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Peugeot 206 (1998-2012)
General information
User manual
General information about Peugeot 206 cars
Vehicle identification
Starting the engine from an auxiliary source
Jacking up the car
Towing a car and driving with a trailer
Wheel replacement
Controls and instruments
Car keys and ignition lock
Control indicators
Digital and analog control devices
Onboard navigation system
Paddle switches
Parking brake
On-board computer
Electric windows
Headlight corrector
Steering wheel adjustment
Sound signal
Rear view mirrors
Lighting outdoor and indoor
Seat adjustment
Belts and airbags
Central locking
Ventilation hatch
Heating and ventilation
Air conditioning
Additional interior equipment
Manual Transmission
Automatic transmission
ABS anti-lock brake system
Hood opening
Trunk opening
Vehicle break-in
Fuses — location and replacement
Accumulator battery
Electronic anti-theft system
Maintenance
View of the engine compartment and maintenance tools
Optimal maintenance intervals
Applicable engine oils
Maintenance interval
Maintenance of a car with a gasoline engine
Maintenance of a car with a diesel engine without turbocharging
Maintenance of a vehicle 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
Dismantling and assembly of the power unit
Special tools and fixtures for engine disassembly
Engine disassembly
Special tools and fixtures for engine assembly
Engine Assembly
Engine break-in after overhaul
Checking the engine on a car after repair
Cylinder block — design features
Cylinder block — check of technical condition
Connecting rod and piston group — design features
Piston assembly with connecting rod
Camshafts — design description
Removal and installation of a gear belt of the EW10J4 engine
Removal and installation of a camshaft of the EW10J4 engine
Draining and filling coolant
Recommended engine oils and their volumes
Draining the oil with a vacuum pump
Removal and installation of the intermediate muffler on the EW10J4 engine
Removal and installation of the fuel level sensor
Removal and installation of a bulk mouth of a fuel tank
Removal and installation of a protective cap of a cover of a fuel tank
Removal and installation of 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 for DW10 TD and DW10 ATED engines
DW8 engine block
DW10 TD engine cylinder head
DW8 engine cylinder head
Crankshaft — general information
Replacing the crankshaft flywheel
Connecting rod and piston group — design description
Drive belt for auxiliary units of the DW8 engine
Gas distribution mechanism (GRM) — general information
Replacing the timing belt
Removal and installation of a camshaft
Draining and filling coolant
Removing and installing radiator support and fan motor assembly
Recommended engine oils and their volumes
Draining the oil with a vacuum pump
Exhaust gas recirculation system
Exhaust Gas Recirculation Valve DW10 TD
Preheating system — general information
Removing, checking and installing glow plugs
Diesel power system
General information about the power supply system of diesel engines
Removal and installation of the fuel filter of the DW8 engine
Removal and installation of the fuel filter of the DW10 TD engine
Removal and installation of fuel injectors of the DW8 engine
Removal and installation of fuel injectors of the DW10 TD engine
Removal and installation of a regulator of a high pressure of fuel on TNVD
Removal and installation of the fuel distributor
Removal and installation of injection pump
Removal and installation of LUCAS injection pump
Checking and adjusting the injection pump
Turbocharging system — general information
Removal and installation of turbocharger DW10 TD
Engine management system
General information about engine management systems
MAGNETI MARELLI 1AP engine management system
MAGNETI MARELLI 8P engine management system
BOSCH MOTRONIC MP5.2 engine management system
BOSCH MOTRONIC MP7.3 engine management system
Transmission
Clutch
Clutch — description and specifications
Bleeding the hydraulic clutch
Removal and installation of a cable of a drive of coupling
Removal, check and installation of coupling
Clutch drive adjustment
Removal, check and installation of the hydrotransformer
Mechanical gearbox
Technical data and characteristics of the BE4/5 gearbox
Removing the gearbox BE4/5
Installing the gearbox BE4/5
Gearbox tightening torques BE4/5
Removing the MA gearbox
Installing the MA gearbox
Removal and installation of external parts and components of the MA box
Removal and installation of the intermediate housing of the box MA
Removing the primary, secondary shafts and differential box MA
Disassembly and assembly of the input shaft of the MA box
Disassembly and assembly of the output shaft of the MA box
Disassembly and assembly of synchronizers of the MA box
Disassembly and assembly of the MA box differential
Disassembly and assembly of the MA box shift mechanism
Removing and installing gearbox control mechanism MA
Automatic gearbox
Description and characteristics of automatic transmission
Replacement of working fluid AT
Removal and installation of an automatic transmission
Removal and installation of the hydraulic block wiring harness
Removal and installation of the vehicle speed sensor
Removal and installation of the gearbox control mechanism
Adjustment of the gearshift mechanism
Drive shafts
General information about the front wheel drive shafts
Removing and installing front wheel drive (models with automatic transmission)
Removing and installing front wheel drive (models with manual transmission)
Replacing the mudguards on a GKN actuator
Replacing mudguards on a PSA actuator
Chassis, running gear
Front suspension
Wheel alignment
Removal and installation of a shock-absorber rack
Stabilizer transverse stability
Removal and installation of a rotary fist
Removal and installation of the lower suspension arm
Removal and installation of silent blocks
Removal and installation of the bearing of a nave of a forward wheel
Removal and installation of a spring of a shock-absorber rack
Adjustment of a convergence of forward wheels
Rear suspension
General information about the rear suspension
Removal and installation of a beam of a back suspension bracket in gathering
Removal and installation of a bar of the stabilizer of cross-section stability
Removal and installation of the rear shock absorber
Removal and installation of rear suspension torsion bars
Steering
General information about steering
Removal and installation of the steering mechanism
Removal and installation of a steering column
Removing and installing rack support
Removal and installation of a dirt-protective cover
Removal and installation of the ignition switch
Removal and installation of the distributive valve
Draining and filling the power steering hydraulic circuit
Steering control and adjustment
Brake system
Tightening torques for threaded connections
Front disc brakes — description
Rear brakes — description
Removal and installation of front brake pads
Removal and installation of front brake mechanisms BOSCH
Removal and installation of rear disc brake pads BOSCH
Removal and installation of BOSCH rear disc brakes
Removal and installation of rear drum brake shoes BOSCH
Removal and installation of rear drum brake pads LUCAS
Removal and installation of the main brake cylinder
Removal and installation of the vacuum amplifier of brakes
Removal and installation of the pressure regulator
Parking brake control and adjustment
Draining, filling and removing air from the hydraulic brake system
Body and interior
Body elements
General information about the car body
Car body and interior care
Removal and installation of a forward bumper
Replacing the front bumper deflector
Removal and installation of a forward wing
Removal and installation of a cable of opening of a cowl
Removal and installation of a back bumper
Doors, locks and windows
Windshield replacement
Installation and adjustment of the front door
Rear door installation
Adjusting the door lock bracket
Removal and installation of the front door opening mechanism
Removal and installation of the panel of an upholstery of a forward door
Removal and installation of the panel of an upholstery of a back door
Removal and installation of a tailgate
Removal and installation of a jet of a washer of back glass
Removing the door glass
Removing the power window
Electrical equipment
Equipment and devices
Technical data of electrical equipment
Search for a faulty consumer in the electrical system
Short circuit source detection
Removal and installation of the generator
Removal and installation of levers of screen wipers
Removal and installation of the electric drive of a screen wiper of a windscreen
Removal and installation of the electric drive of a screen wiper of a door of a luggage compartment
Relay and fuse box
Electrical circuits
Code designation of elements on electrical diagrams
Wiring diagrams 0 to 10
Electrical diagrams from 11 to 20
Electrical diagrams from 21 to 30
Peugeot 207 (2006-2014)
General information
Car care
Vehicle lifting
Self-service frequency
Bonnet — opening and closing
Fuel system
Refueling a car
Engine oil
Cooling liquid
Windshield washer fluid
Brake and clutch fluid
Refueling volumes
Battery care
Battery replacement
Starting the engine with an additional battery
Care of fuses
Replacing headlight bulbs
Replacement of a lamp in indexes of turns
Replacing the Low Beam Bulb
High Beam Bulb Replacement
Replacing the lamp of daytime running, parking lights
Replacing the side turn signal repeater assembly with a lamp
Replacing the rear lights
Vehicle handling and tires
Reinstallation of wheels
Tires with tread wear indicator
Tread pattern height
Tire pressure check
Spare wheel and car tool
Wheels with decorative caps
Wheel removal
Wheel installation
Towing a car
Key with electronic immobilizer
Unlocking the car
Locking car locks
Finding a car in the parking lot
Anti-theft protection
Initializing the remote control and replacing the battery
Security alarm
Opening doors
Emergency locking and unlocking
Central locking
Tailgate
Window lift care
Dimensions and identification data of the car Peugeot 207
Governing bodies
Control devices, indicators and signaling devices
Odometers and pointers
Liquid crystal display on the instrument cluster
Governing bodies
Oil level indicator
Vehicle speed indicator
Fuel level indicator
Coolant temperature gauge in the engine system
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
Steering wheel adjustment
Exterior mirrors
Interior rear view mirror
Illuminated glove box
Illuminated ashtray and cigarette lighter
Front seats with manual adjustment
Headrest adjustment
Heated seats
Rear seats
Seat belts
Airbags
Luggage compartment (sedan)
Air conditioning with manual control
Luggage compartment (station wagon)
Rear window and mirror heater
Automatic air conditioner
Parking brake
Engine shutdown
Driving and operation
Engine starting
Automatic transmission
On-board tire pressure monitoring system
Anti-lock braking system (ABS) and electronic brake force regulator (REF)
Dynamic Stability Program (ESP) and Traction Control (ASR)
Speed control (cruise control)
Anti-corrosion body protection
Power unit
Engine characteristics
Car maintenance frequency
Identification data
Specifications for petrol and diesel engines
Cylinder head (petrol engines 1.4 and 1.6 l, ERZ, TU5)
Cylinder head (diesel engines 1.6 l)
Timing characteristics (gasoline engines 1.4 and 1.6 l, EP3, TU5)
Timing characteristics (diesel engines 1.6 l)
Camshafts (petrol engines 1.4 and 1.6 l, EP3, TU5)
Camshafts (diesel engines)
Characteristics of the cylinder block (gasoline engines 1.4 l, ERZ)
Characteristics of the block of cylinders (petrol engine 1.6 l, TU5)
Characteristics of the cylinder block (diesel engines 1.6 l)
Characteristics of the valve mechanism (gasoline engines 1.4 and 1.6 l, ERZ, TU5)
Valve Gear Specifications (1.6L Diesel Engines)
Characteristics of the crankshaft (gasoline engines 1.4 and 1.6 l, ERZ, TU5)
Crankshaft specifications (1.6L diesel engines)
Characteristics of the piston group (gasoline engines 1.4 and 1.6 l, ERZ, TU5)
Characteristics of the piston group (diesel engines 1.6 l)
Tightening torques for 1.4 and 1.6 liter petrol engines, ERZ, TU5
Tightening torques for 1.6L petrol engines (EP6 series)
Tightening torques for 1.6 l diesel engines
Engine repair
Conditions for cleaning and reassembling the internal combustion engine
Cylinder Leak Check
Compression measurement
Data for checking the cooling system (all engines)
Data for checking the lubrication system (all engines)
Oil Pressure Check Procedure (EP3, EP6 Gasoline Engines)
Oil Pressure Check Procedure (EP6DT Gasoline Engines)
Oil Pressure Check Procedure (Diesel Engines)
Boost pressure test (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)
Accessory Drive Belt Check (Diesel Engines)
Accessory Drive Belt Replacement (1.6L Diesel Engines)
Timing mechanism (EP6, EP6DT gasoline engines)
Timing drive adjustment (gasoline engines 1.4-1.6 l ERZ, TU5)
Adjustment of the timing drive (petrol engines 1.6 l EP6, EP6DT)
Timing Drive Adjustment (Diesel Engines)
Replacing the timing belt (gasoline engines 1.4 and 1.6 l ERZ, TU5)
Removal and installation of the timing actuator (petrol engines 1.6 l EE6, EP6DT)
Replacing the Timing Chain (1.6L EP, EP6DT Gasoline Engines)
Timing Timing Belt Replacement (1.6L Diesel Engines)
Replacement of camshafts (gasoline engines)
Replacement of camshafts (diesel engines)
Removal and installation of the cylinder head on a car (gasoline 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 car (diesel engines)
Cylinder head repair
Replacing the dual damping flywheel
Repair of the engine block
Assembling the piston group of the engine
Checking the side clearance of the crankshaft
Gasoline internal combustion engine — removal
Gasoline ICE — installation
Diesel engine — removal
Diesel engine — installation
Cooling system
Specifications for Cooling System Components (Petrol Engines)
Cooling system device (petrol engine 1.6 l)
Specifications for 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 output unit (diesel engine 2.0 l)
Replacing the coolant outlet unit (diesel engine)
Replacing the coolant outlet unit (petrol engine)
Installing the Aluminum Coolant Outlet Unit
Installing the coolant outlet block with plastic housing
Removal and installation of the lower branch pipes of a radiator with quick-detachable clamps
Radiator replacement (petrol engines)
Radiator replacement (EP6, EP6DT petrol engines)
Replacing the turbocharger cooling pump (EP6DT engines)
Coolant pump replacement (petrol engines)
Coolant pump replacement (diesel engines)
Fault codes related to the engine cooling system
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 (EP3, EP6 gasoline engines)
Replacing the Engine Oil Level and Temperature Sensor (EP6DT Gasoline Engines)
Replacing the engine oil level and temperature sensor (diesel engine)
Engine Oil Pressure Sensor Replacement (Diesel Engine)
Ignition system
General information about the TU5 gasoline engine ignition system
Ignition system device
Ignition coils (TU5 petrol engine)
Speed and crankshaft position sensor (TU5 petrol engine)
Characteristics of ignition components (TU5 petrol engine)
General information about the ignition system of EP series gasoline engines
Characteristics of Ignition Components (EP Series Gasoline Engines)
Speed and crankshaft position sensor (EP series gasoline engines)
Knock Sensor (EP Series Gasoline Engines)
Camshaft Position Sensors (EP Series Gasoline Engines)
Spark plug
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)
Removing coils and spark plugs
General information about the preheating system
Replacing glow plugs (1.6L engine)
Control system (gasoline)
General information about the Bosch MEV 17.4 injection system
On-Board Diagnostic (EOBD)
Injection control unit «Bosch MEV 17.4»
Fault codes for the Bosch MEV 17.4 injection system
Engine System Interface Block BSM
Fuel system (gasoline)
The device of the fuel system of gasoline engines
Fuel filter
Fuel pump (low pressure)
Pressure regulator
Fuel injectors
Fuel pressure measurement
Cleaning the fittings on the high pressure rail
Leakproofness check
Removal and installation of fuel injectors
Replacing the high pressure sensor (EP6DT engines)
Replacing the fuel pump / fuel level sensor assembly
High pressure fuel pump replacement (EP6DT engines)
Replacing the vacuum pump
Removal and installation of the fuel tank (all engines)
Adsorber in the fuel vapor recirculation system
Canister bleed solenoid valve
Evaporative Emission Sensors
Block diagram of the fuel vapor recirculation system
Intake valve lift phase change mode
Valve opening motor
Intake valve position sensor
Throttle valve
Adsorber replacement
Replacing the canister bleed solenoid valve
Removing the intake manifold and throttle valve (EP3, EP6 engines)
Removing the intake manifold and throttle valve (EP6DT engines)
Removing the heat exchanger (vehicles with automatic transmission AL4)
Exhaust system (diesel engine)
Exhaust system device (gasoline engine)
Removal and installation of an exhaust pipe (petrol engine)
Control system (diesel)
Prohibited Operations When Repairing a Diesel Direct Injection System
Diesel fuel injector code
Reading fault information
Emergency operation
Variable geometry turbocharger diagnostics
Compression test
Checking the high pressure circuit
Cleaning the High Pressure Fuel Pipe Fittings
Checking the low pressure circuit
Checking the air supply system
Removal and installation of nozzles
Removal and installation of the fuel filter
Replacing the charge air temperature sensor
Replacing the camshaft position sensor
Air flow sensor replacement
Replacing the crankshaft sensor
Exhaust gas temperature sensor replacement
Fuel temperature sensor replacement
Removal and installation of a turbocharger air cooler
Removal and installation of injection pump (engine 1.6 l)
Removal and installation of the EGR valve
Removal and installation of a turbocharger (engine 1.6 l)
Replacing Exhaust Gas Temperature Sensors
Diesel particulate filter replacement
Transmission
Clutch
Clutch types
Clutch characteristics
Clutch Diagnostics
Pumping the clutch hydraulic drive
Removal and installation of the clutch mechanism
Removal and installation of the hydraulic clutch control unit
Mechanical gearbox
General information about the transmission
Gearbox BE4/5
Gearbox MA5
Diagnostics of the mechanical elements of the MCP
Gearbox control mechanism
Gearbox control adjustment
Adjustment of a cable of a drive of a choice of transfers KP BE4/5
Removal and installation of the gear change drive
Draining and filling oil in manual gearboxes MA5 and BE4/5
Removal and installation of MCP MA5 and BE4/5
Dismantling of MCP MA5 and BE4/5
Dismantling the clutch housing MCP MA5 and BE4 / 5
Features of the repair of gearboxes with and without the 5th gear / reverse gear inhibit system
Dismantling the input shaft of the manual gearbox MA5 and BE4 / 5
Disassembly of the secondary shaft of the MCP MA5 and BE4 / 5
Dismantling the crankcase of the differential MCP MA5 and BE4 / 5
Assembling the differential of the manual gearbox MA5 and BE4 / 5
Adjustment of the console part of the manual gearbox MA5 and BE4 / 5
Assembly of the secondary shaft of the manual gearbox MA5 and BE4 / 5
Assembly of the input shaft of the manual gearbox MA5 and BE4 / 5
Installing the input and output shafts of the MCP MA5 and BE4 / 5
Assembling the clutch housing MCP MA5 and BE4/5
Features of assembling gearboxes with and without a 5th gear / reverse gear inhibit system
Installing the gearbox housing
Gearbox Assembly
Automatic gearbox
General information about automatic transmission AL4
Electronic transmission control
Tightening torques (automatic gearbox 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
Diagnosis of possible oil leaks in automatic transmission AL4
Assignment of connector pins of automatic transmission computer AL4
Transmission Input Shaft Speed Sensor
Gearbox outlet speed sensor
Transmission 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
Executive element for locking the gear selector lever in the «P» position
Automatic gearbox program selector
Multifunction switch
Stop signal switch
Diagnosis of automatic transmission AL4
Control of electrical connections
Removal and installation of automatic transmission AL4
Removal and installation of the hydrotransformer
Removal and installation of the contactor of position of the gear lever
Removal and installation of the hydroblock and electromagnetic valves
Removal and installation of the computer and oil level and temperature sensor, automatic transmission 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
Driveshaft guards
Interchangeability of drive shafts
Arrangement of protective covers of power shafts
Slip-on bearing for drive shafts
Removal and installation of power shafts
Removing thermoplastic protective covers
Removing neoprene protective covers
Replacing the bearing on the gearbox side
Chassis, running gear
Car suspension
Front axle
Rear axle
Bridge geometry
General characteristics and tightening torques of the front suspension
Front axle mounting angles
General characteristics and tightening torques of the rear suspension
Removal and installation of a rotary fist of a forward suspension bracket
Removal and installation of the lower front arm
Removal and installation of a spherical support of a forward rotary fist
Lower Front Arm Repair
Front steering knuckle repair
Features of front suspension wheel bearings
Removal and installation of the front subframe and frame
Removal and installation of the stabilizer bar
Removal and installation of the front anti-roll bar
Removal and installation of the front shock absorber assembly
Dismantling the front shock absorber (on a workbench)
Removal and installation of a nave of a back wheel
Removal and installation of a pin of a back wheel
Removal and installation of the rear axle
Removal and installation of silent blocks of the rear suspension
Steering
General information about steering
Steering column identification
Tightening torques of steering elements
Steering Specifications
Actuator (power steering electric pump unit)
Power steering pump control unit
Steering angle sensor
Checking pressure in the power steering circuit
Draining fluid from the power steering hydraulic circuit
Filling the power steering hydraulic circuit
Bleeding the hydraulic circuit of the power steering
Removal and installation of a steering wheel
Removal and installation of the steering wheel angle sensor
Removal and installation of steering drafts
Adjustment of the middle position of the rail
Removal and installation of the steering mechanism
Steering rack stop adjustment
Removal and installation of a steering column
Brake system
General information about the brake system
Tightening torques for brake system components
Characteristics of the brake system
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 of the vacuum amplifier
Replacing the brake light switch
Removal and installation of the pedal assembly
Replacing the front brake pads
Removal and installation of the front brake caliper
Removal and installation of a forward brake disk
Replacing the rear brake pads
Removal and installation of a support and a nave of a disk of the back brake mechanism
Repair of the rear brake hub
ABS system — general information
The device of the dynamic stabilization system (ESP)
ESP system — general information
ABS / ESP Diagnostics — Reading Errors (DTCs)
MSR system — trajectory control during deceleration
Removal and installation of the valve body and the ABS/ESP ECU
Removal and installation of the sensor of speed of a forward wheel
Removal and installation of the rear wheel speed sensor
Body and interior
Exterior (external elements)
Body — general information
Doors — general information
Glazing — general information
Replacing the front fender liner
Threshold replacement
Replacing the decorative element of the front wing (Version «Sport» and station wagon)
Front bumper replacement
Replacing deflectors and front bumper pads (versions «Sport» and station wagon)
Disassembly and assembly of the front bumper
Hood replacement
Bonnet lock actuator replacement
Front fender replacement
Rear bumper replacement (3- and 5-door hatchback)
Replacing the rear bumper (station wagon)
Disassembly and assembly of the rear bumper (3- and 5-door hatchback)
Disassembly and assembly of the rear bumper (station wagon)
Tailgate replacement (3- and 5-door hatchback)
Replacing the tailgate (station wagon)
Replacement of a bracket of the lock of a door of a back
Disassembly and assembly of the tailgate (3- and 5-door hatchback)
Disassembly and assembly of the tailgate (station wagon)
Front door replacement
Rear door replacement
Body clearances: 3-door hatchback
Body clearances: 5-door hatchback
Body clearances: station wagon
Interior (internal elements)
Replacing the front seat belt
Replacing the rear seat belt
Center console replacement (3- and 5-door hatchback)
Replacing the center console (station wagon)
Replacing the top bezel of the control panel
Replacing the ventilation grille of the control panel
Glove box lid and lock replacement
Replacing the center bezel of the control panel
Car radio replacement
Glove box replacement
Removal and installation of the control panel
Heating and air conditioning
Technical data of the heating and air conditioning system
Safety measures when working with the air conditioning circuit
Air Conditioning System Checks
Checking the air conditioning compressor
Replacing elements of the air conditioning circuit
Diagnosis of malfunctions of the air conditioning circuit
Oil Change — Fill (A/C Compressor)
Tightening torques
Removing and installing dust filter
Removal and installation of motor reducer and interior fan
Removing and installing the fan control module
Removal and installation of tubes and air conditioning compressor
Removal and installation of the fan of an oven of a heater
Removal and installation of temperature sensors supplied to the cabin air
Removal and installation of a heater radiator
Removal and installation of the condenser
Removal and installation of a pulley and coupling of the compressor of the conditioner
Electrical equipment
Equipment and devices
Removal and installation of steering column switches
Switching unit BSI 1
Diagnostic connector (C001)
CANIS network
CAN CAR network
CAN CONFORT network
Diagnosis of control systems for opening body elements
Fault codes for the opening body control system
Re-synchronization of the remote control
Diagnosis of the rear-view mirror control system
Diagnostics of the power window control system
Fault codes associated with the rear-view mirror control system
Fault codes associated with the power window control system
Diagnostics of the wiper and washer control system
Instrument Cluster Diagnosis
Removal and installation of the switching unit BSI 1
Removal and installation of a combination of devices
Removal and installation of an external rear-view mirror and a lateral repeater of turns
Dismantling the outside rear-view mirror
Removal and installation of the mechanism of a forward screen wiper
Removal and installation of the mechanism of a back screen wiper
Headlights and lighting
General information about the lighting system
Understeering's shifter
Controlled headlights
Automatic activation of hazard warning lights
Dual light and rain sensor
Electrical characteristics of the light and rain sensor
Teleloading — general information
Malfunction of the sensor of illumination at the included function of automatic control of light of headlights
Headlight beam adjustment (normal lighting)
Diagnostics of outdoor lighting
Headlight Assembly Replacement
Replacing and adjusting the front fog lights
Emergency operating modes
Fault codes associated with the outdoor lighting system (BSI 1 switch box)
Fault codes related to the exterior lighting system (BSM engine junction box)
Fault codes associated with the operation of the rain sensor and the brightness of outdoor lighting
Replacing the rear combination lamp (hatchback)
Replacing the rear combination lamp (station wagon)
Replacement of a lantern of an additional brake light (hatchback)
Replacement of a lantern of an additional stoplight (station wagon)
Removal and installation of the front lighting control unit and alarm sensor (hatchback)
Removal and installation of the front lighting control unit and alarm sensor (station wagon)
Removal and installation of the sensor of a rain and illumination and an internal rear-view mirror
Power devices
Battery marking
Checking the electrolyte level
Battery test methods
Charging batteries
Disconnecting the battery
Checking the power supply system and electricity consumers
Generator — general information
Accessory drive belt
Checking the generator mountings
Alternator and battery circuit checks
Alternator pulley replacement
Replacing the voltage regulator
Removal and installation of the generator (gasoline engines)
Removal and installation of the generator (diesel engines)
Starter — general information and device
Starter check
Removal and installation of a starter (gasoline engines)
Removal and installation of a starter (diesel engines)
Fault codes related to the interior lighting system (BSI 1 switch box)
Electrical circuits
Symbols used on electrical equipment diagrams
ECU location (hatchback and station wagon)
General location of ground connection points
Starting and charging system (petrol engines)
Starting, charging and preheating system (diesel engines)
Preheating and afterheating (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 gearbox)
Electronic fuel injection system (EP6DT engine)
Preheating fuel injection system (DV6 engine without particulate filter)
Preheating fuel injection system (DV6 engine with particulate filter)
Engine cooling TU5JP
Engine cooling EP3
Engine cooling EP6 with automatic transmission
Engine cooling EP6 with manual gearbox
Engine cooling EP6DT
DV6 engine cooling without particulate filter
DV6 engine cooling with particulate filter
Automatic gearbox (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 warning light)
Instrument cluster (seat belt warning light)
Instrument cluster (outside temperature)
Electric power steering
Airbags and pyrotechnic belt tensioners
Stability System
Vehicle speed limiting system
Tire pressure detection system
Parking assistance
Central electric lock without superlock
Central electric lock with super lock
Engine Immobilizer
Security alarm
Ventilation and heating system
Air conditioning with manual control
Air conditioning with automatic control
ESP system with ABS function
Headlights (low and high beam)
Wiring diagram for headlight washers
Headlight range control (normal light)
Headlight range control (adaptive light)
Fog lights
Reversing lights (vehicles with automatic transmission)
Reversing lights (vehicles with manual gearbox)
Stoplights
Turn signal lights of the emergency alarm
License plate lights
Interior lighting
Windscreen wipers
Rear wiper — windshield washer
Power window wiring diagram
Electrically operated rear-view mirrors (without folding function)
Rear-view mirrors with electric drive (folding)
Power rear window and exterior mirrors (automatic air conditioning)
Dust filter (DV6 engine with particulate filter)
Sunroof wiring diagram
Electric heated seats
Cigarette lighter — ashtray light
Wiring diagram for analog clock
Peugeot 305 (1977-1989)
General information
Maintenance
General description of the car Peugeot 305
Dimensions, weight and filling data
Ongoing maintenance
Recommended lubricants and fluids
Engine Troubleshooting
Engine Compartment — Maintenance Components
Power unit
Gasoline engines
Specification of gasoline engines
General description of gasoline engines
Sleeve Seal Modifications (XL/XR Series Engines)
Main cover side bolts (XR5S engine)
Timing Housing Seal (All Models)
XU Series Engine — General Description
Basic operations possible without removing the engine from the machine
Basic operations requiring removal of the engine from the machine
Engine and transmission — removal
Engine disassembly — general part
Engine Disassembly — Accessories
Removal with gearbox (XU series engine)
Disconnecting the gearbox from the XU series engine
XU Series Engine Disassembly
Cylinder head — removal from the engine standing on the machine
Cylinder liner protrusion — checking and adjusting
Cylinder Head Disassembly (XU Series Engines)
Cylinder head resurfacing (XU series engines)
Cylinder head — installation on the engine standing on the machine
Cylinder Head Assembly (XU Series Engines)
Timing mechanism — removal
Engine and transmission — disconnection
Cylinder head — removal from the engine located on the desktop
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 alignment
Cylinder Liners — Inspection and Tidying
Connecting rods, pistons and piston rings — inspection and tidying
Timing chain and sprockets — inspection and tidying
Camshaft and Rockers — Inspection and Tidying
Oil pump — inspection and tidying up
Intake and exhaust manifolds — inspection
Engine Mounts — Inspection
Engine assembly — general part
Engine — preparation for assembly
Inspection and alignment of XU engine parts (general)
XU Series Engine Assembly
Connecting the XU engine to the gearbox
Installing the XU engine with gearbox on the machine
Crankshaft — installation
Pistons, connecting rods and cylinder liners — installation
Cylinder head — installation on the engine removed from the machine
Engine and gearbox — connecting to each other
Sprocket and Timing Chain — Assembly
Timing cover — assembly and installation
Valve clearances — checking and adjusting
Clutch — Installation
Engine assembly — final operations
Engine and Transmission — Installation
Checking Valve Clearances (XU Series Engines)
Valve Clearance Adjustment (XU Series Engines)
Removal and installation of the camshaft drive belt (the engine is on the machine)
Removal and installation of the camshaft (the engine is on the machine)
Removal and installation of the cylinder head (the engine is on the machine)
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 Troubleshooting
Diesel engines
Diesel engine specification
General information about diesel engines
Ongoing maintenance
Basic operations possible without removing the engine from the machine
Timing belt — inspection, removal, installation and tension
Timing belt tensioner and right engine support bracket — removal and installation
Timing belt intermediate roller — removal and installation
Cylinder head — disassembly, alignment and assembly
Cylinder Head Bolt Identification and Tightening — All Models
Cylinder Head and Pistons — Decarbonizing
Oil 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 mountings — removal and installation
Engine — Removal Method
Engine and transmission — removal
Engine and transmission — 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 putting it in order — the general part
Engine Parts — Inspection and Tidying
Engine assembly — general part
Engine — complete assembly
Engine and gearbox — connecting to each other
Engine and Transmission — Installation
First engine start after overhaul
Engine Troubleshooting
Cooling system (gasoline)
Cooling system specification
General description of the cooling system
Draining the coolant
Flushing the cooling system
Filling 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)
Diagnosis of malfunctions of the cooling system
Cooling system (diesel)
Cooling system specification
General description of the cooling system
Ongoing maintenance
Pressure test cooling system
Draining the coolant
Flushing the cooling system
Filling coolant
Radiator — removal and installation
Thermostat — removal, inspection 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
Carburettors (Latest Models) — Description
Carburetor — Maintenance
Carburetor — regulation
Carburetor — adjusting the upper position of the float
Carburetor — accelerator pump (check and adjustment)
Carburetor — removal and installation
Carburetor — disassembly, tidying up and assembly
Gas pedal cable — removal and installation
Choke cable — removal and installation
Fuel tank — general information
Intake air heating system
Gas exhaust system — general information
Diagnostics of malfunctions of fuel and exhaust system
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
High pressure fuel pump — removal and installation
High-pressure fuel pump (Lucas CAV / Roto-Diesel) — checking and adjusting the injection moment
High-pressure fuel pump (Bosch) — checking and adjusting the injection moment
Fast idle cable — removal, installation and adjustment
Gas pedal cable — removal, installation and adjustment
Idle speed — check and adjustment
Lucas CAV/Roto-Diesel Fuel Pump — Minimum RPM Control
Bosch injection pump manufactured since January 1984 — minimum speed regulation
Maximum engine speed — check and adjustment
Fuel injectors — removal, inspection and installation
Starting heater — description and check
Relay and spark plugs — removal and installation
Shut-off solenoid — description, removal and installation
Injection system — pumping
Injection system (latest models) — pumping
Fuel level sensor (405 models) — check
Interruptions in the operation of the XUD9 engine (405 models with CAV / Roto-Diesel injection pump) — causes
Collectors — removal and installation
Turbocharger — Description
Turbocharger — Precautions
Turbocharger — removal, inspection and installation
Gas exhaust system — inspection, removal and installation
Diagnosis of malfunctions of the injection system
Ignition system
Ignition system specification
General description of the contact ignition system
Breaker contacts — preliminary clearance adjustment
Contact closed angle — regulation
Breaker contacts — removal, tidying up and installation
Capacitor — removal, inspection and installation
Trambler — lubrication
Trambler — removal and installation
Trambler — bulkhead
Setting scale — checking and adjusting
Ignition timing — regulation
Spark Plugs and High Voltage Wires — General
Diagnostic socket
T.M.T. sensor — removal, installation and adjustment
Diagnostics of malfunctions of system of ignition
Electronic (non-contact) ignition system
Transmission
Clutch
Clutch specification
General description of clutch
Clutch — regulation
Clutch cable — removal and installation
Clutch — removal
Clutch — inspection and tidying up
Clutch — Installation
Removal, inspection and installation of the clutch (XU engines)
Drive gear and oil seals — removal and installation
Removal and installation of the clutch release mechanism (XU series engines)
Clutch Troubleshooting
Mechanical gearbox BB8
Gearbox specification
General Description of BB8 Manual Transmission
Gearbox — removal
Gearbox — disassembly
Gearbox — Inspection
Gearbox — Assembly
Connecting the gearbox to the engine
Engine and transmission — installation on the machine
Differential seals — removal and installation
Gear Shift Lever — Overhaul and Adjustment
BB8 Transmission Fault Diagnosis
Mechanical gearbox BE1
Gearbox specification
General Description of BE1 Manual Transmission
Ongoing maintenance
Gearbox — removal and installation
Adjustment of the gearshift 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
Transmission (5-Speed) — Assembly
Transmission (4-Speed) — Assembly
BE1 Transmission Fault Diagnosis
Automatic gearbox ZF4
ZF4 HP14 gearbox specification
General Description of ZF4 HP14 Automatic Transmission
Ongoing maintenance
Changing the transmission fluid filter
Downshift cable adjustment (kickdown)
Downshift cable replacement
Gear selector adjustment
Adjusting the brake band
Transmission fluid radiator — removal and installation
Automatic transmission — removal and installation
Replacement of an epiploon of the hydrotransformer
Starter lock/reverse light switch (general information)
Diagnostics of malfunctions of an automatic transmission
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 Joints — Maintenance
Front hubs (after 1983 models) — removal and installation
Rear wheel bearings — removal and installation
Rear wheel bearings (latest models) — removal and installation
Wheels and tires — general information and maintenance
Diagnosis of malfunctions of drive shafts
Chassis, running gear
Brake system
Brake system specification
General description of the braking system
Ongoing maintenance
Bleeding the brake system
Bleeding the brakes (all latest models)
Brake regulation
Disc brake pads — inspection and replacement
Removal and installation of pads of forward disk brakes on models of release after 1983
Disc brake calipers — removal, reassembly and installation
Rear brake drums — removal and installation
Rear brake pads — removal, inspection and installation
Rear wheel cylinders — removal, reassembly and installation
Brake discs and drums — tidying up by grinding
Hydraulic tubes — inspection and replacement
Master cylinder — removal, reassembly and installation
Vacuum servo booster — removal and installation
Vacuum servo booster — bulkhead
Brake compensator — general information
Handbrake — general information
Diagnostics of malfunctions of the brake system
Car suspension
Suspension and steering specification
General description of the suspension and steering
Ongoing maintenance
Suspension and steering — check and review
Front Suspension on Models since 1983 — Description
Front anti-roll bar — removal and installation
Front Anti-roll Bar Middle Mount — Bulkhead
Front Anti-roll Bar Alignment (Models with XU Engines)
Front pillar — removal and installation
Installing the front strut shock absorber cartridge (models produced before 1983)
Removal and installation of a forward rack (models of release since 1983)
Front suspension strut — bulkhead
Rear pillar — removal and installation
Removal and installation of a shock-absorber of a back rack (Estate models)
Rear suspension 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 of the steering mechanism on models with XU engines
Power steering — general information
Front wheel alignment
Suspension and steering fault diagnosis
Body and interior
Exterior (external elements)
General description of the body
Hinges, Door Latches and Locks — Maintenance
Bonnet 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 of an emphasis of a cover of a luggage carrier (models Saloon)
Removal and installation of a tailgate (Estate models)
Front 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 of seats
Seat belts — description and maintenance
Front seat belt anchor modifications (all models)
Glove box latch repair (pre-1983 models)
Torpedo — removal and installation
Windshield — removal and installation
Cabin heater — removal and installation
Removal and installation of a heater (models of release since 1983)
Plastic parts
Electrical equipment
Equipment and devices
Specification of electrical equipment
General description of electrical equipment
Fuses — location and purpose
Removal and installation of the electric motor of a cleaner of back glass (Estate models)
Removal and installation of a nozzle of a washer of back glass (Estate models)
Dashboard — removal and installation
Removal and installation of the dashboard on production models from 1983
Low Oil Alarm System (1985 Models) — Description
Removal and installation of a rheostat of a blower of a heater of salon
Heater blower control unit (models since 1983) — description and verification
Central locking system — description
Power windows — description
Windscreen wiper brushes — removal and installation
Windshield wiper leashes — removal and installation
Windshield Wiper Mechanism — Diagnosis and Troubleshooting
Windshield wiper mechanism — removal and installation
Windshield washer — general information
Beep — Diagnosis 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 malfunctions of electrical equipment
Headlights and lighting
Headlights — removal, replacement of lamps and installation
Headlights — regulation
Headlight position control depending on the load (Estate models) — description and bulkhead
Muted (daytime) dipped headlights
Rear Combination Lamp — Bulb Replacement
Front Position Lights and Direction Indicators — Bulb Replacement
Rear license plate lamps — removal and installation
Interior interior lighting lamps — removal and installation
Power devices
Battery — removal and installation
Battery — Inspection and Maintenance
Battery — electrolyte replacement
Battery — Charging
Generator — general description
Generator — Maintenance
Generator — Special Precautions
Generator — removal and installation
Alternator Drive Belt — Tension Control
Alternator drive belt — replacement
Generator brushes — removal, inspection and installation
Replacing brushes on a generator with a built-in voltage regulator
Checking the alternator on the machine (all models)
Starter — general description
Starter — checking on the engine
Starter — removal and installation
Starter — disassembly and assembly
Electrical circuits
Key to wiring diagrams (Fig. 10.15-10.18)
The key to the wiring diagrams of the latest models (Fig. 12.119-12.131)
The key to the wiring diagrams of the latest models (Fig. 12.132-12.138)
Pic. 10.15. Wiring Diagram — Models GL and GR
Pic. 10.16. Wiring Diagram — Models GL and GR
Pic. 10.17. Wiring Diagram — SR Models
Pic. 10.18. Wiring Diagram — SR Models
Pic. 12.119. Central Locking System Wiring Diagram (Typical)
Pic. 12.120. Wiring diagram of the central locking system with unlocking and locking the doors without using a key
Pic. 12.121. Wiring diagram for 1979 and 1980 GL models
Pic. 12.122. Wiring diagram for Saloon and GL models 1980 and 1981
Pic. 12.123. Wiring diagram for Saloon and GL models since 1981
Pic. 12.124. Wiring diagram for GR and SR models 1979 and 1980
Pic. 12.125. Wiring diagram for GR and SR models 1980-1982
Pic. 12.126. Wiring diagram for SR models since 1983
Pic. 12.127. Wiring diagram for S models since 1981
Pic. 12.128. Wiring diagram for GT models since 1983
Pic. 12.129. Wiring diagram for Estate and Van models before 1981
Pic. 12.130. Wiring diagram for Estate (except SR) and Van models since 1981
Pic. 12.131. Wiring diagram for GL and GR models 1986
Pic. 12.132. Wiring diagram for Estate and Van models 1986
Pic. 12.133. Wiring diagram for GL and GR models 1986
Pic. 12.134. Wiring diagram for GL and GR models 1987
Pic. 12.135. Wiring diagram for Estate and GTX models with automatic transmission 1986
Pic. 12.136. Wiring diagram for Estate and GTX models with automatic transmission 1987
Pic. 12.137. Wiring diagram for GTX models
Pic. 12.138. Wiring diagram for GT models with automatic transmission
Pic. 12.139. Wiring diagram for dipped beam system
Wiring diagrams (diesel)
Pic. 7.2. The electrical circuit of the car Peugeot 305 until 1985 release
Pic. 7.3. Wiring diagram of a Peugeot 305 after 1985 release
Pic. 7.4. Additional wiring diagram for a Peugeot 305 Estate after 1985
Instructions for working with wiring diagrams
Pic. 8.36. Wiring diagram (205 models): Typical arrangement of starting system, charging system...
Pic. 8.37. Wiring diagram (309 models): Typical arrangement of starting system, charging system...
Pic. 8.38. Wiring diagram (405 models up to 1992): The device of the starting system, charging system...
Pic. 8.39. Wiring diagram (405 models since 1992): The device of the starting system, charging system...
Peugeot 307 (2001-2008)
User manual
Keys, doors and alarm
Introduction to the operation and repair manual Peugeot 307
Car keys
Central electric lock
Remote control
Locking locks
Full blocking of locks
Unlocking locks
Electronic anti-theft system
Identification card of the anti-theft system
Enabling and disabling the anti-theft system
Enabling only the car perimeter control function
Automatic activation of the anti-theft system
Finding your car in the parking lot
Replacing the remote control battery
Remote control initialization
Opening and closing doors
Rear luggage compartment door
Controls and instruments
Controls, instruments and equipment
Control devices
Egnition lock
Steering column switch for direction indicators and headlights
Automatic operation of lighting and light signaling devices
Steering column wiper and washer switch
Headlight corrector
Emergency light signaling
Steering column adjustment
Electric windows
Air vent (on three-door cars)
Electrically operated exterior mirrors
External rear-view mirrors with manual adjustment
Interior rear view mirror
Ceiling lamps for interior lighting
Sun visors with vanity mirror
Ceiling console
Heating and ventilation — general information
Heating and ventilation controls
Air conditioning controls
Auto Air Conditioning Controls
Car Radio Controls
Control of car radios from the steering column switch
Control of the car radio from the front panel
Driving and operation
Automatic transmission «Tiptronic-system Porsche»
Parking brake
Anti-lock braking system (ABS)
Traction Control (ASR) and Dynamic Stability Program (ESP)
Cruise control system
Stationary parking assistance system
Front seats — adjustment
Folding the rear seats
Seat belts — adjustment and check
Airbags — general information
Front airbags
Deactivating the front passenger airbag
Monitoring the serviceability of the airbag
Side and window airbags
Sliding Roof Panel
Fuel tank cap
Bonnet — opening and closing
Engine compartment — inspection and safety measures
Towing a car
Towing a truck, caravan or boat
Wheel replacement and features of their operation
Maintenance
Types and frequency of maintenance
Distance indicator until the next maintenance
Service Intervals and Consumable Replacement Timing
Maintenance interval
List of maintenance work
Engine oil — check and change
Brake fluid and clutch level
Brake fluid and its replacement
Coolant level
Power Steering Reservoir
Windshield and headlight washer reservoir
Accumulator battery
Air filter and cabin dust filter
Front brake pads
Parking brake
Manual Transmission
Automatic transmission
Fuel — control and refueling
Exhaust system check
Checking the tightness of the hoses
Checking the condition of the auxiliary drive V-ribbed belt
Checking the mudguard of the wheel drive shaft
Visual inspection of the gearbox for tightness
Checking the front suspension and steering
Checking the mudguards of the front suspension joints
Shock absorber check
Radiator check
Wiring check
Checking the brake hoses
Wiper blades
Power unit
Petrol engines TU3 and TU5
General information about TU3JP and TU5JP4 engines
Removal and installation of the engine
Cylinder head — removal and installation
Camshafts — removal and installation
Accessory drive belt
Toothed belt — removal and installation
Changes in the details of the timing drive of the TU3JP engine
Lubrication system — removal, inspection and installation
Coolant replacement
Water pump — removal and installation
Power System — Design Description
Exhaust gas exhaust system
Petrol engines EW10
General information about gasoline engines EW10J4
Engine data and tightening torques
Removal and installation of the engine
Engine disassembly
Checking the crankshaft
Piston check
Engine assembly
Cylinder head — removal and installation
Accessory drive belt
Toothed belt — removal and installation
Lubrication system — design description
Changing and checking engine oil
Engine Oil Pressure Check
Cooling system — design description
Coolant replacement
Water pump — removal and installation
Power System — Design Description
Exhaust gas exhaust system
Diesel engines DV10
Engine data and tightening torques
Checking compression in the engine cylinders
Removal and installation of the engine
Cylinder head — removal and installation
Accessory drive belt
Toothed belt — removal and installation
Lubrication system — design description
Cooling system — design description
Coolant replacement
Water pump — removal and installation
Power system — general information
Integrated air supply 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 exhaust system
Diesel engines DW10
Engine data and tightening torques
Checking compression in the engine cylinders
Removal and installation of the engine
Cylinder head — removal and installation
Accessory drive belt
Toothed belt — removal, inspection and installation
Lubrication system — general information and pressure check
Coolant replacement
Water pump — removal and installation
Fuel System — Safety Measures
Fuel distributor (Common Rail) — removal and installation
Fuel injectors — removal and installation
Fuel filter — removal and installation
SIEMENS high pressure fuel pump
Turbocharger — description, removal and installation
Exhaust gas recirculation (EGR) valve
Exhaust gas exhaust system
Transmission
Clutch and drive shafts
General information about the clutch
Replacing the hydraulic clutch
Clutch Disc Replacement
General information about drive shafts
Replacement of half shafts
Replacement of constant velocity joints
Replacement of the intermediate bearing of the right semiaxis
Mechanical gearbox
General information about manual transmission
Technical data of manual transmissions
BE4R gearbox replacement
MA gearbox replacement
BE4R gearbox housing replacement
BE4R gearbox differential housing replacement
Replacing the differential box
Replacing the gearshift mechanism
Checking the level and changing the oil in the gearbox
Automatic gearbox
General information about automatic transmission
Specifications of automatic transmission
Oil aging counter
Precautions for the operation and repair of an automatic transmission
Automatic transmission diagnostics
Replacing the automatic transmission AL4
Replacing the Gear Selector
Replacing the multifunction switch
Replacement of a sealing ring of a shaft of the lever of a choice of transfers
Replacement of sealing rings of semiaxes
Replacing the sealing ring of the torque converter converter
Exchanger replacement
Checking the level and changing the oil in the gearbox
Chassis, running gear
Front suspension
General information and front suspension design
Specifications of the front suspension
Replacing the suspension strut
Disassembly and assembly of the shock absorber strut
Steering knuckle replacement
Front wheel bearing replacement
Steering knuckle ball joint replacement
Lower wishbone replacement
Replacing the front anti-roll bar
Car suspension adjustment — general information
Car front suspension adjustment
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
Replacement of the forward hinge of a beam of a back suspension bracket
Replacing the rear wheel hub
Replacing the hub assembly with bearing and axle
Car rear suspension adjustment
Steering
General information about steering
Steering Specifications
Steering column replacement
Steering gear replacement
Replacing the rack stop
Rack stop adjustment
Control valve replacement
Replacement of a protective cover of steering draft
Tie rod replacement
Power Steering Electric Pump Assembly Replacement
Replacing fluid and removing air from the power steering hydraulic circuit
Front wheel alignment
Brake system
General information about the brake system
Specifications of the brake system
Replacing the master brake cylinder
Replacing the vacuum brake booster
Replacing the front brake pads
Replacing the front brake caliper
Replacing the rear brake pads
Replacing the rear brake caliper
Brake disc replacement
Stoplight Switch Replacement
Parking brake adjustment
Brake Fluid Replacement
Removing 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 body protection
Body dimensions and clearances
Aluminum alloy hood
Front bumper replacement
Replacing the front bumper cover
Rear bumper replacement
Replacing the rear bumper cover
External mirror replacement
Exterior mirror glass replacement
Replacing moldings
Front fender replacement
Gap adjustment between front fender and front door
Windshield replacement
Rear window replacement
Interior (internal elements)
Replacing the center ceiling console
Replacement of the instrument panel assembly
Replacement of a covering of the panel of devices
Replacing the central part of the instrument panel
Center console replacement
Replacing the lower center of the instrument panel
Glove box lock replacement
Front seat replacement
Seat back recline cable replacement
Rear seat replacement
Replacing upholstery panels
Doors, locks and windows
Front door replacement
Replacing the front door panel
Replacing the upholstery of the front door
Replacing the front door lock
Replacing the front door lock cylinder
Front door glass replacement
Rear door upholstery panel replacement
Replacing the rear door lock
Rear door glass replacement
Peugeot 307 tailgate replacement
Peugeot 307 SW tailgate replacement
Tailgate upholstery replacement
Replacing the outer tailgate handle
Replacing the tailgate lock
Replacing the Sliding Roof Panel Assembly
Replacing the sunroof deflector
Heating and air conditioning
Air Conditioning Safety Precautions
Replacing the front panel of the air conditioner
Replacing the cabin air temperature sensor
Replacing the outdoor temperature sensor
Replacing the air conditioning unit
Replacing the gearmotors of the distributor and air flow mixer
Replacing the heater fan resistor
Heater Radiator Replacement
Replacing the additional heating resistor (diesel DW10)
Air conditioner evaporator replacement
Electrical equipment
Equipment and devices
General information about electrical equipment
Electrical circuits — general information
Fault detection in an electrical circuit
Fuses — description, location and replacement
Smart Junction Box — Removal and Installation
Headlights — removal and installation
Rear light replacement
Replacing the upper brake light
Replacing the license plate light
Replacing outdoor lamps
Replacing the instrument cluster
Replacing the steering column switch COM 2000
Replacing the ignition switch
Replacing the multifunction display
Replacing the brightness sensor
Windshield wiper replacement
Wiper blade replacement
Replacing the rear window wiper motor
Replacing the power window of the front door
Replacing the power window rear door
Replacing the power window of the rear door (station wagon SW)
Sliding Roof Motor Replacement
Replacing the sunshade motor
Car radio replacement
Front Door Speaker Replacement
Rear speaker replacement
Replacing the radio antenna
Power devices
Battery — general information
Battery maintenance
Checking the electrolyte level in the battery
Checking the density of the electrolyte in the battery
Charging the battery
Battery aging control
Replacing the battery
Starting the engine from an additional battery
General information about the generator
Generator Safety Precautions
Checking the charging system
Generator replacement
General information about the starter
Starter Replacement
Airbags
General information about airbags
Deactivation of the centralized airbag system
Driver airbag replacement
Front Passenger Airbag Replacement
Side airbag replacement
Replacing the airbag control unit
Replacing the acceleration sensor
Electrical circuits
Code designation of elements on electrical diagrams
Wiring diagrams 1 to 5
Wiring diagrams 6 to 10
Electrical diagrams from 11 to 15
Electrical diagrams from 16 to 20
Electrical diagrams from 21 to 25
Electrical diagrams from 26 to 30
Electrical 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
Front seat and head restraint adjustment
Folding the rear seats
Dashboard
Lighting and signaling
Headlight corrector
Washers and glass cleaners
Optional equipment
Ensuring comfort
Internal heating and ventilation
Heating and ventilation switches
Instrument clusters
Starting a gasoline engine
Diesel engine start
Control lights and pointers
Steering wheel, shifting and brake
Automatic transmission
Wheel replacement
Towing a car
Vehicle identification
Maintenance
Vehicle Specifications
Maintenance interval
Maintenance intervals (up to 1994 release)
Maintenance intervals (since 1994)
Diesel fuel filter dehydration (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 tension of the V-belt (10,000 km / 6 months)
Checking the auxiliary drive belt (10,000 km / 6 months)
Removal, installation and adjustment of the wedge drive belt (10,000 km / 6 months)
Power steering pump (XU9J4) (10000 km/6 months)
Checking the hoses of the crankcase ventilation system (20,000 km / 12 months)
Fuel filter replacement (20,000 km/12 months)
Check idle speed and composition of the mixture (CO) (20000 km / 12 months)
Replacement of spark plugs (20,000 km / 12 months)
Checking, adjusting and lubricating the clutch (20,000 km / 12 months)
Check of a condition of a protective cover of a power shaft (20000 km/12 months)
Checking the condition of the front and rear brake pads (20,000 km / 12 months)
Checking and adjusting the hand brake (20,000 km / 12 months)
Suspension condition check (20000 km/12 months)
Checking drainage holes (20,000 km/12 months)
Lock hinge lubrication (30,000 km / 18 months)
Checking the air conditioner (30,000 km / 18 months)
Coolant change (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 change (40,000 km/2 years)
Checking the oil level in the gearbox (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 gasoline engine — design description
Technical characteristics of engines 1.4 liters
Checking and adjusting valve clearance
Checking and adjusting the ignition timing
Carburetor adjustment
Removing the air filter
Removing the cylinder head
Installing the cylinder head
Removal and installation of the power unit
Features of disassembling a 1.4 liter gasoline engine
TU3 engine disassembly
Dismantling of a head of the block of cylinders
Cylinder head assembly
Determining the size of the inserts
TU3 engine assembly
Removing the oil pump
Oil pump disassembly
Removing the coolant pump
Petrol engines 1.6-2.0 l
Gasoline engines 1.6-2.0 l — design description
Technical characteristics of engines 1.6-2.0 liters
Repair without removing the engine
Cylinder compression check
Checking and adjusting valve clearance
Camshaft drive belt
Toothed belt pulleys
Replacing the camshaft seal
Replacing the crankshaft seals
Alternator drive belt
Air Filter — Carburetor Models
Cylinder head cover — removal and installation
Camshaft — removal, inspection and installation
Removal and installation of a head of the block of cylinders
Dismantling, repair and assembly of the cylinder head
Removing the engine with a manual transmission
Removing the engine with automatic transmission
Engine installation
Engine disassembly
Cleaning and checking parts before assembly
Crankshaft — assembly and installation
Connecting rod-piston assembly — assembly and installation
Assembling the connecting rod-pin-piston assembly — assembly and installation
Starting the engine after a major overhaul
Diesel engines
Diesel engines — design description
Specifications of diesel engines
Checking and adjusting valve clearances
Removal and installation of the high pressure fuel pump
BOSCH high pressure fuel pump installation
Roto Diesel High Pressure Fuel Pump Installation
Removing water from the fuel filter
Bleeding air from the fuel system
Removal and installation of the nozzle
Checking the electrically controlled engine stop valve
Bosch pump adjustment
Adjustment of the Roto Diesel pump
Removal and installation of a turbocharger
Removing the camshaft timing belt
Installation of a gear belt of a drive of a camshaft
Removing the cylinder head
Installing the cylinder head
Cylinder head repair
Removing the diesel engine
Diesel engine installation
Diesel engine disassembly
Diesel engine assembly
Oil pump — removal and installation
Ignition system
Contactless ignition system
Ignition coil — removal and installation
Ignition booster module
Removal and installation of the distributor of ignition
Dismantling and assembly of the Ducellier distributor
Dismantling and assembly of the Bosch distributor
Setting the ignition timing
Checking the centrifugal governor in a car
Checking the vacuum regulator in a car
Composite ignition system (ignition/fuel system)
Ignition coil (composite ignition)
Ignition booster module (composite ignition)
Removing the ignition distributor (composite ignition)
Installing the ignition distributor (composite ignition)
Direct ignition system
Ignition coil (direct ignition)
Ignition Amplifier 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 of the carburetor
Dismantling the carburetor
Carburetor operation
Carburetor adjustment
Launcher OVAD
Aftercooling of the engine
Intake manifold — removal and installation
Exhaust manifold — removal and installation
Single point fuel injection
Single point fuel injection systems
Relieve pressure in the fuel system
Accelerator cable adjustment
Fuel pump — removal and installation
Injector — removal and installation
Checking the fuel injection system
Elements of the Fenix injection system
Elements of the Bosch Monopoint injection system
Elements of the Magneti Marelli injection system
Multipoint fuel injection
Multipoint 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
Elements of the Bosch L3.1-Jetronic injection system
Elements of the Bosch LU2-Jetronic injection system
Elements of the Bosch Motronic injection system
Elements of the Magnetti Marelli injection system
Intake manifold — removal and installation
ACAV air supply system (models with 16 valves)
Cooling and lubrication system
Coolant drain (diesel)
Filling coolant and bleeding (diesel)
Removal and installation of the pump of a cooling liquid (diesel)
Oil pan — removal and installation
Oil pump — removal, inspection and installation
Oil cooler — removal and installation
Oil pressure check
Cooling system — design description
Coolant hoses
Radiator — removal, inspection and installation
Thermostat — removal, inspection and installation
Radiator cooling fan — removal, inspection and installation
Coolant pump — removal and installation
Coolant drain
Filling the coolant and removing air from the system
Exhaust system
Exhaust System (Diesel)
Exhaust system — design description
Exhaust system — removal and installation
Emission Control System
Blow-by gas emission control
Exhaust Gas Control
Fuel vapor control
Emission control system
Catalyst — general information
Transmission
Clutch
Clutch — design description
Clutch specifications
Replacing the disc or the leading part of the clutch
Clutch control adjustment
Clutch cable replacement
Clutch release mechanism — removal, inspection and installation
Manual gearbox MA
Mechanical box type MA — description of the design
Removal and installation of the gearbox type MA
Gearbox disassembly
Disassembly of the secondary and primary shaft
Differential disassembly
Disassembly of the fork assembly with their axles
Disassembly of the synchronizer sleeve
Verification of gearbox parts
Assembly of the synchronizer sleeve
Assembling the fork assembly with their axles
Differential Assembly
Input shaft assembly
Output shaft assembly
Gearbox Assembly
Manual gearbox BE
Manual transmission general information
BE Manual Transmission Specifications
Changing the oil in the gearbox
Shift rod adjustment
Gear shift lever — removal and installation
Shift rod — removal and installation
Reverse gear lock cable
Sealing rings of drive shafts
O-ring of the input shaft
Sealing ring of a shaft of a choice of transfers
Reversing light switch
Speedometer drive — removal and installation
Removal and installation of a transmission
Gearbox disassembly
Differential repair
Input shaft repair
Secondary shaft repair
Gearbox Assembly
Determining the preload of the input shaft tapered bearing
Reinforced O-rings
Distinctive features of the 4x4 drive
4x4 drive system transfer case
Automatic gearbox
Specifications of automatic transmission
Description of the design of automatic transmission
Removal and installation of a transmission
Shift Control Adjustment
Gear selection cable — removal and installation
Selector lever — removal and installation
Cable for forced activation of the downshift
Adjusting the brake band
Removal and installation of the control servomotor
Replacement of a sealing ring of an axis of the selector
Transmission heat exchanger — removal and installation
Drive shafts
Drive Shafts — Design Description
Specifications of drive shafts
Removing drive shafts
Installing the drive shaft
Replacement of covers of hinges of equal angular speeds
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
Steering Specifications
Steering wheel — removal and installation
Steering column — removal, inspection and installation
Ignition lock — removal and installation
Steering gear — removal and installation
Replacement of protective covers of the steering mechanism
Bleeding air from 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
Tie rod — removal and installation
Wheel alignment
Changes in the steering system
Front suspension
Front suspension — design description
Specifications of the front suspension
Swivel fist — removal and installation
Replacing the front wheel bearing
Front pillar — removal and installation
A-pillar repair
Lower arm front suspension — removal and installation
Lower ball joint, front suspension
Stabilizer bar of the front suspension
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 the rear torsion bars
Stabilizer — removal and installation
Rear suspension arm — removal and installation
Removal and installation of a back suspension bracket
Body suspension height adjustment
Rear wheel hubs — removal and installation
Features of the rear suspension of 4x4 cars
Tank replacement
Removal and installation of the suspension arm
Removal and installation of the suspension cylinder
Bleeding the hydraulic circuit
Removal and installation of the pump
Removal and installation of the hub
Brake system
Brake system — general information
Specifications of the brake system
Bleeding the hydraulic brake system
Replacing the front brake pads
Brake lines and hoses
Replacing the rear brake pads on disc brakes
Replacing the rear brake pads on drum brakes
Front brake disc — removal, inspection and installation
Rear brake disc — removal, inspection and installation
Rear brake drum — removal, inspection and installation
Front brake caliper — removal and installation
Rear wheel caliper — 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 brake booster valve
Handbrake adjustment
Handbrake lever — removal and installation
Handbrake cable — removal and installation
The switch of a control lamp of inclusion of a manual brake
Brake pressure control valve
Stoplight switch — removal and installation
Anti-lock braking system (ABS)
Wheel sensor replacement
Removal of air from the brake system
Body and interior
Exterior (external elements)
Body — dimensions and general description
Body and interior care
Repair of minor body damage
Repair of severe damage to the body
Front bumper — removal, installation and repair
Rear bumper — removal and installation
Headlights and direction indicators — removal and installation
Rear light — removal and installation
Front fender — removal and installation
Hood — removal, repair and installation
Bonnet lock cable — removal and installation
Hood lock — removal and installation
Replacing the front panel — removal, repair and installation
External rear-view mirrors — removal and installation
Radiator grill — removal and installation
Grille in front of the windshield — removal and installation
Trims and Emblems — Removal
Interior (internal elements)
Caring for upholstery and rugs
Central locking — removal and installation
Seats — removal and installation
Front seat belt tension mechanism
Front seat seat belt
Rear side seat belts (saloon models)
Rear side seat belts (combi models)
Interior trim — removal and installation
Upholstery of the ceiling — removal and installation
Center console — removal and installation
Instrument panel (models up to 1992)
Dashboard (models since 1993)
Doors, locks and windows
Doors — removal, installation and adjustment
Door upholstery — removal and installation
Lock and door opening 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
Switch Replacement
Oil level and temperature sensor
External lighting bulbs
Interior lighting bulbs
External lighting devices — removal and installation
Headlight adjustment
Instrument cluster — removal and installation
Instrument cluster elements — removal
Clock — removal and installation
Wiper arms — removal and installation
Wiper motor and traction — removal and installation
Rear door wiper motor
Windshield washers — removal and installation
Radio receiver — removal and installation
Loudspeakers — removal and installation
Radio antenna — removal and installation
Anti-theft system
Airbag
Airbag elements — removal and installation
Heating and ventilation system — removal and installation
Electrical circuits
Symbols and designations on wiring diagrams
Symbols on diagrams
Engine start, battery charging, ignition (XU52C/XU92C 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, dimensions and headlights)
External lighting (direction indicators and brake lights)
Interior lighting wiring diagram
Windshield washer/wiper, horn, fan and rear window
Central locking, electric exterior mirrors and radio
Power windows and power sunroof
Standard anti-lock brakes
Simplified anti-lock braking system
Diagram of the starting, charging and heating system (late models)
Heating System Diagram (Turbo Diesel), Radiator Cooling Fan (Late Models)
Engine system diagram (with carburetor) (late models)
Hazard Lamp Diagram and Gauges (Late Models)
Outside Temperature Display Chart, Clock and Ambient Light
Rear Wiper/Washer Diagram, Heater Fan and Heated Rear Window (Late Models)
Diagram of electric mirrors, radio and automatic light switch (late models)
Diagram of central locking and power windows (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
Start from an external source (another car)
If the engine does not start even though the starter is working properly
Checking the tightness of connections
Conditions for towing a car
Weekly checkpoints
General instrument panel
Remote infrared control
Identification card
Locking the rear doors from opening by children
Radio remote control door lock
The lever of opening of the hatch of a mouth of a fuel tank
Electronic anti-theft system
Fuel shut-off valve
Catalytic converter
Instrument panel (gasoline and diesel vehicles)
Dashboards (vehicles with a gasoline engine)
Instrument panel (vehicles with automatic transmission)
Dashboards (vehicles with a diesel engine)
Instrument panel warning devices
Windscreen wiper
Heated rear window and outside rear-view mirrors
Steering wheel adjustment
On-board computer
Heating and ventilation
Air conditioner
Automatic air conditioner
Front airbags
Side airbags
Clock, panel illumination
Automatic transmission
Speed controller
Fuse blocks
List of fuses
Wheels and tires — pressure check
Towing a car
Vehicle identification
Vehicle Specifications
Car fuel consumption
Car radio 4030
Car radio with CD player 4050
Outdoor lighting control
Seat adjustment
Headlight adjustment
Replacing the crankshaft seals
Maintenance (gasoline)
Maintenance technical information
Maintenance interval
View of the engine compartment
Oil and oil filter change (15000 km/12 months)
Checking the oil level in an automatic transmission (15,000 km / 12 months)
Checking the tightness of hoses and leakage of liquids (15,000 km / 12 months)
Replacing the fine air filter in the ventilation system (15,000 km / 12 months)
Checking the operation of the clutch (15000 km / 12 months)
Checking the protective cover of the drive shaft (15000 km / 12 months)
Steering and suspension (15,000 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 gearbox (60,000 km)
Checking the rear brake pads (60,000 km)
Brake fluid change (60,000 km)
Coolant change (120,000 km/24 months)
Maintenance (diesel)
Maintenance technical information
Maintenance interval
View of the engine compartment
Removing water from the fuel filter (10,000 km / 12 months)
Hose leak test and fluid leak detection (10,000 km/12 months)
Replacing the cabin filter (20,000 km)
Replacing the air filter element (30,000 km)
Fuel filter replacement (30,000 km)
Checking the oil level in the gearbox (60,000 km)
Auxiliary drive belt (60000 km)
Every 120,000 km or 2 years
Power unit
Gasoline engines
Gasoline engines — general repair information
Specifications of gasoline engines
Compression pressure test (compression)
Installation of the gas distribution mechanism
Cylinder head cover — removal and installation
Crankshaft pulley — removal and installation
Casing of a gear belt — removal and installation
Toothed belt — removal and installation
Toothed belt tensioner and pulleys
Replacing the camshaft sealing ring
Camshaft and pushers — removal, inspection and installation
Checking and adjusting the valve clearances of 1.6 l engines
Cylinder head — removal and installation
Oil pan — removal and installation
Oil pump — removal, inspection and installation
Oil cooler — removal and installation
Flywheel — removal, inspection and installation
Suspension of the power unit — check and replacement
Major engine malfunctions
Diesel engines
Diesel engines — general repair information
Specifications of diesel engines
Compression pressure test (compression)
Installation of the gas distribution mechanism
Cylinder head cover — removal and installation
Crankshaft pulley — removal and installation
Casing of a gear belt — removal and installation
Toothed belt — removal, inspection and installation
Camshaft pulley — removal and installation
Crankshaft pulley — removal and installation
High pressure fuel pump pulley
Right engine mount and toothed belt tensioner
Toothed belt guide roller — removal and installation
Camshaft and pushers — removal, inspection and installation
Checking and adjusting valve clearances
Removal and installation of a head of the block of cylinders (engines 1.9 l)
Selecting the cylinder head gasket
Checking the cylinder head bolts
Oil pan — removal and installation
Oil pump — removal, inspection and installation
Right crankshaft sealing ring
Left crankshaft seal
Camshaft O-rings
Engine overhaul
Engine Specifications
Removal and installation of the engine and transmission
Removal and installation of engines with automatic transmission
Engine repair — general information
Removal and installation of a head of the block of cylinders (engine 2.1 l)
Dismantling of a head of the block of cylinders
Cleaning and inspection of the cylinder head
Cylinder head assembly
Removing pistons with connecting rods
Removing the crankshaft
Cylinder block
Pistons and connecting rods — check
Crankshaft — check
Inspection of main and connecting rod bearings
Engine assembly sequence during overhaul
Installation of piston rings
Selection of new crankshaft main bearings
Checking the working clearance of the crankshaft main bearings
Installing the crankshaft (XU and XUD engines)
Pistons installation
Starting the engine after a major overhaul
Cooling and heating
Cooling, heating and ventilation systems
Specifications of the cooling system
Connecting the cooling system hoses
Radiator — removal, inspection and installation
Thermostat — removal, inspection and installation
Electric fan — removal, inspection and installation
Thermal sensors — removal, inspection and installation
Coolant Temperature Lamp Sensor
Water pump — removal and installation
Heating and ventilation system
Elements of the heating system — removal and installation
Air conditioning systems
The main malfunctions of the cooling system
Fuel system (gasoline)
Power supply system for gasoline engines
Fuel System Specifications
Air filter and intake ducts — removal and installation
Accelerator cable — removal, installation and adjustment
Accelerator pedal — removal and installation
Fuel injection system
Relieve pressure in the fuel system
Fuel pump — removal and installation
Fuel tank — removal and installation
Fuel system check
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 exhaust system
The main malfunctions of the fuel and exhaust system
Fuel system (diesel)
Fuel system of diesel engines
Fuel System Specifications
Filling and bleeding the fuel system
Air filter and air inlets
Accelerator cable — removal, installation and adjustment
Accelerator pedal — removal and installation
High pressure fuel pump adjustment
Engine stop solenoid valve
Bosch high pressure fuel pump — removal and installation
High pressure fuel pump Lucas — removal and installation
Setting the injection timing
Setting the injection timing on the Bosch injection pump
Setting the injection timing on the Lucas 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 of a turbocharger
Turbocharger check
Intercooler — removal and installation
Engine electrical equipment
Specifications for starting and charging systems
Battery — removal, inspection and installation
Charging system — description and verification
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 (Gasoline Engines) — Description
Checking the ignition system
Ignition coil — removal and installation
Setting the ignition timing
Preheating system (diesel engines)
Glow plugs — removal, inspection and installation
Control unit of the preheating system
Transmission
Clutch and drive shafts
Specifications of clutch m shafts
Clutch cable — removal and installation
Clutch pedal — removal and installation
Hydraulic clutch control system
Leading clutch assembly — removal, inspection and installation
Clutch release mechanism — removal, inspection and installation
Drive shafts — general information
Removal and installation of power shafts
Replacement of covers of hinges of equal angular speeds
Replacing the intermediate bearing of the right drive shaft
Basic clutch malfunctions
The main malfunctions of the drive shafts
Mechanical gearbox
Manual transmission — general description
Specifications of the mechanical box
Changing the oil in the gearbox
Shift Control (BE3 Transmission)
Cable shift gear (ML5T gearbox)
Replacement of O-rings
Reversing light switch — removal, inspection and installation
Speedometer drive sensor — removal and installation
Removing and installing gearbox BE3
Manual transmission ML5T
The main malfunctions of a manual transmission
Automatic gearbox
Automatic transmission — general description
Specifications of automatic transmission
Changing the oil in the gearbox
Removal and installation of a cable of the selector
Removal and installation of the speedometer drive
Removal and installation of a cooler
Removing and installing the multifunction switch
Removal and installation of the electronic control unit (ECU)
Removal and installation of an automatic transmission
Overhaul of automatic transmission
The main malfunctions of an automatic transmission
Chassis, running gear
Brake system
Brake system — general description
Specifications of the brake system
Bleeding the hydraulic brake system
Brake lines and hoses
Replacing the front brake pads
Replacing the rear brake pads
Replacing the rear brake pads on drum brakes
Front brake disc — removal, inspection and installation
Rear brake disc — removal, inspection and installation
Rear brake drum — removal, inspection and installation
Front brake caliper — removal, repair and installation
Rear wheel caliper — 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 brake booster valve
Handbrake adjustment
Handbrake lever — removal and installation
Handbrake cable — removal and installation
Hand brake pads (with disc brakes)
Brake pressure control valve
Stoplight switch — removal and installation
Anti-Lock Braking System (ABS)
Vacuum pump (vehicles with diesel engine)
Checking the vacuum pump (with diesel engines)
The main malfunctions of the brake system
Car suspension
Suspension and steering — general information
Suspension Specifications
Steering knuckles — removal and installation
Replacing the front wheel bearings
Front pillar — removal and installation
A-pillar repair
Lower arm front suspension — removal and installation
Lower ball joint of the front suspension — removal and installation
Stabilizer bar of the front suspension
Front suspension stabilizer bar
Front suspension lower frame — removal and installation
Rear wheel hub — removal and installation
Rear hub bearing replacement
Rear suspension shock absorber — removal, inspection and installation
Rear suspension coil spring — removal and installation
Rear suspension hub trunnion — removal and installation
Lower arm rear suspension — removal and installation
The upper arm of the rear suspension — removal and installation
Rear suspension guide arm — removal and installation
Rear suspension link — removal and installation
Stabilizer bar of the rear suspension
Rear suspension stabilizer bar
Wheel alignment
The main malfunctions of the suspension and steering
Steering
Steering wheel — removal and installation
Steering column — removal, inspection and installation
Steering column intermediate shaft — removal, inspection and installation
Ignition lock — removal and installation
Steering gear — removal and installation
Replacement of protective covers of the steering mechanism
Bleeding air from the power steering system
Power steering pump — removal and installation
Tie rod ball joint — removal and installation
Tie 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 damage to the body
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 rugs
Seats — removal and installation
Front seat belt tension 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 upholstery — removal and installation
Lock and door opening 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
Car sunroof
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 lighting bulbs — replacement
Interior lamps — replacement
External lighting devices — removal and installation
Headlight adjustment
Instrument cluster — removal and installation
Multifunction display — removal and installation
Cigarette lighter — removal and installation
Clock — removal and installation
Sound signal — removal and installation
Wiper arm — removal and installation
Wiper motor and traction — removal and installation
Rear wiper — removal and installation
Windshield washer — removal and installation
Car radio — removal and installation
Speakers (speakers) — removal and installation
Radio antenna — removal and installation
Cruise control control system — removal and installation
Anti-theft system and engine immobilizer
Airbag
Airbag elements — removal and installation
Electrical circuits
Designations on electrical equipment diagrams
Starting and charging systems, radiator fans
Radiator fan, heater fan, ABS
Control lights and pointers
Magneti Marelli MM8P engine management system
Bosch MP5.1.1 engine management system
Headlights, license plate lights, brake lights, bulbs
Direction indicators and alarms, fog light
Interior lighting and headlight adjustment
Headlight washer, front and rear windshield washers/wipers
Cigarette lighter lighting, heated seats, rear window and mirrors, sunroof
Engine lock system
Central locking and front power windows
Front and rear power windows
Radio, CD player, clock and trip computer
Electric mirrors
Peugeot 605 (1989-2000)
General information
User manual
Governing bodies
Dashboard
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
Block of switches for automatic air conditioning
Power windows with electric drive
Radio receiver — general information
Engine starting
Anti-theft system (immobilizer)
Manual Transmission
Automatic transmission
Cruise control
Engine compartment. Vehicles with 2.0L turbocharged petrol engine
Engine compartment. Cars with 24-valve V6 petrol engine
Engine compartment. V6 petrol vehicles
Engine compartment. Vehicles with 2.1L diesel engine
Engine compartment. Vehicles with a 2.5L diesel engine
Engine oil
Brake fluid
Fuses — general information
Maintenance
General provisions and recommendations
Jacking and towing a car
Car care
Starting the Engine — Using the Auxiliary Battery
Maintenance — works
Engine oil level — check and change
Brake fluid — check and change
Checking the brake system
Checking tire pressure and tread height
Checking the cooling system
Checking the transmission fluid level in the gearbox
Checking the condition of the ribbed belt
Replacing the air filter element
Fuel filter replacement
Drive shaft CV joints — check
Checking the steering gear covers
Maintenance plan
Troubleshooting
Determination of engine malfunctions and their elimination
Determination of malfunctions of the engine lubrication system and their elimination
Determination of malfunctions of the engine cooling system and their elimination
Determination of malfunctions of the gasoline injection system and their elimination
Determination of malfunctions of the diesel engine power system and their elimination
Determination of malfunctions of the brake system and their elimination
Clutch Fault Identification and Troubleshooting
Identifying Battery Faults and Troubleshooting
List of starter malfunctions and their elimination
Identifying Generator Faults and Troubleshooting
Determination of malfunctions of a screen wiper and their elimination
Power unit
Petrol engines «XU»
XU Series Gasoline Vehicle Specifications
General information
Timing belt drive of the gas distribution mechanism — removal
Timing belt drive of the gas distribution mechanism — installation
Camshaft — removal
Camshaft — installation
Cylinder head — removal
Cylinder head — installation
Engine — removal
Engine — Installation
Petrol engines «ZPJ»
Specification of vehicles with ZPJ series gasoline engines
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 block — removal and installation
Petrol engines «ES9J4»
Specification for vehicles with ES9J4 gasoline engine
General information
Timing belt drive of the gas distribution mechanism — removal
Timing belt drive of the gas distribution mechanism — installation
Accessory Drive Belt — Removal
Accessory Drive Belt — Installation
Camshafts — removal
Camshafts — installation
Camshaft oil seal — replacement
Front crankshaft oil seal (toothed belt side) — replacement
Rear crankshaft oil seal (flywheel side) — replacement
Cylinder head — removal
Cylinder head — installation
Power block — removal
Power block — installation
Engine lubrication system — general information
Oil pump — removal
Oil pump — installation
Diesel engines
Specification for vehicles with diesel engines
General information
Timing belt drive of the gas distribution mechanism — removal
Timing belt drive of the gas distribution mechanism — installation
Accessory Drive Belt — Removal
Accessory Drive Belt — Installation
Camshaft — removal
Camshaft — installation
Cylinder head — general information
Power block — removal and installation
Cooling and heating
General information
Water pump — removal
Water pump — installation
Radiator — removal and installation
Transmission oil cooler — removal
Transmission oil cooler — installation
Heater — removal and installation
Heater fan — removal and installation
Thermostat — removal and installation
Outside temperature sensor — removal and installation
Coolant temperature sensor — removal and installation
Cooling system — pumping
Fuel system
General information about the fuel injection system
Operation of the petrol engine injection system
Fuel injection system — general check
Intake manifold — removal
Intake Manifold — Installation
Carburetor — general information
Diesel engine power system — general information
Precautions when working on the diesel engine power system
Nozzles — removal and installation
High pressure fuel pump — removal, installation and adjustment
Intake manifold — removal and installation
Fuel System — General Information and Precautions
Rules for cleanliness and safety when working with the fuel system
Fuel tank — removal and installation
Fuel tank — check
Fuel (fuel priming) pump with fuel gauge sensor — removal
Fuel (priming) pump with fuel gauge sensor — installation
Filler neck — removal and installation
Exhaust system
General information about the exhaust system
Catalyst — general information
Turbocharger — principle of operation
Turbocharger — removal and installation
Exhaust system — component replacement
Exhaust system — leak test
Exhaust gas recirculation system — general information
Transmission
Clutch
General clutch information
Clutch pedal — removal
Clutch pedal — installation
Clutch — removal
Clutch — Installation
Mechanical gearbox
Manual Transmission Specifications
General Information of Manual Transmission
Gearshift Mechanism — Removal
Gear Shift Mechanism — Installation
Gear shift box — removal
Gearbox — installation
Automatic gearbox
Automatic transmission specifications
General information about automatic transmission
Gear Oil — Level Check
Transmission oil — change
Torque converter — removal
Torque Converter — Installation
Modulator — Removal
Modulator — Installation
Speedometer sensor — removal and installation
Gearshift mechanism — removal and installation
Gear Shift Mechanism — Adjustment
Gear shift box — removal
Gearbox — installation
Chassis, running gear
Brake system
Brake Specifications
General information
Brake system — pumping
Brake disc — removal
Brake disc — check
Brake pads — removal
Brake pads — installation
Brake caliper — removal
Vacuum brake booster — removal and installation
Parking brake pads — removal
Parking brake cable leash — removal and installation
Parking brake cables — removal and installation
Parking brake — adjustment
Stoplight 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 — removal
Front suspension shock absorber — disassembly
Swivel fist — removal and installation
Front suspension wishbone — removal and installation
Anti-roll bar front suspension — removal and installation
Rear wheel suspension — removal and installation
The upper arm of the rear suspension — removal and installation
Lower wishbone rear suspension — removal
Lower wishbone rear suspension — installation
Rear suspension 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
Paddle switch block — removal and installation
Power steering pump — removal and installation
Power Steering Hydraulic — Fluid Change and Bleeding
Wheel alignment
Body and interior
Body elements
Body and trim — general description
Front bumper — removal and installation
Rear bumper
Hood — removal and installation
Door — removal and installation
The 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
Current measurement
Resistance measurement
Troubleshooting electrical equipment
Battery — check
Starter — removal and installation
Generator — device
Generator — check
Generator — removal
Headlights — removal and installation
Front glass cleaner — removal and installation
Battery tray — removal and installation
Instrument panel — removal and installation
Ignition system — general information and precautions
Spark plugs — general information
Spark plugs — removal
Electrical circuits
Keys to all circuit diagrams
Scheme 1. Bosch LE.2 injection system (XU10J2K engine and automatic transmission)
Scheme 2. Magneti Marelli G5 injection system (XU10J2K engine and manual transmission)
Scheme 3. Bosch MP3.2 injection system (XU10J2TE engine)
Scheme 4. Bosch MP5.1.1 injection system (XU10J4R engine without immobilizer)
Scheme 5. Fenix 4 injection system (ZPJ gasoline engine)
Diagram 6. EPIC Power System (XUD11BTE Diesel Engine)
Scheme 7. Bosch MSA 11 3.6 VP36 power system (DK5ATE engine)
Scheme 8. Central lock
Scheme 9. Instrument panel
Scheme 10. Burglar alarm
Scheme 11. High and low beam headlights
Scheme 12. Washer and glass cleaner, heated jets and washer fluid level sensor
Scheme 13. Rear window heater
Diagram 14. Heating, ventilation and air conditioning (ZPJ, XU102C, XU10J2, XU10J2C engines)
Diagram 15. Heating, ventilation and air conditioning (XUD diesel engine, except XUD11BTE)
Diagram 16. Heating, ventilation and air conditioning (XU10J4R, XU10J2TE, DK5ATE and XUD11BTE engine)
Partner I (1996-2008)
General information
Introduction to the guide
Safety comes first!
Safe driving skills
General provisions
Vehicle dimensions and weights
Purchase of spare parts
Vehicle identification
Lifting and placing the car on supports
General Repair Tips
Disconnecting the battery
Tools and fixtures
Checking the technical condition of the car
Checks performed from the driver's seat
Checks performed with the vehicle on the ground
Checks to be carried out with the vehicle raised and the wheels spinning freely
Exhaust Gas Composition Check
Glossary of technical terms
Faults en route
Repair on the road
Starting the engine from a foreign battery
Wheel replacement
What are the leaks talking about?
Car towing
Troubleshooting
General troubleshooting information
Car engine
Cooling system
Power system and exhaust system
Car clutch
Transmission
Drive axles
Brake system
Steering and suspension
Electrical equipment
Weekly checks
General description
Checkpoints under the hood
Engine oil level
Coolant level
Windshield washer fluid level
The level of the working fluid in the power steering reservoir
Brake fluid level in the hydraulic brake reservoir
Wiper blades
Car battery
Electrical systems
Tire condition and pressure
Types of tire wear
Lubricants and operating fluids
Choosing engine oil for your car
Tire pressure
User manual
General provisions
Vehicle documentation set
Controls, instrumentation and interior equipment
Dashboard
Switch for exterior lighting and direction indicators
Headlight range adjustment switch
Ignition switch and steering column lock, horn switch
Glass Cleaner/Washer switch
Central Button Bar
Cruise control switch box
Turning the system on, off and adjusting the speed
Canceling and resuming cruise control, resetting the speed setpoint
Steering column adjustment lever
Gear lever (manual transmission)
Heating and ventilation controls
Ventilation deflectors
Audio compartment
Parking brake lever
Interior lighting
Mirror adjustment, power window controls
Inertial fuel supply switch (on versions with a gasoline engine)
Seat adjustment
Cigarette lighter and ashtray
Electrical power outlet
Audio remote control switch
Clock/multifunction display
Emergency light alarm switch
Stowage compartments and other places for storing various items
Ceiling hardware
Central locking button
Hood release handle
Sunroof control
Instruments and control lamps
Engine start
Warming up the engine after starting
Engine shutdown
Car parking
Fuel consumption
Fuel system and refueling
Breaking 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
Carriage of luggage
Trailer towing
Anti-skid chains
Winter tires
Locks and anti-theft system
Holding fixtures
Maintenance (petrol)
Engine Specifications
Service Schedule
The location of the elements in the engine compartment and the bottom
General information about maintenance
Current service
Changing engine oil and oil filter
Checking the engine compartment for leaks and checking the condition of the hoses
Checking the covers of the leading semi-axes
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 brake pads of the front disc brakes
Checking the brake pads of the rear drum brakes
Checking and adjusting the parking brake
Exhaust system check
Steering and suspension check
Replacing the timing belt
Brake Fluid Replacement
Replacing spark plugs
Replacing the air filter element
Fuel filter replacement
Checking the oil level in a manual transmission
Checking emission reduction systems
Coolant replacement
Replacing airbags and seat belt pretensioners
Maintenance (diesel)
Vehicle Specifications
Service Schedule — 1.8L and 1.9L Diesel Models
Service Schedule — 2.0L Diesel Models
The location of the elements in the engine compartment and the bottom
General information about maintenance
Current service
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 covers of the leading semi-axes
Lubrication of hinges and locks
Road test
Resetting the Service Interval Display
Replacing the dust filter
Checking and adjusting idle speed and stall prevention speed — 1.8L and 1.9 engines
Checking and replacing the accessory drive belt — 1.8L and 1.9L engines
Drive belt (XUD with manual adjuster on alternator top support)
Drive belt (XUD with manually adjustable idler pulley)
Drive belt (XUD with auto adjust idler)
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 brake pads of the front disc brakes
Checking the brake pads of the rear drum brakes
Checking and adjusting the parking brake
Exhaust system check
Steering and suspension check
Fuel Filter Replacement (1.8L and 1.9L XUD Series Engines)
Fuel Filter Replacement (1.9L DW Series Engines)
Fuel Filter Replacement (2.0L Engines)
Replacing the air filter element
Checking the oil level in a manual transmission
Checking emission reduction systems
Brake Fluid Replacement
Coolant replacement
Replacing airbags and seat belt pretensioners
Power unit
Petrol engines
Gasoline Engine Specifications
General information about gasoline engines
Compression test — description of the procedure and analysis of the results
Mounting holes for engine/camshaft assembly — 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 adjusting
Camshafts and valve levers / 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 test and leak test — description of the procedure and analysis of the results
Mounting holes for engine/camshaft assembly
Cylinder head cover — removal and installation
Crankshaft pulley — removal and installation
Timing belt covers — removal and installation
Timing belt — removal, inspection, installation and tensioning
Toothed pulleys of the timing belt — removal and installation
Right engine mount bracket and timing belt tensioner
Timing belt intermediate roller — removal and installation
Camshaft and pushers — removal, inspection and installation
Valve clearances — checking and adjusting
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 — Inspect and Replace
Diesel engines «DW»
Diesel engine specifications
General information about DW diesel engines
Compression test and leak test — description of the procedure and analysis of the results
Mounting holes for engine/camshaft assembly — general information and use
Cylinder head cover — removal and installation
Crankshaft pulley — removal and installation
Timing belt covers — removal and installation
Timing belt (1.9 l engines) — general information, removal and installation
Timing belt (2.0 l engines) — general information, removal and installation
Timing belt toothed pulleys, intermediate pulley and idler pulley
Camshaft seal — replacement
Camshaft, valve levers and pushers — removal, inspection and installation
Valve clearances — checking and adjusting
Cylinder head (engines 1.9 l) — removal and installation
Oil pan — removal and installation
Oil pump and drive chain — removal, inspection and installation
Crankshaft seals — replacement
Engine/Gearbox Mounts — Inspect and Replace
Overhaul of petrol engines
Gasoline Engine Specifications
General provisions
Engine overhaul — general information
Engine Removal — Technique and Precautions
Engine / transmission — removal and installation
Engine Overhaul — Disassembly Sequence
Cylinder head — disassembly
Cylinder head and valves — cleaning and inspection
Cylinder head — assembly
Pistons assembled with connecting rods — removal
Crankshaft — removal
Cylinder Block/Crankcase — Clean and Inspect
Piston assembly with connecting rod — inspection
Crankshaft — inspection
Main and connecting rod bearings — inspection
Engine Overhaul — Assembly Sequence
Piston rings — installation
Crankshaft — Installation
Piston assembly with connecting rod — installation
Engine — first start after repair
Overhaul of diesel engines
Diesel engine specifications
General information
Engine overhaul — general information
Engine Removal — Technique and Precautions
Engine / transmission — removal and installation
Cylinder head (engines 2.0 l) — removal and installation
Engine Overhaul — Disassembly Sequence
Cylinder head — disassembly
Cylinder head and valves — cleaning and inspection
Cylinder head — assembly
Pistons assembled with connecting rods — removal
Crankshaft — removal
Cylinder Block/Crankcase — Clean and Inspect
Piston assembly with connecting rod — inspection
Crankshaft — inspection
Main and connecting rod bearings — inspection
Engine Overhaul — Assembly Sequence
Piston rings — installation
Crankshaft — Installation
Piston assembly with connecting rod — installation
Engine — first start after repair
Cooling and heating
Cooling system specifications
General information and precautions
Coolant hoses — disconnect and replace
Radiator — removal, inspection and installation
Thermostat — removal, inspection and installation
Electric cooling fans — removal and installation
Electric 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
Elements of the heating / ventilation system — removal and installation
Air conditioning system — general information and precautions
Elements of the air conditioning system — removal and installation
Power and exhaust (petrol)
Power and Exhaust System Specifications
General information and precautions
Air filter assembly and intake ducts — removal and installation
Accelerator cable — removal, installation and adjustment
Accelerator pedal removal and installation
Unleaded Gasoline — General Information and Usage
Engine management system — general information
Fuel System — Pressure Relief and Boost
Fuel pump — removal and installation
Fuel gauge sensor — removal and installation
Fuel tank — removal and installation
Engine management system — check and adjustment
Throttle body — removal and installation
Fuel rail and injectors
Fuel pressure control
Throttle Potentiometer
Electronic control unit
Stepper motor for adjusting the speed of rotation of the crankshaft in idle mode
Engine management sensors
Inlet manifold removal and installation
Exhaust manifold — removal and installation
Release system — general information, removal and installation
Power and exhaust (XUD diesels)
Power and exhaust system specifications
General information and precautions
Fuel System — Filling and Bleeding
Air filter and related elements — removal and installation
Thermostatic sensor of increased idle speed
High pressure fuel pump — removal and installation
Fuel injection advance — methods for checking and adjusting
Fuel Injection Advance (Lucas High Pressure Fuel Pump) — Check and Adjust
Fuel Injection Advance (Bosch High Pressure Fuel Pump) — Check and Adjust
High pressure fuel pump — adjustment
Fuel injectors — check, removal and installation
Accelerator cable — removal, installation and adjustment
Fuel gauge sensor — removal and installation
Collectors — removal and installation
Exhaust system — general information and replacement of elements
Power and exhaust (DW diesels)
Power and Exhaust System Specifications
General information and precautions
High Pressure Diesel Fuel Injection (HDi) Special Information
Air filter assembly and 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 (models with 2.0L engine) — removal and installation
Fuel gauge sensor — removal and installation
High idle thermostatic sensor (models with 1.9L engine)
High pressure fuel pump (models with 1.9L engine) — adjustment
Electrical elements of the fuel injection system — removal and installation
High pressure fuel pump — removal and installation
Fuel injection advance — check and adjustment
Fuel injectors — removal and installation
Fuel rail (models with 2.0 l engine) — removal and installation
Intake manifold — removal and installation
Exhaust manifold — removal and installation
Turbocharger (Models with 2.0L Engine) — Design Description and Precautions
Turbocharger (models with a 2.0 liter engine) — removal, inspection and installation
Release system — general information, removal and installation
Emission reduction
Emission reduction system specifications
General information about the emission reduction system
Emission reduction systems (gasoline engines) — checking and replacing elements
Emission reduction systems (diesel engines) — checking and replacing elements
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 base plate — removal and installation
Charging System — Check
Generator — removal and installation
Generator — Inspection and Overhaul
Starting system check
Starter — removal and installation
Starter — check and repair
Sensor-switch of a control lamp of insufficient oil pressure
Oil level sensor — removal and installation
Ignition System Specifications
Ignition system — general information
Ignition system — check
Ignition coil unit — removal, inspection and installation
Ignition advance — check and adjustment
Knock sensor — removal and installation
Heating System Specifications
Preheating system — description and verification
Glow plugs — removal, inspection and installation
Preheating 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 Refilling Transmission Oil
Lever gear shift mechanism — removal and installation
Cuffs — replacement
The switch of lanterns of a backing — check, removal and installation
Speedometer drive — removal and installation
Manual transmission — removal and installation
Gearbox overhaul — general information
Drive shafts
Axle specifications
General information about drive shafts
Drive axle axles — removal and installation
Rubber covers of the axle shaft joints (half shaft type GKN) — replacement
Rubber boots of the axle shaft joints (PSA type axle shaft) — replacement
Overhaul of the axle shaft — general information
Intermediate support of the right axle shaft — replacement
Chassis, running gear
Brake system
Brake Specifications
General information about the brake 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 — check, removal and installation
Check valve vacuum brake booster — 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
Stoplight switch — removal, installation and adjustment
The switch of a control lamp of activation of a lay brake — removal and installation
Anti-lock braking system (ABS) — general information
Elements of the anti-lock braking system (ABS) — removal and installation
Vacuum Pump (Diesel Models) — Removal and Installation
Vacuum Pump (Diesel Models) — Inspection and Repair
Car suspension
Suspension and steering specifications
General Suspension and Steering Information
Steering knuckle assembly — removal and installation
Front hub bearings and steering knuckle — replacement
Front suspension strut — removal and installation
Front suspension strut — repair
The lower arm of the front suspension — removal, repair and installation
The 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 elements — 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 — Bleeding
Power steering pump — removal and installation
Tie rod end — removal and installation
Wheel alignment — general information
Body and interior
Exterior (external elements)
Vehicle body specifications
General provisions on 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
Lock and cable for unlocking the hood — removal and installation
External rear-view mirrors and mirror glass — removal and installation
Exterior trim elements — removal and installation
Bonnet grille panel — removal and installation
Radiator grill — removal and installation
Interior (internal elements)
Maintenance — upholstery and carpeting
Seats — removal and installation
Seat belt elements — removal and installation
Interior decoration — removal and installation
Center console — removal and installation
Front Panel Elements (Pre-September 2002) — Removal and Installation
Front Panel Elements (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 elements — removal and installation
Elements of the handle and lock of the side sliding door — removal and installation
Elements of the handle and lock of the double-leaf rear door — removal and installation
Glass and window regulator of a window of a forward door — removal and installation
Raised tailgate and support legs — removal and installation
Elements of the lock of the lifted tailgate — removal and installation
Elements of the central locking system — removal and installation
Windshield, liftgate glass and double door glass
Glass windows to be opened — removal and installation
Sunroof — general information
Electrical equipment
Equipment and devices
Specifications of electrical equipment
General information about on-board electrical equipment
Troubleshooting in electrical circuits — general information
Fuses and relays — general information
Switches — removal and installation
Lamps (Outdoor Lighting) — Replacement
Lamps (interior lighting) — replacement
External lighting devices — removal and installation
Headlight adjustment — general information
Instrument panel — removal and installation
Multifunction display — removal and installation
Cigarette lighter / power outlet — removal and installation
Sound signal — removal and installation
Wiper arm — removal and installation
Windshield wiper motor and drive — removal and installation
Liftgate wiper motor 4 luggage compartment — removal and installation
Elements of the windshield washer system — 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 shutdown
Elements of the airbag system — removal and installation
BSI multifunctional electronic box/fuse box
Electrical circuits
Peugeot Partner: Designation on electrical diagrams
Peugeot Partner: Scheme 2. Starting and charging system, audio unit, cigarette lighter, sound signal...
Peugeot Partner: Scheme 3. Fog lights, brake lights, position lights, headlights...
Peugeot Partner: Diagram 4. Airbags, anti-lock brakes, headlight range adjustment...
Peugeot Partner: Diagram 5. Washer/wiper, central locking system with double locking
Peugeot Partner: Scheme 6. Heater fan, engine cooling system, air conditioning...
Peugeot Partner: Scheme 7. Power mirrors, interior lighting, instrument panel
Citroen Berlingo. Scheme 1. Fuse table
Citroen Berlingo. Diagram 2. Washer/wiper, central locking
Citroen Berlingo. Scheme 3. Headlights, marker lights, taillights...
Citroen Berlingo. Scheme 4. Stoplights, reversing lights, pointers...
Citroen Berlingo. Scheme 5. Fog lights / lights, cigarette lighter, horn...
Peugeot 806 (1994-2002)
General information
User manual
Introduction to the guide
Dimensions and weight
Control Panel
Car keys
Remote control
Front doors
Side sliding doors
Rear folding door
Hood opening
Gas tank cap
Dashboard. Control lights
Dashboard
On-board computer
Steering wheel
Rear view mirrors
Heating and ventilation of the passenger compartment
Car air conditioner
Air conditioning with automatic control
Inflatable airbag
Adjustment of fastening of a seat belt on height
Trunk shelf (five-seat version)
Front retractable sunroof
Electric and manual windows
Retractable vents
Engine starting
Engine start blocking
Entering or changing the code
Maintenance
General provisions and recommendations
Poddomkrachivanie car
Threaded connections
Maintenance — works
Engine oil level — check and change
Brake Fluid Level — Check
Brake check
Checking tire pressure and tread height
Checking the coolant level
Checking the cooling system
Checking the transmission fluid level in the gearbox
Checking the condition of the ribbed belt
Replacing the air filter element
Fuel filter replacement
Check of a condition of covers of power shafts
Checking the steering gear covers
Protective caps and play of tie rod ends
Steering play check
Maintenance plan
Power unit
Petrol engines
Engine Specifications
General description of engines
Vehicles with 1.8 liter engine
Vehicles with 2.0 liter engine
Vehicles with 1.9 liter diesel engines
Vehicles 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
Gas distribution mechanism — bulkhead
Gas distribution mechanism — assembly
Valve clearance — adjustment
Pistons and connecting rods — disassembly, inspection and assembly
Cylinder block
Crankshaft and flywheel — removal, inspection and installation
Toothed belt — removal and installation
Using special tools to adjust the timing mechanism
Compression — check
Diesel engines
Diesel engines — removal and installation
Diesel engine — disassembly and assembly
2.1 liter engine disassembly
2.1 liter diesel engine assembly
Cylinder head — removal and installation
Valve clearance — adjustment (1.9 liter engines only)
Pistons and connecting rods — removal, inspection and assembly
Crankshaft
Toothed 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 refilling
Radiator — removal and installation
Water pump — removal and installation
Removing the thermostat
Cooling liquid
Checking the thermal switches
Radiator fan
Coolant hoses
Determination of malfunctions of the engine cooling system and their elimination
Fuel injection (petrol)
Fuel Injection Specifications
General description and precautions
Fuel injection systems — a brief description
Accelerator cable — adjustment
Gas turbine supercharger
Fuel system (diesel)
Diesel engine specifications
General description
Precautions when working on the diesel engine power system
Nozzles — removal and installation
Glow plugs — removal and installation
Fuel filter — replacement of the 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 catalyst
Safety measures when working with ignition systems
Ignition coil
Ignition System Components
Spark plug
ECM Bosch Motronic MP 3.2
General description
Checking the electronic control unit ECM (general check)
Self-diagnosis function
Ignition systems
Crank Angle Sensor (CAS)
Camshaft Position Sensor (CMP)
Ignition booster
Ignition Coil Static Ignition System (DIS)
Ignition coils for direct ignition systems
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 Air Control Valve (ISCV)
Intake manifold heater (IMH)
Turbocharger Wastegate (WCS) (only with turbocharger)
Fuel injection system
Fuel system
Fuel pump
Fuel pressure control
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 clutch
Clutch — removal
Clutch — repair
Clutch — Installation
Clutch release bearing
Clutch Fault Identification and Troubleshooting
Mechanical gearbox
Transmission Specifications
Manual transmission — general information
Gearbox — removal
Gearbox — Installation
Transmission oil — level check and change
Chassis, running gear
Brake system
Brake Specifications
General description of the braking system
Front wheel disc brakes — replacing brake pads
Front wheel disc brakes — caliper repair
Rear drum brakes
Disc brake mechanism of the rear wheels — removal, installation, replacement of brake pads
Master brake cylinder — removal, installation and repair
Vacuum brake booster
Brake System — Bleeding
Parking brake — adjustment
Brake force regulator
Vacuum pump
ABS system
Car suspension
Suspension specifications
Front suspension
Suspension strut — removal, installation and bulkhead
Front wheel hub and hub bearing — removal
Lower transverse arm — 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
Steering neutral position
Tie Rod Ends — Replacement
Wheel alignment
Steering wheel — removal and installation
Power steering — draining and filling fluid, bleeding
Electrical equipment
Equipment and devices
Electrical system specifications
General description of the electrical system
Battery — removal, installation and inspection
Generator general description
Generator — check
Generator — removal and installation
Alternator belt — removal
Alternator Belt — Installation
Starter — check, removal and installation, repair
Lighting — replacing, removing and installing light bulbs
Front glass cleaner
Dashboard
Troubleshooting — Introduction
Identifying Generator Faults and Troubleshooting
List of starter malfunctions and their elimination
Electrical circuits
Designation of network consumers on the diagrams
List of abbreviations used for wiring harnesses
Abbreviations for Wire Insulation Color
Location of symbols on electrical diagrams
Starter, generator
Magnetti-Marelli fuel injection system. 1.8 liter engine
Fuel injection and ignition system. 2.0 liter turbocharged engine
Bosch MP3 fuel injection and ignition system. 2.0 liter 8 valve engine
Cooling system. 2.0 liter turbocharged engine with 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, alternator, preheating system. 1.9 liter diesel engine
Diesel engine with a volume of 2.1 liters. Starter, alternator, preheating system.
Cooling system. 1.9 liter diesel engine with two radiator fans
Cooling system. 2.1 liter diesel engine with two radiator fans
Rear fog lights and fog lights
Brake lights, reversing lights and additional brake lights
Direction indicator and hazard warning lights
Sound signals
Far and near light
Parking lights
Illumination of the instrument panel and cigarette lighter. Illumination of switches and thresholds
Headlight washer
Windshield wiper and washer
Rear window cleaner and washer
Heating and ventilation
Car air conditioner
Oil pressure control system
Brake pad monitoring system
System for monitoring the level of brake fluid and the position of the parking brake
Fuel system
Power windows driver and passenger doors
Electric windows of the rear doors
Heated rear window and exterior mirrors
Automatically adjustable exterior mirrors

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