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PEUGEOT 107 1.4 HDI 2005 Full Service Repair Manual

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๐Ÿท๏ธ Basic Information Identification Make: Peugeot Model: 107 Year: 2005 Engine: 1.4 HDi (DV4) Codes Chassis Code: BMC ๐Ÿ‘‹ Introduction Market Position Segment: City car / Subcompact Target Audience: Budget-conscious urban commuters, first-time car buyers, small families. Competitive Analysis Key Competitors: Toyota Aygo, Citroรซn C1, Fiat Panda, Ford Ka, Hyundai i10. Key Features Manufacturer Claim: Most complete service and repair manual for PEUGEOT 107 1.4 HDI 2005. Utility: Enables DIY repairs, saves time and money, used by local repair shops. Content Quality: Easy to read text, top-quality diagrams, step-by-step instructions, exploded pictures. ๐Ÿ“‹ Manual Details Coverage Areas Regions Covered: Global (likely European focus based on model) Page Count Estimated Page Count: Extensive (as per description implies comprehensive coverage, likely 500+ pages) Manual Type Type: Full Service and Repair Manual Language Language: English Format Format: PDF ๐Ÿ“– Manual Coverage Systems Covered Engine: 1.4 HDi (DV4) diesel engine: disassembly, assembly, inspection, diagnosis, repair, performance tuning. Fuel System: Common Rail Direct Injection (CRDi), fuel pump, injectors, fuel filter, fuel lines, pressure regulation. Ignition System: Glow plug system: diagnosis and replacement. Cooling System: Radiator, hoses, water pump, thermostat, coolant specifications, pressure testing. Exhaust System: Exhaust manifold, catalytic converter (if applicable), muffler, exhaust pipes, emissions control. Transmission: Manual transmission: removal, installation, internal component repair, clutch system, gear shift linkage. Drivetrain: Front wheel drive axle shafts, CV joints, differential (integrated in gearbox). Suspension: Front and rear suspension components: MacPherson struts, control arms, springs, shock absorbers, bushings, alignment specifications. Steering: Power steering system (likely electric or hydraulic assist), steering rack, tie rods, steering column, diagnosis. Brakes: Front disc brakes, rear drum brakes (typical for this segment), brake calipers, master cylinder, brake lines, ABS system (if equipped), bleeding procedures. Electrical System: Battery, alternator, starter motor, lighting system, fuses, relays, wiring diagrams, diagnostic connectors (OBD-II). Body And Frame: Body panel removal/installation, door mechanisms, interior trim, underbody coatings, corrosion protection. HVAC: Heating, ventilation, and air conditioning (HVAC) system: components, refrigerant, diagnosis. Interior: Dashboard removal, seat mechanisms, upholstery, interior trim components. Procedures Included Maintenance: Scheduled maintenance tasks: oil changes, filter replacements (oil, air, fuel, cabin), fluid checks and top-offs, spark plug replacement (N/A for diesel), brake inspection, tire rotation. Troubleshooting: Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides, fault code interpretation (P-codes, manufacturer-specific codes). Repair: Step-by-step instructions for component removal, repair, and installation across all vehicle systems. Disassembly Assembly: Complete disassembly and reassembly instructions for major components and the entire vehicle. Diagnostics: Detailed diagnostic routines for engine management, ABS, airbags, and other electronic systems. Technical Depth Depth: Comprehensive: Covers routine maintenance, in-depth repairs, component overhaul, and advanced diagnostics suitable for professional mechanics and skilled DIY enthusiasts. ๐Ÿ“Š Manual Specifications File Format Format: PDF Print Quality Printability: Full Printable (designed for printing individual pages or sections) Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Features Zoom Capability: YES (Zoom IN/OUT enabled for detailed viewing) Delivery Delivery Method: Instant Download Requirements Software Requirements: Adobe PDF Reader, WinZip (for decompression if needed) Compatibility Operating Systems: All Versions of Windows & Mac โš™๏ธ Engine Specifications Primary Engine Engine Code: DV4 (TDCi variant) Engine Type: Inline 4-cylinder, turbocharged diesel Displacement: 1398 cc (1.4 liters) Bore X Stroke: 73.7 mm x 82.0 mm Compression Ratio: 17.9:1 Performance Horsepower: 54 PS (40 kW) at 4000 rpm Torque: 130 Nm (96 lb-ft) at 1750 rpm Fuel System Fuel Injection: Common Rail Direct Injection (CRDi), Turbocharged Fuel Type: Diesel Cooling System Coolant Type: Antifreeze/Coolant (e.g., G11/G12 equivalent as per PSA specifications) Lubrication Engine Oil Type: SAE 5W-30 Low SAPS (API CF/ACEA C2 or C3 specification, e.g., PSA B71 2290) Oil Capacity: Approx. 4.0 liters (with filter change) ๐Ÿ”ง Transmission Standard Type: 5-speed Manual Transmission Optional Type: Automated Manual Transmission (SensoDrive - possibility, though less common on HDi) Features Clutch Type: Hydraulically operated dry single-plate clutch Fluid Specifications Manual Gearbox Oil: API GL-4, SAE 75W-80 (e.g., PSA S71 2301 specification) ๐Ÿ“ Dimensions Exterior Length: 3430 mm Width: 1630 mm Height: 1465 mm Wheelbase: 2340 mm Weights Curb Weight: Approx. 850-950 kg (depending on equipment) Gross Vehicle Weight: Approx. 1350 kg Cargo Boot Capacity: 139 liters (expandable to 751 liters with rear seats folded) ๐Ÿ›ก๏ธ Safety Features Ratings Euro Ncap Rating: 4 Stars (for original 2005 testing) Active Features ABS: Standard (Anti-lock Braking System) Esp: Optional (Electronic Stability Program) Passive Features Airbags: Driver and passenger airbags standard, side airbags optional. Seatbelts: 3-point seatbelts with pre-tensioners and force limiters. ๐Ÿ’ก Technology Features Infotainment Audio System: Basic radio/CD player (optional), auxiliary input. Driver Assistance Parking Sensors: Optional Connectivity Bluetooth: Optional, aftermarket installations common. ๐Ÿ”ง Maintenance Service Intervals Oil Change Interval: Every 20,000 km or 1 year, whichever comes first. Air Filter Replacement: Every 40,000 km or 2 years. Fuel Filter Replacement: Every 60,000 km or 3 years. Coolant Change: First change at 60,000 km or 4 years,...
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PEUGEOT 107 1.4 HDI 2005 Full Service Repair Manual
๐Ÿท๏ธ Basic Information
Identification
Make:
Peugeot
Model:
107
Year:
2005
Engine:
1.4 HDi (DV4)
Codes
Chassis Code:
BMC
๐Ÿ‘‹ Introduction
Market Position
Segment:
City car / Subcompact
Target Audience:
Budget-conscious urban commuters, first-time car buyers, small families.
Competitive Analysis
Key Competitors:
Toyota Aygo, Citroรซn C1, Fiat Panda, Ford Ka, Hyundai i10.
Key Features
Manufacturer Claim:
Most complete service and repair manual for PEUGEOT 107 1.4 HDI 2005.
Utility:
Enables DIY repairs, saves time and money, used by local repair shops.
Content Quality:
Easy to read text, top-quality diagrams, step-by-step instructions, exploded pictures.
๐Ÿ“‹ Manual Details
Coverage Areas
Regions Covered:
Global (likely European focus based on model)
Page Count
Estimated Page Count:
Extensive (as per description implies comprehensive coverage, likely 500+ pages)
Manual Type
Type:
Full Service and Repair Manual
Language
Language:
English
Format
Format:
PDF
๐Ÿ“– Manual Coverage
Systems Covered
Engine:
1.4 HDi (DV4) diesel engine: disassembly, assembly, inspection, diagnosis, repair, performance tuning.
Fuel System:
Common Rail Direct Injection (CRDi), fuel pump, injectors, fuel filter, fuel lines, pressure regulation.
Ignition System:
Glow plug system: diagnosis and replacement.
Cooling System:
Radiator, hoses, water pump, thermostat, coolant specifications, pressure testing.
Exhaust System:
Exhaust manifold, catalytic converter (if applicable), muffler, exhaust pipes, emissions control.
Transmission:
Manual transmission: removal, installation, internal component repair, clutch system, gear shift linkage.
Drivetrain:
Front wheel drive axle shafts, CV joints, differential (integrated in gearbox).
Suspension:
Front and rear suspension components: MacPherson struts, control arms, springs, shock absorbers, bushings, alignment specifications.
Steering:
Power steering system (likely electric or hydraulic assist), steering rack, tie rods, steering column, diagnosis.
Brakes:
Front disc brakes, rear drum brakes (typical for this segment), brake calipers, master cylinder, brake lines, ABS system (if equipped), bleeding procedures.
Electrical System:
Battery, alternator, starter motor, lighting system, fuses, relays, wiring diagrams, diagnostic connectors (OBD-II).
Body And Frame:
Body panel removal/installation, door mechanisms, interior trim, underbody coatings, corrosion protection.
HVAC:
Heating, ventilation, and air conditioning (HVAC) system: components, refrigerant, diagnosis.
Interior:
Dashboard removal, seat mechanisms, upholstery, interior trim components.
Procedures Included
Maintenance:
Scheduled maintenance tasks: oil changes, filter replacements (oil, air, fuel, cabin), fluid checks and top-offs, spark plug replacement (N/A for diesel), brake inspection, tire rotation.
Troubleshooting:
Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides, fault code interpretation (P-codes, manufacturer-specific codes).
Repair:
Step-by-step instructions for component removal, repair, and installation across all vehicle systems.
Disassembly Assembly:
Complete disassembly and reassembly instructions for major components and the entire vehicle.
Diagnostics:
Detailed diagnostic routines for engine management, ABS, airbags, and other electronic systems.
Technical Depth
Depth:
Comprehensive: Covers routine maintenance, in-depth repairs, component overhaul, and advanced diagnostics suitable for professional mechanics and skilled DIY enthusiasts.
๐Ÿ“Š Manual Specifications
File Format
Format:
PDF
Print Quality
Printability:
Full Printable (designed for printing individual pages or sections)
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Features
Zoom Capability:
YES (Zoom IN/OUT enabled for detailed viewing)
Delivery
Delivery Method:
Instant Download
Requirements
Software Requirements:
Adobe PDF Reader, WinZip (for decompression if needed)
Compatibility
Operating Systems:
All Versions of Windows & Mac
โš™๏ธ Engine Specifications
Primary Engine
Engine Code:
DV4 (TDCi variant)
Engine Type:
Inline 4-cylinder, turbocharged diesel
Displacement:
1398 cc (1.4 liters)
Bore X Stroke:
73.7 mm x 82.0 mm
Compression Ratio:
17.9:1
Performance
Horsepower:
54 PS (40 kW) at 4000 rpm
Torque:
130 Nm (96 lb-ft) at 1750 rpm
Fuel System
Fuel Injection:
Common Rail Direct Injection (CRDi), Turbocharged
Fuel Type:
Diesel
Cooling System
Coolant Type:
Antifreeze/Coolant (e.g., G11/G12 equivalent as per PSA specifications)
Lubrication
Engine Oil Type:
SAE 5W-30 Low SAPS (API CF/ACEA C2 or C3 specification, e.g., PSA B71 2290)
Oil Capacity:
Approx. 4.0 liters (with filter change)
๐Ÿ”ง Transmission
Standard
Type:
5-speed Manual Transmission
Optional
Type:
Automated Manual Transmission (SensoDrive - possibility, though less common on HDi)
Features
Clutch Type:
Hydraulically operated dry single-plate clutch
Fluid Specifications
Manual Gearbox Oil:
API GL-4, SAE 75W-80 (e.g., PSA S71 2301 specification)
๐Ÿ“ Dimensions
Exterior
Length:
3430 mm
Width:
1630 mm
Height:
1465 mm
Wheelbase:
2340 mm
Weights
Curb Weight:
Approx. 850-950 kg (depending on equipment)
Gross Vehicle Weight:
Approx. 1350 kg
Cargo
Boot Capacity:
139 liters (expandable to 751 liters with rear seats folded)
๐Ÿ›ก๏ธ Safety Features
Ratings
Euro Ncap Rating:
4 Stars (for original 2005 testing)
Active Features
ABS:
Standard (Anti-lock Braking System)
Esp:
Optional (Electronic Stability Program)
Passive Features
Airbags:
Driver and passenger airbags standard, side airbags optional.
Seatbelts:
3-point seatbelts with pre-tensioners and force limiters.
๐Ÿ’ก Technology Features
Infotainment
Audio System:
Basic radio/CD player (optional), auxiliary input.
Driver Assistance
Parking Sensors:
Optional
Connectivity
Bluetooth:
Optional, aftermarket installations common.
๐Ÿ”ง Maintenance
Service Intervals
Oil Change Interval:
Every 20,000 km or 1 year, whichever comes first.
Air Filter Replacement:
Every 40,000 km or 2 years.
Fuel Filter Replacement:
Every 60,000 km or 3 years.
Coolant Change:
First change at 60,000 km or 4 years, then every 40,000 km or 2 years.
Fluid Specifications
Brake Fluid Type:
DOT 4
Power Steering Fluid:
Refer to owner's manual for specific type (often proprietary PSA fluid).
Known Issues
Common Problems:
Potential for clutch wear (especially in city driving), diesel particulate filter (DPF) issues if not driven appropriately for regeneration, minor electrical gremlins, exhaust system corrosion.
๐Ÿ“š Vehicle History
Brand Heritage
Peugeot History:
Peugeot, a French automobile manufacturer founded in 1810, is known for its diverse range of vehicles, from city cars to performance models, with a long history of innovation and motorsport.
Model Evolution
107 Origins:
The Peugeot 107 was developed as part of a collaboration with Toyota Motor Corporation, alongside the Toyota Aygo and Citroรซn C1, sharing a common platform and manufacturing facilities in Kolรญn, Czech Republic.
Production
Production Period:
2005-2014 (first generation)
Manufacturing Location:
TPCA (Toyota Peugeot Citroรซn Automobile) plant in Kolรญn, Czech Republic.
๐Ÿ† Awards & Recognition
Recognitions
Safety Awards:
4-star Euro NCAP safety rating demonstrates a good level of occupant protection for its class in 2005.
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