PEUGEOT 208 Rally 4 2021 User Manual Download Page 2

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Version E User Guide 208 Rally 4 - 22/01/2021

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VERSIONS

Version

Date

Author

Comments

16/07/2020

C. Dupuy

Creation

10/08/2020

C. Dupuy

Correction, steering rod tool ref, pin-out added

24/08/2020

C. Dupuy

H-beam stiffness, dashboard panel correction

27/10/2020

C. Dupuy

Sysma manual, engine loom schematic, barrel values

13/01/2021

C. Dupuy

Update following 2021 regulation, correction

Summary of Contents for 208 Rally 4 2021

Page 1: ...Version E User Guide 208 Rally 4 22 01 2021 Return to Content Table P 1 USER GUIDE...

Page 2: ...ments A 16 07 2020 C Dupuy Creation B 10 08 2020 C Dupuy Correction steering rod tool ref pin out added C 24 08 2020 C Dupuy H beam stiffness dashboard panel correction D 27 10 2020 C Dupuy Sysma manu...

Page 3: ...tion 11 4 2 ENGINE RUNNING 11 4 2 1 First engine start 11 4 2 2 Engine start 12 4 2 3 Final check 12 4 3 ENGINE IDENTIFICATION 13 4 4 FLUIDS 13 4 5 ACCESSORIES 14 4 6 SEALS 15 4 7 REMOVAL REFITTING OF...

Page 4: ...ion 33 8 4 2 Rebound 34 8 4 3 Hydraulic Bump Stop PDS 34 8 5 SPRINGS 35 8 5 1 Tarmac 35 8 5 2 Gravel 35 8 6 RIDE HEIGHT 35 8 7 ANTI ROLL BARS ARB 36 8 7 1 Front Anti roll 36 8 7 2 Rear Anti roll 36 8...

Page 5: ...S 61 13 5 1 Throttle Pedal Throttle Body Wastegate Calibration 61 13 5 2 Steering wheel angle zero 61 13 6 AUTOMATIC FIRE EXTINGUISHER 62 13 7 ELECTRICAL LOOMS 63 13 7 1 Position of the main electrica...

Page 6: ...n us commits us daily Our user guide aims to get you familiar with your car as quickly as possible Here you will find detailed information on the mechanical and electronic components of the 208 Rally4...

Page 7: ...rique Latine 2 2 COMMERCIAL SUPPORT Email racingshop mpsa com Telephone 33 1 30 11 27 00 Address Peugeot Citro n Racing Shop 2 rue Gay Lussac 95500 GONESSE FRANCE 2 3 FTP SERVER Please find below the...

Page 8: ...NTATION 3 1 GENERAL DIMENSIONS General dimension according to homologation form A 5780 Total length 4052 mm Total width 1742 mm w o mirrors Wheelbase 2553 mm Front overhang 821 mm Rear overhang 678 mm...

Page 9: ...LLCAGE IDENTIFICATION The rollcage number 208 R XXXX is indicated on a plate welded to the main roll bar behind the B pillar 3 3 CHASSIS IDENTIFICATION VIN The chassis identification number is located...

Page 10: ...Here are the main characteristics of the 208 Rally4 engine Technical data Type 3 cylindres en ligne DOHC 12s Capacity 1199 cm3 Bore x stroke 75 mm x 90 5 mm Maximum power 208ch 5450rpm Maximum torque...

Page 11: ...wn consumption using data acquisitions We advise you to keep a safety volume of 10L in the fuel tank at all time We inform you that there is a risk of surge from 6 7L remaining in the tank 4 2 ENGINE...

Page 12: ...re reaches 70 C and the engine oil temperature reaches 60 C o Switch to page 4 Check page and check the coherence of the temperatures pressures and voltage values o Get the car into first gear press t...

Page 13: ...l quantity 3 5 L 1 5 L with oil radiator circuit We advise to control the oil level at every service The oil quantity is around 3 5L plus 1 5L in the cooling circuit The oil level must always sit betw...

Page 14: ...nsioner roller counter clockwise to loosen the belt A stretchy water pump belt The tension is automatically set by the belt s elasticity The use of the serial tool is strongly advised for its installa...

Page 15: ...s not recognized for FIA rallies 4 7 REMOVAL REFITTING OF THE ENGINE Two lifting hooks are fitted to every engine delivered by Peugeot Citro n Racing Shop For accessibility reasons we advise to fit re...

Page 16: ...hanger and the cockpit heating which is not fitted with a thermostat and is therefore always open The water pump is mechanical and driven by an independent belt The radiator is fitted with a fan it st...

Page 17: ...plate before reassembling the hose Cooling circuit Fill the entire cooling circuit about 6 5L then warm up the car without putting the cap on the degassing tank Regularly open the bleed screw on the...

Page 18: ...as the good installation of the air ducts It is also important to check that the air box is correctly fitted in the front bumper IMPORTANT Never turn the engine off as long as the alarm T_turbo is dis...

Page 19: ...flange the manifold being integrated into the cylinder head An intermediate line fitted with a silencer is available as an optional extra under the reference 904668698B Make sure that the connections...

Page 20: ...re information please refer to the Sadev Technical guide 6 1 GEARBOX The 208 Rally4 is fitted with the Sadev ST82LW 5 speed gearbox 6 1 1 Gear Ratio Only one set of gear ratio is homologated and there...

Page 21: ...ost no difference of speed between the two surface specs 6 1 3 Barrel sensor The gearbox is fitted with a barrel position sensor that send a voltage to the ECU as a function of the angle of the barrel...

Page 22: ...rential The differential preload is adjustable It can be set by replacing the Belleville washer as well as the number of friction faces The number of friction faces FF can vary by switching a smooth d...

Page 23: ...ed warmed up by an oil water intercooler fitted at the front of the gearbox Under normal running condition the gearbox oil temperature ranges from 80 to 120 C 6 2 DRIVESHAFTS We advise you to control...

Page 24: ...tted with the locking nut and pin in tarmac spec we therefore advise to check the tightening torque of the driveshaft nut after the first run 400Nm as well as each service Whenever possible avoid hot...

Page 25: ...ipped with 6 ceramic pads 6 3 1 Assembly The clutch being equipped with two discs a pressure plate as well as an intermediate plate it is important to respect the order and the direction of assembly d...

Page 26: ...hickness of the clutch disc pads is 5 8mm 6 3mm new Below this value we recommend replacing the disc The disc must also be replaced if cracks appear at the base of the pads as illustrated in the princ...

Page 27: ...d torque Approach the screws of the gearbox mounting plate on the box without tightening them Approach the screw passing through the chassis leg on the engine side without tightening them Approach the...

Page 28: ...AXLE PRESENTATION The front end of the 208 Rally4 is of the McPherson type with a reinforced subframe and ball jointed wishbones 8 1 1 Front upright 8 1 2 Wishbones Brake caliper Mount Upright interf...

Page 29: ...damper assembly 8 1 4 Front anti roll bar Rod length pre set 80mm ARB diameter Position Antiroll stiffness N m rad 15 mm In 8 200 Out 10 200 18 mm In 17 200 Out 21 200 22 mm In 39 000 Out 47 000 Axle...

Page 30: ...de of an reinforced H beam with integrated anti roll system The stiffness of the rear cross member is 30 600 N m rad without any bar and 52 500 N m rad with the 22mm bar 8 2 1 Rear H Beam 8 2 2 Rear H...

Page 31: ...ontent Table P 31 8 2 3 Rear Coil over damper assembly 8 2 4 Rear anti roll bar Rod length pre set 80mm ARB diameter Antiroll stiffness N m rad 30 600 19 mm 42 000 22 mm 52 000 24 mm 61 000 Upper Cup...

Page 32: ...mount dismantle the following parts Differential ramps Point D supports Front and rear damper assembly Anti roll bars Front brake discs with their spacers Front brake caliper spacers Rims and tires Re...

Page 33: ...mation is available in the hlins technical documentation 8 4 1 Compression The compression adjustment screws are located on the shock absorber cylinders at the bottom for the front shock absorbers and...

Page 34: ...he entire setting range can be used 8 4 3 Hydraulic Bump Stop PDS The shock absorbers of the 208 Rally4 are fitted with a hydraulic bump stop This one is internal to the shock absorbers and is adjusta...

Page 35: ...Reference Identification Stiffness 1E1420808A 904208088A 45 N mm 1E2521280A 904212808A 40 5 N mm 1E1420806A 904208068A 51 N mm 1E2521278A 904212788A 47 N mm 1E1420805A 904208058A 56 5 N mm 1E2521277A...

Page 36: ...64124C Medium 24 mm 8 8 GEOMETRY 8 8 1 Front The front camber is adjustable by changing the thickness of the camber shims mounted between the strut and its interface The smaller the thickness the grea...

Page 37: ...e shims The car must always be equipped with three blocks the 5mm track block one camber shim and one toe shim To obtain negative camber the shim must slide over the top of the hub To obtain toe in th...

Page 38: ...The rack height is adjustable using the washer s to install between the subframe and the rack 2 x 5mm on tarmac 0mm on gravel 8 9 4 Steering rods Setup Tarmac 5 HA 1 BA Gravel 1 HA 5 BA Straight line...

Page 39: ...iming procedure check the fluid flow in the tank Make sure the liquid level is high enough not to introduce air into the circuit The circuit is bled with the car on jack stands by turning the wheels f...

Page 40: ...Mix 2 Gravel TM Mix 1 TM Performance BRAKE FLUID Brembo HTC 64 T 9 1 PRESENTATION The 208 Rally4 is equipped with a single master cylinder and a proportional type rear brake pressure limiter allowing...

Page 41: ...e mechanic brake page then brake hard until you get 30 bar at the front 9 2 TARMAC GRAVEL ASSEMBLY The callipers are identical but the spacers and screws are specific according to the surface The tarm...

Page 42: ...einforced brake pedal The pedal and the clutch cylinder are standard the bleeder is on the gearbox The brake bleeding tool can also be used to bleed the clutch 10 2 HANDBRAKE The hydraulic hand brake...

Page 43: ...into neutral as well as to shift into reverse Not necessary for upshift A cut off sensor is present on the gearbox see Sadev manual it is triggered by the movement of the barrel control pin in the ge...

Page 44: ...uide 208 Rally 4 22 01 2021 Return to Content Table P 44 11 R00 PROTECTIONS 11 1 SUMPGUARD The car is fitted with a large sumpguard going from the rear of the subframe to the front bumper to ensure op...

Page 45: ...CHES Four wheel arches are fitted on the car regardless of the surface to limit projections 11 3 GRAVEL PROTECTION The ground protections are made of underbody protection blue sill protection yellow a...

Page 46: ...e may vary over time we invite you to measure the capacity of your fuel tank every 6 months by following the procedure in appendix 15 7 If the capacity is greater than 65 5L it is imperative to reduce...

Page 47: ...01 2021 Return to Content Table P 47 13 ELECTRONICS 13 1 CONSOLE 13 1 1 Main switch Power supply to ECU Power Box Dashboard Console 13 1 2 Power Switch After contact power supply supply to the actuat...

Page 48: ...Continue the procedure until the oil pressure has reached 2bars monitor on the dashboard display Engine starting procedure MAIN ON Power ON Gearbox in Neutral it is not necessary to press the clutch...

Page 49: ...ine mappings 13 1 6 Accessories command Window lift command Driver Codriver Active POWER ON Window lift calibration Activate the window until its upper position and maintain for a few seconds MAP 1 Hi...

Page 50: ...eated windscreen cockpit heater Active POWER ON yellow LED ON Fans Forcing function POWER OFF Long press on the button 13 2 LIGHTS WIPERS CONTROL ARMS Left control arm Right indicator Left indicator H...

Page 51: ...2nd notch Low speed wipers 3rd notch High speed wipers Control arm pull windscreen washer High speed wipers 13 3 ADDITIONAL KEYBOARD Reset fuel consomption Dashboard page scroll Long press Fuel pump...

Page 52: ...ear engaged Engine revs LED lighting 1 2 5200 6000 Gradually in Yellow 6100 6150 Fixed Reds 6150 Flashing Reds 3 5300 6000 Gradually in Yellow 6100 6150 Fixed Reds 6150 Flashing Reds 4 5500 6000 Gradu...

Page 53: ...turbo pressure P2 P2P 0 8 bar Engine rev 3500 rpm Throttle 80 Mode Stage for 0 7s Boost Pressure Flashing Blues Shifter Out of Order 0 2 V vShifter 4 8V Engine rev 500 rpm for 1 s SHIFTER HS Flashing...

Page 54: ...1 2021 Return to Content Table P 54 13 4 2 Pages Page 1 Road Page 2 Stage Engine Oil Temperature Engine coolant Temperature Engine Oil Pressure Gear Engaged Engine revs Car Speed Indicators lights and...

Page 55: ...C Fuel Pressure out of HP Feul Pump bar HP Fuel Pressure Target bar Exhaust Temperature C Richness value Throttle Pedal Position Throttle opening Waste gate position Turbo outlet air pressure bar Int...

Page 56: ...2 50 3 14 3 78 4 20 Front Brake Pressure bar Rear Brake Pressure bar Front Brake Temperature C option Car Speed km h Front Brake Pressure bar Rear Brake Pressure bar Steering Angle Vtank Voltage V Bat...

Page 57: ...e calibration Green OK CAN Communication Green OK Sensor status Green OK Steering wheel position Zero steering wheel straight Fuel Circuit Information Gauge voltage HP Fuel Pump Target HP Fuel Pump Lo...

Page 58: ...an Current Radiator Fan Command Left Command State active green Right Electrical Output electrical fault red Brakes Information Front Brake Pressure bar Rear Brake Pressure bar Front Brake Pad Tempera...

Page 59: ...ors Diagnostic This page indicates the operating status of all sensors and actuators in the car RedIndicator Short circuit OrangeIndicator Open Circuit unplugged or cut wire As well as the USB flash d...

Page 60: ...sensor pRail HP Fuel Pump Pressure pBst Turbo Pressure P2P Fuel Low Pressure Fuel Pump pBRK Front then Rean Brake Pressure tWat Water Temperature tInl Inlet Manifold Air Temperature T2P tOil Engine O...

Page 61: ...tart REMINDER The calibration must be carried out after each replacement of engine actuator throttle body waste gate and pedal ECU and engine mapping 13 5 2 Steering wheel angle zero Align the wheels...

Page 62: ...r extinguisher and a LifeLine Zero 275 automatic extinguisher complying with standard FIA 8865 2015 The latter include two independent circuits a cockpit circuit with a 360 nozzle and one reserved for...

Page 63: ...er Guide 208 Rally 4 22 01 2021 Return to Content Table P 63 13 7 ELECTRICAL LOOMS 13 7 1 Position of the main electrical loom Dashboard Console ECU PBE CHASSIS LOOM ENGINE LOOM FRONT AUXILIARY LOOM P...

Page 64: ...Version E User Guide 208 Rally 4 22 01 2021 Return to Content Table P 64 13 7 2 Pin out 13 7 3 Engine loom...

Page 65: ...Sysma software available on the FTP server in System allows you to update your ECU yourself with no needs to physically send it back to us In addition you will be able to modify the circumference of t...

Page 66: ...t table P 66 3 Click on Control to the right of ECU Datalogger I will turn to green once the ECU selected 4 In the ECU tab click on Upload calibration data 5 Click on the TAB E2 logo to send the mappi...

Page 67: ...t 10 Click on Control once disconnected put the Main switch OFF 11 Do not forget to do the throttle calibration after each engine map change 14 2 2 Acquisition table update 1 Open Sysma and load the p...

Page 68: ...A_R4_14 2 2 9_Client_XXSXX TDX then click on Transmit table 4 Click on No 5 Check that the alias is correct press OK otherwise click on Change Alias and enter the desired alias 6 Once finished a messa...

Page 69: ...of tire proceed as follows 1 Open the project folder on Windows then go to PSA_R4_14 2 2 9_VSCC_XXXXXXX_Basic CLX Make a copy of the Tyre Circumference CLX file and rename it as desired eg Tire Circum...

Page 70: ...ew window double click on the line Front wheel circumference 6 Enter the new tire circumference values in the Asphalt 1 and Gravel 1 cells instead of 1916 and 1934 and press Enter each time Once modif...

Page 71: ...L 1 5 L radiator Gearbox Oil 75 W 90 1C2340626A 1 L 0 1 radiator Powersteering Fluid LDS 1615099680 2 L Coolant PSA 35 C 1637756480 6 5 L Brake Fluid BREMBO THC64 PS97633A10 1 5 L Driveshaft Grease N3...

Page 72: ...OT 208 Rally4 Sealing 2020 07 24 FIA pdf 15 5 BASE SETUP Please find on the FTP in Documents Setup three base setups one for gravel and two for tarmac high and low grip 15 5 1 Gravel 208Rally4_Setup_T...

Page 73: ...mologation Regulations for WRC kit variant 9 By means of the FIA sampling connector all the fuel taken on board and available by this method will be taken out measured and accounted for 10 After a com...

Page 74: ...Fuel pump nut tool Set 1 1608323980 1 904678451A TCA Nut socket 1 904661158A Straight line spacer 1 904672751A Steering rod tightening tool 1 0D1121391A Engine mount Silent bloc assembly disassembly...

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