Manual sections
Wiring diagrams- Battery
- Body
- Bodywork
- Braking
- Comfort and convenience
- Current generation
- Dashboard
- Electrical harnesses
- Engine
- Front anti -roll bar
- Front axle
- Front seats
- Front section
- Front shock absorbers
- Gearbox assembly
- General points
- General points about the vehicle
- Instrument panel
- Instruments and controls
- Lighting - signalling
- Mechanical
- Power unit
- Pre-heating
- Protections and doors
- Rear axle
- Rear section
- Roof panel
- Side structure
- Steering
- Suspension
- Transmission
- Washing and wiping
Repair manual
Engine Peugeot Expert I
Step-by-step instructions on "Engine" for Peugeot Expert I (1995–2006). Pick an article — removal, installation, adjustment and diagnostics with illustrations.
Crankshaft
- Removing - refitting: ancillary drive belt (1580 SPI)
- Data: conrods
- Data: crankshaft
- Data: pistons - piston rings
- Data: conrods (DW8B)
- Data: crankshaft (DW8B)
- Data: pistons - piston rings - the piston shaft (DW8B)
- Removing - refitting lip seals (1580 SPI)
- Removing - refitting: ancillary drive belt (DW8)
- Matching: bearing shells (1580 SPI)
- Matching bearing shells (1580 SPI) — variant 2
- Matching: main bearing shells (1580 SPI)
- Identification - data: pistons - piston rings
- Identification - data: crankshaft
- Identification - data: half shells
- Data - identification ancillary shaft (1580 SPI)
- Data - identification pistons - piston rings (1580 SPI)
- Modification: reciprocating gear
- Data - identification conrods (1580 SPI)
- Data - identification crankshaft - half shells (1580 SPI)
- Data - identification conrods
- Check liner protrusion
- Check crankshaft pulley
- Assembly connecting rods - pistons
- Removing - refitting: ancillary drive belt
Ignition
- Pressurising the fuel system
- Pressurising the fuel system — variant 2
- Injection-ignition: BOSCH MP7.0
- Injection-ignition: BOSCH MP7.0 — variant 2
- Help in diagnosis
- Help in diagnosis — variant 2
- Check: ignition advance
- Check: ignition advance — variant 2
- Check high voltage present
- Check high voltage present — variant 2
- Check high voltage present — variant 3
- Check high voltage present — variant 4
- Check high voltage present — variant 5
- Check high voltage present — variant 6
- Foot Off/Foot Down recognition
- Foot Off/Foot Down recognition — variant 2
- Injection-ignition wiring diagram: injection ignition
- Injection-ignition wiring diagram: injection ignition — variant 2
Engine block
- Data: cylinder block (DW8B)
- Sealing: cylinder block - lower cover
- Data - identification cylinder block
- Data - identification cylinder block (1580 SPI)
- Identification - data: cylinder block
- Check: diesel high pressure monitoring function
- Check: diesel high pressure monitoring function — variant 2
- Check: sensor supply function (accelerator pedal sensor, inlet pressure sensor, fuel pressure sensor, cylinder reference sensor)
- Check: sensor supply function (accelerator pedal sensor, inlet pressure sensor, fuel pressure sensor — variant 2
Cylinder head
- Data: cylinder head (DW8B)
- Data: swirl chambers (DW8B)
- Data: valves and valve springs (DW8B)
- Data: valve seats and guides (DW8B)
- Data: cylinder head gasket (DW8B)
- Data: cylinder head bolts - cylinder head tightening
- Stripping-assembling: cylinder head (DW8B)
- Modification: cylinder head
- Refitting: cylinder head
- Refitting: cylinder head - camshaft housing (1580 SPI)
- Data - identification: cylinder head gasket
- Data - identification valve springs (1580 SPI)
- Data cylinder head tightening (1.9 TD, XUD9)
- Identification cylinder head gasket (XUD9, 1.9 TD)
- Data - identification valve guides
- Identification, data, tightening torque(s): cylinder head
- Identification - data: cylinder head gasket
- Identification - data: cylinder head bolts
- Data - identification valves
- Data - identification valve springs
- Data - identification valve seats
- Data - identification cylinder head gasket (1580 SPI)
- Data - identification: cylinder head gasket — variant 2
- Data - identification valve guides (1580 SPI)
- Data valves (1580 SPI)
- Data valve seats (1580 SPI)
- Data: valves
- Data: valve seats
- Data: valve springs
- Data: abutment washer - valve spring
- Identification - data: cylinder head gasket (DW10BTED W3, DW10ATED)
- Identification: cylinder head bolt
- Identification: cylinder head bolt — variant 2
- Identification: cylinder head bolts
- Identification: cylinder head bolts — variant 2
- Removing - refitting cylinder head (1580 SPI)
- Removing - refitting: cylinder head (DW8)
- Removing - refitting cylinder head (1.9 TD)
- Removing - refitting cylinder head (XU7JP)
- Removing - refitting: cylinder head cover (DW10ATED4)
- Removing - refitting: cylinder head (DW10ATED4)
- Stripping - re-assembling: cylinder head (XU7JP)
- Overhaul cylinder head / camshaft housing (1580 SPI)
- Overhaul: cylinder head
- Modification: XU5JP, XU7JP engines (XU7JP)
- Modification: XU5, XU7 engine (XU7JP)
- Data: timing gear
- Checks and adjustments valve clearances (1580 SPI)
- Checks and adjustments: valve clearances (DW8)
- Adjustment: valve clearances (8 valve engine(s)) (XU7JP)
Timing gear
- Data: camshaft (DW8B)
- Data: timing gear (DW8B)
- Data - identification camshafts
- Data identification camshaft housing (1580 SPI)
- Data identification camshaft, valve clearance adjustment shims (1580 SPI)
- Data: camshafts
- Standard replacement
- Timing check camshaft chain (DW10ATED4)
- Check end of compression pressures
- Check end of compression pressures — variant 2
- Removing - refitting: timing belt (1580 SPI)
- Removing - refitting camshaft housing (1580 SPI)
- Removing - refitting camshaft (1580 SPI)
- Removing - refitting: accessories belt dynamic tensioner
- Removing - refitting: camshaft (DW8)
- Removing - refitting: timing belt (DW8)
- Removing - refitting: timing covers (DW8, DW10ATED, DW10TED, DW10BTED W3)
- Removal - refitting: timing covers (DW8, DW10ATED, DW10TED, DW10BTED W3)
- Removing - refitting: timing belt (DW10ATED4)
- Removing - refitting camshaft (DW10ATED4)
- Removing - refitting: timing belt (from RPO No. 10064) (DW8B)
- Removing - refitting: timing belt (second assembly) (DW10ATED)
- Modification: removal of the crankshaft pulley bolt (DW10BTED, DW10ATED, DW10BTED W3, DW10BTED W4, DW10TD, DW10TED)
- Modification: timing gear (DW10BTED W3, DW10BTED)
- Presentation - use: D-TEK de LEYBOLD refrigerant leak detector (part number 9776.X9)
- Presentation - use: D-TEK de LEYBOLD refrigerant leak detector (Part No. 9776.X9)
Exhaust
Emission control
Lubrication
- Capacity of units
- Recommendations lubricants
- Recommendations: lubricants — variant 2
- General: lubrication
- Capacity: engine oil
- Recommendations: oils for petrol engines
- Recommended engine oils (DIESEL)
- Data - tightening torques: lubrication (engine)
- Recommendations: lubricants — variant 3
- Check oil pressure (DW10ATED4)
- Check: oil pressure (With oil pressure switch)
- Check: oil pressure (Without oil pressure switch) (DW10ATED, DW10TD, EW10J4)
- Replace: engine oil filter cartridge
- Suction draining (engine)
- Assembly: new engine oil filter cartridge
- Data: cooling system
- Replace: engine oil filter cartridge (DW10BTED W3, DW10ATED, DW8, DW10TED)
- Replace: engine oil filter cartridge — variant 2
- Replacement: engine oil filter cartridge (DW8, DW10ATED, DW10TED, DW10BTED W3)
- Modification: Lubrication kit
- Maintenance: recommended ingredients, year 2006
Cooling system
- Maintenance: fluids recommendation
- Data cooling system (1580 SPI)
- Identification: components
- Data cooling system (1.9 TD, XUD9)
- Removing - refitting: coolant pump
- Removing - refitting: coolant pump (DW8, DW10ATED4)
- Drain and refill - refilling - bleeding: cooling system
- Application: tooling
- Schematic diagram: coolant thermostat
- Check: coolant thermistor function
- Check: coolant thermistor function — variant 2
- Coolant temperature sensor check
- Coolant temperature sensor check — variant 2
- Check: purge canister solenoid valve function
- Check: purge canister solenoid valve function — variant 2
- Data: air conditioning systems
- Drain and refill - refilling: refrigerant circuit
- Modification: new coolant
Air and fuel supply
- Removing - refitting: diesel filter assembly (DW10TD)
- Recommended tools
- Checks: idling - emission control
- Checks: idling - emission control — variant 2
- Checks: idling - emission control — variant 3
- Checks: idling - emission control — variant 4
- Removal-fitting fuel gauge tank unit - fuel pump (1580 SPI)
- Removing - refitting fuel filler neck (DW8)
- Removal-fitting fuel gauge tank unit - fuel pump (DW8)
- Removing - refitting fuel tank (DW8)
- Removal-fitting: fuel tank (1580 SPI)
- Removal-fitting: fuel filler neck (1580 SPI)
- Removing - refitting: fuel system click-on connectors
- Replacement: stop electrovalve - transponder module (mechanical or semi-electronic pump BOSCH)
- Replacement: stop solenoid valve - transponder module (mechanical or semi-electronic pump BOSCH)
- Replacement: stop electrovalve - coded anti-start module (mechanical or semi-electronic pump BOSCH - metal screening)
- Replacement: stop solenoid valve - coded anti-start module (mechanical or semi-electronic pump BOSCH - metal screening)
- Replacement: stop electrovalve - transponder module (mechanical or semi-electronic pump LUCAS)
- Replacement: stop solenoid valve - transponder module (mechanical or semi-electronic pump LUCAS)
- Removing - refitting fuel filter (DW10ATED4)
- Replacement: diesel fuel filter (DW8)
- Check: ignition advance
- Check: ignition advance — variant 2
- Charging procedure: starting batteries
- Conditions for working on the diesel circuit (DW10TD, DW10ATED)
- Conditions for working on the diesel circuit (DW10ATED, DW10TD)