11I Fuel feed pipe and leave loose.
Fix 22A Chassis panel to 10A Front wheel arc frame with six BM screws.
Fit 22B Pinion shaft support to 22A Chassis planel and 17D Pinion shaft ( illustration below ) and fix with AM screw.
Check function of front wheels steering mechanism : turn any of front wheels ( blue arrow ) to observe in response 17G Shaft rotation ( green arrow ) and vice versa ; turn 17G Shaft ( green arrow ) to observe front wheels turning in response ( blue arrow ).
Assembly drawings
General view
Kit 23
The parts of kit 23
- 23A Firewall
- 23B Fuel/brake lines clamp ( x3 )
- 23C Brake line clamp ( x2 )
- AM M 1,7 x 3 mm (x 3)
Step 3
Fit three 23B Fuel/brake lines clamps to the bottom of 22A Chassis panel.
Pass 11I Fuel feed pipe through three 23B Fuel/brake lines clamps.
Fit two 23C Brake lines clamp to the bottom of 22A Chassis panel and fix each one with AM screw.
Final close-up.
Assembly drawings
General view
Kit 24
The parts of kit 24
- 24A Coolant expansion bottle top
- 24B Coolant expansion bottle bottom
- 24C Cap
- 24D Coolant level sensor
- 24E Coolant level sensor pipe
- 24F Coolant overflow hose
- 24G Radiator coolant hose
- 24H Engine block coolant hose
- 24I Engine wiring loom
- AP 1,7 x 4 mm (x 3)
Step 4
Fit together 24A and 24B Coolant expansion bottle Top and Bottom and fix with AP screw.
Fit 24B Coolant expansion bottle bottom to 23A Firewall and fix with AP screw.
Fit one end of 24E Coolant level sensor pipe to 24D Coolant level sensor , fitting the latter to 24A Coolant expansion bottle top , and free end of 24E Coolant level sensor pipe to lower nozzle on 23A Firewall.
Fit one end of 24F Coolant overflow hose to 24C Cap , fitting the latter to 24A Coolant expansion bottle top , and lead free end of 24F Coolant overflow hose through support ring on the lower side of 24A Coolant expansion bottle top.
Fit 24G Radiator coolant hose to the nozzle on 24A Coolant expansion bottle top.
Fit 24I Engine wiring loom to upper nozzle on 23A Firewall.
Fit 24H Engine block coolant hose to the socket on 8F Right Engine block ( bottom illustrations ).