Peugeot Expert 2004 Manual PDF

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2 LITRE TURBO DIESEL HDI ENGINE (95 bhp / 110 bhp)
1 - Windscreen/headlamp* wash
reservoir.
2 - Power steering reservoir.
3 - Coolant reservoir. 4 -
Brake luid reservoir.
5 - Fuse box.
6 - Battery. 7 -
Air ilter.
8 - Dipstick.
9 - Engine oil iller cap.
* According to destination.

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2 LITRE 16V TURBO DIESEL HDI ENGINE (110 bhp)
1 - Windscreen/headlamp* wash
reservoir.
2 - Power steering reservoir.
3 - Coolant reservoir. 4 -
Brake luid reservoir.
5 - Fuse box.
6 - Battery. 7 -
Air ilter.
8 - Dipstick.
9 - Engine oil iller cap.
* According to destination.

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CHECKING THE LEVELS
Oil level
F Check the level regularly and
top up between changes. The
maximum consumption is 0.5 l
per 600 miles (1000 km).
Check the level with the vehicle level, engine cold, using the oil
level gauge on the instrument
panel or the dipstick.
Dipstick
There are two marks on
the dipstick:
A = maximum
Never ill 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 change
According to the information given in
the servicing booklet.
Note: avoid used oil coming
into prolonged contact with the
skin. Empty the used oil into the
containers intended for this purpose
in the PEUGEOT network. Viscosity selection
In all cases, the oil selected
must meet the manufacturer's
requirements.
Brake luid change:
- must be carried out according to the
manufacturer's servicing schedule.
- use luids recommended by the manufacturer, which fulil DOT4
standards.
Note: brake luid is harmful to health
and very corrosive. Avoid all contact
with the skin.
Cooling system
Use the luid 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
system is pressurised, wait for at
least one hour after the engine has
stopped before carrying out any
work.
Used oil
Power steering reservoir
F Open the reservoir, with the
engine at ambient temperature.
The level should always be above
the MIN. mark and close to the
MAX. mark.
Windscreen and headlamp*
wash level
For best quality cleaning and for
your safety, we would advise that
you use products recommended by
PEUGEOT.
* According to country.
Slacken the cap by two turns to
release the pressure 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.
Do not dispose of used oil, brake
luid or coolant into drains or onto
the ground.

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CHECKS
Battery
At the start of winter, have your
battery checked by a PEUGEOT
dealer.
Air ilter and passenger
compartment ilter
Have the ilter elements replaced
regularly. If you drive in dusty
conditions, change them twice as
often.
Brake pads
Brake pad wear depends on the style
of driving, in particular for vehicles
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.
Oil ilter
Change the ilter regularly, in
accordance with the servicing
schedule.
Manual gearbox
This does not require an oil change.
Check the level in accordance
with the manufacturer's servicing
schedule.
To check the main levels and
certain components, in accordance
with the manufacturer's servicing
schedule, refer to the pages
of the servicing booklet which
correspond to your vehicle's
engine.
Only use products recom-
mended by PEUGEOT.
To ensure best performance
from components as
important as the power
steering and the braking system,
PEUGEOT selects and offers quite
speciic products.
To prevent damage to the electrical
units, avoid washing the engine. - ill the fuel tank with at least ive
litres of diesel,
- squeeze and release the manual re-priming pump, under the bonnet
under the protective cover, until fuel
appears in the transparent pipe,
- operate the starter until the engine starts.
To re-establish the fuel supply, press
the switch on the corner of the front
right-hand suspension assembly,
under the bonnet.
RUNNING OUT OF FUEL
(DIESEL)
FUEL SUPPLY CUT-OFF
(PETROL)
If you should
run out of fuel,
it is necessary
to re-prime the
circuit:
In a serious collision,
a switch prevents fuel
from reaching the
engine.

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CHANGING A WHEEL
Parking the vehicle
- If possible, park the vehicle on level, stable and non-slippery
ground.
- Apply the handbrake, switch off the ignition and engage irst or reverse
gear.
Access to the spare wheel
and the jack
The wheel is located outside
the vehicle, under the rear loor,
supported by a metal carrier.
The tools are located under the
driver’s seat.
- Use the trim remover 1 to unscrew
the jack bolt.
- Remove the trim remover 1, the
jack 2, the wheelbrace 3.
- Using the wheelbrace 3, slacken
the spare wheel carrier retaining
bolt, located on the inside near the
closing system.
- Lift the carrier to release the hook rearwards, then lower it.
Removing a wheel
- If possible, chock the rear of the wheel diagonally opposite the
wheel to be changed.
- Remove the wheel trim, using the wheelbrace 3 (large model) or the
trim remover 1 (small model), by
pulling at the valve passage hole.
- Slacken the wheel bolts.
- Place the jack 2 at one of the four
locations A provided on the sub-
frame, the closest to the wheel to
be changed. Ensure that the entire
surface of the jack base plate is in
contact with the ground.
- Extend the jack, completely unscrew the bolts and remove the
wheel.

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Replacing the wheel in the
carrier
- Replace the wheel in the carrier.
- Lift the wheel, then the carrier and
reposition the hook.
- Do not forget to fully tighten the spare wheel carrier retaining bolt.
- Stow the wheelbrace 3 and the jack
2 under the driver’s seat.
- Unfold the jack using the trim remover 1.
- Put the trim remover 1 back in its
housing.
Reitting the wheel
- After positioning the wheel, lightly pre-tighten the bolts using the
wheelbrace 3.
- Compress the jack 2 and release
it.
- Fully tighten the bolts using the wheelbrace.
- Replace the trim, starting at the valve passage hole, and press it on
using the palm of the hand. For your safety, always
change a wheel:
- on level, stable and non slippery
ground,
- with the handbrake applied,
- with irst or reverse gear engaged,
- with the vehicle chocked,
- never go underneath a vehicle raised using a jack (use an axle
stand ).
After changing the wheel
- Have the tightening of the bolts and the pressure of the spare tyre
checked as soon as possible by a
PEUGEOT dealer.
- Have the punctured tyre repaired and replace it on the vehicle as
soon as possible.

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CHANGING A BULB
Front lights
1. Dipped beam headlamps / Main beam headlamps
(H4-60/55W)
- Disconnect the connector.
- Remove the protective cover A.
- Push the spring towards the right, as indicated on the headlamp.
- Remove and replace bulb. 2. Side lights (W 5 W)
- Turn the bulb holder
B a quarter
turn and remove it.
- Change the bulb. 3. Direction indicators
(PY 21 W amber)
- Turn the bulb holder C a quarter
turn and remove it.
- Change the bulb.
Note: in certain weather conditions
(low temperatures, humidity), the
presence of condensation on the
inside of the headlamp glass is
normal ; it disappears a few minutes
after the lights have been switched
on.

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Only use H4 bulbs
manufactured by:
- GE/TUNGSRAM,
- PHILIPS,
- OSRAM,
to avoid damaging the headlamps.
These meet the anti-UV (ultra-violet)
speciications necessary for the
correct operation and reliability of the
headlamps.
The headlamps are itted with a
polycarbonate lens coated with a
protective varnish. You are strongly
advised to avoid cleaning them using
a dry or abrasive cloth and using
detergent products or solvents.
Use a soft, damp cloth. Direction indicator side repeaters
(WY 5 W amber)
- Push the transparent cover
forwards and release it.
- Turn the bulb holder a quarter turn.
- Change the bulb.
4 - Front fog lamps (H1-55W)
- Remove the closer then the screw, located under the bumper.
- Pull the assembly forwards.
- Disconnect the connector.
- Turn the protective cover A a
quarter turn.
- Disconnect the connector B.
- Move aside the springs C.
- Remove the bulb and change it.
To reit, proceed in the reverse order
to removal.
It is essential that the screw closer
is reitted.
Amber coloured bulbs
(direction indicators and
side repeaters) must
be replaced by bulbs of
identical speciication and
colour.

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Rear lights
1 - Brake lights / Side lights
(P 21 / 5 W).
2 - Direction indicators (P 21 W).
3 - Reversing lights (P 21 W).
4 - Fog lamp (P 21 W). - Open the corresponding rear door.
- Unscrew the two wing nuts
A on
the inside.
- Take out the light unit gently and disconnect it,
- Remove the light unit.
- Unclip the bulb holder by pressing the tabs B,
- Change the faulty bulb.
To reit, proceed in the reverse order
to removal.
Number plate lights (5 W)
Unclip the translucent cover to gain
access to the bulb.

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Third brake light (rear left
door) (P 21 W)
F
Unscrew nut A on the inside.
F Take out the unit from the outside F Unscrew the faulty bulb and
change it.
To reit, proceed in the reverse
order.