engine Peugeot 407 2009 Service Manual

9CHECKS
109
2.2 LITRE HDI 16V AND 2.7 LITRE HDI 24V DIESEL ENGINES
* According to country.

Important: if you have to
remove/refi t the engine style
cover, handle it with care to
avoid damaging the fi xing clips.
Check the levels!

1. Power steering reservoir.

2. Engine coolant reservoir
(expansion bottle).

3. Engine oil fi ller cap.

4. Brake fl uid reservoir.

5. Air fi lter.

6. Dipstick.

7. Windscreen and headlamp wash
fi ller cap *.

8. Priming pump.

9. Degas screw.

9CHECKS
110
CHECKING THE LEVELS
These are normal maintenance opera-
tions which keep your vehicle in good
working order. Consult the instructions
in the PEUGEOT Network or in the
servicing booklet enclosed with this
handbook.
Dipstick There are two marks on
the dipstick:

A = maximum
Never fi ll past this mark.

B = minimum
To maintain the reliability
of engines and emission
control systems, the use
of additives in engine oil is
prohibited.
Oil level

 Check the level regularly and top
up between changes.
Check the level with the vehicle level,
the engine having been off for more
than 15 minutes, using the dipstick. Oil change
It is imperative that this is carried out at
the intervals specifi ed and the viscosity
of the oil chosen must meet the require-
ments laid down in the manufacturer’s
servicing schedule. Consult the instruc-
tions in the PEUGEOT Network.

Note: avoid used oil coming into pro-
longed contact with the skin. Empty the
used oil into the containers provided for
this purpose in the PEUGEOT Network. system is pressurised, wait for at least
one hour after the engine has stopped
before carrying out any work.
Oil filter
Replace the cartridge regularly in
accordance with the recommendations
of the servicing schedule.
Brake fluid change
Use the fl uid recommended by the
manufacturer, which fulfi ls DOT4
Standards.
It is imperative that the brake fl uid is
changed at the intervals specifi ed in
accordance with the manufacturer’s
servicing schedule.

Note: avoid all contact with the skin,
the brake fl uid is harmful to health and
very corrosive. Used oil
Power steering reservoir
Use the fl uid recommended by the
manufacturer.

 Open the reservoir, with the engine
at ambient temperature. The level
should always be above the MIN.
mark and close to the MAX. mark.
Cooling system Windscreen and headlamp
wash level
To guarantee optimum cleaning and
avoid freezing, this fl uid should not be
topped up or replaced with water. Slacken the cap by two turns
to release the pressure to pre-
vent any risk of scalding. When
the pressure has dropped,
remove the cap and top up the
level.

Note: the coolant does not need to be
changed.
Use the fl uid recommended
by the manufacturer.
When the engine is warm, the
temperature of the coolant is
controlled by the engine fan. As this
fan can operate with the ignition key
removed and because the cooling Do not dispose of used oil,
brake fl uid or coolant into
drains or onto the ground.

Important: if you have to
remove/refi t the engine style
cover, handle it with care to
avoid damaging the fi xing clips.

9CHECKS
111
CHECKS
At the start of winter, have
your battery checked by a
PEUGEOT dealer.
Have the fi lter elements
replaced regularly. If you drive
in dusty conditions, change
them twice as often.
Air filter and passenger compartment filter
Particle emission filter (Diesel)
It is imperative that the particle emis-
sion fi lter is maintained in accordance
with the manufacturer’s servicing
schedule, by a PEUGEOT dealer.

Note: following prolonged operation of
the vehicle at very low speed or at idle,
you may, in exceptional circumstances,
notice emissions of water vapour at the
exhaust on acceleration. This does not
have any effect on the performance of
the vehicle or the environment.
On vehicles which are fi tted with a
particle emission fi lter, the fan as-
sembly may operate after the vehicle
has stopped, even when the engine is
cold. Where the handbrake travel is
too great or there is a reduc-
tion in the performance of the
system, the handbrake should
be adjusted.
Have the system checked by a
PEUGEOT dealer.
Handbrake
Disc wear status
For any information relating to checking
disc wear, contact a PEUGEOT dealer.
FUEL SUPPLY CUT-OFF
(PETROL) *
As a safety precaution, in certain circum-stances, a mechanism prevents fuel from reaching the engine. To re-establish the fuel supply:
RUNNING OUT OF FUEL (DIESEL)
If you should run out of fuel, it is neces-
sary to re-prime the circuit.
The repriming pump and the degas
screw are located under the bonnet
(see corresponding illustration in the
technical data section):
1.6 litre 16V HDI engine
- fi ll the fuel tank with at least fi ve
litres of diesel,
- squeeze and release the manual re-priming pump, until fuel appears
in the transparent pipe,
- operate the starter until the engine starts.
2 litre 16V HDI engine
- fi ll the fuel tank with at least fi ve litres of diesel,
- unscrew the degas screw,
- squeeze and release the manual repriming pump until diesel is seen
escaping via the degas screw,
- retighten the degas screw,
- operate the starter until the engine starts.
Brake pad wear depends on
the style of driving, in particu-
lar for vehicles which are used
in town, over short distances.
Brake pads It may be necessary to check
the thickness of the pads,
even between services.
* According to version.
To ensure the best perfor-
mance from components as
important as the power steer-
ing and the braking system, the
manufacturer selects and offers specifi c
products, only use products recom-
mended by PEUGEOT .
Battery
To prevent damage to the electrical units,
high pressure washing of the engine
compartment is strictly prohibited .
 press the red button on the angle of the front right-hand suspension assembly, under the bonnet.

1010PRACTICAL INFORMATION
115
CHANGING A FRONT BULB
Handle the bulbs with a dry cloth.
2 - Main beam headlamps: H7-55 W.

 Remove the protective cover cor-
responding to the faulty bulb.

 Disconnect the connector.

 Press the end of the securing clips
to free the bulb. Change the bulb.

 When fi tting the new bulb, ensure that
the direction notches are positioned
correctly and the securing clips are
fi xed properly.

 Reconnect the connector.

 Refi t the protective cover.

4 -
Direction indicators:
PY 21 W (amber).

 Turn the bulb holder a quarter turn
and remove it.

 Change the bulb.

WARNING: RISK OF
ELECTROCUTION
Front lights
In the engine compartment, remove
the cover secured by one or two but-
terfl y screws, a plastic retainer clip and
two quarter turn screws.

1 - Dipped beam headlamps:
H1-55 W or D2S-35 W xenon bulb.
Xenon bulbs must be replaced by a
PEUGEOT dealer. Amber coloured bulbs (direction
indicators and side repeaters)
must be replaced with bulbs
of identical specifi cation and
colour.
5 - Front fog lamps: H11 - 55 W.
Turn the wheels to full lock.
Access to the bulb is via the fl ap in the
front mud fl ap.
Consult a PEUGEOT dealer.
The headlamps are fi tted with polycar-
bonate glass with a protective coating.
Do not clean them with a dry or abra-
sive cloth, nor with a detergent or sol-
vent product.
Ensure that the liquid used to fi ll the
wash-wipe and headlamp wash reser-
voir is of good quality.

High pressure washing :
when using a high pressure
washer on stubborn dirt, do
not persist on the headlamps,
the lights and their periphery to avoid
damaging their coating and their seal.
In certain climatic conditions (low tem-
perature, humidity), condensation on
the inside surface of the headlamp
glass and rear lights glass is normal;
it disappears a few minutes after the
lights are switched on.

3 - Side lights: W 5 W.

 Remove the protective cover, dis-
connect the connector and then
remove the bulb and change it.

 Put the connector back in place.

 Reconnect the connector.

 Refi t the protective cover.

1010PRACTICAL INFORMATION
118
CHANGING A FUSE
The fuse boxes are placed in the lower
part of the fascia (passenger side in
the glove box) and in the engine com-
partment (left-hand side). Fascia fuses
To access the fuses, open the glove box. Open the fuse box co
ver by pressing the
two tabs at the top.
Replacing a fuse
Before replacing a fuse, the cause of
the incident must be found and recti-
fi ed. The fuse numbers are indicated
on the fuse box. Always replace a faulty fuse
with a fuse of the same rating
(same colour).
Use the special pliers located
on the support next to the fuse box,
this support also contains the replace-
ment fuses.
Fuse N°
Rating

A
Functions

F1 15 Rear wiper.

F2 30 Central locking/deadlocking.

F3 5 Air bags.

F4 10 ESP dual function sensor, diagnostic connector,
sunroof (Saloon), steering wheel angle sensor.

F5 30 Front one-touch electric windows, sunroof
(Saloon), panoramic roof concealing fl ap
(407SW).

F6 30 Rear one-touch electric windows.

F7 5 Glove box light, side repeaters, front and rear
courtesy lights, map reading lights, courtesy
mirror.

F8 20 Multifunction display, audio equipment, steering
wheel control, trailer fuse box, alarm control
unit, navigation-telematics (according to
country).

1010PRACTICAL INFORMATION
118
CHANGING A FUSE
The fuse boxes are placed in the lower
part of the fascia (passenger side in
the glove box) and in the engine com-
partment (left-hand side). Fascia fuses
To access the fuses, open the glove box. Open the fuse box co
ver by pressing the
two tabs at the top.
Replacing a fuse
Before replacing a fuse, the cause of
the incident must be found and recti-
fi ed. The fuse numbers are indicated
on the fuse box. Always replace a faulty fuse
with a fuse of the same rating
(same colour).
Use the special pliers located
on the support next to the fuse box,
this support also contains the replace-
ment fuses.
Fuse N°
Rating

A
Functions

F1 15 Rear wiper.

F2 30 Central locking/deadlocking.

F3 5 Air bags.

F4 10 ESP dual function sensor, diagnostic connector,
sunroof (Saloon), steering wheel angle sensor.

F5 30 Front one-touch electric windows, sunroof
(Saloon), panoramic roof concealing fl ap
(407SW).

F6 30 Rear one-touch electric windows.

F7 5 Glove box light, side repeaters, front and rear
courtesy lights, map reading lights, courtesy
mirror.

F8 20 Multifunction display, audio equipment, steering
wheel control, trailer fuse box, alarm control
unit, navigation-telematics (according to
country).

1010PRACTICAL INFORMATION
119

Fuse N°
Rating

A
Functions

F9 30 Lighter, telematics (according to country), rear 12V accessories so cket (100 W max).

F10 15 Tyre under-infl ation detection unit.

F11 15 Diagnostic socket, ignition switch.

F12 30 Hands-free kit, trailer socket, trailer fuse box, audible rear pa
rking assistance,
passenger’s electric seat, rain and brightness sensor, alarm.

F13 5 Engine fuse box, windscreen wipers relay control.

F14 15 Driver’s electric seat, instrument panel, air conditioning control panel, air bags control unit.

F15 15 Electric child lock, rear doors deadlocking.

F17 40 Heated rear screen.

FS1 - PARC shunt.

1010PRACTICAL INFORMATION
122
The electrical system of your
vehicle is designed to oper-
ate with standard or optional
equipment.
Before installing other electrical equip-
ment or accessories on your vehicle,
contact a PEUGEOT dealer.
PEUGEOT will not accept responsi-
bility for the cost incurred in repairing
your vehicle or for rectifying the mal-
functions resulting from the installa-
tion of accessories not supplied and
not recommended by PEUGEOT and
not installed in accordance with its
instructions, in particular when the
combined consumption of all of the ad-
ditional equipment connected exceeds
10 milliamperes.
The maxi-fuses provide additional
protection for the electrical systems.
All work must be carried out by a
PEUGEOT dealer. CHANGING A WINDSCREEN WIPER BLADE ECONOMY MODE FUNCTION
After the engine has stopped, certain
electrical functions can be used for a
maximum duration of approximately
one hour, to prevent discharging of the
battery.
A fl at battery prevents the
engine from starting.
As winter approaches, have your bat-
tery checked by a PEUGEOT dealer. If the telephone is being used
when economy mode starts,
it will still be possible to fi nish
the call.
Placing the wiper blades in the
maintenance position


Less than one minute after switching
off the ignition, press the windscreen
wiper stalk down once to position the
blades at the top of the windscreen
(maintenance position).
Replacing a blade

 Lift the arm, then unclip the blade
and remove it.

 Fit the new blade and fold down
the arm.
To reposition the blades, switch on the
ignition and operate the windscreen
wiper stalk. This period may be signifi -
cantly reduced if the battery
charge is low.
Once the hour is over, a message ap-
pears on the multi-function display
and the active functions are put on
standby.
These functions are automatically re-
activated when the vehicle is started.

1010PRACTICAL INFORMATION
Engine compartment fuses
To access the fuses located in the
engine compartment (next to the bat-
tery), remove the battery cover and
unclip the fuse box cover.
Close the fuse box cover carefully and
refi t the battery cover when you have
fi nished.
Fuse N°
Rating

A
Functions

1 20 Engine management control unit.

2 15 Horn.

3 10 Front and rear wash-wipe.

4 20 Headlamp wash.

5 15 Engine management actuators (fuel pump,
purge canister solenoid valves, ...).

6 10 Automatic gearbox control unit.

7 10 Switching and protection unit, intake air
fl ow sensor, clutch switch, six-speed
automatic gearbox switch, STOP switches,
electrochromatic mirror, panoramic roof
concealing fl ap controls (407 SW).

8 20 Starter coil.

9 10 Xenon bulb electronic supply, STOP switch,
power steering electropump assembly,
four-speed automatic gearbox control unit,
automatic gearbox locking relay.

10 30 Engine management actuators (ignition coil,
solenoid valves, oxygen sensors).

11 40 Air conditioning blower or not used.

12 30 Windscreen wipers.

13 40 Built-in systems interface supply
(ignition positive).

14 30 Air pump.

1010PRACTICAL INFORMATION
122
The electrical system of your
vehicle is designed to oper-
ate with standard or optional
equipment.
Before installing other electrical equip-
ment or accessories on your vehicle,
contact a PEUGEOT dealer.
PEUGEOT will not accept responsi-
bility for the cost incurred in repairing
your vehicle or for rectifying the mal-
functions resulting from the installa-
tion of accessories not supplied and
not recommended by PEUGEOT and
not installed in accordance with its
instructions, in particular when the
combined consumption of all of the ad-
ditional equipment connected exceeds
10 milliamperes.
The maxi-fuses provide additional
protection for the electrical systems.
All work must be carried out by a
PEUGEOT dealer. CHANGING A WINDSCREEN WIPER BLADE ECONOMY MODE FUNCTION
After the engine has stopped, certain
electrical functions can be used for a
maximum duration of approximately
one hour, to prevent discharging of the
battery.
A fl at battery prevents the
engine from starting.
As winter approaches, have your bat-
tery checked by a PEUGEOT dealer. If the telephone is being used
when economy mode starts,
it will still be possible to fi nish
the call.
Placing the wiper blades in the
maintenance position


Less than one minute after switching
off the ignition, press the windscreen
wiper stalk down once to position the
blades at the top of the windscreen
(maintenance position).
Replacing a blade

 Lift the arm, then unclip the blade
and remove it.

 Fit the new blade and fold down
the arm.
To reposition the blades, switch on the
ignition and operate the windscreen
wiper stalk. This period may be signifi -
cantly reduced if the battery
charge is low.
Once the hour is over, a message ap-
pears on the multi-function display
and the active functions are put on
standby.
These functions are automatically re-
activated when the vehicle is started.