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
------------------------------------------------------------------------------
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
-------------------------------------------------------------------------------------------------
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.
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
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
--------------------------------------------------------------------------
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
-----------------------------------------------------------------------------
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
------------------------------------------------------------------------------
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
---------------------------------------------------------------------------------------
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
-----------------------------------------------------------------------------------------
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
-------------------------------------------------------------------------------------------
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
----------------------------------------------------------------------------------------------
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
-------------------------------------------------------------------------------------------------
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
---------------------------------------------------------------------------------------------
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.
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
https://www.check-mot.service.gov.uk/
GTI6 Info
Don’t drive faster than your guardian angel can fly.