PEUGEOT 208 Rally 4 2021 User manual

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

Version E User Guide 208 Rally 4 - 22/01/2021 Return to Content Table P 2
VERSIONS
Version
Date
Author
Comments
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 manual, engine loom schematic, barrel values
E
13/01/2021
C. Dupuy
Update following 2021 regulation, correction

Version E User Guide 208 Rally 4 - 22/01/2021 Return to Content Table P 3
CONTENT TABLE
1. FOREWORD...................................................................................................................................................6
2. PEUGEOT SPORT CONTACT ...........................................................................................................................7
2.1. TECHNICAL SUPPORT................................................................................................................................................. 7
2.2. COMMERCIAL SUPPORT............................................................................................................................................. 7
2.3. FTP SERVER.......................................................................................................................................................... 7
3. CAR PRESENTATION ......................................................................................................................................8
3.1. GENERAL DIMENSIONS.............................................................................................................................................. 8
3.2. ROLLCAGE IDENTIFICATION................................................................................................................................. 9
3.3. CHASSIS IDENTIFICATION –VIN ........................................................................................................................... 9
4. A00 - ENGINE ..............................................................................................................................................10
4.1. GENERAL INFORMATION .......................................................................................................................................... 10
4.1.1. Characteristics........................................................................................................................................ 10
4.1.2. Fuel consumption ................................................................................................................................... 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 THE ENGINE ............................................................................................................. 15
5. B00 –COOLING ...........................................................................................................................................16
5.1. WATER CIRCUIT ................................................................................................................................................. 16
5.2. TURBOCHARGING CIRCUIT ................................................................................................................................ 18
5.3. ENGINE OIL COOLING .............................................................................................................................................. 19
5.4. EXHAUST............................................................................................................................................................... 19
6. C00 –TRANSMISSION .................................................................................................................................20
6.1. GEARBOX ............................................................................................................................................................. 20
6.1.1. Gear Ratio .............................................................................................................................................. 20
6.1.2. Final Drive .............................................................................................................................................. 20
6.1.3. Barrel sensor .......................................................................................................................................... 21
6.1.4. Maintenance .......................................................................................................................................... 22
6.1.5. Differential ............................................................................................................................................. 22
6.1.6. Gearbox cooling ..................................................................................................................................... 23
6.2. DRIVESHAFTS......................................................................................................................................................... 23
6.3. CLUTCH................................................................................................................................................................ 25
6.3.1. Assembly ................................................................................................................................................ 25
6.3.2. Inspection............................................................................................................................................... 26
7. D00 –ENGINE MOUNTS ..............................................................................................................................27

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8. E00 –TRAINS ..............................................................................................................................................28
8.1. FRONT AXLE PRESENTATION ............................................................................................................................. 28
8.1.1. Front upright .......................................................................................................................................... 28
8.1.2. Wishbones.............................................................................................................................................. 28
8.1.3. Front Coil-over damper assembly .......................................................................................................... 29
8.1.4. Front anti-roll bar................................................................................................................................... 29
8.2. REAR AXLE PRESENTATION ................................................................................................................................ 30
8.2.1. Rear H-Beam .......................................................................................................................................... 30
8.2.2. Rear Hub Carrier..................................................................................................................................... 30
8.2.3. Rear Coil-over damper assembly............................................................................................................ 31
8.2.4. Rear anti-roll bar.................................................................................................................................... 31
8.3. TARMAC /GRAVEL SPECIFIC FEATURES............................................................................................................. 32
8.4. DAMPER SETTINGS ............................................................................................................................................ 33
8.4.1. Compression........................................................................................................................................... 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
8.8. GEOMETRY ........................................................................................................................................................ 36
8.8.1. Front....................................................................................................................................................... 36
8.8.2. Rear........................................................................................................................................................ 37
8.9. STEERING........................................................................................................................................................... 37
8.9.1. Presentation........................................................................................................................................... 37
8.9.2. Steering column ..................................................................................................................................... 37
8.9.3. Steering rack .......................................................................................................................................... 38
8.9.4. Steering rods .......................................................................................................................................... 38
8.9.5. Hydraulic Circuit ..................................................................................................................................... 39
8.9.6. Bleeding / Draining of the circuit ........................................................................................................... 39
9. F00 –BRAKES ..............................................................................................................................................40
9.1. PRESENTATION.................................................................................................................................................. 40
9.2. TARMAC /GRAVEL ASSEMBLY........................................................................................................................... 41
10. G00 –COMMANDS .....................................................................................................................................42
10.1. PEDAL BOX......................................................................................................................................................... 42
10.2. HANDBRAKE ...................................................................................................................................................... 42
10.3. GEARBOX COMMAND ....................................................................................................................................... 43
11. R00 –PROTECTIONS....................................................................................................................................44
11.1. SUMPGUARD......................................................................................................................................................... 44
11.2. WHEELARCHES .................................................................................................................................................. 45
11.3. GRAVEL PROTECTION ........................................................................................................................................ 45

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12. T00 –INTERNAL EQUIPMENT ......................................................................................................................46
12.1. FUEL CIRCUIT ..................................................................................................................................................... 46
12.1.1. Overview .......................................................................................................... Erreur ! Signet non défini.
12.1.2. Fuel Tank ................................................................................................................................................ 46
12.1.3. Fuel pumps ............................................................................................................................................. 46
13. ELECTRONICS ..............................................................................................................................................47
13.1. CONSOLE ........................................................................................................................................................... 47
13.1.1. Main switch:........................................................................................................................................... 47
13.1.2. Power Switch:......................................................................................................................................... 47
13.1.3. Engine Start:........................................................................................................................................... 48
13.1.4. Launch strategy...................................................................................................................................... 48
13.1.5. Engine strategy: ..................................................................................................................................... 49
13.1.6. Accessories command: ........................................................................................................................... 49
13.2. LIGHTS /WIPERS CONTROL ARMS.............................................................................................................................. 50
13.3. ADDITIONAL KEYBOARD ........................................................................................................................................... 51
13.4. DASHBOARD DISPLAY........................................................................................................................................... 52
13.4.1. LEDS ....................................................................................................................................................... 52
13.4.2. Pages...................................................................................................................................................... 54
13.5. AUXILIARY FUNCTIONS....................................................................................................................................... 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 electrical loom....................................................................................................... 63
13.7.2. Pin-out.................................................................................................................................................... 64
13.7.3. Engine loom ........................................................................................................................................... 64
14. DATALOGGER..............................................................................................................................................65
14.1. WINTAX ............................................................................................................................................................. 65
14.2. SYSMA ............................................................................................................................................................... 65
14.2.1. Engine map update ................................................................................................................................ 65
14.2.2. Acquisition table update ........................................................................................................................ 67
14.2.3. Tire diameter change ............................................................................................................................. 69
15. APPENDIXES................................................................................................................................................71
15.1. FLUIDS AND GREASE................................................................................................................................................ 71
15.2. TIGHTENING.......................................................................................................................................................... 71
15.3. MAINTENANCE SCHEDULE........................................................................................................................................ 71
15.4. FIA SEALS............................................................................................................................................................. 72
15.5. BASE SETUP ....................................................................................................................................................... 72
15.5.1. Gravel..................................................................................................................................................... 72
15.5.2. Tarmac –Low grip.................................................................................................................................. 72
15.5.3. Tarmac –High grip................................................................................................................................. 72
15.6. FIA FUEL TANK CAPACITY MEASUREMENT ................................................................................................................... 73
15.7. SPECIFIC TOOLS.................................................................................................................................................... 74
15.7.1. Engine .................................................................................................................................................... 74
15.7.2. Others..................................................................................................................................................... 74
15.8. AUTOMATIC FIRE EXTINGUISHER MANUAL ................................................................................................................ 74

Version E User Guide 208 Rally 4 - 22/01/2021 Return to Content Table P 6
1. FOREWORD
Dear customers,
The whole Peugeot Sport and Peugeot Citroën Racing Shop team thank you for your acquisition
of a Peugeot 208 Rally4.
The trust you place in 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, as well
as information on its operation.
In the event that you would like more information, our technical and commercial, support
teams are at your disposal.
We wish you maximum pleasure, performance and success with the Peugeot 208 Rally4.

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2. PEUGEOT SPORT CONTACT
2.1. TECHNICAL SUPPORT
Name: DUPUY Cyril
Email: [email protected]
Telephone: [phone]
Name: CHALMETON Yann
Email: [email protected]
Telephone: [phone]
Nom : MEILHAUD Florent
E-mail : [email protected]
Téléphone: [phone]
Amérique Latine
2.2. COMMERCIAL SUPPORT
Email: [email protected]
Telephone: [phone]
Address: Peugeot Citroën Racing Shop
2 rue Gay Lussac
95500 GONESSE
FRANCE
2.3. FTP SERVER
Please find below the access to 208Rally4 FTP server. You will find:
-The assembly manuals,
-The Infotech and Infocom,
-The setups,
-All the technical documentation regarding the exploitation of the 208Rally4.
Via a software (eg: FileZilla): Via a web browser (eg: Internet explorer):
Host = 188.130.44.88 Address : ftp://188.130.44.88
User = 208Rally4 User = 208Rally4
Password : A.GZ4zgr Password : A.GZ4zgr

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3. CAR PRESENTATION
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
Total minimum FIA weight:
1080 kg
Balance front / rear:
61% / 39%
Fuel tank capacity:
63 L

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3.2. ROLLCAGE 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 on two stickers, one behind the windscreen and
one on the driver centre pillar.

Version E User Guide 208 Rally 4 - 22/01/2021 Return to Content Table P 10
4. A00 - ENGINE
4.1. GENERAL INFORMATION
4.1.1. Characteristics
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
290 Nm @ 3000rpm
Cooling
Par eau, avec thermostat
Fuel
SP 98
Turbo
Borgwarner –30mm restrictor
Engine management
Magneti Marelli SRG 141