engine PEUGEOT 807 2002.5 Service Manual

2 LITRE AND 2.2 LITRE 16V
PETROL ENGINES
1 Windscreen/headlamp wash
reservoir.
2 Fuse box.
3 Power steering reservoir. 4
Coolant reservoir.
5 Engine oil filler cap.
6 Dipstick.
7 Air filter. 8
Brake and clutch fluid reservoir.
9 Removable towing eye.
10 Wheelbrace.
11 Jack.
PRACTICAL INFORMATION
137
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PRACTICAL INFORMATION
138
2 LITRE AND 2.2 LITRE 16V
HDI DIESEL ENGINES
1
Windscreen/headlamp wash
reservoir.
2 Fuse box.
3 Power steering reservoir. 4
Coolant reservoir.
5 Engine oil filler cap.
6 Dipstick ( a:2.2 litre HDI;
b: 2 litre HDI).
7 Air filter. 8
Brake and clutch fluid reservoir.
9 Removable towing eye.
10 Wheelbrace.
11 Jack.
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PRACTICAL INFORMATION139
CHECKING THE LEVELS
Oil level 
Check the level regularly and top
up between changes (maximum
consumption is 0.5 l per 600 miles
(1000 km).
Checking is carried out with the
vehicle level, engine cold, using
the oil level gauge on the check
module or the dipstick.
Dipstick There are two marks
on the dipstick:
A= maximum
Never fill past this
mark.
B = minimum
To maintain the reliabil
ity of engines and
emission control sys
tems, the use of addi
tives in engine oil is
prohibited.
Oil change
According to the information given in
"PEUGEOT SERVICING".
NOTE: Prevent used oil from coming
into prolonged contact with the skin. Viscosity selection
In all cases, the oil selected must
meet the manufacturer's require
ments.
Brake and clutch fluid level:
The level must always be between
the DANGER and MAXIMUM
marks in the reservoir.
If the level drops substantially, con tact a PEUGEOT dealer immedi
ately.
Fluid change:
must be carried out according to the manufacturer's schedule
use fluids approved by the manu facturer, which fulfil DOT4 stan
dards.
WARNING: brake and clutch fluid is
harmful to health and very corrosive.
Coolant level
Use fluid recommended by the man
ufacturer.
When the engine is warm, the tem
perature of the coolant is controlled
by the engine fan. As this fan can
operate with the ignition off and
because the cooling system is pres
surised, wait for at least one hour
after the engine has stopped before
carrying out any work. Unscrew the cap two turns to allow
the pressure to drop to prevent 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.
Used oil
Do not dispose of used oil, brake
fluid or coolant into drains or onto the
ground.
Power steering reservoir  Open the reservoir, with the
engine at ambient temperature.
The level should always be above
the MINI mark and close to the
MAXI mark.
Windscreen and headlamp
wash reservoir
For best quality cleaning and for your
safety, we recommend that you use
products approved by PEUGEOT
(reservoir capacity 4.5 litres or
6.5 litres with headlamp wash).
Measure the fluid level using the dip
stick incorporated in the reservoir
cap.
Close the air hole on the cap and
remove it, then check the level.
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PRACTICAL INFORMATION
140
Only use products
approved by PEUGEOT.
To ensure best perfor
mance from components
as important as the
power steering and the braking
system,
PEUGEOT selects and offers
quite specific products.
CHECK ...
Battery
At the start of winter, have your bat
tery checked by a PEUGEOT dealer.
Air filter and pollen filter
Have the filter elements replaced
regularly. If you drive in dusty con
ditions, change them twice as
often.
Brake pads
Brake pad wear depends on the
style of driving, in particular for vehi
cles which are used in town, over
short distances .
It may be necessary to check the
thickness of the pads, even between
services.
Handbrake
Where the handbrake travel is too
great or there is a reduction in the
performance of the system, the
handbrake should be adjusted, even
between services. Have the system
checked by a PEUGEOT dealer. Fuel supply cutoff
In a serious collision, a mechanism
automatically prevents fuel from
reaching the engine.
The flashing of this warning
light is accompanied by the
message "Fuel circuit dis
armed" on the multi–func
tion display.
To reestablish the fuel supply :  switch off the ignition.
 remove the key.
 check that there is no odour or
leakage of fuel outside the vehi
cle.
 put the key back in the ignition
 switch on the ignition and start.
Manual gearbox
This does not need an oil change.
Check the level, according to the
manufacturer's service schedule.
Automatic gearbox
This does not need an oil change.
Have the level checked by a
PEUGEOT dealer in accordance
with the manufacturer's service
schedule.
Oil filter
Change the filter regularly, in accor
dance with the service schedule.
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142
CHANGING A WHEEL
Parking the vehicle
 If possible, park the vehicle on
level, stable and nonslippery
ground.
 Apply the handbrake, switch off
the ignition and engage first or
reverse gear (position Pfor the
automatic gearbox) .
Access to the spare wheel  Open the tailgate.
 Pull and turn the towing eye to
unlock the lifting tool and access
the bolt.
 Unscrew the bolt fully, using the
wheelbrace 1to unwind the lifting
tool cable.
 Detach the spare wheel through
the rear of the vehicle.
 Take out the hinged hook via the
wheel shaft to release it. Tools
The following tools are located in the
engine compartment
1
Wheelbrace.
2 Jack
3 Removable towing eye.
4 Alloy wheel embellisher remover
Removing the wheel  Place a chock 3if possible under
the wheel diagonally opposite to
the one to be changed.
 Remove the trim, using the wheel
brace 1, pulling at the valve pas
sage hole. 
Loosen the wheel bolts (for vehi
cles fitted with alloy wheels,
remove the wheel embellisher 4).
 Remove the cover from the jack
suport holder.
 Detach the jack fixing strap and
take it out from the bottom of the
jack support holder.
 Place the jack 2in contact with
one of the four locating points A
on the subframe (the one which
is closest to the wheel to be
changed).
 Extend the jack 2until its base is
in contact with the ground. Ensure
that the centre line of the base of
the jack is straight above the
locating point A.
 Raise the vehicle.
 Unscrew the bolts and remove the
wheel.
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PRACTICAL INFORMATION143
Antitheft bolts*
If your wheels are fitted with an anti
theft bolt (one per wheel), unscrew
the bolt using one of the antitheft
sockets which were given to you on
delivery of your vehicle along with
the duplicate keys and confidential
card and the wheelbrace
1.
Note: make a careful note of the
code number on the head of the anti
theft socket. This willl enable you to
obtain a duplicate antitheft socket.
* According to specification and country. Fitting a wheel
 Position the wheel using the cen
tralising tool, fitted on the hub.
 Tighten the bolts by hand.
 Partly tighten the bolts using the
wheelbrace 1.
 Fold the jack 2completely and
remove it.
 Fully tighten the bolts using the
wheelbrace 1.
 Replace the wheel trim, starting
by placing the wheel trim notch
opposite the valve, and press it on
using the palm of the hand.
 Refit the wheel, with the valve
towards the top, under the vehicle
with the lifting tool, in line with the
illustration.
 Tighten fully and check that the
wheel is lying flat against the rear
floor. For your safety, always
change the wheel:
– on level, stable, nonslippery ground,
– with the handbrake on and the ignition switched off,
– with first or reverse gear engaged (position Pfor the
automatic gearbox),
– with the vehicle chocked.
Never go underneath a vehicle
that is supported only by a jack
(use a ramp).
After changing the wheel:
– have the tightening of the bolts and the tyre pressure checked
by a PEUGEOT dealer as soon
as possible.
– have the punctured wheel repaired and refit it to the vehi
cle as soon as possible.
– ask a Peugeot dealer to check that the spare wheel is fitted cor
rectly.
 Fold down the ring to lock the lift
ing tool.
 Put the tools in the engine com
partment.
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PRACTICAL INFORMATION
146
Fuse n
o
. Rating Functions
1 10 A Rear fog lamp.
2 15 A Rear screen wiper.
4 15 A Supply to functions via the builtin systems interface.
5 10 A Left brake light.
7 20 A Map readers Lighter Passenger lower glove box
lighting Electrochrome interior mirror .
Fascia panel fuses
 Unscrew the bolt a quarter of a
turn with a coin, then pull the
handle to open the cover and
access the fuses.CHANGING A FUSE
The fuse boxes are located under
the fascia (driver's side), in the batte
ry compartment (floor, driver's side)
and in the engine compartment.
The spare fuses and special pliers A
are fixed to the inside of the lid of the
instrument panel fuse box.
Removing and changing a
fuse
Before changing a fuse you must
establish the cause of the fault and
have it corrected. The fuse numbers
are indicated on the fuse box.
 Use the special pliers A.
Always change a faulty fuse for
one of the same rating.
Correct Incorrect
Pliers A
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PRACTICAL INFORMATION
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Engine compartment fuses
Fuse box
To access the fuse box in the engine
compartment (to the left of the
coolant reservoir):
 unclip the cover.
Carefully close the cover when
you have finished. The electrical system of
your vehicle is designed
to operate with standard
or optional equipment.
Before installing other electrical
equipment or accessories on your
vehicle, contact a PEUGEOT dea
ler.
PEUGEOT will not accept respon
sibility for the cost incurred in
repairing your vehicle or for recti
fying the malfunctions resulting
from the installation of accesso
ries not supplied and not recom
mended by PEUGEOT and not
installed in accordance with its
instructions, in particular where
the equipment in question
consumes more than 10 milliam
peres.
* The maxifuses provide additio
nal protection for the electrical
systems. All work must be carried
out by a PEUGEOT dealer.
Fuse N° Rating Functions
1* 50 A Fan unit (high speed).
2* 50 A ABS control unit or ESP control unit.
3* 30 A Not used or ESP solenoid valve or Additional
heating (Diesel).
4* 60 A Builtin Systems Interface supply 1.
5* 70 A Builtin Systems Interface supply 2.
6* 30 A Fan unit (low speed).
7* 40 A Electronic immobiliser.
8* 50 A Air conditioning blowers.
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PRACTICAL INFORMATION151
Fuse N° Rating
Functions
1 10 A Manual gearbox reversing lights switch Xenon headlamps Fan uni t relay control
Engine coolant level Oil heater or preheat unit (Diesel) V ehicle speed sensor or air flow
sensor (Diesel).
2 15 A Fuel pump Exhaust gas recirculation and Turbo pressure regulation solenoid valves
(Diesel).
3 10 A ABS or ESP control unit.
4 10 A Engine wiring housing ignition positive supply
5 10 A Not used or particle emission filter injector (Diesel) Particle emi ssion filter control unit (Diesel).
6 15 A Front fog lamps.
7 20 A Headlamp wash pump.
8 20 A Supply via the engine wiring housing relay Fan unit relay co ntrol (Diesel) –
Diesel high pressure regulation and exhaust gas recirculation sol enoid valves
(Diesel).
9 15 A Left dipped beam Headlamp height adjuster.
10 15 A Right dipped beam.
11 10 A Left main beam.
12 10 A Right main beam.
13 15 A Horn.
14 10 A Front and rear washwipe pump.
15 30 A Oxygen sensor Injectors Ignition coil Canister, timing and exhaust gas recriculation
solenoid valves (Petrol) Injection pump solenoid valve (Diesel).
16 30 A Not used or air pump (Petrol).
17 30 A Front wiper.
18 40 A Additional blowers.
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PRACTICAL INFORMATION
146
Fuse n
o
. Rating Functions
1 10 A Rear fog lamp.
2 15 A Rear screen wiper.
4 15 A Supply to functions via the builtin systems interface.
5 10 A Left brake light.
7 20 A Map readers Lighter Passenger lower glove box
lighting Electrochrome interior mirror .
Fascia panel fuses
 Unscrew the bolt a quarter of a
turn with a coin, then pull the
handle to open the cover and
access the fuses.CHANGING A FUSE
The fuse boxes are located under
the fascia (driver's side), in the batte
ry compartment (floor, driver's side)
and in the engine compartment.
The spare fuses and special pliers A
are fixed to the inside of the lid of the
instrument panel fuse box.
Removing and changing a
fuse
Before changing a fuse you must
establish the cause of the fault and
have it corrected. The fuse numbers
are indicated on the fuse box.
 Use the special pliers A.
Always change a faulty fuse for
one of the same rating.
Correct Incorrect
Pliers A
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