Peugeot Partner 1.6i 16V Petrol 2004 Service Repair Manual
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🏷️ Basic Information Identification Make: Peugeot Model: Partner Year: 2004 Engine Type: 1.6i 16V Petrol Codes Engine Code Identifier: Likely TU5JP4 variant (common for 1.6i 16V in this era) 👋 Introduction Market Position Target Audience: Peugeot Partner owners, independent repair shops, automotive technicians seeking official repair data. Competitive Analysis Value Proposition: Provides official, dealership-level repair information, empowering users to perform maintenance and repairs themselves, saving significant costs compared to professional services. Key Features Official Source: Contains information identical to that used by Peugeot dealership technicians, ensuring accuracy and authenticity. User Friendliness: Step-by-step instructions, detailed diagrams, and illustrations make complex procedures accessible even to novice mechanics. Digital Convenience: PDF format allows for easy storage, printing of specific pages, and digital manipulation (zooming). 📋 Manual Details Coverage Areas Vehicle Generation: First Generation (Peugeot Partner Origin / Type M49) Model Variants Covered: All variants equipped with the 1.6i 16V petrol engine, including passenger and commercial configurations. Page Count Estimated Page Count: Not specified, but described as 'COMPLETE' and 'EVERYTHING YOU WILL NEVER NEED', implying a comprehensive volume. Manual Type Type: Official Factory Service and Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, lubrication system, cooling system, fuel system, ignition system, emissions control system, exhaust system. Transmission: Manual transmission systems, clutch operation, gear shift linkage, drive axles. Chassis: Suspension (front and rear), steering system, braking system (front and rear, ABS if equipped), wheels and tires. Electrical: Battery, charging system, starting system, lighting (interior and exterior), instrumentation, body electrical systems, fuse box diagrams, wiring schematics. Bodywork: Body construction, exterior panels, doors, windows, bumpers, interior trim, seating, HVAC (Heating, Ventilation, and Air Conditioning) system. Procedures Included Maintenance: Scheduled maintenance, fluid changes (oil, coolant, brake fluid), filter replacements, spark plug replacement, belt inspection and replacement. Repair: Engine component replacement (e.g., head gasket, pistons, valves), transmission overhaul, brake caliper/rotor replacement, suspension arm/bush replacement, electrical component diagnosis and repair. Troubleshooting: Diagnostic procedures for common drivability issues, electrical faults, and mechanical problems, often including symptom-based troubleshooting charts. Diagnostics: OBD-II (On-Board Diagnostics) system explanation, fault code interpretation, diagnostic tool usage, sensor testing, actuator testing. Technical Depth Depth: Comprehensive, covering everything from routine maintenance to major component overhaul and complex diagnostics, suitable for both DIY enthusiasts and professional technicians. 📊 Manual Specifications File Format Quality: High-resolution PDF, allowing for clear viewing and printing of diagrams and text. Searchability: Likely searchable text within the PDF, enabling quick access to specific information. Print Quality Printability: Full printable pages, allowing users to print only necessary sections or the entire manual. Zoom Functionality: Yes, allows for zooming in on detailed diagrams and text. Binding Type Format Type: Digital (PDF) Paper Type Digital Format: N/A (Digital file) ⚙️ Engine Specifications Primary Engine Engine Displacement: 1.6 Liters (1587 cc) Engine Configuration: Inline 4-cylinder Valve Train: DOHC (Double Overhead Camshaft), 16 Valves Aspiration: Naturally Aspirated Performance Horsepower Estimate: Approximately 109-110 PS (metric horsepower) or 108-109 bhp (brake horsepower) at around 6000 rpm. (Specific output may vary slightly by market). Torque Estimate: Approximately 147-150 Nm (108-111 lb-ft) at around 4000 rpm. (Specific output may vary slightly by market). Fuel System Fuel Delivery: Electronic Multi-Point Fuel Injection (MPI) Fuel Type: Unleaded Petrol (Gasoline) Engine Management ECU System: Likely Bosch Motronic or Siemens engine management system. 🔧 Transmission Standard Transmission Type: 5-speed Manual Transmission Optional Automatic Transmission: Not typically offered with the 1.6i 16V petrol engine in this model year, though some markets might have had limited availability. Manual transmission is the dominant option. Features Clutch Type: Hydraulically operated single dry plate clutch. 📐 Dimensions Exterior Body Styles: Panel Van, Combi (Passenger variants). Length Approx: Approx. 4139 mm (depending on specific configuration) Width Approx: Approx. 1720 mm (excluding mirrors) Height Approx: Approx. 1790-1810 mm (depending on load and configuration) Cargo Cargo Volume Capacity: Significant for its class, especially in panel van configurations, with detailed specifications likely available in the manual. Weights Gross Vehicle Weight: Details available in manual, typically around 1750-1850 kg. 🛡️ Safety Features Ratings Euro Ncap Rating: Likely 3-star or 4-star for adult occupant protection (Euro NCAP ratings vary by test year and specific configurations). Active Features ABS: Optional on many variants, coverage in manual if equipped. Traction Control: Rarely standard on this model/engine combination, but check manual for availability. Passive Features Airbags: Driver and passenger airbags standard on most passenger versions. Coverage in manual for airbag system diagnosis and replacement. Seatbelts: Front and rear seatbelt systems, including pre-tensioners if equipped. Manual covers adjustments and troubleshooting. 💡 Technology Features Infotainment Audio System: Basic radio/CD player with standard speaker configuration. Manual will cover system components, wiring, and potential upgrades. Driver Assistance Cruise Control: May be optional on higher trims or specific configurations; manual will detail operation and diagnosis if fitted. Connectivity Central Locking: Standard feature, covered in body electrical systems and central...
Provides official, dealership-level repair information, empowering users to perform maintenance and repairs themselves, saving significant costs compared to professional services.
Key Features
Official Source:
Contains information identical to that used by Peugeot dealership technicians, ensuring accuracy and authenticity.
User Friendliness:
Step-by-step instructions, detailed diagrams, and illustrations make complex procedures accessible even to novice mechanics.
Digital Convenience:
PDF format allows for easy storage, printing of specific pages, and digital manipulation (zooming).
📋 Manual Details
Coverage Areas
Vehicle Generation:
First Generation (Peugeot Partner Origin / Type M49)
Model Variants Covered:
All variants equipped with the 1.6i 16V petrol engine, including passenger and commercial configurations.
Page Count
Estimated Page Count:
Not specified, but described as 'COMPLETE' and 'EVERYTHING YOU WILL NEVER NEED', implying a comprehensive volume.
Comprehensive, covering everything from routine maintenance to major component overhaul and complex diagnostics, suitable for both DIY enthusiasts and professional technicians.
📊 Manual Specifications
File Format
Quality:
High-resolution PDF, allowing for clear viewing and printing of diagrams and text.
Searchability:
Likely searchable text within the PDF, enabling quick access to specific information.
Print Quality
Printability:
Full printable pages, allowing users to print only necessary sections or the entire manual.
Zoom Functionality:
Yes, allows for zooming in on detailed diagrams and text.
Binding Type
Format Type:
Digital (PDF)
Paper Type
Digital Format:
N/A (Digital file)
⚙️ Engine Specifications
Primary Engine
Engine Displacement:
1.6 Liters (1587 cc)
Engine Configuration:
Inline 4-cylinder
Valve Train:
DOHC (Double Overhead Camshaft), 16 Valves
Aspiration:
Naturally Aspirated
Performance
Horsepower Estimate:
Approximately 109-110 PS (metric horsepower) or 108-109 bhp (brake horsepower) at around 6000 rpm. (Specific output may vary slightly by market).
Torque Estimate:
Approximately 147-150 Nm (108-111 lb-ft) at around 4000 rpm. (Specific output may vary slightly by market).
Fuel System
Fuel Delivery:
Electronic Multi-Point Fuel Injection (MPI)
Fuel Type:
Unleaded Petrol (Gasoline)
Engine Management
ECU System:
Likely Bosch Motronic or Siemens engine management system.
🔧 Transmission
Standard
Transmission Type:
5-speed Manual Transmission
Optional
Automatic Transmission:
Not typically offered with the 1.6i 16V petrol engine in this model year, though some markets might have had limited availability. Manual transmission is the dominant option.
Features
Clutch Type:
Hydraulically operated single dry plate clutch.
📐 Dimensions
Exterior
Body Styles:
Panel Van, Combi (Passenger variants).
Length Approx:
Approx. 4139 mm (depending on specific configuration)
Width Approx:
Approx. 1720 mm (excluding mirrors)
Height Approx:
Approx. 1790-1810 mm (depending on load and configuration)
Cargo
Cargo Volume Capacity:
Significant for its class, especially in panel van configurations, with detailed specifications likely available in the manual.
Weights
Gross Vehicle Weight:
Details available in manual, typically around 1750-1850 kg.
🛡️ Safety Features
Ratings
Euro Ncap Rating:
Likely 3-star or 4-star for adult occupant protection (Euro NCAP ratings vary by test year and specific configurations).
Active Features
ABS:
Optional on many variants, coverage in manual if equipped.
Traction Control:
Rarely standard on this model/engine combination, but check manual for availability.
Passive Features
Airbags:
Driver and passenger airbags standard on most passenger versions. Coverage in manual for airbag system diagnosis and replacement.
Seatbelts:
Front and rear seatbelt systems, including pre-tensioners if equipped. Manual covers adjustments and troubleshooting.
💡 Technology Features
Infotainment
Audio System:
Basic radio/CD player with standard speaker configuration. Manual will cover system components, wiring, and potential upgrades.
Driver Assistance
Cruise Control:
May be optional on higher trims or specific configurations; manual will detail operation and diagnosis if fitted.
Connectivity
Central Locking:
Standard feature, covered in body electrical systems and central locking system diagnosis within the manual.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000-15,000 miles or 12 months, whichever comes first. Specific recommendation in manual.
Timing Belt Interval:
Crucial for the TU5JP4 engine. Typically around 70,000-90,000 miles or 5-7 years. Critical to follow manual's recommendation.
Brake Fluid Change:
Every 2 years regardless of mileage, as it absorbs moisture.
Fluid Specifications
Engine Oil Type:
Likely API SJ/SL or ACEA A3/B3/B4, with viscosity grade 5W-40 or 10W-40 depending on climate. Refer to manual for exact spec.
Coolant Type:
Ethylene Glycol based, long-life antifreeze/coolant, typically blue or purple, conforming to PSA specifications (e.g., Peugeot PSA S71-2110). Refer to manual for exact spec.
Transmission Oil Type:
Manual gearbox oil, typically SAE 75W-80 or 75W-90 GL-4 specification. Refer to manual for exact spec and capacity.
Known Issues
Common Engine Problems:
Potential for ignition coil failure, thermostat housing leaks, and occasional oil leaks from seals or gaskets over time.
Common Transmission Problems:
Wear on clutch components, potential for gear linkage wear causing imprecise shifting, and occasional bearing noise.
Common Suspension Problems:
Wear in suspension bushings (e.g., control arm bushings), ball joints, and shock absorbers due to the vehicle's utilitarian nature.
📚 Vehicle History
Brand Heritage
Manufacturer:
Peugeot, a historic French automotive manufacturer known for a wide range of vehicles, including light commercial vehicles.
Model Evolution
Partner Lineage:
The Peugeot Partner was launched in 1996 as a compact van, designed to compete with models like the Citroën Berlingo (with which it shared many components). The 2004 model represents the first generation (Type M49) prior to its significant facelift.
Production
Manufacturing Plant:
Produced primarily in Spain (Vigo) and other PSA Group facilities.
🏆 Awards & Recognition
Recognitions
Van Of The Year:
The Peugeot Partner has received various 'Van of the Year' awards in different categories and markets over its production life, though specific awards for the 2004 model year would need detailed historical research.