Peugeot Expert 2.0 HDi 16V Complete Workshop Service Repair Manual 2004 2005

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🏷️ Basic Information Identification Make: Peugeot Model: Expert Generation: First Generation (X) / Phase 1 Product Name: Peugeot Expert 2.0 HDi 16V Complete Workshop Service Repair Manual 2004 2005 Codes Engine Code Primary: DW10ATED (2.0 HDi 16V) Chassis Code: X (Various sub-variants) 👋 Introduction Market Position Vehicle Segment: Light Commercial Vehicle (LCV) / Panel Van / MPV Target Audience For Manual: DIY mechanics, independent repair shops, fleet owners, Peugeot enthusiasts Competitive Analysis Key Competitors Vehicle: Citroën Jumpy/Dispatch, Fiat Scudo, Renault Trafic, Ford Transit, Volkswagen Transporter (T4/T5 era) Key Features Manual Key Selling Point: Enables cost savings through DIY repairs and maintenance, comprehensive coverage A-Z Manual User Friendliness: Easy-to-follow step-by-step instructions and pictures 📋 Manual Details Coverage Areas Vehicle Years Covered: 2004, 2005 Models Covered: All Peugeot Expert 2.0 HDi 16V models, all trim levels, all transmission types Page Count Estimated Page Count: Likely 1000+ pages (typical for a complete workshop manual of this era) Manual Type Manual Type: Complete Workshop Service Repair Manual Language Language: English Format Delivery Format: Digital Download (PDF) File Accessibility: Printable, tablet/smartphone compatible 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, cylinder head, crankshaft, pistons, connecting rods, timing system, lubrication system, cooling system Engine Fuel System: Direct injection (HDi), common rail system, fuel pump, injectors, fuel filter, high-pressure lines, diagnostics Engine Electrical: Engine control unit (ECU), sensors (crankshaft position, camshaft position, manifold pressure, lambda), actuators, glow plug system, starter motor, alternator Transmission Manual: Clutch system, gearbox overhaul, shift linkage, final drive, gearbox oil specifications Transmission Automatic: If applicable to 2.0 HDi 16V variants, coverage would include gearbox operation, fluid changes, and diagnostics (specific coverage depends on actual transmission types offered) Brake System: Front and rear disc brakes, brake calipers, brake pads, brake discs, brake fluid, ABS system (Anti-lock Braking System) diagnostics and components Suspension Steering: Front suspension (MacPherson struts), rear suspension (torsion beam or independent depending on variant), shock absorbers, springs, wheel bearings, power steering system, steering rack, tie rods Electrical System: Battery, charging system, lighting (headlights, taillights, interior), fuses, relays, wiring diagrams, power windows, central locking, mirrors Body Interior: Body panels, doors, hood, tailgate, bumpers, interior trim, seats, dashboard, HVAC system controls Body Exterior: Bodywork repair, rust prevention, paint specifications, panel alignment, glass replacement HVAC: Heating, Ventilation, and Air Conditioning system diagnosis, refrigerant, components (compressor, condenser, evaporator) Diagnostic Troubleshooting: Fault code identification, symptom-based troubleshooting, diagnostic procedures for all major systems Procedures Included Maintenance: Routine servicing, oil and filter changes, air filter replacement, fuel filter replacement, coolant checks, brake fluid replacement, spark plug replacement (if applicable, though typically not for HDi), belt replacement Repair: Component removal and installation, rebuild procedures for major sub-assemblies (engine, transmission), body panel repair, electrical component replacement Troubleshooting: Step-by-step diagnostics for common and uncommon problems, electrical circuit tracing, mechanical fault finding Specifications: Torque specifications for all fasteners, clearances, tolerances, fluid capacities, electrical specifications Wiring Diagrams: Detailed electrical wiring schematics for all systems, color-coded wiring information Technical Depth Depth Of Coverage: Comprehensive (from basic maintenance to major overhaul and diagnostics) Instruction Style: Step-by-step instructions with accompanying illustrations and diagrams Diagnostic Tools: Information on required diagnostic tools and procedures (e.g., OBD-II scanner) 📊 Manual Specifications File Format File Format: PDF Searchability: Likely text-searchable PDF Print Quality Print Quality: High-quality, suitable for professional printing Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-cylinder, Turbocharged Direct Injection Diesel (HDi) Displacement: 2.0 Liters (1997 cc) Valvetrain: DOHC (Double Overhead Camshaft), 16 Valves Performance Horsepower Typical: Approximately 94 PS (93 hp / 69 kW) or 109 PS (108 hp / 80 kW) depending on specific tune of the DW10ATED engine Torque Typical: Approximately 215 Nm (159 lb-ft) for the 94 PS version, and 250 Nm (184 lb-ft) for the 109 PS version Fuel System Fuel Type: Diesel Injection System: Bosch Common Rail Direct Injection Turbocharger: Variable Geometry Turbocharger (VGT) likely on higher output versions Cooling System Coolant Type: Antifreeze/Coolant (G11/G12 equivalent, typically blue or red concentrate) Lubrication System Engine Oil Type: Synthetic or Semi-Synthetic SAE 5W-40 or 5W-30 meeting PSA specifications (e.g., PSA B71 2295, PSA B71 2297) 🔧 Transmission Standard Standard Transmission Type: 5-speed Manual Transmission Optional Optional Transmission Type: Some variants may have offered a 4-speed Automatic Transmission (AL4 or similar) Features Transmission Fluid Type Manual: GL-4 or GL-5 rated Gear Oil (viscosity typically 75W-80 or 75W-90) Clutch Type: Hydraulically operated, single dry plate clutch 📐 Dimensions Exterior Wheelbase: Varies by specific model variant (e.g., Short Wheelbase SWB, Long Wheelbase LWB) Overall Length: Varies by wheelbase (e.g., approximately 4.2m to 4.6m) Overall Width: Approximately 1.8m (excluding mirrors) Overall Height: Approximately 1.8m to 1.9m (standard roof) Weights Gross Vehicle Weight Rating Gvwr: Typically in the range of 2000-2500 kg Curb Weight: Varies by configuration, generally around 1400-1600 kg 🛡️ Safety Features...

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Description

🏷️ Basic Information

Identification

Make:

Peugeot

Model:

Expert

Generation:

First Generation (X) / Phase 1

Product Name:

Peugeot Expert 2.0 HDi 16V Complete Workshop Service Repair Manual 2004 2005

Codes

Engine Code Primary:

DW10ATED (2.0 HDi 16V)

Chassis Code:

X (Various sub-variants)

👋 Introduction

Market Position

Vehicle Segment:

Light Commercial Vehicle (LCV) / Panel Van / MPV

Target Audience For Manual:

DIY mechanics, independent repair shops, fleet owners, Peugeot enthusiasts

Competitive Analysis

Key Competitors Vehicle:

Citroën Jumpy/Dispatch, Fiat Scudo, Renault Trafic, Ford Transit, Volkswagen Transporter (T4/T5 era)

Key Features

Manual Key Selling Point:

Enables cost savings through DIY repairs and maintenance, comprehensive coverage A-Z

Manual User Friendliness:

Easy-to-follow step-by-step instructions and pictures

📋 Manual Details

Coverage Areas

Vehicle Years Covered:

2004, 2005

Models Covered:

All Peugeot Expert 2.0 HDi 16V models, all trim levels, all transmission types

Page Count

Estimated Page Count:

Likely 1000+ pages (typical for a complete workshop manual of this era)

Manual Type

Manual Type:

Complete Workshop Service Repair Manual

Language

Language:

English

Format

Delivery Format:

Digital Download (PDF)

File Accessibility:

Printable, tablet/smartphone compatible

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine overhaul, cylinder head, crankshaft, pistons, connecting rods, timing system, lubrication system, cooling system

Engine Fuel System:

Direct injection (HDi), common rail system, fuel pump, injectors, fuel filter, high-pressure lines, diagnostics

Engine Electrical:

Engine control unit (ECU), sensors (crankshaft position, camshaft position, manifold pressure, lambda), actuators, glow plug system, starter motor, alternator

Transmission Manual:

Clutch system, gearbox overhaul, shift linkage, final drive, gearbox oil specifications

Transmission Automatic:

If applicable to 2.0 HDi 16V variants, coverage would include gearbox operation, fluid changes, and diagnostics (specific coverage depends on actual transmission types offered)

Brake System:

Front and rear disc brakes, brake calipers, brake pads, brake discs, brake fluid, ABS system (Anti-lock Braking System) diagnostics and components

Suspension Steering:

Front suspension (MacPherson struts), rear suspension (torsion beam or independent depending on variant), shock absorbers, springs, wheel bearings, power steering system, steering rack, tie rods

Electrical System:

Battery, charging system, lighting (headlights, taillights, interior), fuses, relays, wiring diagrams, power windows, central locking, mirrors

Body Interior:

Body panels, doors, hood, tailgate, bumpers, interior trim, seats, dashboard, HVAC system controls

Body Exterior:

Bodywork repair, rust prevention, paint specifications, panel alignment, glass replacement

HVAC:

Heating, Ventilation, and Air Conditioning system diagnosis, refrigerant, components (compressor, condenser, evaporator)

Diagnostic Troubleshooting:

Fault code identification, symptom-based troubleshooting, diagnostic procedures for all major systems

Procedures Included

Maintenance:

Routine servicing, oil and filter changes, air filter replacement, fuel filter replacement, coolant checks, brake fluid replacement, spark plug replacement (if applicable, though typically not for HDi), belt replacement

Repair:

Component removal and installation, rebuild procedures for major sub-assemblies (engine, transmission), body panel repair, electrical component replacement

Troubleshooting:

Step-by-step diagnostics for common and uncommon problems, electrical circuit tracing, mechanical fault finding

Specifications:

Torque specifications for all fasteners, clearances, tolerances, fluid capacities, electrical specifications

Wiring Diagrams:

Detailed electrical wiring schematics for all systems, color-coded wiring information

Technical Depth

Depth Of Coverage:

Comprehensive (from basic maintenance to major overhaul and diagnostics)

Instruction Style:

Step-by-step instructions with accompanying illustrations and diagrams

Diagnostic Tools:

Information on required diagnostic tools and procedures (e.g., OBD-II scanner)

📊 Manual Specifications

File Format

File Format:

Searchability:

Likely text-searchable PDF

Print Quality

Print Quality:

High-quality, suitable for professional printing

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline 4-cylinder, Turbocharged Direct Injection Diesel (HDi)

Displacement:

2.0 Liters (1997 cc)

Valvetrain:

DOHC (Double Overhead Camshaft), 16 Valves

Performance

Horsepower Typical:

Approximately 94 PS (93 hp / 69 kW) or 109 PS (108 hp / 80 kW) depending on specific tune of the DW10ATED engine

Torque Typical:

Approximately 215 Nm (159 lb-ft) for the 94 PS version, and 250 Nm (184 lb-ft) for the 109 PS version

Fuel System

Fuel Type:

Diesel

Injection System:

Bosch Common Rail Direct Injection

Turbocharger:

Variable Geometry Turbocharger (VGT) likely on higher output versions

Cooling System

Coolant Type:

Antifreeze/Coolant (G11/G12 equivalent, typically blue or red concentrate)

Lubrication System

Engine Oil Type:

Synthetic or Semi-Synthetic SAE 5W-40 or 5W-30 meeting PSA specifications (e.g., PSA B71 2295, PSA B71 2297)

🔧 Transmission

Standard

Standard Transmission Type:

5-speed Manual Transmission

Optional

Optional Transmission Type:

Some variants may have offered a 4-speed Automatic Transmission (AL4 or similar)

Features

Transmission Fluid Type Manual:

GL-4 or GL-5 rated Gear Oil (viscosity typically 75W-80 or 75W-90)

Clutch Type:

Hydraulically operated, single dry plate clutch

📐 Dimensions

Exterior

Wheelbase:

Varies by specific model variant (e.g., Short Wheelbase SWB, Long Wheelbase LWB)

Overall Length:

Varies by wheelbase (e.g., approximately 4.2m to 4.6m)

Overall Width:

Approximately 1.8m (excluding mirrors)

Overall Height:

Approximately 1.8m to 1.9m (standard roof)

Weights

Gross Vehicle Weight Rating Gvwr:

Typically in the range of 2000-2500 kg

Curb Weight:

Varies by configuration, generally around 1400-1600 kg

🛡️ Safety Features

Ratings

Euro Ncap Rating:

Coverage may include safety ratings for the specific phase and variants, typically 3 or 4 stars for LCVs of this era depending on equipment.

Active Features

Active Safety Features:

ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), potentially ESP (Electronic Stability Program) on higher trims or later models.

Passive Features

Passive Safety Features:

Driver and passenger airbags, seatbelt pre-tensioners, reinforced body structure.

💡 Technology Features

Infotainment

Infotainment System Typical:

Basic radio/CD player, possibly with steering wheel controls. Limited infotainment features compared to modern vehicles.

Driver Assistance

Driver Assistance Features:

ABS, EBD. Cruise control may have been an option on higher trims.

Connectivity

Connectivity Features:

Likely basic aux input for audio. Bluetooth integration or advanced connectivity not standard.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 15,000 miles (25,000 km) or 12 months, whichever comes first. (Refer to manual for exact interval based on driving conditions).

Fuel Filter Replacement Interval:

Approximately 30,000-40,000 miles (50,000-65,000 km) or as per manual recommendations.

Air Filter Replacement Interval:

Every 30,000 miles (50,000 km) or annually.

Timing Belt Replacement Interval:

Crucial for HDi engines. Typically around 75,000 - 100,000 miles (120,000 - 160,000 km) or 5-6 years. Failure can cause catastrophic engine damage.

Fluid Specifications

Brake Fluid Specification:

DOT 4

Power Steering Fluid Type:

ATF (Automatic Transmission Fluid) Dexron II/III or specific PSA fluid.

Known Issues

Common Issues Engine:

EGR valve clogging, turbocharger wastegate issues, injector seal leaks, diesel particulate filter (DPF) clogging (if fitted to specific variants), glow plug failure.

Common Issues Suspension:

Wear on front suspension components (ball joints, drop links), rear axle beam wear, premature wheel bearing failure.

Common Issues Electrical:

Issues with wiring looms (especially in engine bay), faulty sensors (crankshaft/camshaft position), intermittent dashboard warning lights.

📚 Vehicle History

Brand Heritage

Peugeot Heritage:

Peugeot has a long history in vehicle manufacturing, including a strong presence in commercial vehicles and innovative diesel engine technology (HDi).

Model Evolution

Expert First Generation Timeline:

Introduced in 1995, built on the Sevel (Société Européenne de Véhicules Légers) platform shared with Citroën. The 2004-2005 models represent the Phase 1 facelift.

Production

Manufacturing Location:

Primarily manufactured in Europe, often at facilities associated with the PSA Group or Sevel. Specific plant locations for the Expert would be detailed in historical production records.

🏆 Awards & Recognition

Recognitions

Vehicle Awards:

While specific awards for the 2004-2005 Expert are not readily documented, it was part of a successful family of LCVs that received recognition for practicality and utility within the commercial vehicle sector.