Peugeot 208 R2 User manual

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208 R2 USER GUIDE

Update of the 3

rd

February 2014

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SUMMARY

ENGINE Page 3

Start

Crank

Oil Level

Belts

TRANSMISSION Page 4

BRAKE Page 6

Circuit bleeding

Limiter

Bedding-in

Thickness

WHEEL NUTS Page 8

FUEL LEVEL Page 9

WINTAX4 SOFTWARE Page 11

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ENGINE

START

The first start of the engine must be done following this procedure:

- Master switch ON

- Power OFF

- Push the horn button

- Push the start button in the 5 following seconds and keep pushing

- Repeat this operation as long as the oil pressure is under 3.5 bars

- Then follow the process detailed below

Every start in tempered condition must be done as defined below:

- Master switch ON

- Power ON during 3 seconds minimum

- Clutch

- Push the start button. Do not keep pushing; the starter is on as long as

the engine has not started and during a maximum time of 5 seconds.

By cold weather especially when the cooling liquid is under 0°C, we recommend to

follow the specific procedure detailed below:

- Master switch ON

- Power ON then wait during 3 seconds minimum

- Power OFF

- Power ON then wait during 3 seconds (the 3 last points are necessary to

get the fuel pressure in the injection rail)

- Push the horn button and the flash lights buttons to "wake up" the battery

- Clutch

- Push the start button. It is not necessary to keep pushing.

If the engine does not start, reset the system:

- Power OFF

- Master switch OFF

- Master switch ON

- Power ON

Then try a new start of the engine.

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If the engine does not start after 2 tries, do a crank procedure as detailed below:

CRANK

If you can’t start your engine after few tries, we recommend you to do the following

procedure:

- Master switch ON

- Power OFF

- Push the horn button

- Push the start button in the 5 following seconds and keep pushing.

This procedure switch on the starter and the engine is turning without injection or

ignition, to remove the fuel present in excess in the cylinders. This procedure is can

also be used to put oil in the circuit after an oil filter replacing, a first start or a start

of an engine rebuilt.

OIL LEVEL

The recommended oil level is the maximum level of the gauge.

BELTS

We remind you the recommended mileage of accessories and water pump belts is

400 km. We remind you to be attentive to these belts during rallies.

Moreover, we remind you that a water pump belt failure lead to a fast increase of

the water temperature, which can damaged the engine if this one is not stopped

immediately.

In case of water temperature alarm, stop the engine. Before restarting the engine,

check if the water pump belt is in position.

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TRANSMISSION

DRIVESHAFTS BEDDIN-IN

We recommend you to run in your driveshaft before the first use:

Step 1

Car ready to run, on stands, engine running at 3000 rpm in 5th gear during 5

minutes, without playing with the steering wheel.

Step 2

Same as step 1, in same time turn the steering wheel left and right by a half turn.

Step 3

Same as step 2, turn the steering wheel left and right by a complete turn.

Step 4

Drive 10 km; avoid turning the steering wheel up to the stop end.

BRAKING

BRAKE CIRCUIT BLEEDING

The bleeding must be done by 4 persons:

- 1 person in the driver seat

- 1 person to ensure a correct level in the brake reservoirs

- 1 person to bleed the front calliper

- 1 person to bleed the rear calliper

We recommend you to bleed as detailed below:

- Push 3-4 times slowly on the brake pedal then keep pushing

- Open in the same time a bleeding screw of the front calliper and of the

rear calliper.

- Push the pedal up to the stop end and keep pushing

- Close the bleeding screw

- Repeat as long as the liquid of the calliper is not clean and without

bubbles

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Do this procedure as detailed below:

- Front right and rear right callipers, outside bleeding screw

- Front right and rear right callipers, inside bleeding screw

- Front left and rear left callipers, outside bleeding screw

- Front left and rear left callipers, inside bleeding screw

Then tight the bleeding screw:

- 18 N.m for cold calliper

- 14 N.m for hot calliper

Once the bleeding is done, check if the travel of the brake pedal is correct and

adjust the liquid level.

BRAKE LIMITER

To read the setting of the brake limiter, first push 3-4 times on the brake pedal.

Then push up to 60 bars on the front circuit and read the pressure of the rear circuit.

Modify the setting without pushing the brake pedal.

BRAKES BEDDIN-IN

Front pads bedding-in

During the bedding-in, the measured temperature must not exceed 500/550°C. In

case of overheating, drive without braking and use the handbrake to slow down the

car.

Set the brake limiter 2 laps more to the rear to ease the rear brakes bedding-in.

The bedding-in must be done during 10 km at an average speed of 100 km/h. It

represents about 50 braking.

You must do "normal" braking following the pressure target as defined in the graph

below to get a deceleration from 150 to 100 km/h for example. You must not brake

and accelerate in the same time.

If the deceleration is not related to the effort on the brake pedal, release the brake

pedal.

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At the end of bedding-in, drive 3 km at medium speed to cool down discs and pads.

Then set you brake limiter to the initial setting.

Case of discs and pads not bedding-in together

When pads and discs have not been bedding-in in the same time, you must do a

specific bedding-in to associate discs and pads.

During 8 km, warm up gradually the brakes but do not brake and accelerate in the

same time. Then do 5 braking in 5

th

gear.

0

5

10

15

20

25

30

35

40

45

0

50

100

150

200

250

300

350

400

450

0 2 4 6 8 10 12

Pressure

Temperature (°C)

Distance (km)

Targets for pads bedding-in

Pads temperature Front brake pressure

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BRAKE PADS THICKNESS

To avoid an excessive temperature of the brake system and to ensure a good and

free travel, do not use pads with a thickness less than 10 mm.

When you replace the brake pads, we recommend you first to clean the calliper

pistons area first to avoid damaging the pistons.

WHEEL NUTS

To ensure an optimal assembly of the rim on the hub, we recommend you to tight

the wheel nuts at a torque of 110 N.m.

For the first tightening, we recommend you to put copper grease –Loctite 8065 or

Bardhal 9984.07) only on the studs.

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FUEL LEVEL

There is no fuel gauge system to measure the fuel level in the tank. We remind you

it is not allowed to add a gauge or modify the fuel tank foam.

To know the fuel level, you must:

- Sum the fuel volumes add in the fuel tank since the last drain

- Sum the fuels consumptions displayed on the dashboard since the last

drain

- Then, subtract these 2 sums

Please find below 2 examples to calculate the fuel volume. We consider in these 2

examples the fuel tank has been drained.

EXEMPLE 1

Place

Fuel volume

Consumption –

dashboard

information

(litres)

In the fuel tank after

the consumption

(litres)

Volume

added

(litres)

In the

fuel tank

(litres)

Workshop - 0

40 + 10 of

reserve*

40

Service 1 35 40 – 35 = 5 30

30 + 5 =

35

Service 2 35 35 – 35 = 0 20

0 + 20 =

20

Service 3 18 20 – 18 = 2 18

2 + 18 =

20

End of

rally

15 20 – 15 = 5 - -

In this example, after each read of the fuel consumption, the fuel consumption

information is reset.

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EXEMPLE 2

Place

Fuel volume

Consumption since the

start of the rally –

dashboard information

(litres)

In the fuel tank

after the

consumption

(litres)

Volume

added

(litres)

In the

fuel

tank

(litres)

Workshop - 0

40 + 10 of

reserve*

40

Service 1 35 40 – 35 = 5

40 + 30 =

70

70 – 35

= 35

Service 2 70 70 – 70 = 0

70 + 20 =

90

90 – 70

= 20

Service 3 88 90 – 88 = 2

90 + 18 =

108

108 –

88 = 20

End of

rally

103 108 – 103 = 5 - -

In this example, the fuel level is not reset during the rally. The maximum volume

displayed is 325 litres.

*We recommend to have 10 litres in the fuel tank as reserve and to not include it in

your calculation.

Because of the fuel tank shape, it is not possible to drain all of the fuel when the

fuel volume in the tank is more than 22 litres. 4 litres can’t be drained but these 4

litres can be aspirated by the pump when the car is moving (as with the movement

of the car and when there is less than 22 litres, these 4 litres go in the lower part of

the tank).

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WINTAX

PRESENTATION

The 208 R2 is equipped with a data logging system which allows the control of the

engine and chassis of the 208 R2.

To be able to work with the data, you must:

- buy the Ethernet cable, reference 3Z9S89529A

- install the Wintax software

- buy the licence of the software

INSTALLATION OF THE WINTAX4 SOFTWARE

To install the software, you must have at least the OS Windows Vista. The software

is available on the website www.peugeotsport-store.com.

Configure the IP address as defined below:

IP address: 125.125.200.100

Masque de sous-réseau: 255.255.000.000

Then Peugeot Sport sends

the « Password ».

Send by eamil to Peugeot

Sport the « Registration

ID ».

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Then set the network connections

Click on local

network

Click on « Internet

Protocol version 4

(TCP/IPv4) »

Tick

Set these

informations

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In some cases, you must deactivate the firewall to allow the connection with the

car.

DATA DOWNLOAD

Please find the procedure to download the data:

Step 1:

Launch the WinTax4 software.

Step 2:

Click on « Acquisition »

then « Acquisition

Manager »

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Step 3:

On the

« WTX4AcquMan »

window, click on

Acquisition then

« Setup »

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Step 4:

Before every download, it is imperative to fill the following information then

validate with the icon .

Here is an example for a rally:

Track: write the year, month*, the week then the  2013A_S03_MonteCarlo

(* January = A, December= L).

Session: write the day (1

st

day, 2

nd

day….)

Run Name: write information of the type of event (test, shakedown, rally…)

For the first download, a file "Data" will be created in the file "Wintax".

If you have not changed the destination file of the software installation, the

"Wintax4" file will be in "C:"

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Step 5:

To get the connection between the computer and the 208 R2, select your car in the

list and click on (the icon is green as there is a connection between the car and

the computer).

The 208 R2 ECU is named: « 208R2_XX », XX is the serial number of the ECU.

In this case, there is no

connection

+ = no connexion

In this case, there is

connection

+ = connexion OK

Then click on to open the

window to select the runs you

want to download

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Step 6:

The « TLap » window is now opened, select the runs you want to display and then

click on "OK".

DISPLAY THE DATA

Step 1:

Sélection des tours à

télécharger

Click on the icon or click

on « File » then « open

data ».

Runs selected in

blue

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Step 2:

The Wtx4DataBrowser window is displayed.

Click on the icon to select the data file.

Standard location is C:\WinTAX4\Data

Select the file

Then select the runs you

want to display

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MEANINGS OF THE VARIOUS ACQUISITION CHANNELS OF 208 R2

Barrillet V Gear box barrel position

BRK_Fonct - BRK functions

BRK_SW - BRK switches

DDU_Vbatt V MPDU voltage

Diag_Team - Current team analog input diagnostic

DiagAcqAna0 - Current analog input diagnostic

Distance m Elapsed distance

FlagBobCC - Ignition coil short circuit flags

FlagInjCC - Injectors short circuit flags

I_AB A Fog lights current

I_BALISE A Tag current

I_CAPT A Inertial sensor current

I_CARTE A Map light current

I_CODE A Code lights current

I_COIL A Ignition coils current

I_DIURNE A Daytime headlights current

I_ECUs A Electronic calculator unit current

I_ESG A Windshield wipers current

I_GMV1 A Motor radiator fan1 current

I_GMV2 A Motor radiator fan2 current

I_INJ A Injectors current

I_KLAXON A Horn current

I_LAMBDA A Lambda probe current

I_PESS A Fuel pressure current

I_PHARE A Road headlights current

I_POINTE A Ramp headlights current

I_PULS A Inside ventilation fan current

I_RADIO A Radio current

I_RECUL A Reversing lights current

I_STARTER A Starter solenoid current

I_STOP A Rear brake lights current

I_TRIP A Trip-master current

I_VANOS A Phase shifters camshaft current

I_VEILL A Nightlights headlights current

I_VEILLar A Nightlights rear lights current

I_VERROU A Lock reverse solenoid current

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I_VIRAGE A Turns headlights current

LEVEL l Fuel level

Lim_all rpm Ignition limiter

Lim_inj rpm Injection limiter

P0 mbar Dynamic barometric pressure

P_Frein_A_M Bar Hand brake pressure

P_FreinAR Bar Rear brake pressure

P_FreinAV Bar Front brake pressure

Pap % Motorized throttle sensor position

Pdl % Pedal sensor position

Poil Bar Motor oil pressure

Rapport_BV - Gear displayed

Regime rpm Engine speed

Richesse - Proportional lambda richness

RxBufDiag1BRK0 - Buffer diagnostic1 BRK

RxBufDiag2BRK0 - Buffer diagnostic2 BRK

SWshift_State - Shifter switch state

T0 °C Dynamic atmospheric temperature

T_frein °C Front right brake-pad temperature

Teau °C Coolant temperature

Vbatt V Battery voltage

VitAVD_filt Km/h Front right wheel speed

VitAVG_filt Km/h Front left wheel speed

Vrs_Diag - Engine diagnostic

VVEH Km/h Car speed

VVT1_Error °vil VVT1 position delta setpoint

VVT1_Phase °vil VVT1 cam position // static position

VVT1_Target °vil VVT1 position setpoint f(rpm/throttle)

VVT2_Error °vil VVT2 position delta setpoint

VVT2_Phase °vil VVT2 cam position // static position

VVT2_Target °vil VVT2 position setpoint f(rpm/throttle)

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Peugeot 208 R2 User manual

Peugeot 208 R2 User manual

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