206 cc Roof Problems

[LJB1]

I have got a Peugeot 206 cc which had a problems when I tried to open to roof. It stopped half way. I did manage to close it slowly but was getting beeps in the car. The roof wont open now and the catch beeps don't sound anymore either. I have reset the BSI a few times now but now the car starts intermittently. When it doesn't start the car does a clicking noise as if the starter motor isn't engaging. I have been tempted into getting a diagnostic computer from ebay for about £13.00-£30 which includes a code book (has anyone used one of these and are they any good). Any advise would be gratly appreciated. This is my new toy and it hasn't been on the road.

[mo7amed3arafa]

Check the roof hoses and the oil level.

[Capncol]

A cheap code reader will only give you eobd engine codes. It won't be any good for the roof.

[DJromT]

Hi, I'm new on this forum, and wanted to share some useful feedback on fixing a 206cc (2001 2.0 SE) roof problem (comparable to what is described at the beginning of this post). I did fix it on my own, with no mechanic or automotive skills.

This forum helped me to change properly the entire hydrolic system for the boot lid, however there were a couple of things missing on the forum that I'd like to enumerate here.

Problem:
- Roof was working fine for a number of month, then sometimes stopped in the middle of the folding/unfolding motion. Sometimes working again but with a loud noise coming from the hydraulic pump behind the back seats.
- small oil leak detected on the boot lid garnment, at that time I didn't even know the rams where hydraulic, thought it was all electrical motors.
- I thought root cause would be found with diagnostic computer, or that it would be an electrical problem. When I saw the feedback on the charges from Peugeot to just look for the issue, and then costs of parts and labor, I thought I'd give it a crack.

What I've done:
-inspected all four hydraulic rams for oil leaks (the 2x that open the boot, the 2x that open the rood). Turned out that a hose was leaking on one of the boot lid ram, everytime the pump was activated and pushing pressure. I found on internet that a lot of roof problems come from leaks from those damn boot lid rams. The right ram has four connections on it (2 that go to the pump, 2 that go to the left ram).
- inspected the pump itself (very easy to access and detach), no leak, however the oil tank on the side was really low.
- I ordered on eBay the full boot lid hydraulic system (hoses that connect to the pump, 2x rams attached to the hoses). I preferred to have the rams already connected to their hoses from manufacturers, decreasing the risk of me attaching the hoses in a bad way. I don't regret that at all.
- on a dry afternoon, I removed the lid garnement, boot garnment hiding the pump, and started to mark the hoses with a marker (the two hoses that connect to the pump). Followed the usual procedure to release pressure with the small allen key on the pump.
- removed the old rams, made sure to put back immediately the metal bits in the hinges so that I could still operate the lid (managed to loose a pin unfortunately). The hoses can be unstrapped easily from the boot frame bar.
- unscrewed hoses from the pump, replaced with the new hoses from the set I bought on ebay.
- removed the pump oil tank (nobody seem to have ever successfully used the re-fill hole), removed the old hydraulic oil, filled up again with new clean one. Re-sealed the little oil tank.
- reverse operation for everything else to fit the rams and the hoses where they belong

Result:
- total work involved 2 hours (including discovering the process as I went a long a little bit)
- folding/unfolding cycles working well, had to make 10/15 cycles to bleed out all the air and have again smooth movements and stop the pump from screaming.
- i'll keep having a look for the next few weeks for oil leaks on each ram and pump. I don't know how good the eBay parts are (from car breaker) and if I did a good job at reconnecting the hoses on the pump.
- total costs:
- £32 for the rams and hoses on eBay
- £15 for 1L of Mercedes ISO32 Aral Vitamol ZHM hydraulic oil from Peugeot/Mercedes car dealer
- 2 hours of preparations research on internet (including this forum)
- 2 hours of work on the car itself

Lessons learned:
- the hydaulic oil is very specific and you should by all means avoid at all costs jack oil. I couldn't find on eBay or anywhere the Aral Vitamol ZHM, so went to a local peugeot dealer who had a parts/service desk. Peugeot sells this very oil under part number 9735 57, £14 for 250ml. The garage service dealer also explained that this specific Aral oil is available from Mercedes, under a different part number, same price for a whole bottle of 1L. I went for the Mercedes one. Please make the effort to go to a Peugeot part desk and get the right oil, don't make a silly decision on jack oil.
- clean with a dry cloth your hose endings before attaching them to the pump. A grain of sand would cause a small leak or damage the tight bolting.
- the oil pump automatically bleeds out any air left in the oil hoses after the work is done. There's no need to worry about getting rid of the air or - worst idea to think of - manually bleed out the hoses by running a roof cycle with the oil return hose detached from the pump.
- be very careful when you remove the rams from their natural fixings on the lid; there is a pin holding the bolt on both end of each ram. I dropped one in the boot, impossible to find. Had to use a paperclip to replace it. Still impossible to find one on eBay or from a car breaker (they always try to sell the full lid or roof together, not selling the spare pin or bolt if you lost one).
- you will need a flat head screwdriver to remove all the little clips from your boot garnments, also the Allen key for releasing the pressure on the pump. I had to use a wench with a longer handle to unscrew the hoses from the pump (make sure you hold the pump tight when you do it)

Thanks to the forum for publishing so many useful feedback, I had to write mine to add up to the information that wasn't there.

[Capncol]

Thanks DJromT for that. Another idea for those having similar problems.

Regarding your missing *pin*, what about a split pin or "R" clip

[DJromT]

Thanks Capncol.
The pin is actually not like those, it's a thin crown-shaped pin, like a basic DIY flat shaped ring with an opening on one side, just a millimeter thin, with a small hinge opposite from the opening for extraction. Tried to post a drawing of it, however the forum says "You are not authorized to post url links, please remove or rename:"

Any idea what's the name of such item? Remember this from a previous job on a 206cc ram ? :-)

I may well order a few sizes of R clips and see if I find something that would do the job. Only issue is that the R clips are thicker when the diameter of the part they're supposed to hold is larger. I need something fairly thin (millimeter) but that can hold on to a bolt head with a diameter of about 1 cm.

[gazza82]

Had a quick look on Servicebox but couldn't see anything like the clip you describe .. but they do list various "packs"

On that subject you can create you own account and refer to the parts lists and drawing for free ...

http://public.servicebox.peugeot.com

Create an account and set up a password .. fill-in fields with dummy data if needed ...

Once in you will find all the roof mechanics and parts under "Bodywork" then "Sunroof/Bonnet" and

Roof_ServiceBox_1.jpg

[Capncol]

Can you PM me the link for the pin?

[DJromT]

Thanks for the link to the Peugeot site, brilliant diagrams and everything in there.

I found that part in one of the assembly schematic for the boot lid, this "pin" is part ref 8484 S8, called in the website "MUL ANNEAU ARRET". Unfortunately I can't order from their website, asking for a french VAT and company registration (I'm french living in Blighty for 8 years now btw).

By the way I don't have the rights to send you a PM, I'm using a number of forums using PHPbb forum technology, and my user rights are really limited here (no URLs, no PM). As a moderator, could you either PM me to fetch the URL, or raise a little my rights, please? :-) . Thanks, Jerome

[Capncol]

Sorry, but the limitations were put in by admin so I can't change them.
Is this the type of clip? Scroll right to see it.

Taken from http://www.peugeot206cc.co.uk/repair-206/








if so use an "E" clip

[DJromT]

You are my savior, thank you so much!
Buying a box of those on eBay of all sizes, I'm sure I'll find what I need.

[gazza82]

As a free user your functions on Service box are limited ... but it's worth it just for the diagrams and to know what you are buying ...

This is the same software the dealers use, but they pay for the privilege!

[DJromT]

Hi, so that boot lid ram's clip (normally Peugeot part 8484 S8) can be replaced by a standard E clip 6.40mm. Thanks for helping out, my boot/roof hydraulic repairs are now finished.

[sinclair]

Hi

I am new to to site, and cant see how to post a question.

My roof wont go down, when i unlock to front hooks it does not 'boing' and when i press the open roof switch it just beeps. really puzzled, its a 206cc 03 plate. I am in the Leeds area. Last night i looked at the clip where you slide the boot cover over to activate the sensor and then taped the sensor down (thinking that might help) but alas still no 'boing', I am not mechanically minded sorry. Can anyone help please please.

thanks Vicky

[Enright]

See here:
http://www.peugeot206cc.co.uk/viewtopic ... ng#p118827