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Peugeot 206
(1998-2012)
General information
User manual
General information about Peugeot 206 cars
Vehicle identification data
Starting the engine from an auxiliary source
Lifting a car with a jack
Towing a car and driving with a trailer
Wheel replacement
Controls and instruments
Car keys and ignition switch
Control indicators
Digital and analog control devices
On-board navigation system
Steering column switches
Parking brake
On-board computer
Electric windows
Headlight corrector
Adjusting the position of the steering wheel
Sound signal
Rear view mirrors
Lighting external and internal
Seat adjustment
Seat belts and airbags
Central lock
Ventilation hatch
Heating and ventilation
Air conditioning
Additional interior equipment
Manual transmission
Automatic transmission
ABS anti-lock brake system
Opening the hood
Opening the trunk
Running in a car
Fuses — location and replacement
Rechargeable battery
Electronic anti-theft system
Maintenance
View of the engine compartment and maintenance tools
Optimal maintenance intervals
Applicable motor oils
Maintenance intervals
Maintenance of a car with a gasoline engine
Maintenance of a vehicle with a diesel engine without turbocharging
Maintenance of a car with a turbocharged diesel engine
General vehicle checks
General requirements for car repair
Types of fasteners and tightening torques
Power unit
Gasoline engines
Removal and installation of the power unit
Disassembly and assembly of the power unit
Special tools and devices for engine disassembly
Disassembling the engine
Special tools and devices for engine assembly
Engine assembly
Running in the engine after major repairs
Checking the engine on a car after repair
Cylinder block — design features
Cylinder block — checking technical condition
Connecting rod and piston group — design features
Assembling the piston with the connecting rod
Camshafts — Design Description
Removal and installation the timing belt of the EW10J4 engine
Removal and installation the camshaft of the EW10J4 engine
Draining and filling coolant
Recommended motor oils and their volumes
Draining oil using a vacuum pump
Removal and installation the intermediate muffler on the EW10J4 engine
Removal and installation the fuel level sensor
Removal and installation the fuel tank filler neck
Removal and installation the protective cap of the fuel tank cover
Removal and installation the fuel tank
Exhaust gas recirculation system
General information about gasoline engines
Diesel engines
General information about diesel engines
DW10 TD Engine — Removal and Installation
DW8 Engine — Removal and Installation
Cylinder block of engines DW10 TD and DW10 ATED
DW8 engine cylinder block
Cylinder head of the DW10 TD engine
Cylinder head of the DW8 engine
Crankshaft — General Information
Replacing the crankshaft flywheel
Connecting rod and piston group — design description
DW8 Engine Auxiliary Drive Belt
Timing mechanism (GRM) — general information
Timing Belt Replacement
Removal and installation the camshaft
Draining and filling coolant
Removal and installation the radiator support and fan motor unit
Recommended motor oils and their volumes
Draining oil using a vacuum pump
Exhaust gas recirculation system
Engine Exhaust Gas Recirculation Valve DW10 TD
Pre-heating system — general information
Removal, checking and installation glow plugs
Diesel power system
General information about the fuel system of diesel engines
Removal and installation the fuel filter of the DW8 engine
Removal and installation the fuel filter of the DW10 TD engine
Removal and installation fuel injectors on the DW8 engine
Removal and installation fuel injectors of the DW10 TD engine
Removal and installation the high pressure fuel regulator on the high pressure fuel pump
Removal and installation the fuel distributor
Removal and installation of fuel injection pump
Removal and installation of fuel injection pumps from LUCAS
Checking and adjusting the fuel injection pump
Turbocharging system — general information
Removal and installation of turbocharger DW10 TD
Engine management system
General information about engine management systems
Engine management system MAGNETI MARELLI 1AP
Engine management system MAGNETI MARELLI 8P
Engine management system BOSCH MOTRONIC MP5.2
Engine management system BOSCH MOTRONIC MP7.3
Transmission
Clutch
Clutch — description and technical characteristics
Bleeding the hydraulic clutch drive
Removal and installation the clutch cable
Removal, checking and installation the clutch
Adjusting the clutch drive
Removal, inspection and installation of the torque converter
Mechanical gearbox
Technical data and characteristics of the BE4/5 gearbox
Removal the BE4/5 gearbox
Installation of gearbox BE4/5
Tightening torques for gearbox BE4/5
Removal the MA gearbox
Installation of MA gearbox
Removal and installation of external parts and units of the MA gearbox
Removal and installation the intermediate housing of the MA gearbox
Removal the primary, secondary shafts and differential of the MA gearbox
Disassembly and assembly of the primary shaft of the MA gearbox
Disassembly and assembly of the secondary shaft of the MA gearbox
Disassembly and assembly of MA gearbox synchronizers
Disassembly and assembly of the differential of the MA gearbox
Disassembly and assembly of the MA gearbox shift mechanism
Removal and installation of the MA gearbox control mechanism
Automatic gearbox
Description and characteristics of automatic transmission
Replacement of AT working fluid
Removal and installation of automatic transmission
Removal and installation the hydraulic unit wiring harness
Removal and installation the vehicle speed sensor
Removal and installation the gearbox control mechanism
Adjusting the gear shift mechanism
Drive shafts
General information about front wheel drive shafts
Removal and installation the front wheel drive (models with automatic transmission)
Removal and installation front wheel drive (models with manual transmission)
Replacing mudguards on a GKN drive
Replacement of mudguards on the drive manufactured by PSA
Chassis, running gear
Front suspension
Wheel alignment angles
Removal and installation the shock absorber strut
Transverse stability stabilizer
Removal and installation the steering knuckle
Removal and installation the lower suspension arm
Removal and installation of silent blocks
Removal and installation the front wheel hub bearing
Removal and installation the shock absorber spring
Adjusting the front wheel alignment
Rear suspension
General information about the rear suspension
Removal and installation the rear suspension beam assembly
Removal and installation the anti-roll bar
Removal and installation the rear shock absorber
Removal and installation rear suspension torsion bars
Steering
General information about steering
Removal and installation the steering gear
Removal and installation the steering column
Removal and installation the toothed rack support
Removal and installation the mudguard
Removal and installation the ignition switch
Removal and installation the distribution valve
Draining and filling the hydraulic circuit of the power steering
Control and adjustment of the steering mechanism
Brake system
Tightening torques for threaded connections
Front disc brakes — description
Rear brakes — description
Removal and installation front brake pads
Removal and installation of front brake mechanisms BOSCH
Removal and installation rear disc brake pads BOSCH
Removal and installation of rear disc brakes BOSCH
Removal and installation rear drum brake shoes BOSCH
Removal and installation rear drum brake shoes LUCAS
Removal and installation the master brake cylinder
Removal and installation the brake booster
Removal and installation the pressure regulator
Checking the operation and adjusting the parking brake
Draining, filling and removing air from the hydraulic drive of the brake system
Body and interior
Body elements
General information about the car body
Car body and interior care
Removal and installation the front bumper
Replacing the front bumper deflector
Removal and installation the front wing
Removal and installation the hood release cable
Removal and installation the rear bumper
Doors, locks and windows
Windshield replacement
Installation and adjustment of the front door
Installing the rear door
Adjusting the door lock bracket
Removal and installation the front door opening mechanism
Removal and installation the front door trim panel
Removal and installation the rear door trim panel
Removal and installation the tailgate
Removal and installation the rear window washer jet
Removal the door glass
Removal the window regulator
Electrical equipment
Equipment and devices
Technical data of electrical equipment
Finding a faulty consumer in an electrical system
Detecting the source of a short circuit
Removal and installation the generator
Removal and installation windshield wiper arms
Removal and installation the windshield wiper electric drive
Removal and installation the electric drive of the windshield wiper of the luggage compartment door
Relay and fuse box
Electrical circuits
Code designation of elements on electrical circuits
Electrical Equipment Diagrams 0 to 10
Electrical equipment diagrams from 11 to 20
Electrical equipment diagrams from 21 to 30
Peugeot 207
(2006-2014)
General information
Car care
Lifting a car
Frequency of self-service
Hood — opening and closing
Fuel system
Refueling a car
Motor oil
Cooling liquid
Windscreen washer fluid
Brake and Clutch Hydraulic Fluid
Filling volumes
Battery care
Replacing the battery
Starting the engine with an additional battery
Maintenance of fuses
Replacing headlight bulbs
Replacing the bulb in the direction indicators
Replacing the low beam lamp
Replacing the high beam lamp
Replacement of daytime running lights, parking lights
Replacing the side turn signal repeater assembly with the lamp
Replacing the rear lights
Car handling and tires
Wheel reinstallation
Tires with tread wear indicator
Tread pattern height
Checking tire pressure
Spare tire and car tool
Wheels with decorative caps
Wheel removal
Wheel installation
Towing a car
Key with electronic immobilizer
Unlocking car locks
Locking the car locks
Search for a car in a parking lot
Anti-theft protection
Initializing the remote control and replacing the battery
Security alarm
Opening doors
Emergency locking and unlocking of locks
Central lock
Tailgate
Window lifter maintenance
Dimensions and identification data of the Peugeot 207
Governing bodies
Control devices, indicators and signaling devices
Odometers and indicators
Liquid crystal display on the instrument cluster
Governing bodies
Oil level indicator
Vehicle speed indicator
Fuel level indicator
Engine coolant temperature gauge
Engine oil temperature gauge
Control lamps and signaling devices
Diagnostic reset button
Light switches
Headlight Delay Function
Remote switching on of external lighting devices
Headlight adjustment
Direction indicators
Emergency light signaling
Interior lighting
Adjusting the position of the steering wheel
Exterior rear view mirrors
Interior rear view mirror
Glove box with illumination
Ashtray with illumination and cigarette lighter
Manually adjustable front seats
Headrest adjustment
Heated seats
Rear seats
Seat belts
Airbags
Luggage compartment (sedan)
Manual air conditioner
Luggage compartment (station wagon)
Electric heated rear window and mirrors
Automatic air conditioner
Parking brake
Engine shutdown
Driving and operation
Starting the engine
Automatic transmission
On-board tire pressure monitoring system
Anti-lock braking system (ABS) and electronic brake force regulator (REF)
Electronic Stability Program (ESP) and Anti-Slip Regulation (ASR)
Speed control (cruise control)
Anti-corrosion protection of the body
Power unit
Engine characteristics
Frequency of vehicle maintenance
Identification data
Technical characteristics of petrol and diesel engines
Cylinder head (petrol engines 1.4 and 1.6 l, EPZ, TU5)
Cylinder head (1.6L diesel engines)
Timing belt characteristics (petrol engines 1.4 and 1.6 l, EP3, TU5)
Timing belt characteristics (1.6L diesel engines)
Camshafts (petrol engines 1.4 and 1.6 l, EP3, TU5)
Camshafts (diesel engines)
Characteristics of the cylinder block (petrol engines 1.4 l, EPZ)
Cylinder Block Specifications (1.6L Petrol Engine, TU5)
Cylinder Block Characteristics (1.6L Diesel Engines)
Valve mechanism characteristics (petrol engines 1.4 and 1.6 l, EPZ, TU5)
Valve train characteristics (1.6L diesel engines)
Crankshaft characteristics (petrol engines 1.4 and 1.6 l, EPZ, TU5)
Crankshaft characteristics (1.6L diesel engines)
Characteristics of the piston group (petrol engines 1.4 and 1.6 l, EPZ, TU5)
Piston group characteristics (1.6 l diesel engines)
Tightening torques for petrol engines 1.4 and 1.6 l, EPZ, TU5
Tightening torques for 1.6L petrol engines (EP6 series)
Tightening torques for 1.6L diesel engines
Engine repair
Conditions for cleaning and reassembling the internal combustion engine
Checking for a cylinder leak
Compression measurement
Cooling system test data (all engines)
Lubrication system test data (all engines)
Oil pressure check procedure (petrol engines EP3, EP6)
Oil Pressure Check Procedure (EP6DT Petrol Engines)
Oil Pressure Check Procedure (Diesel Engines)
Checking the boost pressure (EP6DT petrol engines)
Checking the low pressure fuel supply circuit
Draining the working fluid
Filling the cooling system and removing air bubbles from it
Replacing the accessory drive belt (petrol engines)
Checking the accessory drive belt (diesel engines)
Replacement of auxiliary drive belt (1.6L diesel engines)
Timing mechanism (petrol engines EP6, EP6DT)
Timing drive adjustment (petrol engines 1.4-1.6 l EPZ, TU5)
Timing drive adjustment (petrol engines 1.6 l EP6, EP6DT)
Timing drive adjustment (diesel engines)
Replacing the timing belt (petrol engines 1.4 and 1.6 l EPZ, TU5)
Removal and installation of the timing drive actuator (1.6 l petrol engines EE6, EP6DT)
Timing chain replacement (petrol engines 1.6 l EP, EP6DT)
Replacing the timing belt (1.6L diesel engines)
Replacing camshafts (petrol engines)
Replacement of camshafts (diesel engines)
Removal and installation of the cylinder head on a car (petrol engines 1.4 l and 1.6 l EP3, TU5)
Removal and installation of the cylinder head on a car (petrol engines 1.6 l EP6, EP6DT)
Removal and installation of the cylinder head on a vehicle (diesel engines)
Cylinder head repair
Replacing the dual damper flywheel
Engine Cylinder Block Repair
Assembly of the engine piston group
Checking the crankshaft side clearance
Gasoline ICE — Removal
Gasoline ICE — installation
Diesel ICE — Removal
Diesel ICE — installation
Cooling system
Technical characteristics of cooling system components (petrol engines)
Cooling system device (petrol engine 1.6 l)
Technical characteristics of cooling system components (diesel engines)
Electric Fan Assembly
Cooling system device (diesel engine)
Coolant temperature sensor
Controlled thermostat
Replacing the coolant temperature sensor
Changes in the design of the liquid outlet unit (2.0 l diesel engine)
Replacing the coolant outlet unit (diesel engine)
Replacing the coolant outlet unit (petrol engine)
Installing a Coolant Outlet Block with an Aluminum Housing
Installing a coolant outlet block with a plastic housing
Removal and installation lower radiator hoses with quick-release fasteners
Replacing the radiator (petrol engines)
Radiator replacement (petrol engines EP6, EP6DT)
Turbocharger Cooling Pump Replacement (EP6DT Engines)
Replacing the coolant pump (petrol engines)
Replacing the coolant pump (diesel engines)
Engine Cooling System Error Codes
Lubrication system
Replacing the oil filter element
Replacing the engine oil level and temperature sensor (TU5 engine)
Replacing the engine oil level and temperature sensor (petrol engines EP3, EP6)
Replacing the engine oil level and temperature sensor (EP6DT petrol engines)
Replacing the engine oil level and temperature sensor (diesel engine)
Replacing the engine oil pressure sensor (diesel engine)
Ignition system
General information about the ignition system of the TU5 petrol engine
Ignition system device
Ignition coils (TU5 petrol engine)
Crankshaft speed and position sensor (TU5 petrol engine)
Characteristics of ignition components (TU5 petrol engine)
General information about the ignition system of gasoline engines of the EP series
Characteristics of ignition components (EP series gasoline engines)
Crankshaft speed and position sensor (EP series gasoline engines)
Knock sensor (EP series gasoline engines)
Camshaft Position Sensors (EP Series Gasoline Engines)
Spark plugs
Replacing the crankshaft sensor (petrol engine)
Replacing the crankshaft sensor (diesel engines)
Replacing the knock sensor (petrol engines)
Replacing the camshaft position sensor (petrol engines)
Replacing the camshaft position sensor (diesel engines)
Removal coils and spark plugs
General information about the pre-heating system
Replacing glow plugs (1.6L engine)
Control system (gasoline)
General information about the injection system «Bosch MEV 17.4»
On-Board Diagnostics (EOBD)
ECU of the injection system «Bosch MEV 17.4»
Fault codes for the injection system «Bosch MEV 17.4»
Engine System Interface Block BSM
Fuel system (gasoline)
The device of the fuel system of gasoline engines
Fuel filter
Fuel lift pump (low pressure)
Pressure regulator
Fuel injectors
Measuring fuel pressure
Cleaning the fittings on the high-pressure fuel rail
Checking for leaks
Removal and installation fuel injectors
Replacing the high pressure sensor (EP6DT engines)
Replacing the fuel pump/fuel level sensor assembly
Replacing the high pressure fuel pump (EP6DT engines)
Replacing the vacuum pump
Removal and installation the fuel tank (all engines)
Adsorber in the fuel vapor recirculation system
Electromagnetic valve for bleeding the adsorber
Fuel Vapor Recirculation System Sensors
Block diagram of the fuel vapor recirculation system
Variable intake valve lift mode
Electric motor for opening valves
Intake valve position sensor
Throttle valve
Replacing the adsorber
Replacing the solenoid valve for bleeding the adsorber
Removal the intake manifold and throttle valve (EP3, EP6 engines)
Removal the intake manifold and throttle valve (EP6DT engines)
Removal the heat exchanger (cars with AL4 automatic transmission)
Exhaust system (diesel engine)
Exhaust system device (petrol engine)
Removal and installation the exhaust pipe (petrol engine)
Control system (diesel)
Prohibited operations during repair of the direct injection system of diesel fuel
Diesel Fuel Injector Code
Reading fault information
Emergency operation mode
Diagnostics of a variable geometry turbocharger
Compression check
Checking the high pressure circuit
Cleaning the fuel line fittings of the high-pressure circuit
Checking the low pressure circuit
Checking the air supply system
Removal and installation injectors
Removal and installation the fuel filter
Replacing the charge air temperature sensor
Replacing the camshaft position sensor
Replacing the air flow sensor
Replacing the crankshaft sensor
Replacing the exhaust gas temperature sensor
Replacing the fuel temperature sensor
Removal and installation the turbocharger air cooler
Removal and installation of fuel injection pump (1.6 l engine)
Removal and installation the EGR valve
Removal and installation a turbocharger (1.6L engine)
Replacing exhaust gas temperature sensors
Replacing the diesel particulate filter
Transmission
Clutch
Types of Clutch
Clutch characteristics
Clutch diagnostics
Bleeding the clutch hydraulic drive
Removal and installation the clutch mechanism
Removal and installation the hydraulic clutch control unit
Mechanical gearbox
General information about transmission
Gearbox BE4/5
Gearbox MA5
Diagnostics of mechanical elements of manual transmission
Gearbox control mechanism
Adjusting the gearbox control mechanism
Adjusting the gear selection drive cable of the BE4/5 gearbox
Removal and installation the gear shift drive
Draining and filling oil in manual gearboxes MA5 and BE4/5
Removal and installation of manual transmission MA5 and BE4/5
Disassembling MA5 and BE4/5 manual transmissions
Disassembling the clutch housing of the MA5 and BE4/5 manual transmissions
Features of repair of gearboxes with and without a system for prohibiting the inclusion of 5th gear/reverse gear
Disassembling the primary shaft of the MA5 and BE4/5 manual transmissions
Disassembling the secondary shaft of the MA5 and BE4/5 manual transmissions
Disassembling the differential housing of the MA5 and BE4/5 manual transmissions
Assembly of differential manual transmission MA5 and BE4/5
Adjustment of the console part of the MA5 and BE4/5 manual transmission
Assembly of the secondary shaft of the MA5 and BE4/5 manual transmissions
Assembly of the primary shaft of the MA5 and BE4/5 manual transmissions
Installation of primary and secondary shafts of manual transmissions MA5 and BE4/5
Assembly of the clutch housing of the MA5 and BE4/5 manual transmission
Features of gearbox assembly with and without a 5th gear/reverse gear interlock system
Installing the gearbox housing
Gearbox assembly
Automatic gearbox
General information about the AL4 automatic transmission
Electronic gearbox control
Tightening torques (automatic transmission AL4)
Precautions when working with automatic transmission
Checking the oil pressure in the automatic transmission
Draining, filling and checking the level of automatic transmission oil
Diagnostics of possible places of oil leakage of automatic transmission AL4
Assignment of contacts of the ECU connector of automatic transmission AL4
Gearbox primary shaft speed sensor
Gearbox Output Speed Sensor
Gearbox Oil Temperature Sensor
Gearbox oil level and temperature sensor
Downshift sensor («Kickdown»)
Shift Sequence Solenoid Valves (EVS 1 — EVS 6)
Pressure change solenoid valves
Heat Exchanger Flow Control Solenoid Valve (EPDE)
Gear selector lever
Actuator for locking the gear selector lever in position «P»
Automatic transmission program selector
Multifunctional switch
Brake light switch
Diagnostics of automatic transmission AL4
Checking electrical connections
Removal and installation of automatic transmission AL4
Removal and installation of the torque converter
Removal and installation the gearshift lever position contactor
Removal and installation of the hydraulic unit and electromagnetic valves
Removal and installation of the ECU and the automatic transmission oil level and temperature sensor AL4
Drive shafts
Designation and type of drive shafts
Drive mechanism — general information
Drive shafts «Glaenzer» (GKN)
Drive shafts «Rzeppa» PSA
Identification of drive shafts
Protective covers for drive shafts
Interchangeability of drive shafts
Location of drive shaft protective covers
Slip-on drive shaft support
Removal and installation drive shafts
Removal thermoplastic protective covers
Removal the neoprene protective covers
Replacing the bearing on the gearbox side
Chassis, running gear
Car suspension
Front axle
Rear axle
Geometry of bridges
General characteristics and tightening torques of the front suspension
Front axle alignment angles
General characteristics and tightening torques of the rear suspension
Removal and installation the front suspension steering knuckle
Removal and installation the lower front arm
Removal and installation the ball joint of the front steering knuckle
Lower Front Arm Repair
Front steering knuckle repair
Features of front suspension wheel bearings
Removal and installation the front subframe and frame
Removal and installation the stabilizer bar
Removal and installation the front anti-roll bar
Removal and installation the front shock absorber assembly
Disassembling the front shock absorber (on the workbench)
Removal and installation the rear wheel hub
Removal and installation the rear wheel trunnion
Removal and installation the rear axle
Removal and installation rear suspension silent blocks
Steering
General information about steering
Steering column identification
Tightening torques for steering components
Technical characteristics of the steering system
Executive mechanism (power steering electric pump unit)
Power steering pump control unit
Steering wheel angle sensor
Checking the pressure in the power steering circuit
Draining fluid from the hydraulic circuit of the power steering
Filling the hydraulic circuit of the power steering
Bleeding the hydraulic circuit of the power steering
Removal and installation the steering wheel
Removal and installation the steering wheel angle sensor
Removal and installation of steering rods
Adjusting the rack's middle position
Removal and installation the steering gear
Adjusting the steering rack stop
Removal and installation the steering column
Brake system
General information about the braking system
Tightening torques for brake system components
Brake system characteristics
Checking and adjusting the parking brake
Draining, filling and bleeding the brake circuit
Checking the front brake discs
Checking the rear brake discs
Checking the rear brake drum
Replacing the parking brake cables
Replacing the master brake cylinder
Removal and installation the vacuum booster
Replacing the brake light switch
Removal and installation the pedal assembly
Replacing the front brake pads
Removal and installation the front brake caliper
Removal and installation the front brake disc
Replacing rear brake pads
Removal and installation the caliper and hub of the rear brake disc
Repair of the rear brake hub
ABS system — general information
Electronic Stability Program (ESP) device
ESP system — general information
ABS/ESP diagnostics — reading errors (fault codes)
MSR system — trajectory control during deceleration
Removal and installation of the hydraulic unit and ABS/ESP ECU
Removal and installation the front wheel speed sensor
Removal and installation the rear wheel speed sensor
Body and interior
Exterior (external elements)
Body — general information
Doors — General Information
Glazing — General Information
Replacing the front mudguard
Replacing the threshold trim
Replacing the decorative element of the front wing (Sport and station wagon versions)
Front bumper replacement
Replacement of deflectors and front bumper pads (Sport and station wagon versions)
Disassembling and assembling the front bumper
Replacing the hood
Replacing the hood lock drive
Front Fender Replacement
Rear bumper replacement (3- and 5-door hatchback)
Rear bumper replacement (station wagon)
Disassembly and assembly of the rear bumper (3- and 5-door hatchback)
Disassembly and assembly of the rear bumper (station wagon)
Replacement of the tailgate (3- and 5-door hatchback)
Tailgate Replacement (station wagon)
Replacing the tailgate lock bracket
Disassembly and assembly of the tailgate (3- and 5-door hatchback)
Disassembling and assembling the tailgate (station wagon)
Front door replacement
Rear door replacement
Body clearances: 3-door hatchback
Body gaps: 5-door hatchback
Body gaps: station wagon
Interior (internal elements)
Replacing the front seat belt
Replacing the rear seat belt
Replacement of the center console (3- and 5-door hatchback)
Center console replacement (station wagon)
Replacing the upper front part of the control panel
Replacing the control panel ventilation grille
Replacing the glove box lid and lock
Replacing the central front part of the control panel
Replacing a car radio
Replacing the glove box
Removal and installation the control panel
Heating and air conditioning
Technical data of heating and air conditioning system
Safety precautions when working with the air conditioning circuit
Air conditioning system checks
Checking the air conditioning compressor
Replacement of air conditioning system circuit elements
Air Conditioning Circuit Fault Diagnosis
Oil change — filling (air conditioning compressor)
Tightening torques
Removal and installation the dust filter
Removal and installation the gear motor and cabin fan
Removal and installation the fan control module
Removal and installation air conditioning system tubes and compressor
Removal and installation the heater fan
Removal and installation the temperature sensors for the air supplied to the passenger compartment
Removal and installation the heater radiator
Removal and installation the capacitor
Removal and installation the pulley and clutch of the air conditioning compressor
Electrical equipment
Equipment and devices
Removal and installation steering column switches
Switching unit BSI 1
Diagnostic connector (C001)
CAN IS Network
CAN CAR Network
CAN CONFORT network
Diagnostics of body opening element control systems
Fault codes for the opening elements control system
Re-syncing the remote control
Diagnostics of the rear view mirror control system
Diagnostics of the electric window control system
Rearview Mirror Control System Related Error Codes
Power Window Control System Related Error Codes
Diagnostics of the windshield wiper and washer control system
Instrument cluster diagnostics
Removal and installation the BSI 1 switching unit
Removal and installation the instrument cluster
Removal and installation the outside rearview mirror and side turn signal repeater
Disassembling the outside rearview mirror
Removal and installation the front windshield wiper mechanism
Removal and installation the rear wiper mechanism
Headlights and lighting
General information about the lighting system
Steering column switch
Controlled headlights
Automatic activation of hazard warning lights
Dual light and rain sensor
Electrical characteristics of the light and rain sensor
Teleloading — General Information
Light sensor malfunction with automatic headlight control function enabled
Headlight adjustment (normal lighting)
Outdoor Lighting Diagnostics
Replacing the headlight assembly
Replacement and adjustment of front fog lights
Emergency operating modes
Fault codes related to the exterior lighting system (BSI 1 switch unit)
Exterior Lighting System Related Fault Codes (BSM Engine Switch Module)
Error codes related to the operation of the rain and outside light sensor
Replacing the rear combination light (hatchback)
Replacing the rear combination light (station wagon)
Replacing the additional brake light (hatchback)
Replacing the additional brake light (station wagon)
Removal and installation the front lighting control unit and alarm sensor (hatchback)
Removal and installation the front lighting control unit and alarm sensor (station wagon)
Removal and installation the rain and light sensor and the interior rearview mirror
Power devices
Battery marking
Checking the electrolyte level
Battery Testing Methods
Charging batteries
Disconnecting the battery
Checking the power supply system and electricity consumers
Generator — General Information
Auxiliary drive belt
Checking the generator mounts
Generator and battery circuit checks
Replacing the generator pulley
Replacing the voltage regulator
Removal and installation the generator (petrol engines)
Removal and installation of the generator (diesel engines)
Starter — general information and device
Checking the starter
Removal and installation the starter (petrol engines)
Removal and installation the starter (diesel engines)
Fault codes related to the interior lighting system (BSI 1 switch unit)
Electrical circuits
Symbols used in electrical equipment diagrams
ECU location (hatchback and station wagon)
General arrangement of ground connection points
Starting and charging system (petrol engines)
Starting, charging and pre-heating system (diesel engines)
Pre-start and post-heating (DV6 engines with particulate filter)
Electronic fuel injection system (TU5JP engine)
Electronic fuel injection system (EP3 engine)
Electronic fuel injection system (EP6 engine, vehicles with automatic transmission)
Electronic fuel injection system (EP6 engine, vehicles with manual transmission)
Electronic fuel injection system (EP6DT engine)
Fuel injection system for pre-heating (DV6 engine without diesel particulate filter)
Fuel injection system for pre-heating (DV6 engine with diesel particulate filter)
Engine cooling TU5JP
Engine cooling EP3
Cooling of EP6 engine with automatic transmission
Cooling of EP6 engine with manual transmission
EP6DT Engine Cooling
Cooling of DV6 engine without particulate filter
Cooling of the DV6 engine with a particulate filter
Automatic transmission (EP6 engines)
Instrument cluster (speedometer and odometer)
Instrument cluster (coolant level and temperature)
Instrument cluster (level, pressure, engine oil temperature)
Instrument cluster (fuel gauge)
Instrument cluster (door status information)
Instrument cluster (brake system malfunction indicator)
Instrument cluster (seat belt warning light)
Instrument cluster (outside air temperature)
Electric power steering
Inflatable airbags and pyrotechnic seat belt tensioners
Electronic stability control system
Vehicle speed limiting system
Tire Insufficient Air Pressure Detection System
Parking assistance system
Central electric lock without superlock
Central electric lock with superlock
Engine immobilizer
Security alarm
Ventilation and heating system
Manual air conditioner
Automatic air conditioning
ESP system with ABS function
Headlights (low and high beam)
Wiring diagram of headlight washers
Headlight corrector (normal light)
Headlight range control (adaptive light)
Fog lights
Reversing lights (cars with automatic transmission)
Reversing lights (cars with manual transmission)
Brake lights
Direction indicator lights and hazard warning lights
License plate lights
Interior lighting
Windscreen wipers
Rear windshield wiper — washer
Electrical diagram of window lifters
Electrically operated rear view mirrors (non-folding)
Electrically operated rear view mirrors (folding)
Electrically adjustable rear window and exterior mirrors (automatic air conditioning)
Dust filter (DV6 engine with diesel particulate filter)
Sunroof Wiring Diagram
Electrically heated seats
Cigarette lighter — ashtray illumination
Analog clock circuit diagram
Peugeot 305
(1977-1989)
General information
Maintenance
General description of the Peugeot 305
Dimensions, weight and fuel data
Routine maintenance
Recommended lubricants and working fluids
Engine fault diagnostics
Engine Compartment — Maintenance Components
Power unit
Gasoline engines
Petrol Engine Specifications
General description of gasoline engines
Modifications to liner seals (XL/XR series engines)
Side main cover bolts (XR5S engine)
Timing mechanism housing seal (all models)
XU Series Engine — General Description
Basic operations possible without removing the engine from the car
Basic operations requiring removal of the engine from the vehicle
Engine and gearbox — removal
Engine disassembly — general part
Engine Disassembly — Auxiliary Equipment
Removal with gearbox (XU series engine)
Disconnecting the gearbox from the XU series engine
Disassembling the XU series engine
Cylinder head — removal from engine while it is on the vehicle
Cylinder liner protrusion value — checking and adjustment
Disassembling the cylinder head (XU series engines)
Cylinder head regrinding (XU series engines)
Cylinder head — installation on the engine standing on the car
Cylinder Head Assembly (XU Series Engines)
Valve timing mechanism — removal
Engine and gearbox — disconnection
Cylinder head — removal from engine on work bench
Pistons, connecting rods and crankshaft — removal
Piston rings — removal
Camshaft — removal
Lubrication system — description
Oil filter — removal and installation
Cylinder head — disassembly, inspection and installation
Connecting rod and main bearings — inspection and tidying up
Cylinder liners — inspection and cleaning
Connecting rods, pistons and piston rings — inspection and cleaning
Timing chain and sprockets — inspection and tidying up
Camshaft and rockers — inspection and tidying up
Oil pump — inspection and maintenance
Intake and exhaust manifolds — inspection
Engine mounts — inspection
Engine assembly — general part
Engine — preparation for assembly
Inspection and tidying up of XU engine parts (general part)
Assembly of XU series engine
Connecting the XU engine to the gearbox
Installing an XU engine with a gearbox on a car
Crankshaft — installation
Pistons, connecting rods and cylinder liners — installation
Cylinder head — installation on an engine removed from a car
Engine and gearbox — connection to each other
Sprocket and timing chain — assembly
Timing mechanism housing — assembly and installation
Valve clearances — checking and adjustment
Clutch — installation
Engine assembly — final operations
Engine and gearbox — installation
Checking valve clearances (XU series engines)
Valve clearance adjustment (XU series engines)
Removal and installation the camshaft drive belt (engine is on the car)
Removal and installation the camshaft (engine is on the car)
Removal and installation the cylinder head (engine is on the car)
Modification of the crankcase ventilation system
Cylinder Head Bolt Modifications (XU Series Engines from December 1986)
Engine — first start after overhaul
XU Series Engines — First Start After Overhaul
Engine fault diagnostics
Diesel engines
Diesel Engine Specifications
General information about diesel engines
Routine maintenance
Basic operations possible without removing the engine from the car
Timing Belt — Inspection, Removal, Installation and Tensioning
Timing Belt Tensioner and Right Engine Mounting Bracket — Removal and Installation
Timing Belt Idler Roller — Removal and Installation
Cylinder head — disassembly, cleaning and assembly
Identifying and Tightening Cylinder Head Bolts — All Models
Cylinder head and pistons — cleaning from carbon deposits
Seals — replacement
Pallet — removal and installation
Oil pump — removal, inspection and installation
Pistons and connecting rods — removal and installation
Flywheel — removal and installation
Engine/gearbox mounts — removal and installation
Engine — Removal Method
Engine and gearbox — removal
Engine and gearbox — disconnection
Engine disassembly — general part
Engine — complete disassembly
Oil level and temperature sensors — general information
XUD7T and XUD9TE engines — disassembly
Inspection of the engine and its tidying up — general part
Engine parts — inspection and cleaning
Engine assembly — general part
Engine — complete assembly
Engine and gearbox — connection to each other
Engine and gearbox — installation
First engine start after overhaul
Engine fault diagnostics
Cooling system (gasoline)
Cooling system specification
General description of the cooling system
Draining the coolant
Flushing the cooling system
Filling with coolant
Water Pump Drive Belt — Removal and Installation
Antifreeze mixture
Coolant temperature gauge and sensor
Low Coolant Level Sensor (General Information)
Water Hose Clamps (All Models)
Diagnostics of cooling system faults
Cooling system (diesel)
Cooling system specification
General description of the cooling system
Routine maintenance
Pressure testing of the cooling system
Draining the coolant
Flushing the cooling system
Filling with coolant
Radiator — removal and installation
Thermostat — Removal, Checking and Installation
Water pump — removal and installation
Electric Cooling Fans — Removal and Installation
Fuel system (gasoline)
Fuel and exhaust system specification
General description of the fuel and exhaust system
Air filter — removal and installation
Fuel pump — removal, maintenance and installation
Carburetor — General Description
Carburetors (latest models) — description
Carburetor — Maintenance
Carburetor — adjustment
Carburetor — Adjusting the Upper Position of the Float
Carburetor — accelerator pump (checking and adjustment)
Carburetor — removal and installation
Carburetor — disassembly, cleaning and assembly
Gas pedal cable — removal and installation
Choke Cable — Removal and Installation
Fuel tank — general information
Intake air heating system
Exhaust system — general information
Diagnostics of fuel and exhaust system faults
Fuel system (diesel)
Fuel and exhaust system specification
General description of the fuel and exhaust system
Fuel filter housing — modifications
Air Cleaner and Air Filter — Removal and Installation
Fuel injection pump — removal and installation
Fuel injection pump (Lucas CAV/Roto-Diesel) — checking and adjusting the injection timing
Fuel injection pump (Bosch) — checking and adjusting the injection timing
Fast Idle Speed Cable — Removal, Installation and Adjustment
Gas pedal cable — removal, installation and adjustment
Idle speed — checking and adjustment
Lucas CAV/Roto-Diesel Fuel Pump — Minimum Speed Control
Bosch injection pump manufactured since January 1984 — minimum speed control
Maximum engine speed — checking and adjustment
Fuel injectors — removal, inspection and installation
Pre-heater — description and testing
Pre-heater relay and spark plugs — removal and installation
Shut-off solenoid — description, removal and installation
Injection system — bleeding
Injection system (latest models) — bleeding
Fuel level sensor (405 models) — checking
XUD9 Engine Misfires (405 Models with CAV/Roto-Diesel Fuel Pump) — Causes
Collectors — removal and installation
Turbocharger — Description
Turbocharger — Precautions
Turbocharger — removal, inspection and installation
Exhaust system — inspection, removal and installation
Diagnostics of injection system faults
Ignition system
Ignition system specification
General description of the contact ignition system
Breaker contacts — preliminary gap adjustment
Angle of closed state of contacts — regulation
Breaker contacts — removal, tidying up and installation
Capacitor — removal, inspection and installation
Distributor — lubrication
Distributor — removal and installation
Distributor — overhaul
Setting scale — checking and adjustment
Ignition timing — regulation
Spark plugs and high tension wires — common part
Diagnostic socket
TDC sensor — removal, installation and adjustment
Ignition system fault diagnostics
Electronic (contactless) ignition system
Transmission
Clutch
Clutch specification
General description of the clutch
Clutch — adjustment
Clutch cable — removal and installation
Clutch — removal
Clutch — inspection and tidying up
Clutch — installation
Removal, inspection and installation of the clutch (XU engines)
Pinion and seals — removal and installation
Removal and installation the clutch release mechanism (XU series engines)
Diagnosing Clutch Faults
Mechanical gearbox BB8
Gearbox specification
General description of the BB8 manual transmission
Gearbox — removal
Gearbox — disassembly
Gearbox — inspection
Gearbox — assembly
Connecting the gearbox to the engine
Engine and gearbox — installation on the car
Differential seals — removal and installation
Gear shift lever mechanism — overhaul and adjustment
BB8 Gearbox Fault Diagnosis
Mechanical gearbox BE1
Gearbox specification
General description of the manual transmission BE1
Routine maintenance
Gearbox — removal and installation
Adjusting the gear shift lever mechanism
Gearbox (5-speed) — disassembly into main components
Gearbox (4-speed) — disassembly into main components
Gearbox — inspection and tidying up
Drive shaft — disassembly and assembly
Output shaft — disassembly and assembly
Gear shift mechanism — disassembly and assembly
Differential — disassembly and assembly
Gearbox (5-speed) — assembly
Gearbox (4-speed) — assembly
BE1 Gearbox Fault Diagnosis
Automatic gearbox ZF4
ZF4 HP14 Gearbox Specification
General description of the automatic transmission ZF4 HP14
Routine maintenance
Replacing the transmission fluid filter
Downshift cable adjustment (kickdown)
Replacing the downshift cable
Adjusting the gear selection mechanism
Adjusting the brake band
Transmission Fluid Radiator — Removal and Installation
Automatic transmission — removal and installation
Replacing the torque converter seal
Starter Interlock/Reverse Light Switch (General Information)
Automatic transmission fault diagnostics
Shafts, hubs and wheels
Specification of drive shafts, hubs, wheels and tires
General description of drive shafts
Drive shafts — removal and installation
Drive shafts (models with XU engines)
Drive shaft CV joints — maintenance
Front Hubs (1983+ Models) — Removal and Installation
Rear hub bearings — removal and installation
Rear Wheel Bearings (Latest Models) — Removal and Installation
Wheels and Tires — General Information and Maintenance
Diagnosis of drive shaft faults
Chassis, running gear
Brake system
Brake system specification
General description of the braking system
Routine maintenance
Bleeding the brake system
Bleeding brakes (all latest models)
Brake adjustment
Disc brake pads — inspection and replacement
Removal and installation front disc brake pads on models produced after 1983.
Disc Brake Calipers — Removal, Overhaul and Installation
Rear brake drums — removal and installation
Rear brake pads — removal, inspection and installation
Rear wheel cylinders — removal, overhaul and installation
Brake discs and drums — tidying up by regrinding
Hydraulic tubes — inspection and replacement
Master cylinder — removal, overhaul and installation
Vacuum servo booster — removal and installation
Vacuum servo booster — overhaul
Brake compensator — general information
Handbrake — General Information
Diagnostics of brake system faults
Car suspension
Suspension and steering specifications
General description of suspension and steering
Routine maintenance
Suspension and steering — check and inspection
Front suspension on models produced since 1983 — description
Front Anti-Roll Bar — Removal and Installation
Front Anti-Roll Bar Center Mount — Bulkhead
Front Anti-Roll Bar Alignment (XU Engine Models)
Front pillar — removal and installation
Installing the front strut shock absorber cartridge (models produced before 1983)
Removal and installation the front pillar (models produced since 1983)
Front suspension strut — bulkhead
Rear pillar — removal and installation
Removal and installation the rear strut shock absorber (Estate models)
Rear Control Arm — Removal and Installation (Estate Models)
Rear suspension strut — bulkhead
Rear axle assembly — removal and installation
Rear Suspension Trailing Arm — Removal and Installation
Steering
Steering gear — removal and installation
Removal and installation the steering gear on models with XU engines
Power Steering — General Information
Front wheel alignment angles
Diagnosis of suspension and steering faults
Body and interior
Exterior (external elements)
General description of the body
Hinges, Door Latches and Locks — Maintenance
Hood cover — removal and installation
Doors — removal and installation
Door glass — removal and installation
Door Lock Cylinder — Removal and Installation
Sliding sunroof — general information
Removal and installation the trunk lid stop (Saloon models)
Removal and installation the tailgate (Estate models)
Front Radiator Grille — Removal and Installation
Front and rear bumpers — removal and installation
Interior (internal elements)
Interior door trim — removal and installation
Heater core — removal and installation
Removal and installation seats
Seat belts — description and maintenance
Modification of front seat belt anchorages (all models)
Glove Compartment Latch Repair (Pre-1983 Models)
Torpedo — removal and installation
Windshield — Removal and Installation
Interior heater — removal and installation
Removal and installation the heater (models produced since 1983)
Plastic parts
Electrical equipment
Equipment and devices
Electrical Equipment Specification
General description of electrical equipment
Fuses — location and purpose
Removal and installation the rear window wiper motor (Estate models)
Removal and installation the rear window washer nozzle (Estate models)
Instrument panel — removal and installation
Removal and installation of the instrument panel on models produced since 1983.
Low Oil Warning System (1985 Models) — Description
Removal and installation the interior heater blower rheostat
Heater Blower Control Unit (1983 and later models) — Description and Testing
Central locking system — description
Electric windows — description
Windshield Wiper Blades — Removal and Installation
Windshield Wiper Arms — Removal and Installation
Windshield Wiper Mechanism — Diagnosis and Troubleshooting
Windshield wiper mechanism — removal and installation
Windscreen Washer — General Information
Sound signal — diagnostics and troubleshooting
Radios and car radios — installation (general part)
Radios and car radios — radio interference suppression (general part)
Radio interference from front brake calipers
Diagnostics of electrical equipment faults
Headlights and lighting
Headlights — Removal, Replacement of Bulbs and Installation
Headlights — regulation
Load Sensing Headlamp Positioner (Estate Models) — Description and Overhaul
Dimmed (daytime) low beam headlights
Rear Combination Light — Bulb Replacement
Front Side Lights and Direction Indicators — Bulb Replacement
Rear License Plate Light Bulbs — Removal and Installation
Interior Lighting Lamps — Removal and Installation
Power devices
Battery — Removal and Installation
Battery — Inspection and Maintenance
Battery — replacement of electrolyte
Battery — charging
Generator — General Description
Generator — Maintenance
Generator — Special Precautions
Generator — removal and installation
Generator Drive Belt — Tension Adjustment
Generator Drive Belt — Replacement
Generator brushes — removal, inspection and installation
Replacing brushes on a generator with a built-in voltage regulator
Checking the generator on the car (all models)
Starter — General Description
Starter — Check on Engine
Starter — removal and installation
Starter — disassembly and assembly
Electrical circuits
Key to the wiring diagrams (Fig. 10.15-10.18)
Key to the wiring diagrams of the latest models (Fig. 12.119-12.131)
Key to the wiring diagrams of the latest models (Fig. 12.132-12.138)
Fig. 10.15. Wiring diagram — models GL and GR
Fig. 10.16. Wiring diagram — GL and GR models
Fig. 10.17. Wiring diagram — SR models
Fig. 10.18. Wiring diagram — SR models
Fig. 12.119. Wiring diagram of the central locking system (typical)
Fig. 12.120. Wiring diagram of the central locking system with keyless door locking and unlocking
Fig. 12.121. Wiring diagram for GL models 1979 and 1980
Fig. 12.122. Wiring diagram for Saloon and GL models 1980 and 1981
Fig. 12.123. Wiring diagram for Saloon and GL models produced since 1981
Fig. 12.124. Wiring diagram for GR and SR models 1979 and 1980
Fig. 12.125. Wiring diagram for GR and SR models 1980-1982
Fig. 12.126. Wiring diagram for SR models produced since 1983
Fig. 12.127. Wiring diagram for S models produced since 1981
Fig. 12.128. Wiring diagram for GT models produced since 1983
Fig. 12.129. Wiring diagram for Estate and Van models produced before 1981
Fig. 12.130. Wiring diagram for Estate (except SR) and Van models produced since 1981
Fig. 12.131. Wiring diagram for GL and GR models 1986
Fig. 12.132. Wiring diagram for Estate and Van models 1986
Fig. 12.133. Wiring diagram for GL and GR models 1986
Fig. 12.134. Wiring diagram for GL and GR models 1987
Fig. 12.135. Wiring diagram for Estate and GTX models with automatic transmission 1986
Fig. 12.136. Wiring diagram for Estate and GTX models with automatic transmission 1987
Fig. 12.137. Wiring diagram for GTX models
Fig. 12.138. Wiring diagram for GT models with automatic transmission
Fig. 12.139. Wiring diagram for the low beam headlight system
Wiring diagrams (diesel)
Fig. 7.2. Electrical diagram of the Peugeot 305 car manufactured before 1985
Fig. 7.3. Electrical diagram of the Peugeot 305 car after 1985
Fig. 7.4. Additional electrical diagram of the Peugeot 305 Estate car after 1985
Instructions for working with wiring diagrams
Fig. 8.36. Assembly diagram (205 models): Typical device of the starting system, charging system...
Fig. 8.37. Assembly diagram (309 models): Typical device of the starting system, charging system...
Fig. 8.38. Assembly diagram (405 models before 1992): Starting system, charging system...
Fig. 8.39. Assembly diagram (405 models since 1992): Starting system, charging system...
Peugeot 307
(2001-2008)
User manual
Keys, doors and alarm
Introduction to the Peugeot 307 Operation and Repair Manual
Car keys
Central electric lock
Remote control unit
Locking the locks
Complete lockout
Unlocking locks
Electronic anti-theft system
Anti-theft system identification card
Turning the anti-theft system on and off
Enable only the vehicle perimeter monitoring function
Automatic activation of the anti-theft system
Finding your car in the parking lot
Replacing the remote control battery
Initializing the remote control
Opening and closing doors
Rear luggage compartment door
Controls and instruments
Controls, instruments and equipment
Control devices
Ignition switch
Steering column switch for direction indicators and headlights
Automatic operation of lighting and light signaling devices
Windscreen wiper and washer switch under the steering wheel
Headlight corrector
Emergency light signaling
Steering column adjustment
Electric windows
Window (on three-door cars)
Electrically adjustable exterior mirrors
Manually adjustable exterior rear view mirrors
Interior rear view mirror
Interior lighting fixtures
Sun visors with vanity mirror
Ceiling console
Heating and ventilation — general information
Heating and ventilation controls
Air Conditioning Controls
Automatic air conditioning controls
Car radio controls
Control of car radios from the steering column switch
Controlling the car radio from the front panel
Driving and operation
Automatic transmission «Tiptronic-system Porsche»
Parking brake
Anti-lock braking system (ABS)
Traction control system (ASR) and electronic stability program (ESP)
Cruise control system
Parking assistance system for station wagons
Front seats — adjustment
Folding the rear seats
Seat belts — adjustment and inspection
Airbags — General Information
Front airbags
Disabling the front passenger airbag
Checking the airbag's functionality
Side and window airbags
Lift and slide roof panel
Fuel tank filler cap
Hood — opening and closing
Engine bay — inspection and safety precautions
Towing a car
Towing a cargo trailer, caravan or boat
Wheel replacement and features of their operation
Maintenance
Types and frequency of maintenance
Mileage indicator until next maintenance
Maintenance intervals and replacement periods for consumables
Maintenance intervals
List of works during maintenance
Engine Oil — Checking and Changing
Brake fluid and clutch drive level
Brake fluid and its replacement
Coolant level
Power steering fluid reservoir
Windshield and headlight washer reservoir
Rechargeable battery
Air filter and cabin dust filter
Front brake pads
Parking brake
Manual transmission
Automatic transmission
Fuel — control and refueling
Checking the exhaust system
Checking the tightness of the hoses
Checking the condition of the auxiliary drive poly V-belt
Checking the mudguard of the wheel drive shaft
Visual inspection of gearbox tightness
Checking the front suspension and steering
Checking the mudguards of the front suspension joints
Checking the shock absorber
Radiator check
Checking the electrical wiring
Checking brake hoses
Windscreen wiper blades
Power unit
Petrol engines TU3 and TU5
General information about TU3JP and TU5JP4 engines
Removal and installation the engine
Cylinder head — removal and installation
Camshafts — Removal and Installation
Auxiliary drive belt
Timing belt — removal and installation
Changes in the timing drive parts of the TU3JP engine
Lubrication system — removal, inspection and installation
Replacing the coolant
Water pump — removal and installation
Power supply system — design description
Exhaust gas system
Petrol engines EW10
General information about petrol engines EW10J4
Engine technical data and tightening torques
Removal and installation the engine
Disassembling the engine
Checking the crankshaft
Checking the pistons
Engine assembly
Cylinder head — removal and installation
Auxiliary drive belt
Timing belt — removal and installation
Lubrication system — design description
Changing and checking engine oil
Checking engine oil pressure
Cooling system — design description
Replacing the coolant
Water pump — removal and installation
Power supply system — design description
Exhaust gas system
Diesel engines DV10
Engine technical data and tightening torques
Checking the compression in the engine cylinders
Removal and installation the engine
Cylinder head — removal and installation
Auxiliary drive belt
Timing belt — removal and installation
Lubrication system — design description
Cooling system — design description
Replacing the coolant
Water pump — removal and installation
Power supply system — general information
Integrated Air Supply System Unit
Fuel injectors — removal and installation
Fuel distributor (Common Rail) — removal and installation
Turbocharger — description, removal and installation
Fuel filter — removal and installation
Exhaust gas system
Diesel engines DW10
Engine technical data and tightening torques
Checking the compression in the engine cylinders
Removal and installation the engine
Cylinder head — removal and installation
Auxiliary drive belt
Timing Belt — Removal, Checking and Installation
Lubrication system — general information and pressure check
Replacing the coolant
Water pump — removal and installation
Fuel system — safety precautions
Fuel distributor (Common Rail) — removal and installation
Fuel injectors — removal and installation
Fuel filter — removal and installation
High pressure fuel pump SIEMENS
Turbocharger — description, removal and installation
Exhaust Gas Recirculation (EGR) Valve
Exhaust gas system
Transmission
Clutch and drive shafts
General information about the clutch
Replacing the hydraulic clutch drive
Replacing the clutch disc
General information about drive shafts
Replacing axle shafts
Replacement of constant velocity joints
Replacing the intermediate bearing of the right half-shaft
Mechanical gearbox
General information about mechanical transmission
Technical data of manual gearboxes
Gearbox replacement BE4R
MA gearbox replacement
Replacement of the BE4R gearbox housing
Replacing the differential housing of the BE4R gearbox
Replacing the differential box
Replacing the gear shift mechanism
Checking the level and replacing the oil in the gearbox
Automatic gearbox
General information about automatic transmission
Automatic transmission specifications
Oil aging counter
Precautions for operation and repair of automatic transmission
Automatic transmission diagnostics
Replacement of automatic transmission AL4
Replacing the gear selection mechanism
Replacing the multifunction switch
Replacing the gear selector lever axle sealing ring
Replacing axle shaft sealing rings
Replacing the torque converter sealing ring
Replacing the heat exchanger
Checking the level and replacing the oil in the gearbox
Chassis, running gear
Front suspension
General information and design of the front suspension
Front suspension specifications
Replacing the shock absorber strut
Disassembly and assembly of the shock absorber strut
Replacing the steering knuckle
Replacing the front wheel hub bearing
Replacing the ball joint of the steering knuckle
Replacing the lower control arm
Replacing the front anti-roll bar
Car suspension adjustment — general information
Adjusting the front suspension of the car
Rear suspension
General information and design of the rear suspension
Rear suspension specifications
Replacing the rear suspension beam
Replacing the rear suspension spring
Replacing the rear shock absorber
Replacing the front hinge of the rear suspension beam
Replacing the rear wheel hub
Replacing the hub assembly with bearing and axle
Adjusting the rear suspension of the car
Steering
General information about steering
Technical characteristics of the steering system
Steering column replacement
Replacing the steering gear
Replacing the rack stop
Adjusting the rack stop
Replacing the distribution valve
Replacing the steering rod protective boot
Replacing the steering rod
Replacing the Electric Power Steering Pump Unit
Replacing fluid and bleeding air from the power steering hydraulic circuit
Front wheel alignment angles
Brake system
General information about the braking system
Technical characteristics of the brake system
Replacing the master brake cylinder
Replacing the brake booster
Replacing the front brake pads
Replacing the front brake caliper
Replacing rear brake pads
Replacing the rear brake caliper
Replacing the brake disc
Replacing the brake light switch
Adjusting the parking brake
Replacing brake fluid
Bleeding air from the hydraulic brake drive
Diagnostics of the EVA BOSCH system
Body and interior
Exterior (external elements)
General information about the car body
Recommendations for the use of welding in body repair
Anti-corrosion protection of the body
Body dimensions and clearances
Aluminum alloy hood
Front bumper replacement
Replacing the front bumper trim
Replacing the rear bumper
Replacing the rear bumper trim
Replacing the outside mirror
Replacing the glass of the outside mirror
Replacing moldings
Front Fender Replacement
Adjusting the gap between the front wing and the front door
Windshield replacement
Rear window replacement
Interior (internal elements)
Replacing the central ceiling console
Replacing the instrument panel assembly
Replacing the instrument panel trim
Replacing the central part of the instrument panel
Replacing the center console
Replacing the lower center part of the instrument panel
Replacing the glove compartment lock
Front seat replacement
Replacing the seat back forward folding cable
Replacing the rear seat
Replacement of interior trim panels
Doors, locks and windows
Front door replacement
Front door panel replacement
Replacing the front door trim
Replacing the front door lock
Replacing the front door lock cylinder
Front door glass replacement
Replacing the rear door trim panel
Replacing the rear door lock
Rear door glass replacement
Replacement of the tailgate of Peugeot 307
Replacement of the tailgate of Peugeot 307 SW
Replacement of the trunk door trim
Replacing the outer tailgate handle
Replacement of the tailgate lock
Replacing the lift and slide roof panel assembly
Replacing the deflector of the sliding and lifting roof panel
Heating and air conditioning
Safety precautions when working with the air conditioning system
Replacing the front panel of the air conditioning system
Replacing the cabin air temperature sensor
Replacing the outside air temperature sensor
Replacing the air conditioning unit
Replacement of distributor and air flow mixer gear motors
Replacing the heater fan resistor
Replacing the heater radiator
Replacing the additional heating resistor (diesel DW10)
Replacing the air conditioner evaporator
Electrical equipment
Equipment and devices
General information about electrical equipment
Electrical circuits — general information
Detecting faults in electrical circuits
Fuses — Description, Location and Replacement
Intelligent Switching Unit — Removal and Installation
Headlights — removal and installation
Replacing the rear light
Replacing the high brake light
Replacing the license plate light
Replacing external lighting lamps
Replacing the instrument cluster
Replacing the steering column switch unit COM 2000
Replacing the ignition switch
Replacing the multifunction display
Replacing the light brightness sensor
Windshield wiper replacement
Replacing the wiper blade
Replacing the rear window wiper motor
Replacing the front door window regulator
Replacing the rear door window regulator
Replacing the rear door window regulator (SW wagon)
Replacing the electric motor of the lifting and sliding roof panel
Replacing the sunshade drive motor
Replacing a car radio
Front door speaker replacement
Replacing the rear speakers
Replacing the radio antenna
Power devices
Battery — General Information
Battery Maintenance
Checking the electrolyte level in the battery
Checking the density of electrolyte in the battery
Charging the battery
Battery Aging Monitoring
Replacing the battery
Starting the engine from an additional battery
General information about the generator
Safety precautions when operating a generator
Checking the charging system
Generator replacement
General information about the starter
Starter replacement
Airbags
General information about airbags
Disabling the central airbag system
Driver's airbag replacement
Replacing the front passenger airbag
Replacing the side airbag
Replacing the airbag control unit
Replacing the acceleration sensor
Electrical circuits
Code designation of elements on electrical circuits
Electrical Equipment Diagrams 1 to 5
Electrical equipment diagrams 6 to 10
Electrical equipment diagrams 11 to 15
Electrical equipment diagrams from 16 to 20
Electrical equipment diagrams from 21 to 25
Electrical equipment diagrams 26 to 30
Electrical equipment diagrams from 31 to 35
Peugeot 405
(1987-1997)
General information
User manual
Description of the car Peugeot 405
Controls, instruments and equipment
Car keys
Tire pressure
Door lock
Fuel filler neck, trunk, hood
Seat belts — description and adjustment
Adjusting the front seats and headrests
Folding the rear seats
Instrument panel
Lighting and signaling
Headlight corrector
Glass washers and cleaners
Additional equipment
Providing comfort
Internal heating and ventilation
Heating and ventilation system switches
Instrument clusters
Starting a gasoline engine
Starting a diesel engine
Control lights and indicators
Steering wheel, gear shift and brake
Automatic transmission
Wheel replacement
Towing a car
Vehicle identification
Maintenance
Technical characteristics of the car
Maintenance intervals
Maintenance intervals (before 1994)
Maintenance intervals (since 1994)
Dehydration of diesel engine fuel filter (7500 km)
Engine oil and filter change (10,000 km/6 months)
Checking the transmission oil level (10,000 km/6 months)
Checking and adjusting the V-belt tension (10,000 km/6 months)
Checking the auxiliary drive belt (10,000 km/6 months)
Removal, installation and adjustment of the V-belt (10,000 km/6 months)
Power steering pump (XU9J4) (10000 km/6 months)
Checking the engine crankcase ventilation hoses (20,000 km/12 months)
Fuel filter replacement (20,000 km/12 months)
Checking idle speed and mixture composition (CO) (20,000 km/12 months)
Replacement of spark plugs (20,000 km/12 months)
Checking, adjusting and lubricating the clutch (20,000 km/12 months)
Checking the condition of the drive shaft protective cover (20,000 km/12 months)
Checking the condition of the front and rear brake pads (20,000 km/12 months)
Checking and adjusting the handbrake (20,000 km/12 months)
Suspension condition check (20,000 km/12 months)
Checking drainage holes (20,000 km/12 months)
Lubrication of the lock hinge (30,000 km/18 months)
Air conditioning check (30,000 km/18 months)
Coolant replacement (40,000 km/2 years)
Air filter replacement (40,000 km/2 years)
Checking the ignition system (40,000 km/2 years)
Transmission oil change (40,000 km/2 years)
Brake fluid replacement (40,000 km/2 years)
Checking the gearbox oil level (60,000 km/3 years)
Replacing the heater air intake filter (60,000 km/3 years)
Power unit
Petrol engines 1.4 l
1.4 liter petrol engine — design description
Technical characteristics of 1.4 liter engines
Checking and adjusting valve clearance
Checking and adjusting the ignition timing angle
Carburetor adjustment
Removal the air filter
Removal the cylinder head
Installing the cylinder head
Removal and installation of the power unit
Features of disassembling a 1.4 L petrol engine
Disassembling the TU3 engine
Disassembling the cylinder head
Cylinder head assembly
Determining the size of the liners
TU3 Engine Assembly
Removal the oil pump
Disassembling the oil pump
Removal the coolant pump
Petrol engines 1.6-2.0 l
Petrol engines 1.6-2.0 l — design description
Technical characteristics of engines 1.6-2.0 liters
Repairs that do not require engine removal
Checking the compression in the cylinders
Checking and adjusting valve clearance
Camshaft drive belt
Timing Belt Pulleys
Replacing the camshaft seal
Replacing crankshaft seals
Generator drive belt
Air Filter — Carburetor Models
Cylinder Head Cover — Removal and Installation
Camshaft — Removal, Inspection and Installation
Removal and installation the cylinder head
Disassembly, repair and assembly of the cylinder head
Removal the engine with a manual transmission
Removal the engine with automatic transmission
Engine installation
Disassembling the engine
Cleaning and checking parts before assembly
Crankshaft — assembly and installation
Connecting rod-piston unit — assembly and installation
Connecting rod-pin-piston assembly — assembly and installation
Starting the engine after major repairs
Diesel engines
Diesel engines — design description
Technical characteristics of diesel engines
Checking and adjusting valve clearances
Removal and installation the high pressure fuel pump
Installation of high pressure fuel pump BOSCH
Roto Diesel High Pressure Fuel Pump Installation
Removal water from the fuel filter
Removal air from the fuel system
Removal and installation the injector
Checking the electrically controlled engine stop valve
Adjusting the Bosch pump
Roto Diesel Pump Adjustment
Removal and installation a turbocharger
Removal the camshaft drive timing belt
Installing the camshaft drive timing belt
Removal the cylinder head
Installing the cylinder head
Cylinder head repair
Removal a diesel engine
Installation of a diesel engine
Disassembling a diesel engine
Assembly of a diesel engine
Oil pump — removal and installation
Ignition system
Contactless ignition system
Ignition coil — removal and installation
Ignition System Amplifier Module
Removal and installation the ignition distributor
Disassembly and assembly of the Ducellier distributor
Disassembly and assembly of the Bosch distributor
Setting the ignition timing
Checking the centrifugal regulator in a car
Checking the vacuum regulator in a car
Composite ignition system (ignition/fuel system)
Ignition coil (composite ignition)
Ignition system amplifier module (composite ignition)
Removal the ignition distributor (composite ignition)
Installing the ignition distributor (composite ignition)
Direct ignition system
Ignition coil (direct ignition)
Ignition system booster modules (direct ignition)
Fuel system (carburetor)
Fuel pump — removal, inspection and installation
Fuel level sensor in the tank
Fuel tank — removal and installation
Removal and installation the carburetor
Disassembling the carburetor
Carburetor operation
Carburetor adjustment
OVAD Launcher
Engine post-cooling
Intake manifold — removal and installation
Exhaust manifold — removal and installation
Single point fuel injection
Single point fuel injection systems
Relieving pressure in the fuel system
Adjusting the accelerator cable
Fuel pump — removal and installation
Injector — removal and installation
Checking the fuel injection system
Fenix injection system components
Bosch Monopoint injection system components
Magneti Marelli injection system components
Multipoint fuel injection
Multi-point fuel injection systems
Air filter — removal and installation
Accelerator cable — removal and installation
Fuel injection systems
Checking and adjusting fuel injection systems
Throttle body — removal and installation
Bosch L3.1-Jetronic injection system components
Bosch LU2-Jetronic injection system components
Bosch Motronic injection system components
Magnetti Marelli injection system components
Intake manifold — removal and installation
ACAV Air Supply System (16-valve models)
Cooling and lubrication system
Draining the coolant (diesel)
Filling coolant and bleeding air (diesel)
Removal and installation the coolant pump (diesel)
Oil pan — removal and installation
Oil pump — removal, inspection and installation
Oil radiator — removal and installation
Checking oil pressure
Cooling system — design description
Cooling system hoses
Radiator — removal, inspection and installation
Thermostat — Removal, Checking and Installation
Radiator cooling fan — removal, inspection and installation
Coolant pump — removal and installation
Draining the coolant
Filling the coolant and bleeding the system
Exhaust system
Exhaust system (diesel)
Exhaust system — design description
Exhaust system — removal and installation
Exhaust emission control system
Crankcase emission control
Exhaust gas monitoring
Fuel vapor emission control
Exhaust emission control system
Catalyst — General Information
Transmission
Clutch
Clutch — design description
Clutch specifications
Replacing the clutch disc or leading part
Adjusting the clutch control unit
Replacing the clutch cable
Clutch release mechanism — removal, inspection and installation
Manual gearbox MA
Mechanical gearbox type MA — design description
Removal and installation of gearbox type MA
Disassembling the gearbox
Disassembling the secondary and primary shaft
Disassembling the differential
Disassembling the fork assembly with its axles
Disassembling the synchronizer bushing
Verification of gearbox parts
Assembly of synchronizer bushings
Assembly of the fork assembly with its axles
Differential assembly
Assembling the primary shaft
Secondary shaft assembly
Gearbox assembly
Manual gearbox BE
Manual transmission general information
Technical characteristics of the BE mechanical transmission
Gearbox oil change
Adjusting the gear shift rod
Gear Shift Lever — Removal and Installation
Gear shift rod — removal and installation
Reverse gear lock cable
Drive shaft sealing rings
Input shaft seal ring
Gear Selector Shaft Seal Ring
Reverse light switch
Speedometer drive — removal and installation
Removal and installation the gearbox
Disassembling the gearbox
Differential repair
Primary shaft repair
Secondary shaft repair
Gearbox assembly
Determining the interference fit of the primary shaft tapered bearing
Reinforced sealing rings
Distinctive features of 4x4 drive
Transfer case of 4x4 drive system
Automatic gearbox
Automatic transmission specifications
Description of the design of automatic transmission
Removal and installation the gearbox
Adjusting the gear shift control
Gear Selector Cable — Removal and Installation
Selector lever — removal and installation
The cable of forced engagement of reduction gear
Adjusting the brake band
Removal and installation the control servomotor
Replacing the selector shaft sealing ring
Gearbox Heat Exchanger — Removal and Installation
Drive shafts
Drive shafts — design description
Technical characteristics of drive shafts
Removal drive shafts
Installing the drive shaft
Replacement of constant velocity joint boots
Replacing the intermediate bearing of the right drive shaft
Front wheel drive with 4x4 powertrain
Rear wheel drive with 4x4 powertrain
Chassis, running gear
Steering
Steering — design description
Technical characteristics of the steering system
Steering wheel — removal and installation
Steering column — removal, inspection and installation
Ignition switch — removal and installation
Steering gear — removal and installation
Replacing the steering gear protective covers
Bleeding the Power Steering System
Power Steering Pump — Removal and Installation
Checking the oil level in the power steering system
Tie Rod End — Removal and Installation
Steering rod — removal and installation
Wheel alignment angles
Changes in the steering system
Front suspension
Front suspension — design description
Front suspension specifications
Steering knuckle — removal and installation
Replacing the front hub bearing
Front pillar — removal and installation
Front pillar repair
Lower control arm front suspension — removal and installation
Front suspension lower ball joint
Front suspension anti-roll bar
Front suspension stabilizer bar connector
Front Suspension Lower Frame — Removal and Installation
Rear suspension
Rear suspension — design description
Rear suspension specifications
Replacing the rear shock absorber
Replacing rear torsion bars
Stabilizer — removal and installation
Rear suspension arm — removal and installation
Removal and installation the rear suspension
Adjusting the height of the body suspension
Rear wheel hubs — removal and installation
Features of the rear suspension of 4x4 vehicles
Replacement of the tank
Removal and installation the suspension arm
Removal and installation the suspension cylinder
Bleeding air from the hydraulic circuit
Removal and installation the pump
Removal and installation the hub
Brake system
Brake system — general information
Technical characteristics of the brake system
Bleeding the hydraulic brake system
Replacing the front brake pads
Brake lines and hoses
Replacing rear brake pads on disc brakes
Replacing rear brake shoes on drum brakes
Front brake disc — removal, inspection and installation
Rear brake disc — removal, inspection and installation
Rear Brake Drum — Removal, Checking and Installation
Front Brake Caliper — Removal and Installation
Rear Wheel Support — Removal and Installation
Rear Brake Cylinder — Removal and Installation
Master Brake Cylinder — Removal, Repair and Installation
Brake pedal — removal and installation
Vacuum brake booster — removal, inspection and installation
One-way valve of the brake booster
Adjusting the handbrake
Handbrake lever — removal and installation
Handbrake cable — removal and installation
Handbrake indicator light switch
Brake pressure regulating valve
Brake light switch — removal and installation
Anti-lock braking system (ABS)
Replacing the wheel sensor
Bleeding the brake system
Body and interior
Exterior (external elements)
Body — dimensions and general description
Car body and interior care
Repair of minor body damage
Repair of severe body damage
Front bumper — removal, installation and repair
Rear bumper — removal and installation
Headlights and direction indicators — removal and installation
Tail light — removal and installation
Front wing — removal and installation
Hood — removal, repair and installation
Bonnet Lock Cable — Removal and Installation
Hood lock — removal and installation
Front Panel Replacement — Removal, Repair and Installation
External rear view mirrors — removal and installation
Radiator grille — removal and installation
Grille in front of the windshield — removal and installation
Overlays and emblems — removal
Interior (internal elements)
Caring for upholstery and carpets
Central locking — removal and installation
Seats — removal and installation
Front seat belt tensioner mechanism
Front seat safety belt
Rear side seat belts (sedan models)
Rear side seat belts (combi models)
Interior trim — removal and installation
Headlining — Removal and Installation
Center console — removal and installation
Instrument cluster (models before 1992)
Instrument cluster (models from 1993)
Doors, locks and windows
Doors — removal, installation and adjustment
Door trim — removal and installation
Door lock and handles — removal and installation
Door glass — removal and installation
Trunk lid (Sedan models) — removal and installation
Trunk lid lock (Sedan models) — removal and installation
Rear door (Combi models) — removal and installation
Rear door lock (Combi models) — removal and installation
Electric windows
Windshield and rear glass
Sunroof — Removal and Installation
Electrical equipment
Equipment and devices
Technical characteristics of electrical equipment
Open Circuit Detection
Generator — removal and installation
Starter — removal, installation and repair
Replacing switches
Oil level and temperature sensor
External lighting bulbs
Interior Light Bulbs
External Lighting Devices — Removal and Installation
Headlight adjustment
Instrument cluster — removal and installation
Instrument cluster elements — removal
Watch — removal and installation
Windscreen wiper arms — removal and installation
Windscreen wiper motor and rods — removal and installation
Rear door wiper motor
Windscreen washers — removal and installation
Radio receiver — removal and installation
Loudspeakers — Removal and Installation
Radio Antenna — Removal and Installation
Anti-theft system
Airbag system
Airbag Components — Removal and Installation
Heating and ventilation system — removal and installation
Electrical circuits
Symbols and designations on electrical circuits
Designations on diagrams
Engine starting, battery charging, ignition (XU52C/XU92C models only), cooling fan...
Injection and ignition system (XU5M2-3Z MMBA G5)
Injection and ignition system (XU9J2 L3.1 Jetronic)
Injection and ignition system (XU9J2 MP3.1 Motronic)
Injection and ignition system (XU9M/ Z FENIX 1B)
Injection and ignition system (XU9J1/ Z LU2 Jetronic)
Injection and ignition system (XU9JA/ Z M1.3 Motronic)
Injection and ignition system (XU9J4 and XU9J4/ Z M1.3 Motronic)
External lighting (fog, side lights and headlights)
External lighting (direction indicators and brake lights)
Interior lighting wiring diagram
Windscreen washer/wiper, horn, fan and rear window
Central locking, electric exterior mirrors and radio
Electric windows and electric sunroof
Standard anti-lock braking system
Simplified anti-lock braking system
Starting, charging and heating system diagram (late models)
Heating system diagram (turbo diesel), radiator cooling fan (late models)
Engine System Diagram (with Carburetor) (Late Models)
Warning Light and Control Gauges Diagram (Late Models)
Display diagram of outside temperature, clock and outside light
Rear Wiper/Washer, Heater Fan and Rear Defroster Diagram (Late Models)
Electrical mirror diagram, radio and automatic light switch (late models)
Central locking and electric windows diagram (late models)
Peugeot 406
(1995-2004)
General information
User manual
General description of Peugeot 406 cars
If the engine does not start and the starter does not work
Starting from an external source (another car)
If the engine does not start even though the starter works normally
Checking the tightness of connections
Conditions for towing a vehicle
Weekly inspection locations
General instrument panel
Infrared remote control
Identification card
Child lock for rear doors
Remote control door lock
Fuel filler flap opening lever
Electronic anti-theft system
Fuel shut-off valve
Catalytic converter
Instrument panel (petrol and diesel vehicles)
Instrument panels (petrol vehicles)
Instrument panel (cars with automatic transmission)
Instrument panels (vehicles with diesel engine)
Instrument panel indicators
Windshield wiper
Electric heated rear window and outside rear view mirrors
Adjusting the position of the steering wheel
On-board computer
Heating and ventilation
Air conditioner
Automatic air conditioner
Front airbags
Side airbags
Clock, panel backlight
Automatic transmission
Speed controller
Fuse boxes
List of fuses
Wheels and tires — checking pressure
Towing a car
Vehicle identification data
Technical characteristics of the car
Fuel consumption of cars
Car radio 4030
Car radio with CD player 4050
Control of outdoor lighting devices
Seat adjustment
Headlight adjustment
Replacing crankshaft seals
Maintenance (gasoline)
Technical information for maintenance
Maintenance intervals
View of the engine compartment
Oil and oil filter change (15000 km/12 months)
Checking the oil level in the automatic transmission (15,000 km/12 months)
Checking the tightness of hoses and leakage of liquids (15,000 km/12 months)
Replacement of fine air filter in the ventilation system (15,000 km/12 months)
Checking the clutch operation (15,000 km/12 months)
Checking the drive shaft protective cover (15,000 km/12 months)
Steering and suspension (15000 km/12 months)
Shock absorber check (15000 km/12 months)
Checking the front brake pads (30,000 km)
Checking the rear brake pads and handbrake (30,000 km)
Replacing spark plugs and checking the ignition system (60,000 km)
Replacing the air filter element (60,000 km)
Fuel filter replacement (60,000 km)
Checking and replacing the auxiliary drive belt (60,000 km)
Checking the oil level in a manual transmission (60,000 km)
Checking rear brake pads (60,000 km)
Brake fluid replacement (60,000 km)
Coolant replacement (120,000 km/24 months)
Maintenance (diesel)
Technical information for maintenance
Maintenance intervals
View of the engine compartment
Removal water from the fuel filter (10,000 km/12 months)
Checking the tightness of hoses and detecting liquid leaks (10,000 km/12 months)
Cabin filter replacement (20,000 km)
Replacing the air filter element (30,000 km)
Fuel filter replacement (30,000 km)
Checking the gearbox oil level (60,000 km)
Auxiliary drive belt (60,000 km)
Every 120,000 km or 2 years
Power unit
Gasoline engines
Gasoline engines — general information about repair
Technical characteristics of gasoline engines
Checking the compression pressure (compression)
Installation of the valve timing mechanism
Cylinder Head Cover — Removal and Installation
Crankshaft pulley — removal and installation
Timing Belt Cover — Removal and Installation
Timing belt — removal and installation
Timing Belt Tensioner and Pulleys
Replacing the camshaft sealing ring
Camshaft and tappets — removal, inspection and installation
Checking and adjusting valve clearances of 1.6L engines
Cylinder head — removal and installation
Oil pan — removal and installation
Oil pump — removal, inspection and installation
Oil radiator — removal and installation
Flywheel — removal, inspection and installation
Powertrain suspension — inspection and replacement
Main engine faults
Diesel engines
Diesel engines — general information about repair
Technical characteristics of diesel engines
Checking the compression pressure (compression)
Installation of the valve timing mechanism
Cylinder Head Cover — Removal and Installation
Crankshaft pulley — removal and installation
Timing Belt Cover — Removal and Installation
Timing Belt — Removal, Checking and Installation
Camshaft Pulley — Removal and Installation
Crankshaft pulley — removal and installation
High pressure fuel pump pulley
Right engine mount and timing belt tensioner
Timing Belt Guide Roller — Removal and Installation
Camshaft and tappets — removal, inspection and installation
Checking and adjusting valve clearances
Removal and installation the cylinder head (1.9 l engines)
Selecting a Cylinder Head Gasket
Checking the cylinder head bolts
Oil pan — removal and installation
Oil pump — removal, inspection and installation
Right crankshaft seal ring
Left crankshaft seal ring
Camshaft sealing rings
Engine overhaul
Engine specifications
Removal and installation of engine and gearbox
Removal and installation of engines with automatic transmission
Engine repair — general information
Removal and installation the cylinder head (2.1L engine)
Disassembling the cylinder head
Cleaning and inspection of the cylinder head
Cylinder head assembly
Removal pistons with connecting rods
Removal the crankshaft
Cylinder block
Pistons and connecting rods — check
Crankshaft — check
Inspection of main and connecting rod bearings
Sequence of engine assembly during major repairs
Installing piston rings
Selecting New Crankshaft Main Bearings
Checking the working clearance of the crankshaft main bearings
Installing the crankshaft (XU and XUD engines)
Installing pistons
Starting the engine after major repairs
Cooling and heating
Cooling, heating and ventilation systems
Technical characteristics of the cooling system
Connecting the cooling system hoses
Radiator — removal, inspection and installation
Thermostat — Removal, Checking and Installation
Electric Fan — Removal, Checking and Installation
Thermal sensors — removal, testing and installation
Coolant Temperature High Lamp Sensor
Water pump — removal and installation
Heating and ventilation system
Heating system elements — removal and installation
Air conditioning systems
Main faults of the cooling system
Fuel system (gasoline)
Fuel system of gasoline engines
Fuel system specifications
Air Filter and Intake Ports — Removal and Installation
Accelerator cable — removal, installation and adjustment
Accelerator pedal — removal and installation
Fuel injection system
Relieving pressure in the fuel system
Fuel pump — removal and installation
Fuel tank — removal and installation
Checking the fuel system
Throttle body — removal and installation
Bosch Motronic MP511 injection system — removal and installation
Magneti Marelli 8P injection system — removal and installation
Intake manifold — removal and installation
Exhaust manifold — removal and installation
Exhaust gas system
Main faults of fuel and exhaust systems
Fuel system (diesel)
Fuel system of diesel engines
Fuel system specifications
Filling and bleeding the fuel system
Air filter and air intake ducts
Accelerator cable — removal, installation and adjustment
Accelerator pedal — removal and installation
Adjusting the high pressure fuel pump
Engine stop solenoid valve
Bosch High Pressure Fuel Pump — Removal and Installation
Lucas High Pressure Fuel Pump — Removal and Installation
Setting the injection timing
Setting the injection timing on a Bosch fuel injection pump
Setting the injection timing on the Lucas fuel injection pump
Fuel injectors — removal, inspection and installation
Sensors and actuators of the Bosch AS3 system
Sensors and actuators (Lucas EPIC)
Intake manifold — removal and installation
Exhaust manifold — removal and installation
Turbocharger — Description and Precautions
Removal and installation a turbocharger
Checking the turbocharger
Intercooler — Removal and Installation
Engine electrical equipment
Technical characteristics of starting and charging systems
Battery — Removal, Checking and Installation
Charging system — description and testing
Alternator — Removal and Installation
Engine Starting System — Check
Starter — removal and installation
Oil pressure sensor — removal and installation
Oil level sensor — removal and installation
Ignition system (petrol engines) — description
Checking the ignition system
Ignition coil — removal and installation
Setting the ignition timing
Pre-heating system (diesel engines)
Glow Plugs — Removal, Checking and Installation
Pre-heating system control unit
Transmission
Clutch and drive shafts
Technical characteristics of the clutch and shafts
Clutch cable — removal and installation
Clutch pedal — removal and installation
Hydraulic clutch control system
Clutch master assembly — removal, inspection and installation
Clutch release mechanism — removal, inspection and installation
Drive shafts — general information
Removal and installation drive shafts
Replacement of constant velocity joint boots
Replacing the intermediate bearing of the right drive shaft
Main clutch faults
Main faults of drive shafts
Mechanical gearbox
Manual transmission — general description
Technical characteristics of the manual transmission
Gearbox oil change
Gear shift control (BE3 gearbox)
Cable shift drive (ML5T gearbox)
Replacing sealing rings
Reverse Light Switch — Removal, Checking and Installation
Speedometer Drive Sensor — Removal and Installation
Removal and installation of the BE3 gearbox
Manual transmission ML5T
Main faults of a manual gearbox
Automatic gearbox
Automatic transmission — general description
Automatic transmission specifications
Gearbox oil change
Removal and installation the selector cable
Removal and installation the speedometer drive
Removal and installation the cooler
Removal and installation the multifunction switch
Removal and installation the electronic control unit (ECU)
Removal and installation of automatic transmission
Overhaul of automatic transmission
Main faults of automatic transmission
Chassis, running gear
Brake system
Brake system — general description
Technical characteristics of the brake system
Bleeding the hydraulic brake system
Brake lines and hoses
Replacing the front brake pads
Replacing rear brake pads
Replacing rear brake shoes on drum brakes
Front brake disc — removal, inspection and installation
Rear brake disc — removal, inspection and installation
Rear Brake Drum — Removal, Checking and Installation
Front Brake Caliper — Removal, Repair and Installation
Rear Wheel Support — Removal, Repair and Installation
Rear Brake Cylinder — Removal and Installation
Master Brake Cylinder — Removal, Repair and Installation
Brake pedal — removal and installation
Vacuum brake booster — removal, inspection and installation
One-way valve of the brake booster
Adjusting the handbrake
Handbrake lever — removal and installation
Handbrake cable — removal and installation
Handbrake pads (with disc brakes)
Brake pressure regulating valve
Brake light switch — removal and installation
Anti-lock braking system (ABS)
Vacuum pump (vehicles with diesel engine)
Checking the vacuum pump (with diesel engines)
Main faults of the brake system
Car suspension
Suspension and steering — general information
Suspension specifications
Steering knuckles — removal and installation
Replacing the front hub bearings
Front pillar — removal and installation
Front pillar repair
Lower control arm front suspension — removal and installation
Lower ball joint of the front suspension — removal and installation
Front suspension anti-roll bar
Front suspension anti-roll bar linkage
Front Suspension Lower Frame — Removal and Installation
Rear wheel hub — removal and installation
Replacing rear hub bearings
Rear shock absorber — removal, inspection and installation
Rear Suspension Coil Spring — Removal and Installation
Rear suspension hub journal — removal and installation
Lower arm rear suspension — removal and installation
Upper Rear Suspension Arm — Removal and Installation
Rear Suspension Guide Arm — Removal and Installation
Rear suspension rod — removal and installation
Rear suspension anti-roll bar
Rear suspension stabilizer link
Wheel alignment angles
Basic faults of suspension and steering
Steering
Steering wheel — removal and installation
Steering column — removal, inspection and installation
Intermediate shaft of the steering column — removal, inspection and installation
Ignition switch — removal and installation
Steering gear — removal and installation
Replacing the steering gear protective covers
Bleeding the Power Steering System
Power Steering Pump — Removal and Installation
Steering Tie Rod Ball Joint — Removal and Installation
Steering rod — removal and installation
Body and interior
Exterior (external elements)
General information about the car body
Car body care
Repair of minor body damage
Repair of severe body damage
Front bumper — removal and installation
Rear bumper — removal and installation
Hood — removal and installation
Bonnet Lock Cable — Removal and Installation
Hood lock — removal and installation
External rear view mirrors — removal and installation
Overlays and emblems
Interior (internal elements)
Caring for upholstery and carpets
Seats — removal and installation
Front seat belt tensioner mechanism
Seat belts — removal and installation
Interior trim — removal and installation
Center console — removal and installation
Instrument panel — removal and installation
Doors, locks and windows
Doors — removal, installation and adjustment
Door trim — removal and installation
Door lock and handles — removal and installation
Door glass — removal and installation
Trunk lid — removal and installation
Trunk lock — removal and installation
Rear door — removal and installation
Rear Door Lock — Removal and Installation
Central locking system — removal and installation
Electric windows
Windshield and rear glass
Sunroof in a car
Electrical equipment
Equipment and devices
General information about electrical equipment
Technical characteristics of electrical equipment
Open Circuit Detection
Fuses and relays
Switches and switches — removal and installation
External Light Bulbs — Replacement
Interior Lighting Bulbs — Replacement
External lighting devices — removal and installation
Headlight adjustment
Instrument cluster — removal and installation
Multifunctional display — removal and installation
Cigarette lighter — removal and installation
Watch — removal and installation
Sound signal — removal and installation
Windscreen wiper arm — removal and installation
Windscreen wiper motor and rods — removal and installation
Rear wiper — removal and installation
Windscreen washer — removal and installation
Car radio — removal and installation
Speakers (speakers) — removal and installation
Radio Antenna — Removal and Installation
Cruise control system — removal and installation
Anti-theft system and engine immobilizer
Airbag system
Airbag Components — Removal and Installation
Electrical circuits
Designations on electrical equipment diagrams
Starting and charging systems, radiator fans
Radiator fan, heater fan, ABS
Control lights and indicators
Engine Management System Magneti Marelli MM8P
Engine management system Bosch MP5.1.1
Headlights, number plate lights, brake lights, bulbs
Direction indicators and hazard warning lights, fog lights
Interior lighting and headlight adjustment
Headlamp washers, front and rear windscreen washers/wipers
Cigarette lighter illumination, heated seats, rear window and mirrors, sunroof
Engine immobilizer system
Central locking and front electric windows
Front and rear electric windows
Radio, CD player, clock and trip computer
Electric mirrors
Peugeot 605
(1989-2000)
General information
User manual
Governing bodies
Instrument panel
Signal lights
Keys — General Information
Security alarm
On-board computer
Steering wheel
Heating and ventilation of the passenger compartment
Heater Switch Block
Air Conditioning — General Information
Automatic air conditioner switch block
Electric power windows
Radio receiver — general information
Starting the engine
Anti-theft system (immobilizer)
Manual transmission
Automatic transmission
Cruise control
Engine bay. Cars with 2.0L turbocharged petrol engine
Engine bay. Cars with V6 petrol engine with 24 valves
Engine bay. Cars with V6 petrol engine
Engine compartment. Cars with a 2.1L diesel engine
Engine compartment. Cars with a 2.5 liter diesel engine
Motor oil
Brake fluid
Fuses — General Information
Maintenance
General Provisions and Recommendations
Jacking and towing a car
Vehicle care
Starting the engine — using a booster battery
Maintenance — works
Engine Oil Level — Checking and Replacing
Brake fluid — checking and replacing
Checking the brake system
Checking tire pressure and tread depth
Checking the cooling system
Checking the transmission fluid level in the gearbox
Checking the condition of the V-belt
Replacing the replaceable air filter element
Replacing the fuel filter
Drive shaft CV joint covers — inspection
Checking the steering gear covers
Maintenance plan
Troubleshooting
Identifying and troubleshooting engine faults
Identifying and troubleshooting engine lubrication system faults
Identifying and troubleshooting engine cooling system faults
Identifying and troubleshooting gasoline injection system faults
Identifying and troubleshooting diesel engine fuel system faults
Identifying and troubleshooting brake system faults
Identifying and troubleshooting clutch problems
Identifying and troubleshooting battery problems
List of starter faults and their elimination
Identifying and troubleshooting generator faults
Identifying and troubleshooting windshield wiper problems
Power unit
Petrol engines «XU»
Specifications of XU Series Gasoline Engine Vehicles
General information
Timing belt of the gas distribution mechanism drive — removal
Timing belt of the gas distribution mechanism drive — installation
Camshaft — Removal
Camshaft — Installation
Cylinder head — removal
Cylinder head — installation
Engine — removal
Engine — installation
Petrol engines «ZPJ»
Specification of cars with petrol engines of the ZPJ series
General information
Balance shaft drive chain — removal
Balance Shaft Drive Chain — Installation
Timing chains — removal
Timing Chains — Installation
Cylinder head — removal
Cylinder head — installation
Power unit — removal and installation
Petrol engines «ES9J4»
Specification of cars with petrol engine ES9J4
General information
Timing belt of the gas distribution mechanism drive — removal
Timing belt of the gas distribution mechanism drive — installation
Accessory Drive Belt — Removal
Accessory Drive Belt — Installation
Camshafts — Removal
Camshafts — Installation
Camshaft Seal — Replacement
Front crankshaft oil seal (timing belt side) — replacement
Rear Crankshaft Oil Seal (Flywheel Side) — Replacement
Cylinder head — removal
Cylinder head — installation
Power Block — Removal
Power unit — installation
Engine lubrication system — general information
Oil pump — removal
Oil pump — installation
Diesel engines
Specification of cars with diesel engines
General information
Timing belt of the gas distribution mechanism drive — removal
Timing belt of the gas distribution mechanism drive — installation
Accessory Drive Belt — Removal
Accessory Drive Belt — Installation
Camshaft — Removal
Camshaft — Installation
Cylinder head — general information
Power unit — removal and installation
Cooling and heating
General information
Water Pump — Removal
Water pump — installation
Radiator — removal and installation
Transmission Oil Cooler Radiator — Removal
Transmission Oil Cooling Radiator — Installation
Heater — removal and installation
Heater Fan — Removal and Installation
Thermostat — removal and installation
Outside Air Temperature Sensor — Removal and Installation
Coolant Temperature Sensor — Removal and Installation
Cooling system — bleeding
Fuel system
General information about the fuel injection system
Functioning of the injection system of a gasoline engine
Fuel injection system — general check
Intake Manifold — Removal
Intake manifold — installation
Carburetor — General Information
Diesel Engine Fuel System — General Information
Precautions when working on the fuel system of a diesel engine
Injectors — removal and installation
High pressure fuel pump — removal, installation and adjustment
Intake manifold — removal and installation
Fuel System — General Information and Precautions
Cleanliness and safety rules when working with the fuel system
Fuel tank — removal and installation
Fuel tank — check
Fuel (fuel lift) pump with fuel gauge sensor — removal
Fuel (fuel booster) pump with fuel gauge sensor — installation
Filler neck — removal and installation
Exhaust system
General information about the exhaust system
Catalyst — General Information
Turbocharger — operating principle
Turbocharger — removal and installation
Exhaust system — replacement of components
Exhaust system — leak test
Exhaust Gas Recirculation System — General Information
Transmission
Clutch
General information about the clutch
Clutch pedal — removal
Clutch pedal — installation
Clutch — removal
Clutch — installation
Mechanical gearbox
Manual Transmission Specifications
General information about mechanical transmission
Gear Shift Mechanism — Removal
Gear Shift Mechanism — Installation
Gearshift box-removal
Gearbox — installation
Automatic gearbox
Automatic Transmission Specifications
General information about automatic transmission
Transmission Oil — Checking Level
Transmission oil — replacement
Torque Converter — Removal
Torque converter — installation
Modulator — removal
Modulator — installation
Speedometer sensor — removal and installation
Gear shift mechanism — removal and installation
Gear shift mechanism — adjustment
Gearshift box-removal
Gearbox — installation
Chassis, running gear
Brake system
Brake system specifications
General information
Brake system — bleeding
Brake disc — removal
Brake disc — check
Brake pads — removal
Brake pads — installation
Brake Caliper — Removal
Brake booster vacuum — removal and installation
Parking brake shoes — removal
Parking brake cable leash — removal and installation
Parking brake cables — removal and installation
Parking brake — adjustment
Brake light switch — removal and installation
Wheel speed sensors (ABS sensors) — removal and installation
Car suspension
Suspension and steering specifications
Front suspension — general information
Front Suspension Shock Absorber Strut — Removal
Front suspension shock absorber strut — disassembly
Steering knuckle — removal and installation
Front Suspension Wishbone — Removal and Installation
Front suspension anti-roll bar — removal and installation
Rear wheel suspension — removal and installation
Upper Rear Suspension Arm — Removal and Installation
Lower wishbone rear suspension — removal
Rear Lower Wishbone Installation
Rear shock absorber — removal and installation
Rear wheel hub — removal and installation
Drive shafts — removal
Drive shafts — installation
Steering
Steering — General Information
Steering gear — removal and installation
Steering wheel — removal and installation
Steering column switch block — removal and installation
Power Steering Pump — Removal and Installation
Power Steering Hydraulics — Fluid Replacement and Bleeding
Wheel alignment angles
Body and interior
Body elements
Body and interior trim — general description
Front bumper — removal and installation
Rear bumper
Hood — removal and installation
Door — removal and installation
Rear of the center console — removal and installation
Glove box — removal and installation
Side deflector — removal and installation
Trunk lid — removal and installation
Electrical equipment
Power devices
Electrical System — General Description and Precautions
Measuring instruments
Voltage measurement
Measuring current
Measuring resistance
Troubleshooting electrical equipment
Battery capacity — check
Starter — removal and installation
Generator — device
Generator — check
Generator — removal
Headlights — removal and installation
Windscreen wiper — removal and installation
Battery tray — removal and installation
Instrument cluster — removal and installation
Ignition System — General Information and Precautions
Spark plugs — general information
Spark plugs — removal
Electrical circuits
Keys to all basic electrical circuit diagrams
Scheme 1. Bosch LE.2 injection system (engine XU10J2K and automatic transmission)
Scheme 2. Magneti Marelli G5 injection system (engine XU10J2K and manual transmission)
Scheme 3. Bosch MP3.2 injection system (engine XU10J2TE)
Scheme 4. Bosch MP5.1.1 injection system (XU10J4R engine without immobilizer)
Scheme 5. Fenix 4 injection system (ZPJ petrol engine)
Diagram 6. EPIC power supply system (XUD11BTE diesel engine)
Scheme 7. Power supply system Bosch MSA 11 3.6 VP36 (engine DK5ATE)
Scheme 8. Central lock
Scheme 9. Instrument panel
Scheme 10. Security alarm
Scheme 11. High and low beam headlights
Scheme 12. Windscreen washer and wiper, heated jets and washing fluid level sensor
Scheme 13. Rear window defroster
Scheme 14. Heating, ventilation and air conditioning (engines ZPJ, XU102C, XU10J2, XU10J2C)
Diagram 15. Heating, ventilation and air conditioning (XUD diesel engine, except XUD11BTE)
Scheme 16. Heating, ventilation and air conditioning (engine XU10J4R, XU10J2TE, DK5ATE and XUD11BTE)
Partner I
(1996-2008)
General information
Introduction to the guide
Safety comes first!
Safe Driving Skills
General Provisions
Dimensions and weights of the car
Purchase of spare parts
Vehicle identification
Lifting and installing the car on supports
General tips for carrying out repairs
Disconnecting the battery
Tools and accessories
Checking the technical condition of the car
Checks performed from the driver's seat
Checks performed on a vehicle standing on the ground
Checks performed on a raised vehicle with wheels rotating freely
Checking the composition of exhaust gases
Dictionary of technical terms
Faults en route
Repairs on the road
Starting the engine from an external battery
Wheel replacement
What do the smudges mean?
Towing a car
Troubleshooting
General information about troubleshooting
Car engine
Cooling system
Fuel system and exhaust system
Car clutch
Transmission
Drive axle shafts
Brake system
Steering and suspension
Electrical equipment
Weekly checks
General description
Check points under the hood
Engine oil level
Coolant level
Windscreen washer fluid level
Power steering fluid level in reservoir
Brake fluid level in the brake hydraulic reservoir
Windscreen wiper blades
Car battery
Electrical systems
Tire condition and pressure
Types of tire wear
Lubricants and operating fluids
Choosing Motor Oil for Your Car
Tire pressure
User manual
General Provisions
A set of documentation for the car
Controls, instrumentation and cabin equipment
Instrument panel
Exterior lighting and direction indicator switch
Headlight leveling switch
Ignition switch and steering column lock, horn switch
Windscreen wiper/washer switch
Central button panel
Cruise control switch block
Turning the system on, off and adjusting the speed
Cancelling and resuming cruise control, resetting the set speed value
Steering column adjustment lever
Gear shift lever (manual transmission)
Heating and ventilation controls
Ventilation deflectors
Audio system compartment
Parking brake lever
Interior lighting
Mirror adjustment, window lift control
Inertia fuel switch (on petrol engine variants)
Adjusting the position of the seats
Cigarette lighter and ashtray
Electrical power outlet
Audio Remote Control Switch
Clock/Multi-function display
Hazard warning light switch
Storage compartments and other places for storing various items
Ceiling equipment
Central locking button
Hood release handle
Sunroof control
Instruments and control lamps
Starting the engine
Warming up the engine after starting
Engine shutdown
Car parking
Fuel consumption
Fuel system and refueling
Running in a new car
Rules for operating a car with a catalytic converter
Cruise control system
Brake system
Anti-lock braking system
Heating and ventilation
Luggage transportation
Towing a trailer
Anti-skid chains
Winter tires
Locks and anti-theft system
Retaining devices
Maintenance (petrol)
Engine specifications
Maintenance schedule
Arrangement of elements in the engine compartment and underbody
General information about maintenance
Routine maintenance
Changing engine oil and oil filter
Checking the engine compartment for leaks and checking the condition of the hoses
Checking the drive axle shaft covers
Lubrication of hinges and locks
Road test
Resetting the Service Interval Display
Replacing the dust filter
Checking and replacing the accessory drive belt
Checking the front disc brake pads
Checking the brake shoes of the rear drum brakes
Checking and adjusting the parking brake
Checking the exhaust system
Checking the steering and suspension
Replacing the timing belt
Replacing brake fluid
Replacing spark plugs
Replacing the air filter element
Replacing the fuel filter
Checking the oil level in a manual transmission
Testing of emission control systems
Replacing the coolant
Replacing airbags and seat belt pretensioners
Maintenance (diesel)
Car specifications
Service Schedule — 1.8L and 1.9L Diesel Models
Service Schedule — 2.0L Diesel Models
Arrangement of elements in the engine compartment and underbody
General information about maintenance
Routine maintenance
Changing engine oil and oil filter
Draining condensate from the fuel filter
Checking the engine compartment for leaks and checking the condition of the hoses
Checking the drive axle shaft covers
Lubrication of hinges and locks
Road test
Resetting the Service Interval Display
Replacing the dust filter
Checking and adjusting the idle speed and anti-stall speed — 1.8L and 1.9L engines
Checking and replacing the accessory drive belt — 1.8L and 1.9L engines
Drive belt (XUD with manual adjuster on the upper support of the generator)
Drive belt (XUD with manually adjustable tension pulley)
Drive belt (XUD with automatic tensioner pulley)
Drive belt (DW engines without power steering)
Drive belt (DW with power steering, without air conditioning, with manual tensioner)
Drive belt (DW engines with power steering)
Drive belt (DW engines with air conditioning)
Checking and replacing the accessory drive belt — 2.0L engines
Checking the front disc brake pads
Checking the brake shoes of the rear drum brakes
Checking and adjusting the parking brake
Checking the exhaust system
Checking the steering and suspension
Replacing the fuel filter (1.8L and 1.9L XUD series engines)
Replacing the fuel filter (1.9L DW series engines)
Replacing the fuel filter (2.0L engines)
Replacing the air filter element
Checking the oil level in a manual transmission
Testing of emission control systems
Replacing brake fluid
Replacing the coolant
Replacing airbags and seat belt pretensioners
Power unit
Petrol engines
Petrol Engine Specifications
General information about gasoline engines
Compression Testing — Procedure Description and Results Analysis
Engine Assembly/Camshaft Timing Mounting Holes — General Information and Use
Cylinder Head Cover — Removal and Installation
Timing Belt Covers — Removal and Installation
Timing Belt — General Information, Removal and Installation
Timing Belt Tensioner and Toothed Pulleys — Removal, Inspection and Installation
Camshaft Seals — Replacement
Valve clearances — checking and adjustment
Camshafts and Valve Lifters/Pushers — Removal, Inspection and Installation
Cylinder head — removal and installation
Oil pan — removal and installation
Oil pump — removal, inspection and installation
Crankshaft seals — replacement
Flywheel — removal, inspection and installation
Engine/Gearbox Mounts — Inspection and Replacement
Diesel engines «XUD»
Diesel Engine Specifications
General information about XUD diesel engines
Compression Testing and Leak Testing — Procedure Description and Results Analysis
Engine/camshaft assembly mounting holes
Cylinder Head Cover — Removal and Installation
Crankshaft pulley — removal and installation
Timing Belt Covers — Removal and Installation
Timing Belt — Removal, Inspection, Installation and Tensioning
Timing Belt Pulleys — Removal and Installation
Right engine mount bracket and timing belt tensioner
Timing Belt Idler Roller — Removal and Installation
Camshaft and tappets — removal, inspection and installation
Valve clearances — checking and adjustment
Cylinder head — removal and installation
Oil pan — removal and installation
Oil pump and drive chain — removal, inspection and installation
Cuffs — replacement
Flywheel — removal, inspection and installation
Engine Oil Cooler — Removal and Installation
Engine/Gearbox Mounts — Inspection and Replacement
Diesel engines «DW»
Diesel Engine Specifications
General information about DW diesel engines
Compression Testing and Leak Testing — Procedure Description and Results Analysis
Engine Assembly/Camshaft Timing Mounting Holes — General Information and Use
Cylinder Head Cover — Removal and Installation
Crankshaft pulley — removal and installation
Timing Belt Covers — Removal and Installation
Timing Belt (1.9L Engines) — General Information, Removal and Installation
Timing Belt (2.0L Engines) — General Information, Removal and Installation
Timing belt pulleys, idler pulley and tensioner pulley
Camshaft Seal — Replacement
Camshaft, valve levers and tappets — removal, inspection and installation
Valve clearances — checking and adjustment
Cylinder head (1.9L engines) — removal and installation
Oil pan — removal and installation
Oil pump and drive chain — removal, inspection and installation
Crankshaft seals — replacement
Engine/Gearbox Mounts — Inspection and Replacement
Overhaul of petrol engines
Petrol Engine Specifications
General Provisions
Engine Overhaul — General Information
Engine Removal — Method and Precautions
Engine/gearbox — removal and installation
Engine Overhaul — Disassembly Sequence
Cylinder head — disassembly
Cylinder head and valves — cleaning and inspection
Cylinder head — assembly
Pistons with connecting rods — removal
Crankshaft — Removal
Cylinder Block/Crankcase — Cleaning and Inspection
Piston assembly with connecting rod — inspection
Crankshaft — inspection
Main and connecting rod bearings — inspection
Engine Overhaul — Assembly Sequence
Piston rings — installation
Crankshaft — installation
Piston with connecting rod assembly — installation
Engine — first start after repair
Overhaul of diesel engines
Diesel Engine Specifications
General information
Engine Overhaul — General Information
Engine Removal — Method and Precautions
Engine/gearbox — removal and installation
Cylinder Head (2.0L Engines) — Removal and Installation
Engine Overhaul — Disassembly Sequence
Cylinder head — disassembly
Cylinder head and valves — cleaning and inspection
Cylinder head — assembly
Pistons with connecting rods — removal
Crankshaft — Removal
Cylinder Block/Crankcase — Cleaning and Inspection
Piston assembly with connecting rod — inspection
Crankshaft — inspection
Main and connecting rod bearings — inspection
Engine Overhaul — Assembly Sequence
Piston rings — installation
Crankshaft — installation
Piston with connecting rod assembly — installation
Engine — first start after repair
Cooling and heating
Cooling system specifications
General information and precautions
Coolant Hoses — Disconnecting and Replacing
Radiator — removal, inspection and installation
Thermostat — Removal, Checking and Installation
Electric Cooling Fans — Removal and Installation
Electrical switches and sensors of the cooling system — removal and installation
Coolant pump — removal and installation
Thermostat/Fuel Filter Housing (1.8L and 1.9L Diesel Models)
Heating and ventilation system — general information
Heating/ventilation system elements — removal and installation
Air Conditioning System — General Information and Precautions
Air conditioning system components — removal and installation
Power and exhaust (petrol)
Fuel and exhaust system specifications
General information and precautions
Air Filter Assembly and Air Intake Ducts — Removal and Installation
Accelerator cable — removal, installation and adjustment
Accelerator pedal removal and installation
Unleaded Gasoline — General Information and Uses
Engine Management System — General Information
Fuel system — pressure relief and pressure increase
Fuel pump — removal and installation
Fuel level indicator sensor — removal and installation
Fuel tank — removal and installation
Engine management system — checking and adjustment
Throttle body — removal and installation
Fuel rail and injectors
Fuel pressure regulator
Throttle potentiometer
Electronic control unit
Stepper motor for adjusting the crankshaft speed in idle mode
Engine Management System Sensors
Intake manifold removal and installation
Exhaust manifold — removal and installation
Exhaust system — general information, removal and installation
Power and exhaust (XUD diesels)
Fuel and Exhaust System Specifications
General information and precautions
Fuel system — filling and bleeding
Air filter and related components — removal and installation
Thermostatic high idle speed sensor
High pressure fuel pump — removal and installation
Fuel injection advance — methods of checking and adjustment
Fuel injection advance (Lucas high pressure fuel pump) — checking and adjustment
Fuel injection advance (Bosch high pressure fuel pump) — checking and adjustment
High pressure fuel pump — adjustment
Fuel injectors — checking, removal and installation
Accelerator cable — removal, installation and adjustment
Fuel level indicator sensor — removal and installation
Collectors — removal and installation
Exhaust system — general information and replacement of components
Power and exhaust (DW diesels)
Fuel and exhaust system specifications
General information and precautions
High Pressure Diesel Injection (HDi) System — Special Information
Air Filter Assembly and Air Intake Ducts — Removal and Installation
Accelerator cable — removal, installation and adjustment
Accelerator pedal — removal and installation
Fuel system — filling and bleeding
Low Pressure Fuel Pump (2.0L Engine Models) — Removal and Installation
Fuel level indicator sensor — removal and installation
High Idle Speed Thermostatic Sensor (1.9L Engine Models)
High Pressure Fuel Pump (1.9L Engine Models) — Adjustment
Electrical components of the fuel injection system — removal and installation
High pressure fuel pump — removal and installation
Fuel injection advance — checking and adjustment
Fuel injectors — removal and installation
Fuel Rail (2.0L Engine Models) — Removal and Installation
Intake manifold — removal and installation
Exhaust manifold — removal and installation
Turbocharger (2.0L Engine Models) — Design Description and Precautions
Turbocharger (models with 2.0L engine) — removal, inspection and installation
Exhaust system — general information, removal and installation
Emission reduction
Emission Control System Specifications
General information about the emission reduction system
Emission Control Systems (Gasoline Engines) — Checking and Replacing Components
Emission Control Systems (Diesel Engines) — Checking and Replacing Components
Catalytic Converter — General Information and Precautions
Starting and charging system
Starting and charging system specifications
General information and precautions
Battery — Checking and Charging
Battery — Removal and Installation
Battery Shelf and Support Plate — Removal and Installation
Charging system — check
Generator — removal and installation
Generator — Checking and Overhaul
Starting system check
Starter — removal and installation
Starter — check and repair
Low Oil Pressure Warning Light Switch Sensor
Oil level sensor — removal and installation
Ignition System Specifications
Ignition system — general information
Ignition system — check
Ignition Coil Block — Removal, Checking and Installation
Ignition timing — checking and adjustment
Knock sensor — removal and installation
Heating system specifications
Pre-heating system — description and testing
Glow Plugs — Removal, Inspection and Installation
Pre-heating system control unit — removal and installation
Transmission
Clutch
Clutch specifications
General information
Clutch cable — removal and installation
Clutch pedal — removal and installation
Clutch assembly — removal, inspection and installation
Clutch release mechanism — removal, inspection and installation
Mechanical gearbox
Gearbox specifications
General information about manual transmission
Manual transmission — draining and filling transmission oil
Gear Shift Lever Mechanism — Removal and Installation
Cuffs — replacement
Reverse Light Switch — Checking, Removing and Installing
Speedometer drive — removal and installation
Manual gearbox — removal and installation
Gearbox Overhaul — General Information
Drive shafts
Axle shaft specifications
General information about drive shafts
Drive axle half shafts — removal and installation
Rubber boots for axle shaft joints (GKN axle shaft) — replacement
Rubber boots for axle shaft joints (PSA axle shaft) — replacement
Overhaul of the axle shaft — general information
Right axle intermediate support — replacement
Chassis, running gear
Brake system
Brake system specifications
General information about the braking system
Hydraulic drive — air removal
Hydraulic lines and hoses — replacement
Front brake pads — replacement
Rear brake pads — replacement
Front brake disc — inspection, removal and installation
Rear brake drum — inspection, removal and installation
Front Brake Caliper — Removal, Repair and Installation
Rear Brake Wheel Cylinder — Removal, Repair and Installation
Master Cylinder — Removal, Repair and Installation
Vacuum brake booster — checking, removal and installation
Brake booster check valve — removal, inspection and installation
Parking brake — adjustment
Parking brake lever — removal and installation
Parking brake cables — removal and installation
Rear Brake Pressure Regulator — Removal and Installation
Brake light switch — removal, installation and adjustment
Parking Brake Activation Indicator Lamp Switch — Removal and Installation
Anti-lock braking system (ABS) — general information
Anti-lock braking system (ABS) components — removal and installation
Vacuum Pump (Diesel Engine Models) — Removal and Installation
Vacuum Pump (Diesel Engine Models) — Checking and Repairing
Car suspension
Suspension and steering specifications
General information about suspension and steering
Steering knuckle assembly — removal and installation
Front Hub Bearings and Steering Knuckle — Replacement
Front suspension strut — removal and installation
Front suspension strut — repair
Lower control arm front suspension — removal, repair and installation
Ball joint of the lower arm of the front suspension — removal and installation
Front Anti-Roll Bar — Removal and Installation
Front Anti-Roll Bar — Removal and Installation
Front subframe — removal and installation
Rear Hub Assembly — Removal and Installation
Rear Hub Bearings — Replacement
Rear suspension components — general information
Rear shock absorber — removal, inspection and installation
Rear axle assembly — removal and installation
Vehicle ground clearance — check
Steering
Steering wheel — removal and installation
Steering column — removal, inspection and installation
Ignition Switch/Steering Column Lock — Removal and Installation
Steering gear assembly — removal, repair and installation
Power Steering System — Air Bleed
Power Steering Pump — Removal and Installation
Tie Rod End — Removal and Installation
Wheel alignment angles — general information
Body and interior
Exterior (external elements)
Car body specifications
General provisions about the car body
Service — Body and Subframe
Minor body damage — repair
Serious body damage — repair
Front bumper — removal and installation
Rear bumper — removal and installation
Hood — removal, installation and adjustment
Hood Lock and Cable — Removal and Installation
Exterior rear view mirrors and mirror glass — removal and installation
Exterior body trim elements — removal and installation
Hood Grille Panel — Removal and Installation
Radiator grille — removal and installation
Interior (internal elements)
Service — Upholstery and Carpeting
Seats — removal and installation
Seat belt components — removal and installation
Interior Finishing — Removal and Installation
Center console — removal and installation
Front panel elements (manufactured before September 2002) — removal and installation
Front panel elements (produced after September 2002) — removal and installation
Doors, locks and windows
Doors — removal and installation
Interior Door Trim Panels — Removal and Installation
Front Door Handle and Lock Components — Removal and Installation
Side sliding door handle and lock components — removal and installation
Double-leaf rear door handle and lock components — removal and installation
Glass and window lifter of the front door — removal and installation
Liftgate and support pillars — removal and installation
Liftgate Lock Components — Removal and Installation
Elements of the centralized locking system — removal and installation
Windscreen, glass for the liftgate and glass for the rear split door
Glass of opening windows — removal and installation
Roof hatch — general information
Electrical equipment
Equipment and devices
Electrical Equipment Specifications
General information about on-board electrical equipment
Troubleshooting Electrical Circuits — General Information
Fuses and Relays — General Information
Switches — Removal and Installation
Lamps (exterior lighting fixtures) — replacement
Lamps (interior lighting) — replacement
External Lighting Devices — Removal and Installation
Headlight adjustment — general information
Instrument cluster — removal and installation
Multifunctional display — removal and installation
Cigarette Lighter/Power Socket — Removal and Installation
Sound signal — removal and installation
Windscreen wiper arm — removal and installation
Windshield wiper motor and drive — removal and installation
Electric motor of the windshield wiper of the lifting door 4 of the luggage compartment — removal and installation
Windshield Washer System Components — Removal and Installation
Audio block — removal and installation
Speakers — Removal and Installation
Engine Immobilizer and Anti-Theft Alarm System — General Information
Airbag system — general information, precautions and deactivation
Airbag System Components — Removal and Installation
Multifunctional electronic unit BSI/fuse box
Electrical circuits
Peugeot Partner: Electrical diagram symbols
Peugeot Partner: Scheme 2. Starting and charging system, audio unit, cigarette lighter, sound signal...
Peugeot Partner: Diagram 3. Fog lights, brake lights, side lights, headlights...
Peugeot Partner: Scheme 4. Airbags, anti-lock braking system, headlight leveling...
Peugeot Partner: Diagram 5. Washer/wiper, central locking system with double locking
Peugeot Partner: Diagram 6. Heater fan, engine cooling system, air conditioning...
Peugeot Partner: Scheme 7. Electric mirrors, interior lighting, instrument panel
Citroen Berlingo. Scheme 1. Table of fuses
Citroen Berlingo. Scheme 2. Washer/wiper, central locking
Citroen Berlingo. Scheme 3. Headlights, side lights, rear lights...
Citroen Berlingo. Scheme 4. Brake lights, reversing lights, indicators...
Citroen Berlingo. Scheme 5. Fog lights/lamps, cigarette lighter, horn...
Peugeot 806
(1994-2002)
General information
User manual
Introduction to the manual
Dimensions and weight
Control Panel
Car keys
Remote control unit
Front doors
Side sliding doors
Rear drop door
Opening the hood
Fuel tank cap
Instrument panel. Control lights
Dashboard
On-board computer
Steering wheel
Rear view mirrors
Heating and ventilation of the passenger compartment
Car air conditioning
Automatic air conditioning
Inflatable airbag
Adjusting the height of the seat belt fastening
Luggage compartment shelf (five-seat version)
Front retractable sunroof
Electric and manual windows
Sliding vents
Starting the engine
Engine start blocking
Entering or changing the code
Maintenance
General Provisions and Recommendations
Jacking up a car
Threaded connections
Maintenance — works
Engine Oil Level — Checking and Replacing
Brake fluid level — check
Checking the brakes
Checking tire pressure and tread depth
Checking the coolant level
Checking the cooling system
Checking the transmission fluid level in the gearbox
Checking the condition of the V-belt
Replacing the replaceable air filter element
Replacing the fuel filter
Checking the condition of the drive shaft covers
Checking the steering gear covers
Protective caps and play of the tie rod ends
Checking the steering play
Maintenance plan
Power unit
Petrol engines
Engine specifications
General description of engines
Cars with 1.8 liter engine
Cars with 2.0 liter engine
Cars with 1.9 liter diesel engines
Cars with a 2.1 liter diesel engine
Vehicle and engine identification
Power unit — removal and installation
Engine installation
Engine — disassembly
Engine — complete disassembly
Engine — assembly
Cylinder head — removal and installation
Valve train — overhaul
Gas distribution mechanism — assembly
Valve clearance — adjustment
Pistons and connecting rods — disassembly, inspection and assembly
Cylinder block
Crankshaft and flywheel — removal, inspection and installation
Timing belt — removal and installation
Using special tools to adjust the valve timing
Compression — check
Diesel engines
Diesel engines — removal and installation
Diesel engine — disassembly and assembly
Disassembling a 2.1 liter engine
Assembling a 2.1 liter diesel engine
Cylinder head — removal and installation
Valve clearance — adjustment (1.9 liter engines only)
Pistons and connecting rods — removal, inspection and assembly
Crankshaft
Timing belt — removal and installation
Lubrication system
Engine lubrication system
Oil pump — removal and installation
Oil filter
Oil radiator
Oil pressure — check
Engine oil leak
Cooling system
Cooling system specifications
General description and precautions
Coolant — draining and filling
Radiator — removal and installation
Water pump — removal and installation
Removal the thermostat
Cooling liquid
Checking thermal switches
Radiator blower fan
Coolant hoses
Identifying and troubleshooting engine cooling system faults
Fuel injection (petrol)
Fuel injection system specifications
General description and precautions
Fuel injection systems — brief characteristics
Accelerator cable — adjustment
Gas turbine supercharger
Fuel system (diesel)
Diesel Engine Specifications
General description
Precautions when working on the fuel system of a diesel engine
Injectors — removal and installation
Glow Plugs — Removal and Installation
Fuel filter — replacement of filter element, removal of condensate
High pressure fuel pump — adjustment
Ignition and exhaust systems
General description of the exhaust system
Exhaust system — removal and installation
Automotive catalytic converter
Safety precautions when working with ignition systems
Ignition coil
Ignition System Components
Spark plugs
ECM Bosch Motronic MP 3.2
General description
Checking the electronic control unit ECM (general check)
Self-diagnosis function
Ignition systems
Crankshaft Angle Sensor (CAS)
Camshaft position sensor (CMP)
Ignition booster
Ignition coil of the static ignition system (DIS)
Ignition coils of the direct ignition system
Intake Air Temperature Sensor and Coolant Temperature Sensor (ATS and CTS)
Knock Sensor (KS)
Manifold Absolute Pressure (MAP) Sensor
Throttle Position Sensor (TPS)
Vehicle Speed Sensor (VSS)
Induction Changeover Valve (ICOV) (Non-turbocharged models only)
Idle Speed Control Valve (ISCV)
Intake Manifold Heater (IMH)
Turbocharger Wastegate Valve (WCS) (with turbocharger only)
Fuel injection system
Fuel system
Fuel pump
Fuel pressure regulator
Fuel pump relay
Catalytic converter and emission control system
Oxygen sensor (OS)
ECM Magneti-Marelli (MM)
General description
Ignition systems
Static (distributorless) ignition system (DIS)
Secondary winding of the ignition coil
Intake Air Temperature Sensor and Coolant Temperature Sensor (ATS and CTS)
Knock Sensor (KS) (some models only)
Manifold Absolute Pressure (MAP) Sensor
Throttle Position Sensor (TPS)
Vehicle Speed Sensor (VSS)
Drives. Idle stepper motor
Fuel injection system
Catalytic converter and emission control system
Transmission
Clutch
Clutch specifications
General description of the clutch
Clutch — removal
Clutch — repair
Clutch — installation
Clutch release bearing
Identifying and troubleshooting clutch problems
Mechanical gearbox
Transmission Specifications
Manual transmission — general information
Gearbox — removal
Gearbox — installation
Transmission Oil — Checking Level and Replacing
Chassis, running gear
Brake system
Brake system specifications
General description of the braking system
Front Disc Brakes — Brake Pad Replacement
Front Disc Brake Mechanisms — Caliper Repair
Rear drum brakes
Rear disc brake mechanism — removal, installation, replacement of brake pads
Master Brake Cylinder — Removal, Installation and Repair
Brake booster vacuum
Brake system — bleeding
Parking brake — adjustment
Brake force regulator
Vacuum pump
ABS system
Car suspension
Suspension specifications
Front suspension
Shock absorber strut — removal, installation and overhaul
Front Wheel Hub and Hub Bearing — Removal
Lower wishbone — removal and installation
Rear suspension — removal and installation
Rear wheel hubs and hub bearing — removal and installation
Drive shafts — removal
Drive shafts — installation
Drive shafts — repair
Drive shaft support bearing
Steering
Steering gear — removal
Steering gear — installation and repair
Neutral position of the steering gear
Tie Rod Ends — Replacement
Wheel alignment angles
Steering wheel — removal and installation
Power steering — draining and filling fluid, bleeding air
Electrical equipment
Equipment and devices
Electrical System Specifications
General description of the electrical system
Battery — Removal, Installation and Checking
Generator general description
Generator — check
Generator — removal and installation
Alternator Belt — Removal
Alternator Belt — Installation
Starter — checking, removal and installation, repair
Lighting — replacement, removal and installation of light bulbs
Windscreen wiper
Instrument panel
Troubleshooting — Introduction
Identifying and troubleshooting generator faults
List of starter faults and their elimination
Electrical circuits
Designation of network consumers on diagrams
List of abbreviations used to designate wire harnesses
Abbreviations used to designate the color of wire insulation
Location of symbols on electrical diagrams
Starter, generator
Fuel injection system Magnetti-Marelli. Engine capacity 1.8 liters
Fuel injection and ignition system. 2.0 liter turbocharged engine
Fuel injection and ignition system Bosch MP3. Engine capacity 2.0 liters with 8 valves
Cooling system. 2.0 liter engine with turbocharger and one
2.0-liter turbocharged engine with two radiator fans. Cooling system
Cooling system. 1.8 liter engine with one radiator fan
Cooling system. 2.0 liter engine with two radiator fans
Starter, generator, preheating system. Diesel engine with a capacity of 1.9 liters
2.1 liter diesel engine. Starter, generator, preheating system.
Cooling system. Diesel engine with a capacity of 1.9 liters with two radiator fans
Cooling system. 2.1 liter diesel engine with two radiator fans
Rear fog lights and fog lamps
Brake lights, reversing lights and additional brake lights
Direction indicator and hazard warning lights
Sound signals
High and low beam
Parking lights
Instrument cluster and cigarette lighter lighting. Switch and threshold lighting
Headlight washer
Windscreen wiper and washer
Rear window wiper and washer
Heating and ventilation
Car air conditioner
Oil pressure monitoring system
Brake pad condition monitoring system
Brake fluid level and parking brake position monitoring system
Fuel system
Electric windows for driver and passenger doors
Electric rear windows
Heated rear window and outside rearview mirrors
Automatically adjustable outside rearview mirrors
3278
Repair manuals:
Peugeot 206
(1998-2012)
Peugeot 207
(2006-2014)
Peugeot 305
(1977-1989)
Peugeot 307
(2001-2008)
Peugeot 405
(1987-1997)
Peugeot 406
(1995-2004)
Peugeot 605
(1989-2000)
Partner I
(1996-2008)
Peugeot 806
(1994-2002)
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Peugeot owners
206
(1998-2012)
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207
(2006-2014)
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305
(1977-1989)
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307
(2001-2008)
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405
(1987-1997)
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406
(1995-2004)
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605
(1989-2000)
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Partner-I
(1996-2008)
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Eurovans-806
(1994-2002)
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