Guide: GTI6 collected info

[cully]

Technical Data


  wheels.pdf (Size: 34 KB / Downloads: 257)

  wheel alignment.pdf (Size: 35.49 KB / Downloads: 239)

  vin engine number location.pdf (Size: 46.01 KB / Downloads: 240)

  Timing belt replacement interva.pdf (Size: 219.59 KB / Downloads: 337)

  service reset.pdf (Size: 48.3 KB / Downloads: 202)

  belt-jacking.pdf (Size: 761.12 KB / Downloads: 253)

  technical data.pdf (Size: 128.2 KB / Downloads: 225)

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Known Fixes


  airbag-srs.pdf (Size: 11.62 KB / Downloads: 214)

  body.pdf (Size: 10.91 KB / Downloads: 226)

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Engine managment pin data


  engine managment pin data.pdf (Size: 681.81 KB / Downloads: 260)

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Engine bay Layout


  enginebay layout.pdf (Size: 126.04 KB / Downloads: 231)

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Engine management component testing


  Control system.pdf (Size: 98.23 KB / Downloads: 195)

  Emission control system.pdf (Size: 89.42 KB / Downloads: 216)

  Engine sensors.pdf (Size: 166.64 KB / Downloads: 273)

  fuel system.pdf (Size: 165.01 KB / Downloads: 192)

  Ignition system.pdf (Size: 109.1 KB / Downloads: 213)

  Intake system.pdf (Size: 150.65 KB / Downloads: 225)

  service adjustments.pdf (Size: 12.83 KB / Downloads: 198)

  Vehicle sensors.pdf (Size: 83.13 KB / Downloads: 204)

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Fault Finding


  backfiring.pdf (Size: 10.79 KB / Downloads: 181)

  engine difficult start.pdf (Size: 11.18 KB / Downloads: 182)

  engine non start.pdf (Size: 11.23 KB / Downloads: 185)

  engine start then stops.pdf (Size: 10.83 KB / Downloads: 182)

  erratic idling.pdf (Size: 11.07 KB / Downloads: 193)

  excessive fuel consumption.pdf (Size: 10.98 KB / Downloads: 175)

  hesitation poor acceleration.pdf (Size: 10.67 KB / Downloads: 180)

  high CO level.pdf (Size: 11.01 KB / Downloads: 168)

  high idle.pdf (Size: 10.66 KB / Downloads: 178)

  knocking pinking.pdf (Size: 10.74 KB / Downloads: 168)

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  lack power high speed.pdf (Size: 10.61 KB / Downloads: 167)

  lack power low speed.pdf (Size: 10.72 KB / Downloads: 172)

  low CO level.pdf (Size: 10.67 KB / Downloads: 158)

  low idle.pdf (Size: 10.64 KB / Downloads: 175)

  misfire.pdf (Size: 10.72 KB / Downloads: 165)

  overheating.pdf (Size: 10.44 KB / Downloads: 180)

  poor start engine cold.pdf (Size: 10.68 KB / Downloads: 170)

  running on.pdf (Size: 10.64 KB / Downloads: 175)

  smell of petrol.pdf (Size: 10.45 KB / Downloads: 167)

  stalling cutting out.pdf (Size: 10.68 KB / Downloads: 175)

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Wiring diagrams


  engine -5-97.pdf (Size: 158.75 KB / Downloads: 222)

  engine +5-97.pdf (Size: 155.98 KB / Downloads: 211)

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  abs +97.pdf (Size: 108.31 KB / Downloads: 184)

  AC fans -5-99.pdf (Size: 154.5 KB / Downloads: 217)

  AC fans +6-99.pdf (Size: 156.7 KB / Downloads: 187)

  earth points.pdf (Size: 38.56 KB / Downloads: 203)

  fuseboard 13.pdf (Size: 133.95 KB / Downloads: 199)

  fuseboard 30.pdf (Size: 162.59 KB / Downloads: 203)

[cully]

cold air feed

   

136 cambelt


   

ECU


   

window


   

Heated rear screen and mirrors

   

cooling Fans


   

Cooling Pipework


   

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  peugeot_306_gti-6_service_guide.pdf (Size: 810.78 KB / Downloads: 288)

  xu10j4rs-technical.pdf (Size: 704.61 KB / Downloads: 231)

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cooling fan wiring layout and operation

   
   
   
   

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Electric window parts list

   

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cambelt part numbers

   
   
   

[cully]

Usfull info...

BE3/6 gearbox

Ratios
1st 2.92
2nd 1.87
3rd 1,.41
4th 1.15
5th 0.95
6th 0.79
Final drive 3.94:1 or 4.05:1

Box MARKING (TA38) TA38 - REAR AXLE HYPOID GEARSET 19 X 75 UNTIL RPO 07430  Ratio 3.94:1
Box MARKING TD43 (TD43) (TA70) TA70- REAR AXLE HYPOID GEARSET 19 X 77 AND TACHO TORQUE 22X19 SINCE RPO 07431 Ratio 4.05:1

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to use A/C Button for Fan override
Disconnect A/c pump electricly
Unplug A/c Pressure switch
then bridge pins in A/c Pressure switch loom side plug, one or the other not both
Bridge pins 1&2 = low speed from both fans
Bridge pins 1&3 = high speed from both fans

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gear rods

If you are struggling to get 2nd/4th/6th/reverse you need to shorten the large gear rod,if your struggling to get 1st/3rd/5th the large gear rod needs to be lengthened

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CLUTCH FORK BUSH KIT
PART NUMBER: 217520, 217521

There is an older and newer design of fork bushes.

Older bush part numbers:
2175 21 FORK BEARING SUP BA- - WHITE - UNTIL RPO 08484
2175 20 FORK BEARING INF BA- - WHITE- UNTIL RPO 08484

Newer bush part numbers:
2175 55 SUP - SINCE RPO 08485
2175 54 INF - SINCE RPO 08485
2175 56 PROTECTOR 20,4X25,9-11 - SINCE RPO 08485

That bottom one (2175 56) is a seal /insert for the later lower fork bush. I think it might be to do with addressing issue of water getting in and rusting the shaft which can increase wear. But otherwise not sure but that is the additional part for later bushes.

The later bushes appear on cars after 01.02.2000

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Gti6 bottom rad hose
1351 X9 WTR OUTLET HOSE - INJECTION XU10J4RS UNTIL RPO No. 07972
1351 Z3 - INJECTION XU10J4RS SINCE RPO No. 07973 UNTIL RPO No. 08357
1351 ZV - INJECTION XU10J4RS SINCE RPO No. 08358
1343 Z4 - later type bottom hose seal ring + top hose seal ring to thermostat housing

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soft unlock ecu

disconnet ecu with engine running then cut the transponder wires cut them at the small engine loom plug on the inner wing cut the 3 wires 820,821,822

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Head info
There is a small notch at one end which has rough casting in it. There will be a "step" up from this onto the gasket face. Once this "step" disappears there is no more meat on the head to skim off

To see if the head has been skimmed previously measure its total height between the cam ladders,
standard is 137mm +/- 0.05.
minimum height is 136.8mm +/- 0.05.
 i.e 0.2mm.
 standard Headgasket is 1.2mm, Peugeot  0209Z2

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PH2-3 engine loom differences

MAP sensor
1920 9H <RPO 08056
1920 AN >RPO 08057

oil pressure switch
1131 82 UNTIL RPO No. 07874
1131 C5 SINCE RPO No. 07875

PAS sensor
4015 02 UNTIL RPO No. 08036
4015 08 SINCE RPO No. 08037

gearbox reverse switch
2257 41 UNTIL RPO No. 08420
2257 59 SINCE RPO No. 08421

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engine parts part numbers

XU10J4RS
Head Gasket 45.84 GBP  
Peugeot  0209Z2

Head Bolts 7.57 GBP  
Peugeot 0204AO UP TO O 08581 REMOVE WASHER 0205 47

Rear Crankshaft Oil Seal 18.74 GBP
Peugeot CRANKSHAFT BEARING SEAL 90X110-7SFCM - 0127 28

Camshaft Oil Seal  11.80 GBP   
Peugeot ENGINE CAMSHAFT SEAL DIAM 36X50-7  0236 44

Front Crankshaft Oil Seal 14.34 GBP
Peugeot CRANKSHAFT BEARING SEAL 42X62-7  0326 22


Valve Stem Seals 1.39 GBP  
Peugeot ENGINE VALVE STEM SEAL DIAM 12 - H 10 095638

VALVE GUIDE Stem REPAR 0220 96  18.55 GBP
SET OF 2 VALVE SPING  0952 A6   5.54 GBP   
Valve collets 0950 20  2.51 GBP  

Inlet valve  28.44 GBP   
Peugeot 094882

Exhaust valve  37.32 GBP   
Peugeot 0949 87

VALVE SPRING RETAINER Top 0951 36  2.40 GBP   
VALVE SPRING RETAINER Lower 0953 20  2.56 GBP   

Timing Belt Kit 98.98 GBP   
Peugeot DISTRIBUTION MOTOR KIT  0831 48  RP 0831 R5

Timing Belt  42.14 GBP   
Peugeot TIMING BELT 136 DTS HT=34  0816 98

peugeot TIMING TENSION ROLLER 0829 35  53.33 GBP   
Bolt GEAR-BOX HOUSING COLUMN SCREW M8X125(2) LG 16-34 0820 17
Bolt SELF LOCKING SELF-TAP SCREWS DIAM 8X125-25  6923 78
Peugeot RETRACTOR ROLLER  0830 37 RP 0830 63  27.44 GBP   
Bolt HEX HEAD CAPSCREW DIAM 10X150-50 6921 C2  RP 6921 91

Hydraulic Cam Follower  27.38 GBP
Peugeot 0942 31

Cam cover screws
SCREW WITH BASE DIAM 6X100-38  0205 51
SOCKET CHEESEHEAD SCREW DIAM 6X100-25  6913 F6 /  RP 6913 N8

COOLANT MANIFOLD GASKET DIAM 42 (back of block) 1339 83  1.52 GBP   
WATER PUMP GASKET  1206 A4   2.58 GBP   
ENGINE WATER THERMOSTAT 83 DEG 1338 39  21.65 GBP   
ENGINE WATER THERMOSTAT GASKET DIAM 51X57-4,5  1340 48  1.10 GBP   
ENGINE WATER HOUSING-Block SEAL 1340 33  3.48 GBP   

ENGINE GASKET KIT  0197 W2  115.87 GBP   

GEAR-BOX SEAL 40X58-10  3121 44  RP 16 088 167 80  11.00 GBP   
GEAR-BOX SEAL RIGHT29X47-11 3121 46  12.94 GBP  

INLET MANIFOL GASKET 0349 G1
THOTTLE BODY SEAL PIECE 1635 C3
EXH MANIFOL GASKET  0349 F4
EXH DOWNPIPE FIXING KIT 1798 75

oil filter 1109AL
Fuel filter 1567 93

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Fan "Bitron" control box's

G. CARTIER 60 299 007/60 336 101 80 triggers (PV) low speed fans at 90 ° C.
G. CARTIER 60 299 008/60 336 102 80 triggers (PV) low speed fans at 96 ° C.

Accuracy: start-up in low-speed (PV) motor fans after turning off the ignition (petrol or diesel) is part of the Post-ventilation function.
This function is active when the temperature unit 8010 is supplied with + 12V permanent its pin 4. Thus, to cut off + Contact at pin 15, during and only during the 6 minutes after the ignition is switched off: the microcontroller comparing the resistance seen at the terminals of the thermistor 8008 brown (pins 7 and 14) to a value corresponding to the temperature of 105 degrees Celsius, or about 3075 ohms (+/- 25 ohms).
If this resistance (which increases with temperature = CTP) reaches or exceeds the value corresponding to de105 degrees threshold, the microcontroller applies a high level at its terminal 10 for a fixed duration of 6 minutes, causing the set to the potential of Masse Pin 1 of the housing and therefore the starting of the motorized fan PV.
In short: from the first second after switching off the ignition and up to 6 minutes later, a temperature of at least 105 degrees causes the PV start-up of fan units for 6 minutes, whatever the variation in this temperature during this time.
On the Diesel 2.1 (XUD11) the post-cooling is controlled by a thermal switch placed on the radiator and beyond the above description.
Note: the delivery of contact during this time of 6 minutes replace the housing in its normal operating configuration. Other behavior of the cooling system should be considered abnormal.

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Bilstein B4 Fronts part numbers 22-045959 (n/s) and 22-045966 (o/s)
Bilstein B8 Sprint Suspension Front Shock Absorber- 35-041337....35-041344

[welshpug]

Later clutch bushes, it is indeed a seal that sits on a lip of the white bush to prevent water getting in and rusting the shaft.

[cully]

I must say credit for this must go to a lot of people, I have collected the data over time, this is just a collection of info i have found...
if some of the info has come from yourself then thank you!

the more i find the more i will add

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Front door loom plugs PH3

   
   

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Instrument panel

   

[cully]

clock temp display

   

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alarm and central locking PH2

central locking box under rear bench


   
   

alarm box behind B panel above drivers seatbelt real

*8600 : Dipped headlight relay command
*8603 : Theft protection alarm cut-off command
*8605 : Theft protection alarm siren info
*8617 : Connection to central locking controller
*8619 : Interior protection neutralisation info
*8611 : Left-hand front door open info
*8618 : Connection to central locking controller
*8612 : Right-hand front door open info
*8604 : anti-theft alarm siren control
*8602 : Theft protection alarm command
*8601 : Bonnet open info
*M860 : Ground/Earth
*8606 : L Ultrasonic sensor
*8607 : L Ultrasonic sensor
*8608 : R Ultrasonic sensor
*8609 : R Ultrasonic sensor
*2335 : rear right direction indicator
*2345 : rear left direction indicator
*C033 : ACC 12v IGN
*B142 : 12v

   
   

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  alarm.pdf (Size: 569.17 KB / Downloads: 214)    

[silverzx]

Don't have a '6 but would love a resource like this if I did. Good work old dog.

[Matt]

This is amazing! Will be using this for future reference!

[Poodle]

Wow, fantastic contribution mate, fair play!

[cully]

   

[cully]

Bilstein B8 Sprint Shock Absorbers
The old part numbers for the Peugeot 306 have been superseeded. Front left damper 35-041337 and Front Right damper 35-041344 have been replaced by 22-247308 and 22-247315

Bilstein B8 Front Left Damper
1 x Bilstein B8 Damper - 22-247308 (mono tube) +£123.20 (+£147.84 Incl. Tax)

Bilstein B8 Front Right Damper
1 x Bilstein B8 Damper - 22-247315 (mono tube) +£123.20 (+£147.84 Incl. Tax)


Bilstein B8 Rear Left Damper
1 x Bilstein B6 / B8 Damper - 24-020749 (B36-2074) (mono tube) +£85.36 (+£102.43 Incl. Tax)

Bilstein B8 Rear Right Damper
1 x Bilstein B6 / B8 Damper - 24-020749 (B36-2074) (mono tube) +£85.36 (+£102.43 Incl. Tax)

http://www.kamracing.co.uk/car-tuning/pe...r-kit.html

[DeeTurbo]

Is earth MC34 the one under the fuse box, point 9 in the earth point PDF?

[cully]

possibly yes that point runs to a common link plug block behind the fuse board somewhere

[DeeTurbo]

Good stuff.

[cully]

PistonHeads buying guide!
http://www.pistonheads.com/features/ph-b...uide/34887



  Peugeot 306 GTI Buying Guide.docx (Size: 382.19 KB / Downloads: 191)

  Peugeot 306 GTI Buying Guide.pdf (Size: 393.13 KB / Downloads: 267)

[cully]