2004-2011 Peugeot 407 (Diesel) Service & Repair Manual

REPAIRS AND OVERHAUL Engine and associated systems 1.6 litre. engine in-car repair procedures 2.0 litre engine in-car repair procedures Engine removal and overhaul procedures Cooling, heating and ventilation systems Fuel and e~haust systems Emission co.ntrol systems Sbirting and cnarging systems Pre/post-heating system Transmission Clutch Manual transmission Automatic transmission Driveshafts Brakes and suspension Braking system Suspension and steering Body equipment Bodywork and fittings Body electrical system Wiring diagrams REFERENCE Dimensions and weights Fuel economy Conversion factors Buying spare parts General repair procedures Jacking and vehicle support Vehicle identification numbers Tools and working facilities MOT test checks Fault finding Glossary of technical terms Index Contents Page 2A•1 Pag~ ·2B•1 Page 2C•1 Pa.ge 3•1 Page 4A•1 Page 48•1 Page 5A•1 Page 58•1 Page 7A•.1 Page 9•1 Page 10•1 Page 11•1 Page 12•1 Page 12•25 Page REF•1 Page REF•2 Page REF•6 Page REF•7. Pa~e .·RE.F•8 Page REF•9' .... f Page· REF.•f) . Page REF•24

o•4 Introduction The Peugeot 407 was introduced into the UK in February 2004. At its launch, the 407 was offered with a choice of 1.8 litre, 2.0 litre, 2.2 litre and 3.0 litre petrol engines, or 1.6 litre and 2.0 litre turbo-diesel engines. It was available in two body styles - saloon or estate (SW), and in October 2005 the coupe model was released. The engines fitted to the 407 range are all versions of the well-proven units which have appeared In many Peugeot/Citroen vehicles over the years, including the 1.6 litre HDi engine, which was developed in a joint venture with the Ford Motor Co. The engine is mounted transversely at the front of vehicle, with the transmission mounted on its left-hand end. All engines are fitted with a manual transmission as standard (an automatic transmission is available on certain engines). The front suspension is fitted with double wishbones, with a drop-linked alloy support for the hub carrier and incorporating shock absorbers, coil springs and an anti-roll bar. The rear suspension is a 5-point multi-link suspension with anti-roll bar and shock absorbers, which are angled to enhance stability. A wide range of standard and optional equipment is available within the range to suit most tastes, including central locking, electric windows and front, side and curtain airbags. An air conditioning system is available on all models. Provided that regular servicing is carried out in accordance with the manufacturer's recommendations, the vehicle should prove reliable and very economical. The engine compartment is well designed, and most of the items requiring frequent attention are easily accessible. Your Peugeot 407 manual The aim of this manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done (evE')n should you choose to get it done by a garage). It will also provide information on routine maintenance and servicing, and give a logical course of action and diagnosis when random faults occur. However, it is hoped that you will use the manual by tackling the work yourself. On simpler jobs it may even be quicker than booking the car into a garage and going there twice, to leave and collect it. Perhaps most important, a lot of money can be saved by avoiding the costs a garage must charge to cover its labour and overheads. The manu~I. has drawings iind descriptions to showtheft.inction of the various components so that their layout can be understood. Tasks are described and photographed in a clear step-by-step sequence. References to the 'left' and 'right' of the vehicle are in the sense of a person in the driver's seat facing forward. Acknowledgements Thanks are due to Draper tools Limited, who provided some of the workshop tools, and to all those people at Sparkford who helped in the production of this manual. We take great pride in the accuracy of information given in this manual, but vehicle manufacturers make alterations and design changes during the production run of a particular vehicle of which they do not inform us. No liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

Working on your car can be dangerous. This page shows just some of the potential risks and hazards, with the aim of creating a safety-conscious attitude. General hazards Scalding • Don't remove the radiator or expansion tank cap while the engine is hot. •Engine oil, transmission fluid or power steering fluid may also be dangerously hot if the engine has recently been running. Burning • Beware of burns from the exhaust system and from any part of the engine. Brake discs and drums can also be extremely hot immediately after use. Crushing •When w9rking under or near da a rljlised vehicle, always .... •. !!: supplement the Jack ~~ . ~ w!tti.ax.le.sta.nds, ///, ~ ;,;,.lt or use drive-on I~ --- ramps. Never venture • II )) under a car \ll~. dJ~~SJ~ which is.only ~~b- supportedby a Jack• • l"ake, care if loosening or tightening high- torque nuts when the vehicle is on stands. Initial loosening and final tightening should be done with the wheels on the ground. Fire • Fuel. is highly flammable; fuel vapollr, is explosive. • Don't.let fuel spill onto a hot engine. • Do not smoke or allow naked lights (including pilot lights) anywhere near a . vehicle being worked on. Also beware of creating sparks (electrically or by use of tools). • Fuel vapour is heavier than air, so don't work on the fuel system with the vehicle over an inspection pit. • Another cause of fire is an electrical overload or short-circuit. Take care when repairing or modifying the vehicle wiring. • Keep a fire extinguisher handy, of a type suitable for use on fuel and electrical fires. Electric shock • Ignition HT and Xenon headlight voltages can be dangerous, especially to ,.,. people with ,.r heart problems or .f a pacemaker. Don't ..f work on or near ./ , these systems with ) ~ the engine running or J j \ ~ \ ""- the ignition switched on. • Mains voltage is also dangerous. Make sure that any mains-operated equipment is correctly earthed. Mains power points should be protected by a residual current device (RCD) circuit breaker. fume. or gas intoxication • Exhaust fumes are poisonous; they can contain carbon monoxide, which is rapidly fatal if inhaled. Never run the engine in a confined space such as a garage with the doors shut. • Fuel vapour is also poisonous, as are the vapours from some cleaning solvents and paint thinners. Poisonous or.irritant substances . . •Avoid skin contact with batter,y aciclar:id with any fuel, .fluid or lubricant, especially antifreeze, brake hydraulic fluid and Diesel fuel. Don't syphon them by mouth. If such a sut;,.stance isswljlllowed orgets into the eyes, seek medical advice. • Pr9lor,iged contact with used engine oil can cau~e skin cancer.Wear gloves or use a barrier cream if necessar,y: Change out of oil-$oaked clothes .and do not k!3ep oily rags in your pocket. • Air conditioning refrigerant forms a poisonous gas if exposed to a naked flame (including a cigarette). It can also cause skin burns on contact. Asbestos •Asbestos clust .can cause·caneer if inhaled or swallowed: Asbestos may be found in gaskets and in brake. and clutch linings. When dealing with such components it is saf(;lstto assume that they contain asbestos. Safety First! o•s Special hazards Hydrofluoric acid • This extremely corrosive acid is formed when certain types of synthetic rubber, found in some 0-rings, oil seals, fuel hoses etc, are exposed to temperatures above 4000C. The rubber changes into a charred or sticky substance containing the acid. Once formed, the acid remains dangerous for years. If it gets onto the skin, it may be necessary to amputate the limb concerned. • When dealing with a vehicle which has suffered a fire, or with components salvaged from such a vehicle, wear.protective gloves and discard them after use. The battery • Batteries contain sulphuric acid, which attacks clothing, eyes and.skin. Take.care when topping-up or carr,yiRgthe battery, •The hydrogen gas given off by the batter,y is highly explosive. Never cause a spark or allow a naked light nearby. Be carefur when connecting and disconnecting batter,y chargers or jump leads. Air bags • Air bags can cause injur,y if they go off accidentally. Take care when removing the steering wheel and trim panels. Special storage instructions. may apply. Diesel injection equipment • Diesel injection pumps supply fuel at ver,y high pressure. Take care when working on the fuelinjectors and fuel pipes. · + Wa. rm.'ng. : N .. ever exp.· .. o.se ... thehands, ,Lil.· face or any other part ofthe body to injector spray; the fuel can penetrate the skin with potentially fatal .results.

o•6 Roadside repairs The following pages are intended to help in dealing with common roadside emergencies and breakdowns. You will find more detailed fault finding information at the back of the manual, and repair information in the main chapters. If your car won't start and the starter motor doesn't turn O If it's a model with automatic transmission, make sure the selector is in the P or N position. O Open the bonnet and make sure that the battery terminals are clean and tight. O Switch on the headlights and try to start the engine. lf the headlights go very dim when you're trying to start, the battery is probably flat. Try jump starting (see next page) using another car. If your car won't start even though the starter motor turns as normal D ls there fuel in the tank? D Is there moisture on electrical components under the bonnet? Switch off the ignition, and then wipe off any obvious dampness with a dry cloth. Spray a water-repellent aerosol product (WD-40 or equivalent) on fuel system electrical connectors like those shown in the photos. A Remove the plastic cover and check the condition and security of the battery connections. B Check .that the fuel system wiring connectors are securely connected. C Check that th.e alt~rnator wiring connectors are securely connectecj. Check that electrical connections are secure (with the ignition switched off) and spray them with a water dispersant spray like WD-40 if you suspect a problem due to damp. D Check tt:iat all fuses are .still in .good condition and none have blown.

Connect one.end of the red jump lead to the positive (+) terminal of the flat battery - . - When jump-starting a car, observe the following precautions: ./ Before connecting the booster battery, make sure that the ignition is switched off. Caution: Remove the key in case the central locking engages when the jump leads are connected ./ Ensure that all electrical equipment (lights! heater, wipers, etc) is switched off. .t Take note of any special precautions printed on the battery c13se, .r Make .sure that the booster battery is the same voltage as the discharged one in the vehicle. - Connect the other end ofthe red lead to the positive (+)terminal of the booster battery. --, r -- I I I _J r - I I I - -- - ....... -I Roadside repairs 0·1 Jump starting ./ If the battery is being jump-started from the battery in another vehicle, the two vehicles MUST NOT TOUCH each other. ./ Make sure that the transmission is in neutral (or PARK, in the case of automatic transmission). Connect the other end oftfl.eblack jump lead to a bolt or .bracket on th.e engii:le bloc~, well away from the battery, on the vehi.cle to be started. I Make. sure t.hatthe jump leads will not come into contact with the fan, driv~-belts or other moving parts of the engine. i Start the engine using the booster battery and run it at idle speed. Switch on the lights, rear window demister and heater blower motor, then disconnect the jump leads in the reverse order of connection. Turn off the lights etc .

o•a Roadside repairs Wheel changing IA_ warning: Do not change a wheel Chang'ng the whe I ~ in a situation where you risk being I e hit by another vehicle. On busy roads, try to stop in a lay-by or a gateway. Be wary of passing traffic while changing the wheel - it is easy to become distracted by the job in hand. Preparation D When a puncture occurs, stop as soon as it is safe to do so. D Park on firm level ground, if possible, and well out of the way of other traffic. D Use hazard warning lights if necessary. D If you have one, use a warning triangle to alert other drivers of your presence. D Apply the handbrake and engage first or reverse gear (or Park on models with automatic transmission). D If the ground is soft, use a flat piece of wood to spread the load under the foot of the jack. 1 The spare wheel and tools are stored in the luggage compartment, lift up the floor panel/carpet. Release the retaining strap and remove the tool kit and jack from the centre of the spare wheel. Remov.e the spare wheel. 2 On models with steel wheels, remove the wheel trim/hub cap. On models with alloy wheel~ remove the plastic cover using the yellow plastic toolin the tool kit .•• 3 ... t.hen .unscrew the anti-theft bolt using the special tool provided - normally stored in the passenger glovebox or toolkit. 4 With the vehicle still on the ground, use the tool provided to slacken each wheel bolt by half a turn. 5 Make sure the jack is located on firm ground, and engage the jack head correctly with the sill. Then raise the jack until the wheel is raised clear of the ground. Use a stone to chock the wheel diagonally opposite the wheel to be removed to prevent the car from rolling. 6 Unscrew the wheel bolts and remove the wheel. Place the wheel under the vehicle sill in case the jack fails.

Roadside repairs o•9 7 . . F:ifoh. e spare wheel and screw in the bolts. Ligl1t.ly t.ightel1 tfle bol.ts with the wheel brace then lower the car to the ground. ·· 8 · ... S ·' .c .. • .• thew.flee! bolts ln a diagonal sequence then refit th~JIV!ieaf trir,)l<hub cap{V'{hef;11 b.olt covers (as applicable). Stow the p9r:ictμrec:L1¥heel and .tools l;>ack ln the boot, and secure them in position. Finally ••• O Remove the wheel chock. O Check the tyre pressure on the wheel just fitted. If it is low, or if you don't have a pressure gauge with you, drive slowly to thf;1 next garage and inflate the tyre to the correct pressure. only; whilstthf;1 spare is fitted, the vehicle should not be driven at speeds in excess of qp mph. The Wheel bo.lts should be slackened and retightened to the specified torque at the earliest possible opportunity {see Chapter 1 ). Have the damaged tyre or wheel repaired as soon as possible, or another puncture will leave you stranded. O On models with a space-saver spare wheel, a higher pressure is given for the spare tyre and note that this spare is for temporary use Towing When. au else fails, ·you may find yourself having to get a tow home - or of course you may be helping somebody else. Long-distance recovery s.hould only be done by a garage or breakdown service. For shorter distances, DIY towing using another car is easy enough, but observe the following points: G)U~e a prop~r tow-rope - they are not e¥pensive. The. vehicle being towed must di~play an ON TOW sign in its. rear window'. drf'he towing eye is kept inside the spare wheel (see Wheel changing) .. To fit the eye, unclip the access .cover from the relevant bumper and· $crew the eye firmly into position (see illustrations). DAlways turn· the ignition key to the 'on' position when the vehicle is being towed, so that the steering lock is released, and that the direction indicator and brake lights work. ••• then use the wheel brace to screw the towing eye in securely O Before being towed, release the .handbrake and select neutral on the transmission. Caution: On models with automatic transmission, do not tow tf:le c.ar.at speeds in excess of 30 mph or for .a distance greater than 30 miles. If towing speeds/ distances are to ex;ceed these limits, then the carmust be towed with,~ts front wnee/s off the ground. O Note that greater~than-usual pedal pressure will be required to operate the. brakes, since the vacuum servo unit is only operational with the engine running. OThe driver of the car being towed must keep the tow-rope taut at all times.to avoid snatching. 0 Make sure that both drivers know the route before setting off. O Only drive at moderate speeds and keep the Use the towing eye to unclip the cover in the front bumper ••• distance towed to a minimum. Drive smoothly and allow plenty of time for slowing down at junctions. Unclip the cover from the rear bumper ••• ••. and then screw the towing eye firmly into position

0•10 Roadside repairs Identifying leaks Puddles on the garage floor or drive, or obvious wetness under the bonnet or underneath the car, suggest a leak that needs investigating. It can sometimes be difficult to decide where the leak is corning from, especially if an engine undershield is fitted. Leaking oil or fluid can also be blown rearwards by the passage of air under the car, giving a false impression of where the problem lies. Engine oil may leak from the drain plug ... Antifreeze Leaking antifreeze often leaves a crystalline deposit like this: Warning: Most automotive oils and fluids are poisonous. Wash them off skin, a.nd change out of contaminated clothing, without delay. . .. or from the base of the oil filter. Brake fluid A leak occurring at a wheel is almost certainly brake fluid. Gearbox oil can leak from the seals at the inboard ends of the driveshafts. Power steering fl.uid Power steering fluid may leak from the pipe connectors on the steering rack.

2004-2011 Peugeot 407 (Diesel) Service & Repair Manual

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