Peugeot Partner 1.9 D 2004 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Peugeot Model: Partner Year: 2004 Engine Type: Diesel Engine Code: DW8B (likely) Generation Generation Identifier: First Generation (M49/M59) 👋 Introduction Market Position Vehicle Segment: Compact Panel Van / Leisure Activity Vehicle (LAV) Competitive Analysis Direct Competitors: Ford Transit Connect, Renault Kangoo, Citroën Berlingo, Fiat Doblò, Volkswagen Caddy. Key Features Primary Use: Commercial light utility, small business transport, cargo hauling, and family use in its passenger variants. Manual Value Proposition: Empowers both professional technicians and DIY enthusiasts with factory-level diagnostic and repair information, promoting cost-effective maintenance and repair. 📋 Manual Details Coverage Areas Coverage Type: Workshop Service Repair Page Count Estimated Page Count: Hundreds of pages (specific count not provided, but implies comprehensive coverage) Manual Type Manual Format Type: Official Full Factory Service Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine disassembly, assembly, repair, troubleshooting, including cylinder head, block, pistons, crankshaft, camshaft, timing, valve train. Fuel System Diesel: Fuel injection system, injectors, fuel pump, fuel filter, lines, troubleshooting and repair. Cooling System: Radiator, thermostat, water pump, coolant lines, fan operation, diagnosis and repair. Exhaust System: Exhaust manifold, catalytic converter (if applicable), muffler, pipes, diagnosis and replacement. Transmission Manual: Clutch operation, gearbox disassembly, assembly, repair, fluid changes, troubleshooting. Drivetrain: Front-wheel drive system, drive shafts, CV joints, differential (integral to gearbox), inspection and repair. Suspension Front: MacPherson struts, control arms, ball joints, bushings, springs, shock absorbers, alignment specifications. Suspension Rear: Torsion beam axle or independent suspension (depending on specific variant), shock absorbers, bushings, alignment specifications. Steering System: Steering rack, tie rods, power steering system (if equipped), diagnosis and repair. Braking System: Front disc brakes, rear drum brakes (typical), brake fluid specifications, bleeding procedures, caliper/wheel cylinder repair, master cylinder, parking brake. Electrical System General: Battery, alternator, starter motor, ignition system (glow plugs for diesel), wiring diagrams, fuses, relays. Lighting System: Headlights, taillights, interior lights, bulb replacement, wiring. Instrumentation: Dashboard gauges, warning lights, sensor diagnostics. Body And Chassis: Body panel removal and installation, doors, hinges, latches, glass, interior trim, body repair, structural information. HVAC System: Heating, ventilation, and air conditioning system components, operation, and common faults. Procedures Included Maintenance Procedures: Oil changes, filter replacements, fluid checks and top-offs, belt inspections and replacement, spark plug/glow plug replacement, brake pad/shoe replacement, coolant flush. Troubleshooting Guides: Systematic diagnostic procedures for common and uncommon faults, fault code interpretation (if applicable). Repair Procedures: Detailed, step-by-step instructions for the repair of all major vehicle components and systems. Disassembly Assembly: Comprehensive guidance on the correct procedures for taking apart and reassembling components. Cleaning Reinstallation: Instructions on cleaning components before reassembly and proper reinstallation techniques. Technical Depth Diagnostic Capabilities: Advanced diagnostics, including reference to diagnostic tools and procedures. Rebuild Instructions: Complete rebuild procedures for major mechanical components like the engine and gearbox. Wiring Diagrams: Inclusion of detailed electrical wiring diagrams for various vehicle systems. Specification Data: Extensive torque specifications, clearances, fluid capacities, and other critical technical data. 📊 Manual Specifications File Format File Type: PDF Print Quality Printability: Full Printable Zoom Capability: YES (Zoom IN/OUT) Binding Type Binding: Digital Download (Printable sections as needed) Paper Type Paper Equivalent: Digital PDF, allowing for on-demand printing of specific pages, mimicking a physical manual. ⚙️ Engine Specifications Primary Engine Engine Displacement: 1.9 Liters (1868cc) Engine Configuration: Inline 4-Cylinder, Naturally Aspirated Diesel Valvetrain: SOHC (Single Overhead Camshaft) Performance Horsepower: Approx. 69-71 PS (51-53 kW) at 4600 rpm (typical for DW8B) Torque: Approx. 125-130 Nm (92-96 lb-ft) at 2000-2500 rpm (typical for DW8B) Fuel System Fuel Injection Type: Indirect Injection (IDI) with Bosch VE or similar rotary injection pump. Glow Plug System: Pre-heating system essential for cold starts. Engine Codes Engine Code Examples: DW8B, DW8C (common variations) 🔧 Transmission Standard Transmission Type: 5-Speed Manual Transmission Optional Transmission Options: Automatic transmission was generally not offered with the 1.9D engine in this generation, predominantly manual. Features Clutch Type: Hydraulically actuated dry single-plate clutch. 📐 Dimensions Exterior Body Styles: Panel Van, Combi Van (Passenger version), Platform Chassis (less common). Wheelbase: 2690 mm (standard) Weights Curb Weight: Approx. 1250-1350 kg (depending on configuration) Gross Vehicle Weight Rating Gvw: Approx. 1800-2000 kg (depending on variant) 🛡️ Safety Features Ratings Crash Test Information: Euro NCAP ratings for this generation typically showed moderate protection. Specific ratings vary by year and exact configuration. Active Features Braking System Features: ABS (Anti-lock Braking System) was often an optional extra or standard on higher trims. Passive Features Airbags: Driver airbag typically standard, passenger airbag optional or standard on passenger variants. 💡 Technology Features Infotainment Audio System: Basic radio/cassette or CD player options, often with aftermarket upgrade potential. Driver Assistance Traction Control: Traction control systems were not common or standard on this model and engine variant. Connectivity Connectivity Features: Limited to basic connectivity for audio systems; no integrated Bluetooth or advanced mobile integration. 🔧 Maintenance...
Compact Panel Van / Leisure Activity Vehicle (LAV)
Competitive Analysis
Direct Competitors:
Ford Transit Connect, Renault Kangoo, Citroën Berlingo, Fiat Doblò, Volkswagen Caddy.
Key Features
Primary Use:
Commercial light utility, small business transport, cargo hauling, and family use in its passenger variants.
Manual Value Proposition:
Empowers both professional technicians and DIY enthusiasts with factory-level diagnostic and repair information, promoting cost-effective maintenance and repair.
📋 Manual Details
Coverage Areas
Coverage Type:
Workshop Service Repair
Page Count
Estimated Page Count:
Hundreds of pages (specific count not provided, but implies comprehensive coverage)
Body panel removal and installation, doors, hinges, latches, glass, interior trim, body repair, structural information.
HVAC System:
Heating, ventilation, and air conditioning system components, operation, and common faults.
Procedures Included
Maintenance Procedures:
Oil changes, filter replacements, fluid checks and top-offs, belt inspections and replacement, spark plug/glow plug replacement, brake pad/shoe replacement, coolant flush.
Troubleshooting Guides:
Systematic diagnostic procedures for common and uncommon faults, fault code interpretation (if applicable).
Repair Procedures:
Detailed, step-by-step instructions for the repair of all major vehicle components and systems.
Disassembly Assembly:
Comprehensive guidance on the correct procedures for taking apart and reassembling components.
Cleaning Reinstallation:
Instructions on cleaning components before reassembly and proper reinstallation techniques.
Technical Depth
Diagnostic Capabilities:
Advanced diagnostics, including reference to diagnostic tools and procedures.
Rebuild Instructions:
Complete rebuild procedures for major mechanical components like the engine and gearbox.
Wiring Diagrams:
Inclusion of detailed electrical wiring diagrams for various vehicle systems.
Specification Data:
Extensive torque specifications, clearances, fluid capacities, and other critical technical data.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Printability:
Full Printable
Zoom Capability:
YES (Zoom IN/OUT)
Binding Type
Binding:
Digital Download (Printable sections as needed)
Paper Type
Paper Equivalent:
Digital PDF, allowing for on-demand printing of specific pages, mimicking a physical manual.
⚙️ Engine Specifications
Primary Engine
Engine Displacement:
1.9 Liters (1868cc)
Engine Configuration:
Inline 4-Cylinder, Naturally Aspirated Diesel
Valvetrain:
SOHC (Single Overhead Camshaft)
Performance
Horsepower:
Approx. 69-71 PS (51-53 kW) at 4600 rpm (typical for DW8B)
Torque:
Approx. 125-130 Nm (92-96 lb-ft) at 2000-2500 rpm (typical for DW8B)
Fuel System
Fuel Injection Type:
Indirect Injection (IDI) with Bosch VE or similar rotary injection pump.
Glow Plug System:
Pre-heating system essential for cold starts.
Engine Codes
Engine Code Examples:
DW8B, DW8C (common variations)
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual Transmission
Optional
Transmission Options:
Automatic transmission was generally not offered with the 1.9D engine in this generation, predominantly manual.
Features
Clutch Type:
Hydraulically actuated dry single-plate clutch.
📐 Dimensions
Exterior
Body Styles:
Panel Van, Combi Van (Passenger version), Platform Chassis (less common).
Wheelbase:
2690 mm (standard)
Weights
Curb Weight:
Approx. 1250-1350 kg (depending on configuration)
Gross Vehicle Weight Rating Gvw:
Approx. 1800-2000 kg (depending on variant)
🛡️ Safety Features
Ratings
Crash Test Information:
Euro NCAP ratings for this generation typically showed moderate protection. Specific ratings vary by year and exact configuration.
Active Features
Braking System Features:
ABS (Anti-lock Braking System) was often an optional extra or standard on higher trims.
Passive Features
Airbags:
Driver airbag typically standard, passenger airbag optional or standard on passenger variants.
💡 Technology Features
Infotainment
Audio System:
Basic radio/cassette or CD player options, often with aftermarket upgrade potential.
Driver Assistance
Traction Control:
Traction control systems were not common or standard on this model and engine variant.
Connectivity
Connectivity Features:
Limited to basic connectivity for audio systems; no integrated Bluetooth or advanced mobile integration.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Typically every 10,000-15,000 km or 12 months, whichever comes first, using appropriate diesel engine oil.
Fuel Filter Replacement:
Recommended every 30,000-40,000 km or as per manual, crucial for diesel engine longevity.
Air Filter Replacement:
Check every 15,000-20,000 km, replace as needed or annually.
Timing Belt Replacement:
Crucial interval, typically 80,000-100,000 km or 5-6 years. Failure can cause severe engine damage. (Manual will specify exact interval and part number for the belt kit).
Fluid Specifications
Engine Oil Specification:
API CG-4 or CH-4, ACEA E2 or E3/E5. Viscosity typically 10W-40 or 5W-40. Manual will specify exact Peugeot approval.
Coolant Type:
Antifreeze concentrate based on ethylene glycol, meeting PSA specifications (e.g., PSA S70-159 or equivalent).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Gearbox Oil Type:
Hypoid gear oil, API GL-4, SAE 75W-80 or 75W-90. Manual will confirm specific viscosity and capacity.
Known Issues
Diesel Engine Glow Plugs:
Glow plugs can fail over time, leading to difficult cold starts.
Suspension Wear:
Worn bushings, ball joints, and tie rod ends are common due to vehicle's utility use and road conditions.
Clutch Wear:
The clutch can wear out with heavy use or mileage, leading to slipping or difficult engagement.
Exhaust System Corrosion:
Corrosion on exhaust components can occur, especially in areas with road salt.
📚 Vehicle History
Brand Heritage
Peugeot Light Commercial:
Peugeot has a long history of producing reliable and practical light commercial vehicles, dating back to models like the D3A and later the J7 and J9 vans.
Model Evolution
Partner Introduction:
The Peugeot Partner was first introduced in 1996 as a joint venture with Citroën (which sold it as the Citroën Berlingo), aiming to capture the burgeoning compact van segment.
Production
Manufacturing Locations:
Primarily manufactured in Europe, with significant production facilities in France and potentially other PSA Group plants.
🏆 Awards & Recognition
Recognitions
Van Of The Year:
While this specific 2004 1.9D may not have won a 'Van of the Year' award itself, the Peugeot Partner platform (and its Citroën Berlingo counterpart) has historically received numerous accolades and positive reviews in the commercial vehicle sector.
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