Manual sections
Wiring diagrams- Battery
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- Bodywork
- Braking
- Comfort and convenience
- Confort
- Connector pinouts
- Current generation
- Dashboard
- Driver information
- Electrical harnesses
- Engine
- Front anti -roll bar
- Front axle
- Front doors
- Front seats
- Front section
- Front shock absorbers
- Gearbox assembly
- General points
- General points about the vehicle
- Glovebox
- Instrument panel
- Instruments and controls
- Lighting - signalling
- Mechanical
- Other
- Power unit
- Pre-heating
- Protections and doors
- Rear axle
- Rear door trim
- Rear seats
- Rear section
- Roof panel
- Side structure
- Starting
- Steering
- Suspension
- Towbar
- Transmission
- Washing and wiping
Repair manual
Engine Peugeot 807 I
Step-by-step instructions on "Engine" for Peugeot 807 I (2002–2008). Pick an article — removal, installation, adjustment and diagnostics with illustrations.
Crankshaft
- Data: conrods andhalf shells (ES9J4S)
- Data: crankshaft and bearing half-shells (ES9J4S)
- Data: pistons - little ends - piston rings (ES9J4S)
- Identification - data: crankshaft and bearing half-shells (DW12BTED4)
- Identification - data: under engine (2.0 HDi 163 FAP, DW10CBDTR)
- Data - tightening torques: engine equipment (ES9J4S)
- Identification: data - tightening torques: engine equipment (DW10ATED4, DW12TED4)
- Tightening torques: reciprocating gear (DW12TED4)
- Identification - tightening torques reciprocating gear (DW10ATED4)
- Identification - data: crankshaft (EW12J4)
- Data - tightening torques: engine equipment (EW10A)
- Identification - data: pistons - the piston shaft - piston rings (EW10J4, EW10A)
- Data: connecting rods / connecting rod bearing halfshells (EW10J4, EW10A)
- Data: crankshaft - crankshaft half bearing shells (EW10A, EW10J4)
- Data: conrods (DW10UTED4, DW10BTED4)
- Data: crankshaft - crankshaft half bearing shells (DW10BTED4, DW10UTED4)
- Data: pistons - little ends - piston rings (DW10UTED4, DW10BTED4)
- Check - removing - refitting - adjustment: balance shafts (DW12BTED4)
- Checks - removing - refitting - adjustment: balance shafts (EW12J4)
- Dismantling - refitting: conrods - pistons (ES9J4S)
- Matching: main shell bearings (ES9J4S)
- Removing - refitting: ancillary drive belt (DW12BTED4)
- Removing - refitting: ancillary drive belt (2.0 HDi 163 FAP, DW10CBDTR)
- Removing - refitting: engine ring seals (DW12BTED4, DW10CBDTR, DW10BTED4, DW10ATED4, 2.0 HDi 163 FAP, DW10UTED4)
- Removing - refitting: ancillary drive belt (DW12TED4)
- Removing - refitting: ancillary drive belt (DW10ATED4)
- Removing - refitting ancillary drive belt (ES9J4S)
- Removing - refitting: double damping flywheel (DVA) (DW10UTED4)
- Removing - refitting: ancillary drive belt (EW10A)
- Removing - refitting: ancillary drive belt (DW10BTED4)
- Matching: bearing shells (EW10J4, EW10A)
- Dismantling - re-assembly: pistons/con.rods (EW10A)
- Data - identification conrods (ES9J4S)
- Data - identification pistons - piston rings (ES9J4S)
- Data: conrods (EW12J4)
- Data: half shells (EW12J4)
- Identification - data: pistons - piston rings - the piston shaft (EW12J4)
- Removing - refitting: counterbalance shaft (DW12TED4)
- Aid to mechanical diagnosis: double damped engine flywheel
- Removing - refitting: ancillary drive belt (EW10J4, EW12J4)
Timing gear
- Data: camshaft (ES9J4S)
- Data: camshaft (EW10J4, EW10A)
- Data: camshafts (DW10BTED4, DW10UTED4)
- Data: timing gear (DW10BTED4, DW10UTED4)
- Removing - refitting: camshaft (DW12BTED4)
- Removing - refitting: camshaft seal (DW10UTED4)
- Removing - refitting: camshafts (DW10UTED4)
- Removing - refitting: camshaft oil seal (DW10BTED4)
- Removing - refitting: camshafts (DW10BTED4)
- Identification - data - tightening torques: timing gear (ES9J4S)
- Identification - data - tightening torques: timing gear (EW10J4, EW10A)
- Identification - data - tightening torques: timing gear (EW12J4)
- Data: camshaft (EW12J4)
- Identification: valves - valve springs (EW10A)
- Check: setting the valve timing (DW12BTED4)
- Check: setting the valve timing (2.0 HDi 163 FAP, DW10CBDTR)
- Check: setting the valve timing (DW10UTED4)
- Check: setting the valve timing (DW10BTED4)
- Removing - refitting: timing belt (DW12BTED4)
- Removing - refitting: timing belt (2.0 HDi 163 FAP, DW10CBDTR)
- Removing - refitting: camshafts (ES9J4S)
- Removing - refitting: timing belt (first assembly) (EW12J4)
- Removing - refitting Variable Timing Camshaft (VTC) (EW12J4)
- Removing - refitting camshafts (EW12J4)
- Removing - refitting camshafts (EW10J4)
- Removing - refitting camshaft (DW10ATED4, DW12TED4)
- Removing - refitting: timing belt (first assembly) (EW10J4)
- Removing - refitting: timing belt (DW10ATED4, DW12TED4)
- Removing - refitting: timing belt (ES9J4S)
- Removing - refitting Variable Timing Camshaft (VTC) (ES9J4S)
- Removing - refitting: timing belt (second assembly) (EW10J4)
- Removing - refitting: timing belt (second assembly) (EW12J4)
- Removing - refitting: timing belt (EW10A)
- Removing - refitting: timing belt (DW10UTED4)
- Removing - refitting: timing belt (DW10BTED4)
- Modification: removal of the crankshaft pulley bolt (DW10UTED4, DW12TED4, DW10ATED4, DW12BTED4, DW10CBDTR, 2.0 HDi 163 FAP, DW10BTED4)
Lubrication
- Removing - refitting: lower cover (DW12TED4)
- General: lubrication
- Capacity: engine oil
- Recommendations: oils for petrol engines
- Recommended engine oils (DIESEL)
- Data - tightening torques: lubrication (engine)
- Check: oil pressure (DW12BTED4)
- Check: oil pressure (DW10CBDTR, 2.0 HDi 163 FAP)
- Check oil pressure
- Check: oil pressure (With oil pressure switch)
- Check: oil pressure (Without oil pressure switch)
- Check: oil pressure (DW10UTED4)
- Check: oil pressure (DW10BTED4)
- Removing - refitting: engine oil temperature and level sensor (DW12BTED4)
- Removing - refitting: oil pressure sensor (DW12BTED4)
- Removing - refitting: oil pressure sensor (DW10CBDTR, 2.0 HDi 163 FAP)
- Removing - refitting: engine oil temperature and level sensor (DW10CBDTR, 2.0 HDi 163 FAP)
- Removing - refitting: oil pump (2.0 HDi 163 FAP, DW10CBDTR)
- Removing - refitting: oil filter (DW10CBDTR, 2.0 HDi 163 FAP)
- Removing - refitting lower cover (DW10ATED4, DW12TED4)
- Removing - refitting lower cover (EW12J4, EW10J4)
- Modification: Lubrication kit
- Maintenance: recommended ingredients, year 2006
Exhaust
- Identification - data: exhaust system (DW12BTED4)
- Tightening torques: exhaust system (DW10CBDTR, 2.0 HDi 163 FAP)
- Identification of tightening torques exhaust
- Identification - tightening torques: exhaust (EW10A)
- General specifications: exhaust system (DW10UTED4)
- Tightening torques: exhaust system (DW10BTED4)
- General specifications: exhaust system (DW10BTED4)
- Removing - refitting: pre-catalyst (DW12BTED4)
- Removing - refitting: exhaust manifold (DW12BTED4)
- Removing - refitting: exhaust system (2.0 HDi 163 FAP, DW10CBDTR)
- Removing - refitting: pre-catalyst (2.0 HDi 163 FAP, DW10CBDTR)
- Removing - refitting exhaust manifolds (ES9J4S)
- Removing - refitting particle filter (DW12TED4, DW10ATED4)
- Removing - refitting pre-catalysers (ES9J4S)
- Removing - refitting: exhaust manifold (EW10A)
- Removing - refitting: exhaust system (DW10UTED4)
- Removing - refitting: pre-catalyst (DW10UTED4)
- Removing - refitting: pre-catalyst (DW10BTED4)
- Removing - refitting: exhaust system (DW12BTED4, DW10BTED4)
- Removing - refitting: particle filter (DW12BTED4)
- Removing - refitting: exhaust gas pressure sensor pressure take-off (DW12BTED4)
- Removing - refitting: exhaust gas pressure sensor pressure take-off (DW10CBDTR, 2.0 HDi 163 FAP)
- Removing - refitting: particle filter (DW10CBDTR, 2.0 HDi 163 FAP)
- Removing - refitting: exhaust gas pressure sensor pressure take-off (DW10BTED4)
- Removing - refitting: particle filter (DW10BTED4)
- Forced regeneration: particle filter
- Forced regeneration: particle filter (technical note)
- Presentation: particle filter (OS2)
Cylinder head
- Data: valve seats and guides (ES9J4S)
- Data: valves and valve springs (ES9J4S)
- Data: cylinder head (ES9J4S)
- Data: cylinder head gasket (ES9J4S)
- Data: cylinder head bolts (ES9J4S)
- Identification - data: cylinder head bolts - cylinder head tightening (DW12BTED4)
- Identification - data: engine top (2.0 HDi 163 FAP, DW10CBDTR)
- Identification - data - tightening torques: cylinder head (EW12J4)
- Identifications - data - tightening torques: cylinder head (EW10J4)
- Data: cylinder head gasket (DW10ATED4, DW10UTED4)
- Data: cylinder head (DW10BTED4)
- Data: valve guides (EW10J4, EW10A)
- Data: valves and valve springs (EW10A, EW10J4)
- Data: valve seats (EW10A, EW10J4)
- Data: cylinder head gasket (DW10BTED4)
- Data: cylinder head bolts - cylinder head tightening (DW10UTED4, DW10BTED4)
- Data: cylinder head - cylinder head gasket - cylinder head bolts (EW10A, EW10J4)
- Data: valve seats and guides (DW10BTED4, DW10UTED4)
- Data: valves and valve springs (DW10BTED4, DW10UTED4)
- Stripping-assembling: cylinder head (ES9J4S and ES9A engine) (ES9J4S)
- Stripping: cylinder head (EW10A, EW10J4)
- Re-assembling: cylinder head (EW10J4, EW10A)
- Stripping-assembling: cylinder head (DW10BTED4, DW10UTED4)
- Identification - data - tightening torques: cylinder head (ES9J4S)
- Identification - data cylinder head (DW12TED4, DW10ATED4)
- Data - identification valve springs (ES9J4S)
- Data - identification valves (ES9J4S)
- Identification - data: cylinder head (EW12J4)
- Data: seats - valve guides (EW12J4)
- Data: cylinder head gasket (EW12J4)
- Data: cylinder head bolts - cylinder head tightening (EW12J4)
- Tightening torques: cylinder head equipment (EW10A)
- Removing - refitting: cylinder head (on vehicle) (DW12BTED4)
- Removing - refitting: cylinder head (on vehicle) (2.0 HDi 163 FAP, DW10CBDTR)
- Removing - refitting cylinder head (EW12J4)
- Removing - refitting cylinder head (EW10J4)
- Removing - refitting cylinder head (DW10ATED4, DW12TED4)
- Removing - refitting cylinder head (ES9J4S)
- Removing - refitting: cylinder head (on vehicle) (DW10UTED4)
- Removing - refitting: cylinder head (on the vehicle) (DW10BTED4)
- Stripping - re-assembling: cylinder head (EW12J4)
- Data: valves and valve springs (EW12J4)
- Removing - refitting: inlet air metering unit (2.0 HDi 163 FAP, DW10CBDTR)
- Removing - refitting: air inlet manifold (DW10CBDTR, 2.0 HDi 163 FAP)
Engine block
Cooling system
- Maintenance: fluids recommendation
- Identification - data: engine cooling system DW12BTED4 (DW12BTED4)
- Identification - data: engine cooling system (type DW12BTED4 AM6) (DW12BTED4)
- Data - identification: cooling system
- Identification - tightening torques cooling system (DW12TED4, DW10ATED4)
- Capacity: cooling system
- Identification - data: cooling system (EW10A)
- General specifications: engine cooling system (DW10UTED4, DW10BTED4)
- Removing - refitting: coolant pump (DW12BTED4)
- Removing - refitting: coolant temperature sensor (DW12BTED4)
- Removing - refitting: coolant outlet housing (DW12BTED4)
- Removing - refitting: additional heating unit (DW12BTED4)
- Removing - refitting: engine cooling radiator (DW12BTED4)
- Removing - refitting: engine cooling radiator (2.0 HDi 163 FAP, DW10CBDTR)
- Removing - refitting: coolant outlet housing (DW10CBDTR, 2.0 HDi 163 FAP)
- Removing - refitting: Coolant pump (2.0 HDi 163 FAP, DW10CBDTR)
- Removing - refitting: coolant pump (ES9J4S)
- Removing - refitting: engine cooling radiator
- Removing - refitting coolant pump (DW10ATED4, DW12TED4)
- Removing - refitting coolant pump (EW12J4, EW10J4)
- Removing - refitting: radiator (EW10J4, EW10A, ES9J4S, EW12J4)
- Removing - refitting: coolant outlet housing (DW10UTED4)
- Removing - refitting: additional heating unit (DW10UTED4)
- Removing - refitting: engine cooling radiator (DW10UTED4)
- Removing - refitting: coolant outlet housing temperature sensor (DW10UTED4)
- Removing - refitting: coolant outlet housing temperature sensor (DW10BTED4)
- Removing - refitting: engine cooling radiator (DW10BTED4)
- Removing - refitting: coolant outlet housing (DW10BTED4)
- Removing - refitting: additional heating unit (DW10BTED4)
- Drain and refill - refilling - bleeding: cooling system
- Data: air conditioning systems
- Table: fault codes - additional heating ECU
Air and fuel supply
- Check: air supply circuit (DW10BTED4, DW10UTED4)
- Removing - refitting: fuel filter (DW12BTED4)
- Removing - refitting: air inlet manifold (DW12BTED4)
- Removing - refitting: fuel filter (DW10CBDTR, 2.0 HDi 163 FAP)
- Removing - refitting: inlet air pressure and temperature sensor (2.0 HDi 163 FAP, DW10CBDTR)
- Removing - refitting: fuel tank (DW10CBDTR, 2.0 HDi 163 FAP)
- Removing - refitting: fuel pump-gauge assembly (DW10CBDTR, 2.0 HDi 163 FAP)
- Removing - refitting inlet manifold (ES9J4S)
- Removing - refitting lower manifold (ES9J4S)
- Removal-fitting: fuel gauge tank unit - fuel pump
- Removing - refitting fuel filter (DW12TED4, DW10ATED4)
- Removing - refitting: intake air distributor (EW12J4)
- Removing - refitting: fuel tank (EW10A)
- Removing - refitting: fuel filter (DW10UTED4)
- Removing - refitting: fuel pump and gauge assembly (DW10UTED4)
- Removing - refitting: fuel tank (DW10UTED4)
- Removing - refitting: fuel filter (DW10BTED4)
- Removing - refitting: fuel tank (DW10BTED4, DW12BTED4)
- Removing - refitting: fuel pump and gauge assembly (DW12BTED4, DW10BTED4)
- Removing - refitting: air inlet manifold (DW10BTED4)
- Drain and refill: fuel tank
- Check: additive level (DW12BTED4)
- Check: fuel additive circuit
- Check: fuel additive level (DW10BTED4)
- Removing - refitting: additive injector (DW10BTED4, DW12BTED4)
- Removing - refitting: additive injector (DW10ATED4, DW12TED4)
- Removing - refitting: additive reservoir (DW12TED4, DW10ATED4)
- Removing - refitting: additive tank (DW10BTED4)
- Removing - refitting: additive tank (2.0 HDi 163 FAP, DW12BTED4, DW10CBDTR)
- Refilling: additive tank (DW10CBDTR, DW12BTED4, 2.0 HDi 163 FAP)
- Refilling: additive reservoir (DW10ATED4, DW12TED4)
- Refilling: additive tank (DW10BTED4)
- Modification: particle filter additive
- Removing - refitting fuel filler flap
- Charging procedure: starting batteries
- Table: fault codes - Fuel additive ECU
Emission control
- Removing - refitting: actuator / exhaust gas recycling solenoid valve (DW12BTED4)
- Removing - refitting: oxygen sensor (DW10CBDTR, 2.0 HDi 163 FAP)
- Check: exhaust gas recirculation circuit (DW10CBDTR, 2.0 HDi 163 FAP)
- Removing - refitting: exhaust gas differential pressure sensor (DW12BTED4, DW10CBDTR, 2.0 HDi 163 FAP)
- Removing - refitting: exhaust gas temperature sensor (DW12BTED4)
- Removing - refitting: exhaust gas temperature sensor (2.0 HDi 163 FAP, DW10CBDTR)
- Removing - refitting: exhaust gas recycling module (DW10CBDTR, 2.0 HDi 163 FAP)
- Removing - refitting exhaust gas recycling valve (EGR) (DW10ATED4, DW12TED4)
- Removing - refitting: exhaust gas recycling solenoid valve (DW10UTED4)
- Removing - refitting: exhaust gas recycling solenoid valve (DW10BTED4)
- Removing - refitting: exhaust gas temperature sensors (DW10BTED4)
- Removing - refitting: exhaust gas pressure sensor (DW10BTED4)
- Operations to be carried out on the particulate emission filter with 80 000 Km (EOLYS DPX42 additive) or with 120 000 Km (EOLYS 176 additive) or when the system is clogged (DW10ATED4, DW12TED4)
- Modification: oxygen sensor
- Modification: particle filter additive - frequency of service operations (DW12TED4, DW10ATED4)
- Frequency of service operations
- Help in diagnosis: electric EGR valve DW10B / DW10U SIEMENS engine type (Summary) (DW10BTED4)
- Help in diagnosis: electric EGR valve DW12B BOSCH engine type (Summary) (DW12BTED4)
Turbocharging
- Check: turbocharge pressure (DW12BTED4)
- Check: turbocharger pressure (2.0 HDi 163 FAP, DW10CBDTR)
- Check: turbocharge pressure (DW10UTED4)
- Check: turbocharge pressure (DW10BTED4)
- Removing - refitting: turbocharger pressure regulation electrovalve (DW12BTED4)
- Removing - refitting: turbocharger air cooler (DW12BTED4)
- Removing - refitting: turbocharger (DW12BTED4)
- Removing - refitting: turbo pressure regulator pneumatic control (DW12BTED4)
- Removing - refitting: turbocharger air cooler (2.0 HDi 163 FAP, DW10CBDTR)
- Removing - refitting: control solenoid valves (turbocharger, inlet air mixing, inlet air cooling, EGR) (DW10CBDTR, 2.0 HDi 163 FAP)
- Removing - refitting: Turbocharger (2.0 HDi 163 FAP, DW10CBDTR)
- Removing - refitting turbocharger (DW10ATED4, DW12TED4)
- Removing - refitting: turbocharger air cooler (DW10UTED4)
- Removing - refitting: turbocharger (DW10UTED4)
- Removing - refitting: turbocharger (DW10BTED4)
- Removing - refitting: turbocharger air cooler (DW10BTED4)