Toasted 206 return to former glory

[Enright]

Costs so far have been very low - I've spent £117, and the biggest bill was £20 on a set of number plates.
The salvage yard where I bought the car from had said that I was welcome to go back and take whatever I needed to finish the job off from another similar CC that they were breaking. So I headed up there a few days ago and came back with a boot and rear seat full of stuff that needed to be replaced. You can have a little game of "recognise all the bits" in the first pic if you like!

There were a couple of "optional extras" that I managed to obtain at the same time that weren't strictly necessary, like the Allure drilled pedal covers, a set of mats, and the Climate Control Assembly. I suspected that the option to convert to full climate control would just be an assembly swap, and for anyone who's interested - I was right. If you already have A/C, then it's all just plug and play. However it turned out to be a bit of a sore point, because when I proudly showed it to Lisa she preferred the look and pretty colours of the standard control panel - doh!!!

So now, unless anyone's interested on here, I’ll have to eBay the upgrade unit.

Latest progress is that the replacement main loom has now just about all been installed. There are just a few remaining components to connect in the front around the washer bottle area, and all of the interior apart from the steering column has gone back in. I’ve even managed to get the boot nice and clear. So I’m hoping that we may have a ceremonial key-turning at the weekend!

[Thar]

It's looking great already, can't wait to see the finished result!

[fatboyslim]

and the Climate Control Assembly. I suspected that the option to convert to full climate control would just be an assembly swap, and for anyone who's interested - I was right. If you already have A/C, then it's all just plug and play.

So just remove the old panel with the twisty and slidey controls and plug in the nice new digital display unit
Nothing else needed??

[Enright]

Not quite. It's more than just the panel, because it controls the air distribution flaps, and the motor speed. The panel has a microprocessor in it, which moves all the flaps via servos. So you have to change the heater matrix/blower assembly. See the big black lump in the centre of the first pic in my last post? It's that. To get it out you have to be prepared to remove and replace your facia. But if you have a Haynes and can do that, then it shouldn't be a problem. Does anyone know how much Climate Control cost as an option when 206's were originally made?

[Thar]

Does anyone know how much Climate Control cost as an option when 206's were originally made?

Difficult to say, it's not listed as an optional extra. Some models had it fitted, e.g. the Allure and others didn't, e.g. Sport.

[Enright]

I'm annoyed. I wanted to get the car started this weekend, but I've hit a few snags that have slowed me right down:

The things that are causing me the most confusion are a couple of spare plugs in the front driver's side corner area, and I could use some forum help if possible. The wiring loom goes down by the washer bottle, then splits off towards the radiator. At this point it divides into 4: One plug goes to the horn, and another goes to the aircon condensor. This leaves 2, but I don't know what they are for:
One plug is brown with a yellow and a green/yellow wire going to it. The other has a green clip which attaches it to the radiator housing - the plug is grey with a grey and a green/yellow wire going to it. Can anyone trace these on their car and tell me what they are supposed to plug into please?

The other problems are as follows, but these just require time or money chucking at them:

The accelerator pedal wouldn't connect up, and because of the position of it (hidden right up behind the fusebox), it took me a long while to work out that the plug on the new wiring loom is different to the plug on the old one. The old one has 5 terminals, whereas the new one only has 4. And I haven't been able to find one for a reasonable price anywhere yet.

The replacement PAS pipe that I got is a different shape - it probably came out of a 2 litre car. It connected up OK (eventually), but won't be routed or secured properly in the engine bay and will need changing ASAP.

The lambda sensor won't unbolt from the manifold on the spare engine. This will be sorted this morning - I'm grinding the bu66er out!

The radiator that had been fitted before I bought the car is wrong. It physically fits, but the pipework will have to be modified, which I don't like.

The oil filter assembly is different too, resulting in a different sized cap and filter. I want these to be the correct size for the age to avoid future confusion when buying spares.

There are a few broken plugs on the new wiring loom around the lights, which need to be replaced, but that shouldn't be too difficult.

That's all folks!

[Capncol]

Welcome to the world of French parts (non)interchangability!!
You may find some of the plugs are redundant. They are often fitted to the loom, but the components they are for are not fitted to your vehicle.
The throttle should only be a 4 wire plug. Are you sure you have the right loom for the car?

[Enright]

Good point. I've just remembered that a couple of plugs/sockets had blanking plugs fitted to them on my original loom. I'll search those out to see if they are the same ones.
That's the wierd thing - the original plug and socket on the loom that came out was a 5 pin jobby.
I stripped the entire replacement wiring loom out of what I think was a 2004 CC at the salvage yard. Just about everything else has matched up perfectly, and that was the 4 pin one - I hope all the ECU wiring is going to be OK otherwise fault-fininding will be a nightmare.

Before you get too involved, take a moment to familiarise yourself with some of the procedures, such as battery disconnect / reconnect & BSI functions. You don't want to fry any new parts!

Er, the car didn't come with a manual. Any chance to a link of exactly what you mean please?
I've had a pretty productive day, and although I'm not going to be able to start the car today, I'm on course to be able to get the battery connected and to check out a good few of the electrical systems...

[GrandadMonkey]

http://www.peugeot206cc.co.uk/viewtopic ... 23&t=13473

[Enright]

Thanks for that - very useful.

Having made more progress under the bonnet, I managed to get the battery connected up yesterday evening, and was greeted by a few problems:
1) The MFD says "Engine Immobiliser Fault". However this could be due to the throttle pedal, injectors, and a couple of other sensors not being plugged in because they have different plugs on them. I need to get these sorted then the ECU may all initialise properly.
2) When connected to the battery and with nothing switched on, about 1.5 amps was being drawn constantly. I'd expect a few milliamps for the alarm and a bit of earth leakage, but this is huge and needs urgent investigation as it will soon kill batteries.
3) The boot would lock with the central locking, but wouldn't unlock.
4) The blower wouldn't work, and
5) neither would the driver's side mirror - however that has been bashed at some point so could just be dead.

On the plus side, the CD/radio is great, all of the lights (which are currently installed) work fine, there's about 3/4 of a tank of petrol in it (bonus!), and best of all - the roof operates! I had to give it a try (while humming the Thunderbirds theme) - well, you just HAVE to don't you?!?

[Capncol]

Point#3 Boot shouldn't unlock with central locking, so is correct.
Well done so far

[Enright]

Brilliant! I would have wasted ages trying to rectify that "non-fault" if you hadn't said, so thank you very much.

[Enright]

2 weeks after I first posted my job list - here's an update on it:

Priority Jobs:
* Trace Current Drain/Repair Electrical Fault & Blower Motor
* Fit Oil Pressure Switch
* Check Oil Level, Replace Oil & Filter
* Replace Engine Earth Lead
* Replace Green Temperature Sensor
* Secure Engine Harness (behind engine)
* Repair Broken Plugs (N/S/F Indicator & O/S/F Foglamp)
* Replace Timing Belt Cover & Check Timing Belt

To Do List:
* Check/Clear Fault Codes (after startup)
* Replace Antifreeze & check for leaks (after startup & drain plug)
* Check Brakes/ABS (after startup)
* Check Headlamp Beam Alignment (after startup)
Replace Pedal Covers

Shopping List:
* Gearbox End Cover & Gasket
* Crank Position Sensor
* Accelerator Pedal
* Oil Filter Cover
* Radiator Drain Plug
Fusebox Cover
Bonnet Latch Switch
Battery Clamp
Clutch Lever Grommet
F Middle Bumper Fastener
PAS Pipe
Radiator
Bonnet
N/S Wing
N/S Mirror Glass
O/S Mirror Shroud
* Windscreen (inc Rain-X)
* N/S/F & O/S/F Tyres
* MoT Test
Recharge Aircon
Spare Key & Fob
Owner's Handbook

Completed Jobs:
Check Alternator Belt
Clean Bodywork, T-Cut, Polish & Rain-X Windows
Clean Engine Bay (WD40 & Jetwash), Interior (Cockpit Shine) & Boot
Clean Wheels, Check & Re-paint Brake Calipers (Black Smoothrite)
* Repair Driver's Seat Mechanism
* Replace Aircon Pipes
* Replace Air Intake Pipe & Air Filter Housing
* Replace Battery Tray & Battery
Replace Bonnet Release Cable
* Replace Blown Bulbs (N/S/F Sidelight & Multi-function Display)
Replace Bumper Trim Strip (Black EXL Spray)
* Replace N/S Headlamp Levelling Motor & Bulbs
Replace Roof Button
* Replace Clutch Slave Cylinder & Pipe, Bleed Brakes & Clutch
Replace Dipstick
Replace Earth Lead
* Replace Engine Bolt-ons (Oil Pressure Switch, T'stat Housing, Lambdas, Pipe/Wiring Mountings, Spark Plug Cover)
* Replace Fuel Pipe
* Replace Number Plates
* Replace PAS Pipe, Pump Cap, Pump Cover and Fluid
Replace Radiator Grille
* Replace Screenwash Pipework
Replace Sound-Proofing & fixings
* Replace Starter Motor
* Replace Water Hoses & Bottle
* Replace 2 Wheel Nuts
* Replace Windscreen Wiper Motor & Trim Panel
* Replace Wiring Harnesses (Engine & Main)
Haynes & Workshop Manual on CD

I've now got a lot more in the "Completed" list than I have in the "Priority" and "To Do" lists put together.
Unfortunately as is always the way, the more you do the more you find. So the "Shopping" list has grown a lot. Still, it's all progress...

[Enright]

A couple of breakthroughs to report - the first is worth sharing simply because I found it amusing, and the second is a brilliant official source of information that I didn't realise was in the public domain, and is well worth knowing about:

The first breakthrough concerns my radiator/drain plug. When I first connected the main pipes from the thermostat housing etc I found that they had to be bent and stretched quite a bit to reach the radiator, which hinted at the wrong model of radiator having been fitted. Also the pipe back to the expansion tank wouldn't fit without modification, but I figured that I'd do that later.
Then I tried filling the system, and promptly got wet feet!
It appeared that the drain plug in the bottom left-hand corner had been left out.
I contacted the salvage yard to ask for a replacement radiator. They weren't too happy about this as they said there are only 2 types and they were sure the right one was on the car. Still, the owners would have a chat about it and let me know.
Armed with this info I went back to have another look at the car, and suddenly realised what had happened - they'd only gone and put the radiator in upside-down!!!
What I thought had been the "missing drain plug" from the bottom left was actually the expansion tank pipe fitting which should have been at the top right. Amazingly Peugeot in their wisdom made the rad with the top and bottom lugs in the same place, and the top and bottom hoses, while off-centre, still fit.
Turning it over cured everything - it slotted in beautifully and saved me either an argument or a lot of expense all in one go!

The second breakthrough happened yesterday, when I called in at a Peugeot main dealer to price up a few parts that I was struggling to find at local breakers' yards.
The chap behind the Parts Dept counter was really helpful, going through all the exploded views to find the bits that I was interested in. After printing off an estimate I asked him if he knew of any information in the public domain that could help me identify parts in advance of a visit.
He advised me that doing a Google search for "Service Box" would give me everything I need - all I have to do is register myself as a professional motor repairer (as he had already done) on Peugeot's own website.
Well, I've done it, and having just had a browse, can confirm that it's really good. Now I can find what I need online and even print pictures and part numbers. With a bit more experience I may even be able to find out prices without having to bother dealerships at all.

[fatboyslim]

mate service box is the dogs danglies
When you've logged in and entered your VIN number in the top left box with VIN/VIS in then click 'OK'
A new list appears under there if you click on 'CHARACTERISTICS' a whole list comes up which tells you everything about your car
Anyways to find the price of something is easy, you find the part you need in the exploded diagram
Then go to the description list to the right you'll see that as you move your cursor over the description they turn blue and the number of the part in the diagram turns blue also
When you're sure it's that part if you double click the description,on the main page of service box on the upper right side is a box which says 'PARTS' and 'LABOUR' at the top,after double clicking the part description you should see that the part number appears in this box by magic!!
Close the diagram pop-up and on the main page scroll to the top and you should see a shopping trolley type icon( top-right) it'll say 'order parts' when you put your cursor on it, click this
A new page comes up which asks for your details (ignore this unless you DO have an account somewhere)
There's four symbols at the top one looks like a person and car,spanner and piece of paper,SHOPPING BASKET and piece of paper in an envelope
Click on the shopping basket and a list comes up which has all your part numbers,description and prices on it,it even tells you the non-VAT price and the VAT included price
It also warns you that these prices are only Pugs recommended price,so you may end up paying a bit more or less,the few times I've looked on Service box for prices the dealer in Newark has usually charged less!!