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

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

Version E User Guide 208 Rally 4 - 22/01/2021 Return to Content Table P 5
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.

Version E User Guide 208 Rally 4 - 22/01/2021 Return to Content Table P 7
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

Version E User Guide 208 Rally 4 - 22/01/2021 Return to Content Table P 8
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

Version E User Guide 208 Rally 4 - 22/01/2021 Return to Content Table P 9
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

Version E User Guide 208 Rally 4 - 22/01/2021 Return to Content Table P 11
4.1.2. Fuel consumption
As a baseline, you can use the following values to calculate your fuel consumption.
Road : 13L/100km
Stage –Tarmac : 56L/100km
Stage –Gravel : 60L/100km
These values depend on the driving style, the profile of the roads as well as the average speed of the
rally, it will be necessary thereafter to calculate your own 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 RUNNING
4.2.1. First engine start
A procedure is used to calibrate the actuators: throttle pedal, throttle body and turbocompressor
actuator (waste-gate).
This procedure must be carried out after replacement of any of the following part:
-Engine;
-ECU;
-Turbo and/or waste gatevalve;
-Throttle body;
-Throttle pedal.
The procedure is detailed here: § 13.5.1
NOTA: On idle, the waste gate position (eWG) must not reach 100%.

Version E User Guide 208 Rally 4 - 22/01/2021 Return to Content Table P 12
4.2.2. Engine start
Please find below the running procedure of your 208 Rally4 once all levels have been checked.
Engine crank procedure to prime oil pressure:
This procedure needs to carry out after every oil change or after a period of 2h without
running.
oMain switch ON, Power OFF.
oEnsure that the gearbox is in Neutral.
oPress on the HORN button and then hold START button. The starter will turn as long as
you keep the start button pressed.
oMaintain Start button until oil pressure raises above 2bar, repeat if necessary.
We advise you no to touch the clutch pedal during this procedure.
Engine and transmission warm up:
oMain switch ON, Power ON, car on stands.
oPress the start button once (no need to keep the button pressed) to start the engine.
oLet the engine warm up on idle until the water temperature reaches 70 °C and the engine
oil temperature reaches 60 °C.
oSwitch to "page 4 –Check page" and check the coherence of the temperatures, pressures
and voltage values.
oGet the car into first gear (press the lock button whilst pulling the gear lever) and
accelerate to bring the engine to 4000/5000 rpm and shift up through all five gears.
oShift back down to first gear at 3000 rpm (press the lock button whilst pushing the gear
lever to reach the Neutral position). Then try the reverse gear and come back to neutral.
oWarm up the engine until the water fan turns on (starts at Twater = 92°C, stop at 90°C).
IMPORTANT :
In general, to protect the engine, never drive the car when Twater is < 70°C.
Engine oil is cooled by an air / oil exchanger, if the oil temperature does not reach 80 ° C, you must
plan to partially cover the oil exchanger by using tape for example.
4.2.3. Final check
After this warm up cycle, we invite to check for any possible leak (engine oil, gearbox oil, power
steering oil) as well as reviewing the car's data.
If in doubt, do not hesitate to contact us and send us data for analysis.

Version E User Guide 208 Rally 4 - 22/01/2021 Return to Content Table P 13
4.3. ENGINE IDENTIFICATION
The engine serial number is indicated on a plate positioned
on the rocker cover.
4.4. FLUIDS
Engine oil:
-TOTAL Quartz INEO FIRST 0W30, reference PS97727A10
-Oil 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 between the ¾ and the max level of the gauge without exceeding it.
Coolant:
-PSA coolant -35°C 5L reference 1637756480
-Coolant quantity:6,5 L
We advise you to check the coolant level at every service. It must remain on the maximum line when
the car is cold.
Min Max

Version E User Guide 208 Rally 4 - 22/01/2021 Return to Content Table P 14
4.5. ACCESSORIES
The engine is fitted with two accessory belts:
-One belt drives the alternator and the steering pump. The tension is managed by using a
dynamic tensioner 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 installation.
Reference
Designation
Quantity
5750VT
Accessory belt 1125 K6
1
1611426280
Dynamic tensioner roller
1
9675874180
Water pump belt
1
1607274880
Water pump belt fitting tool
1
Belt path:
Accessory Belt
Tension Roller
Water Pump
Belt

Version E User Guide 208 Rally 4 - 22/01/2021 Return to Content Table P 15
4.6. SEALS
Every engine sold by Peugeot Citroën Racing Shop is sealed. One seal is fitted on the rocker cover
while another one is fitted on the oil sump.
The turbos sold by Peugeot Citroën Racing Shop are also fitted with a Peugeot Sport seal. This seal
is mandatory to participate to the 208 Rally Cup but is not recognized for FIA rallies.
4.7. REMOVAL / REFITTING OF THE ENGINE
Two lifting hooks are fitted to every engine delivered by Peugeot Citroën Racing Shop.
For accessibility reasons, we advise to fit / remove the engine with the Peugeot Sport engine mount
instead of the serial support on the timing side.
A workshop support is available for sale; it allows an ideal maintenance of the engine assembled
with its gearbox once the powertrain is out of the car.
Reference
Designation
Quantity
904647071A
Workshop engine mount
1
6925P9
Collar screw M10 x 60
2
6925W9
Collar screw M8 x 30
1

Version E User Guide 208 Rally 4 - 22/01/2021 Return to Content Table P 16
5. B00 –COOLING
5.1. WATER CIRCUIT
This car has two water circuits, one for the water radiator equipped with a mechanical thermostat.
The thermostat opens completely at 87 ° C, so there is no need to mask the water radiator.
At the same time, a second circuit includes the gearbox exchanger 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 starts at 92 °C and stops at 90 °C.
There is no water pressure sensor; however, the expansion tank cap is rated at 1.4bar.
Homologation: do not drill the radiator.
As an option, it is possible to add a second radiator fan since 1st of January 2021. The part list is
available on the nomenclature.
GBox Exchanger
Heater
Engine
*: By pass when
thermostat is closed
*

Version E User Guide 208 Rally 4 - 22/01/2021 Return to Content Table P 17
Attention:
When disassembling the water hose from the engine to the gearbox exchanger, it is possible that the
water flange remains in the hose. It is imperative to replace the gauge in the upper oil 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 heating lines to release air from the circuit.
Always have the coolant level above the maximum during the bleeding procedure, add liquid at any
time if necessary.
Continue to warm up the engine until the fan starts (92 °C).
Upper oil plate
Water flange
Coolant bleeding Screw

Version E User Guide 208 Rally 4 - 22/01/2021 Return to Content Table P 18
5.2. TURBOCHARGING CIRCUIT
The air to air intercooler is located on the front face above the water radiator.
To obtain the maximum efficiency, it is important to check the good condition as well 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 displayed on the dashboard.
From 1st of January 2021, a 30mm turbo restrictor must be fitted to all cars in the 208Rally4
category, regardless of the competition.
All information are available on Infotech 20-11 and the A27 notice.
Turbo Outlet
Engine Intake
P2P / T2P Sensor

Version E User Guide 208 Rally 4 - 22/01/2021 Return to Content Table P 19
5.3. ENGINE OIL COOLING
An oil radiator is fitted at the front right corner of the 208 Rally4 front face.
If the oil temperature drops below 70°C (long road sections or cold rallies), it might be necessary to
mask the radiator with tape (ex: reinforced tape).
For optimal operation, the engine oil temperature must remain between 95°C and 125 °C.
5.4. EXHAUST
The turbo is mounted directly on the engine via a 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 as well as the thermal protections are always in good condition.
The catalytic converter, at the end of the exhaust line, is the following model: ROSI 95032 100 2N.
The catalytic converter is approved by the FIA on the technical list #8 and registered under the
registration form FFSA‐005‐50321/95032 from July 2001.
The homologation form can be purchased from the FFSA.
Engine Outlet
Engine return
Intermediate
tube (base)
Turbo outlet
pipe
Silencer (option)
Rear catalytic
tube

Version E User Guide 208 Rally 4 - 22/01/2021 Return to Content Table P 20
6. C00 –TRANSMISSION
This chapter will give you general information, for more 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 therefore sold by Peugeot Citroën Racing Shop.
6.1.2. Final Drive
Only one final drive is homologated and therefore
sold at Peugeot Citroën Racing Shop: