Peugeot Expert 2003 Service Manual

22-04-2003
2.0i 16V ENGINEIV-1
56
B

CHECKS*57IV-1
Beware:When working under the bonnet, the cooling fan could operate if
the engine is hot (even when switched off). The engine oil level should be checked frequently between services (as recommended by the manufacturer), as well as before long journeys.
Air filter Follow the recommenda- tions in the maintenanceguide.
22-04-2003
Coolant The level should be bet- ween the maximum andminimum marks on the
reservoir. If the engine is hot, wait 15 minutes.Oil quality: see Ç Lubricants and
fluids È.
Never work on the cooling sys- tem if the engine is hot. (see
Ç Levels È).
Windscreen, rear screenand headlamp washerfluid It is recommended to use
manufacturer approved products.
12 volt batterySee Ç Emergency starting
with a slave battery È. Engine oilCheck with the vehicle on level ground, and the
engine off for at least
10 minutes. Level: see Ç Levels È.
Oil quality: see Ç Lubricants and
fluids È.
Take out the oil dipstick.The level must be bet- ween the MAX and MINmarks on the dipstick.
It must not exceed
the maximum mark. Brake fluid The level should be bet- ween the maximum andminimum marks on the
reservoir. Level: see Ç Levels È.
Oil quality: see Ç Lubricants and
fluids È.
If the warning lamp comes on: stop the vehicle
Power steering oilCheck the level with the
engine switched off. Level: see Ç Levels È.
Oil quality: see Ç Lubricants and
fluids È.
B
Max Min
* According to model or country

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1.9 D ENGINEIV-2
58
B
A

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CHECKS*59IV-2
Beware:When working under the bonnet, the cooling fan could operate if
the engine is hot (even when switched off). The engine oil level should be checked frequently between services (as recommended by the manufacturer), as well as before long journeys.
Priming pump Refer to the section
Ç Diesel
injection equipment È.
CoolantThe level should be bet- ween the maximum andminimum marks on the
reservoir. If the engine is hot, wait 15 minutes.Oil quality: see Ç Lubricants and
fluids È.
Never work on the cooling sys- tem if the engine is hot. (see
Ç Levels È).
Windscreen, rear screenand headlamp washerfluid It is recommended to use
manufacturer approved products.
12 volt batterySee Ç Emergency starting
with a slave battery È. Engine oilCheck with the vehicle on level ground, and the
engine off for at least
10 minutes. Level: see Ç Levels È.
Oil quality: see Ç Lubricants and
fluids È.
Take out the oil dipstick.The level must be bet- ween the MAX and MINmarks on the dipstick.
It must not exceed
the maximum mark. Brake fluid The level should be bet- ween the maximum andminimum marks on the
reservoir. Level: see Ç Levels È.
Oil quality: see Ç Lubricants and
fluids È.
If the warning lamp comes on: stop the vehicle
Power steering oilCheck the level with the
engine switched off. Level: see Ç Levels È.
Oil quality: see Ç Lubricants and
fluids È.
A
Air filter Follow the recommendations in the maintenance guide.
B
Max Min
* According to model or country

2.0 HDi ENGINEIV-2
60
The 2.0 HDi engine makes use of advanced technology.
Any repair work must be carried out by suitably qualified
personnel, such as can be provided by the dealer network.
Due to the fact that the diesel sys- tem is a high pressure system:
IT IS FORBIDDEN TO CARRY OUT
ANY REPAIRS TO THE SYSTEM.
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B

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CHECKS*61IV-2
Beware:When working under the bonnet, the cooling fan could operate if
the engine is hot (even when switched off). The engine oil level should be checked frequently between services (as recommended by the manufacturer), as well as before long journeys.
Air filter Follow the recommenda- tions in the maintenanceguide. Coolant The level should be bet- ween the maximum andminimum marks on the
reservoir. If the engine is hot, wait 15 minutes.Oil quality: see Ç Lubricants and
fluids È.
Never work on the cooling sys- tem if the engine is hot. (see
Ç Levels È).
Windscreen, rear screenand headlamp washerfluid It is recommended to use
manufacturer approved products.
12 volt batterySee Ç Emergency starting
with a slave battery È. Engine oilCheck with the vehicle on level ground, and the
engine off for at least
10 minutes. Level: see Ç Levels È.
Oil quality: see Ç Lubricants and
fluids È.
Take out the oil dipstick.The level must be bet- ween the MAX and MINmarks on the dipstick.
It must not exceed
the maximum mark. Brake fluid The level should be bet- ween the maximum andminimum marks on the
reservoir. Level: see Ç Levels È.
Oil quality: see Ç Lubricants and
fluids È.
If the warning lamp comes on: stop the vehicle
Power steering oilCheck the level with the
engine switched off. Level: see Ç Levels È.
Oil quality: see Ç Lubricants and
fluids È.
B
Max Min
* According to model or country

DIESEL INJECTION EQUIPMENT*IV-3
62
The 2.0 HDi engine makes use of advanced technology.
Any repair work must be carried out by suitably qualified
personnel, such as can be provided by the dealer network.
Priming the fuel system In the event of running out of fuel:
A 1.9 D ENGINE: - After filling (5 litres minimum), operate the manual priming pump untilsome resistance is felt.
- Operate the starter motor while depressing the accelerator pedal slightly until the engine starts.
If the engine fails to start at the first attempt, wait 15 seconds before trying again. If the engine fails to start after several attempts, repeat the procedure from the beginning. When the engine is idling, accelerate slightly to complete the bleeding of the circuit. Engine 2.0 HDi: After adding fuel, turn the ignition key to position M, then operate the star-
ter motor until the engine starts. Injection pump Do not remove the seals on the pump setting screws under any circum- stances. Alteration of the settings might lead to early engine failure and loss of war-
ranty cover.
B Draining water from the fuel filter Bleed regularly (each time the engine is drained).
To remove the water, loosen the bleed screw at the bottom of the filter.Operate until all the water has been expelled.
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* According to model or country
A
B

FUEL CUT-OFF SWITCH*63IV-4
Before switching on the ignition,
make sure that there are no fuel leaks or smells.
To provide additional security in the event of front or rear impacts, your vehicle
is fitted with a safety device which cuts off the fuel supply.
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Fuel cut-off switch The switch is located in the engine compartment on either the left or right hand front suspension tower depending on engine type.
To re-establish the fuel supply
, depress the upper section of the switch as shown in the diagram.
* According to model or country

LEVELSIV-5
64
Beware: When working under the bonnet, the cooling fan could operate if the engi-
ne is hot (even when switched off).
Power steering oil Check the level with the engine
switched off. The level should be between the maximum
and minimum marks on
the reservoir. Never run the engine without oil in the pump reservoir; the pump willbe severely damaged and couldseize. Oil quality: see Ç Lubricants and
fluids È.
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Engine oil Check with the vehicle on level
ground, and the engine off for atleast 10 minutes.
Take out the oil dipstick.The level must be between the MAX and MIN marks on the dips-
tick. Adding engine oil Remove the dipstick before topping up. Check the level after filling.It must not exceed the maximum mark. The oil level should be topped up between services (up to 0.5 l every600 miles). Screw on the cap before shutting the bonnet. Oil quality:
see Ç Lubricants and
fluids È.

LEVELS65IV-5
Beware: When working under the bonnet, the cooling fan could operate if the engi-
ne is hot (even when switched off).
Topping up the cooling system The coolant level should be between the MAXIMUM and MINIMUM marks on the header tank.
Top up the level. If more than I litre is required to top up, have
the cooling system checked by your dealer. Ensure that the cap is fully tightened to the second notch. Note:
Frequent topping up could indicate a fault within the cooling system.
Have it checked as soon as possible.The replacement of the coolant must be carried out by the dealer network. Coolant The antifreeze in the coolant protects against low temperatures and provides anti-corrosion protection and resistance to high operating temperatures.However these properties degrade progressively with time. Oil quality: see Ç Lubricants and fluids È.
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Radiator - coolant The coolant must only be checked or topped up if the engine is cold. Engine hot:
Wait 15 minutes or until the tempe- rature is below 100 degrees C.Using a cloth to protect your hands,slowly slacken the filler cap as far
as the safety catch. Allow the pres-sure to reduce before removingfiller cap.