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Peugeot 205 GTI 1.9 - Box 11
BOX 11 - Kits 41-42-43-44
Kit 41
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The parts of kit 41
- 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)
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Step 1
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Assembly drawings
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General view
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Kit 42
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The parts of kit 42
- 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)
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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.
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Align 42A Exhaust silencer top to 42C Exhaust silencer bottom following engraved arrows pointed by green arrow.
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Fix 42A Exhaust silencer top to 42C Exhaust silencer bottom with two AP screws.
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Assembled Exhaust line
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Fit 42E Exhaust mount to 30A Chassis rear section and fix with CM screw ( top and bottom illustrations ).
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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 ).
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Assembly drawings
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General view
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Kit 43
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The parts of kit 43
- 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
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Step 3
Pass one end of 43B Fuel return pipe down into blue circled area between 24A Coolant bottle and 26A Air filter housing.
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Turn chassis over and continue to lead 43B Fuel return pipe vis three 23B Clamps leaving the end loose.
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43B Fuel return pipe fit along chassis panel . Note 11I Fuel feed pipe loose end to be used in further assembly.
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Turn the chassis back on wheels , and fit 43B Fuel return pipe to 7E Fuel injection rail stub-pipe.
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43B Fuel return pipe fitted to 7E Fuel injection rail stub-pipe.
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Fit 43D Lock nut to 43A Right side fuel tank niche and secure it with 43E Lock nut keeper and two JP screws.
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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 ).
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Fit 43A Right side fuel tank to the niche on 22A Chassis panel and fix with two BM screws ( bottom illustrations ).
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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.
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Assembly drawings
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General view
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Kit 44
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The parts of kit 44
- 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)
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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)
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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 .
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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 ).
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Plug 43F Battery compartment cable A ( red - black ) to Nest A of 44H Circuit board as shown next.
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43F Battery compartment cable A ( red - black ) plugged into Nest A of 44H Circuit board.
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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 ).
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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 ).
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Fit 44E Battery cover lock screw through 44D Battery cover.
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Fit one by one , 44G Pop up spring and 44F Washer on 44E Battery cover lock screw.
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44G Pop up spring and 44F Washer fitted to 44E Battery cover lock screw.
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Fit 44D Battery cover to 43A Right side fuel tank and fix 44E Battery cover lock with screwdriver.
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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.
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Assembly drawings
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General view
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