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PEUGEOT 208 Rally 4 2021 User Manual

PEUGEOT 208 Rally 4 2021
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Version E User Guide 208 Rally 4 - 22/01/2021 Return to Content Table P 1
USER GUIDE

Table of Contents

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PEUGEOT 208 Rally 4 2021 Specifications

General IconGeneral
BrandPEUGEOT
Model208 Rally 4 2021
CategoryAutomobile
LanguageEnglish

Summary

Vehicle Versions and History

Chassis and Suspension Systems

Front Axle Presentation

Overview of the front axle system, including uprights and wishbones.

Rear Axle Presentation

Overview of the rear axle system, including the H-beam and hub carriers.

Damper Settings and Adjustments

Adjustments for shock absorber compression, rebound, and bump stops.

Wheel Geometry Specifications

Adjustments for front and rear wheel geometry (camber, toe).

Steering System Components

Components and adjustments of the steering system.

Internal Equipment and Electronics

Fuel Circuit Details

Details on the fuel tank and fuel pumps.

Console Controls and Functions

Description of the main console buttons and functions.

Dashboard Display Overview

Information on dashboard display pages, LEDs, and alarms.

Document Foreword

Peugeot Sport Contact Information

Technical Support Contacts

Contact details for technical assistance.

FTP Server Access

Access details for the FTP server.

Vehicle Presentation and Identification

General Vehicle Dimensions

Overall dimensions and weight of the car.

Rollcage Identification Method

How to identify the rollcage number.

Chassis Identification (VIN) Location

Location of the chassis identification (VIN) number.

Engine Specifications and Operation

General Engine Information

General engine specifications and characteristics.

Engine Characteristics Details

Detailed technical data of the engine (capacity, power, torque).

Fuel Consumption Estimates

Estimated fuel consumption figures for different driving conditions.

Engine Running Procedures

Procedures for engine start and warm-up.

First Engine Start Calibration

Procedure for calibrating actuators during the first engine start.

Engine Start and Warm-up

Procedures for priming oil pressure and engine warm-up.

Post Warm-up Final Checks

Final checks after engine warm-up, including leak inspection.

Engine Identification

Location of the engine serial number.

Fluid Specifications

Details on engine oil and coolant types and quantities.

Engine Accessories Overview

Information on accessory belts and tensioner roller.

Engine and Turbo Seals

Description of engine and turbo seals.

Engine Removal and Refitting

Procedure for engine removal and refitting, including workshop support.

Cooling System Details

Water Circuit Description

Description of the car's two water cooling circuits.

Cooling Circuit Filling and Bleeding

Procedure for filling and bleeding the cooling circuit.

Turbocharging Circuit

Description of the air-to-air intercooler and turbocharging system.

Engine Oil Cooling System

Information on the engine oil radiator and temperature range.

Exhaust System Components

Details on the exhaust system, silencer, and catalytic converter.

Transmission and Drivetrain Components

Gearbox Overview

Overview of the Sadev ST82LW 5-speed gearbox.

Homologated Gear Ratios

Homologated gear ratios for the gearbox.

Homologated Final Drive

Homologated final drive specifications.

Gearbox Barrel Sensor Function

Function and voltage output of the barrel position sensor.

Gearbox Maintenance Procedures

Maintenance procedures for the gearbox, including oil and strainer cleaning.

Differential Adjustment and Friction Faces

Information on differential preload adjustment and friction faces.

Gearbox Oil Cooling Operation

Operation of the gearbox oil cooler.

Driveshaft Inspection Advice

Advice on checking driveshafts and boots.

Tarmac Driveshaft Specificity

Specificity for tarmac driveshaft assembly and tightening.

Clutch System Overview

Details on the clutch type and assembly.

Clutch Assembly Procedure

Procedure for clutch assembly, respecting component order.

Clutch Disc Inspection

Clutch disc pad minimum thickness and inspection criteria.

Engine Mounts and Powertrain Support

Front Axle and Suspension Systems

Front Axle Presentation

Description of the McPherson front axle, subframe, and wishbones.

Front Coil-over Damper Assembly

Components of the front coil-over damper.

Front Anti-roll Bar Specifications

Details on front anti-roll bar diameters and stiffness.

Rear Axle and Suspension Systems

Rear Axle Presentation

Description of the reinforced H-beam rear axle.

Rear Hub Carrier Details

Information on rear hub carriers and allowed shims.

Rear Coil-over Damper Assembly

Components of the rear coil-over damper.

Rear Anti-roll Bar Specifications

Details on rear anti-roll bar diameters and stiffness.

Surface-Specific Features and Settings

Tarmac vs. Gravel Configuration Changes

Parts to change/mount/dismantle for surface configuration changes.

Damper Adjustment Settings

Overview of damper adjustment settings.

Shock Absorber Compression Adjustment

Adjustment of low and high-speed compression on shock absorbers.

Shock Absorber Rebound Adjustment

Adjustment of front and rear shock absorber rebound.

Hydraulic Bump Stop (PDS) Adjustment

Adjustment of the hydraulic bump stop (PDS) on shock absorbers.

Spring Stiffness Options

Details on spring stiffness for front and rear axles.

Tarmac Spring Specifications

Spring references and stiffness for tarmac use.

Gravel Spring Specifications

Spring references and stiffness for gravel use.

Ride Height Adjustment Procedure

How to adjust the car's ride height.

Anti-Roll Bar (ARB) Options

Details on anti-roll bar options.

Front Anti-roll Bar Details

Front anti-roll bar stiffness and diameter options.

Rear Anti-roll Bar Details

Rear anti-roll bar stiffness and diameter options.

Wheel Geometry Adjustments

Overview of geometry adjustments.

Front Geometry Adjustments

Front geometry adjustments (camber, toe) and their effects.

Rear Geometry Adjustments

Rear geometry adjustments (camber, toe) using shims.

Steering System Overview

Overview of the steering system.

Steering Column Components

Components of the steering column assembly.

Steering Rack Details

Details on the steering rack and its height adjustability.

Steering Rod Specifications

Specifications and setup for steering rods (outer rods).

Steering Hydraulic Circuit

Information on the steering hydraulic circuit.

Steering Circuit Bleeding and Draining

Procedures for bleeding and draining the steering hydraulic circuit.

Braking System

Brake System Presentation

Overview of brake calipers, discs, pads, and fluid.

Tarmac and Gravel Brake Assembly

Specific caliper and disc assemblies for tarmac and gravel.

Vehicle Controls and Commands

Pedal Box Configuration

Description of the pedal box, throttle, and brake pedals.

Handbrake Operation

Operation of the hydraulic handbrake and its locking system.

Gearbox Shift Command

Operation of the gearbox shift lever and cut-off sensor.

Protection Systems

Sumpguard Description

Description of the car's sumpguard for protection.

Wheel Arch Functionality

Function of wheel arches to limit projections.

Gravel Protection Elements

Description of ground protection for gravel use.

Internal Equipment Details

Fuel Circuit and Tank Capacity

Details on the fuel tank capacity and fuel pumps.

Electronic Systems and Controls

Console Button Functions

Description of the console buttons and their functions.

Main Switch Operation

Function of the main power switch.

Power Switch Functions

Function of the power switch for actuators and ignition.

Engine Start Procedures

Procedures for engine start and oil pressure priming.

Launch Strategy Activation

Procedure for activating and using the launch control strategy.

Engine Strategy Modes and Maps

Details on different engine modes (ROAD, STAGE, TARMAC/GRAVEL) and maps.

Accessory Command: Window Lift

Operation of window lift command and calibration.

Control Arms Functions Overview

Operation of Klaxon, Warning, and Demister functions.

Lights and Wipers Control Arms

Operation of the left and right control arms for lights and wipers.

Additional Keyboard Functions

Functions of the additional keyboard buttons (reset, brightness, angle).

Dashboard Display and LEDs

Information on dashboard display pages, LEDs, and alarms.

Engine Revs LEDs Explanation

Explanation of engine revs LEDs and their lighting patterns.

Alarm LED Indicators

Explanation of various alarm LEDs and their corresponding conditions/messages.

Dashboard Display Pages

Overview of different dashboard display pages (Road, Stage).

Check Fuel Display Page

Display of fuel consumption data.

Check Page: System Parameters

Display of engine and system parameters.

Brake Bedding Display Page

Display of brake pressures and temperature.

Mechanical Page 1 Display

Display of gearbox, actuator, and steering data.

Mechanical Page 2 Display

Display of fuel circuit information.

High Current Equipment Status

Status of high current equipment and electrical outputs.

Low Current Equipment Status

Status of low current equipment and indicators.

Sensors and Actuators Diagnostic

Operating status of sensors and actuators, including USB drive status.

Auxiliary Functions and Calibration

Throttle Pedal Calibration Procedure

Procedure for calibrating throttle pedal, body, and wastegate.

Steering Wheel Angle Zeroing

Procedure to set the steering wheel angle sensor to zero.

Automatic Fire Extinguisher System

Electrical Loom Layout and Pinouts

Main Electrical Loom Positions

Diagram showing the layout of the main electrical looms.

Device Pin-out Configurations

Pin-out configurations for various electrical devices.

Engine Loom Connector Pinout

Connector pin-out for the engine loom.

Data Logging and ECU Management

Wintax Data Logging Software

Information on Wintax software licenses and usage.

Sysma ECU Software

Information on Sysma software for ECU updates and diagnostics.

Engine Map Update Procedure

Procedure for updating the engine map using Sysma software.

Acquisition Table Update Procedure

Procedure for updating acquisition tables using Sysma software.

Tire Diameter Change via Sysma

Procedure for changing tire circumference values in Sysma.

Tire Circumference Update Steps (1)

Steps for updating tire circumference in Sysma.

Tire Circumference Update Steps (2)

Final steps for updating tire circumference values in Sysma.

Appendices and Reference Information

Fluids and Greases List

Table of fluids and greases with references and quantities.

Tightening Torque Documentation

Information on tightening torque documentation.

Maintenance Schedule Documentation

Information on the maintenance schedule documentation.

FIA Seals Information

Information on FIA seals documentation.

Base Setup Documentation

Information on base setup documentation.

Gravel Base Setup

Base setup documentation for gravel configuration.

Tarmac Low Grip Base Setup

Base setup documentation for tarmac low grip.

FIA Fuel Tank Capacity Measurement

Method for measuring fuel tank capacity according to FIA regulations.

Specific Tools List

List of specific tools required for maintenance.

Engine Specific Tools

List of specific tools for engine maintenance.

Other Specific Tools

List of other specific tools required.

Automatic Fire Extinguisher Manual Reference

Reference to the automatic fire extinguisher manual.

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