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Peugeot 607 2000-2010 Full Service & Repair Manual

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🏷️ Basic Information Identification Make: Peugeot Model: 607 Model Years Covered: 2000-2010 👋 Introduction Market Position Vehicle Segment: Executive/Luxury Sedan Brand Perception: Peugeot's flagship model during its production run, aimed at comfort, refinement, and advanced features for its time. Competitive Analysis Competitors: Competed with other European executive sedans such as the BMW 5 Series, Mercedes-Benz E-Class, Audi A6, and the Citroën C6. Key Features Design: Distinctive styling, often praised for its elegant and aerodynamic lines. Interior focused on high-quality materials and driver comfort. Technology Early Adoption: Featured advanced technologies for its era, including sophisticated electronic control units, premium audio systems, and often a powerful diesel engine option. 📋 Manual Details Coverage Areas Manual Type: Factory Service Repair Workshop Manual Coverage Scope: Full Service, Repair, and Troubleshooting Format File Format: PDF Download Accessibility: Instant download, usable on multiple devices (computer, tablet, smartphone) Printability: Printable (single pages or entire manual) Licensing Usage License: Lifetime use, no expiry, no renewal fees Version Type: Full, unrestricted version Language Language: English (assumed based on product description) Compatibility Operating Systems: Windows and macOS compatible 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed overhaul, repair, and diagnostic procedures for all engine variants (e.g., 2.0L EW10 J4, 2.2L EW12 J4, 2.2L HDi Diesel DW12 TED4/TED4-4). Engine Management: Ignition system, fuel injection system (Bosch Motronic, Siemens, etc.), emission control systems, sensor diagnostics, ECU testing and replacement. Transmission Manual: Repair and overhaul of manual gearboxes (e.g., BE4, ML5C), clutch system, linkage adjustments. Transmission Automatic: Service, repair, and diagnostic procedures for automatic transmissions (e.g., AL4 - DPO), torque converter, valve body, electronic control. Braking System: Front and rear brake component replacement (discs, pads, calipers), ABS/ESP system diagnostics and repair, hydraulic system bleeding. Suspension Steering: Front and rear suspension component replacement (struts, shocks, bushings, ball joints), power steering system repair, wheel alignment procedures. Electrical System: Wiring diagrams, battery, charging system (alternator, starter), lighting systems, auxiliary electrical components, fuse and relay identification. Body Interior: Body panel removal and installation, interior trim components, seating systems, door mechanisms, HVAC system service, climate control diagnostics. Body Exterior: Bumpers, fenders, hood, trunk lid, glass replacement, mirror assemblies, paint and corrosion protection. Comfort Convenience: Power windows, power locks, central locking system, sunroof operation, seat adjustment systems, parking sensors, cruise control. Safety Systems Airbag System: Airbag module replacement, SRS system diagnostics, seat belt pre-tensioners, crash sensor location and replacement. Procedures Included Scheduled Maintenance: Detailed service intervals for oil changes, filter replacements, brake fluid flush, coolant replacement, spark plug replacement, timing belt/chain inspection/replacement. Troubleshooting: Systematic diagnostic flowcharts and common fault finding procedures for engine performance issues, electrical faults, HVAC problems, and more. Repair Overhaul: Step-by-step instructions for component replacement, engine rebuilding, transmission overhauling, suspension and brake system repairs. Diagnostics: Information on diagnostic trouble codes (DTCs), sensor data interpretation, and using diagnostic tools (e.g., Peugeot Planet System - PPS). Specifications Data: Torque specifications for all fasteners, fluid capacities and types, component clearances, electrical resistance values, and battery specifications. Technical Depth Detail Level: Comprehensive, suitable for professional mechanics and advanced DIY enthusiasts. Includes detailed exploded diagrams and high-resolution photos. 📊 Manual Specifications File Characteristics File Quality: High-resolution digital format, ensuring clarity of diagrams and text. Searchability: Likely text-searchable PDF (common for modern digital manuals), allowing quick access to specific topics. Physical Attributes Binding Type: Not applicable (downloadable PDF) Paper Type: Not applicable (downloadable PDF) ⚙️ Engine Specifications Primary Engine Petrol Engine Codes: EW10 J4 (2.0L), EW12 J4 (2.2L) Displacement 2.0L: 1997 cc Power 2.0L: 136 PS (134 hp / 100 kW) at 6000 rpm Torque 2.0L: 190 Nm (140 lb-ft) at 4100 rpm Displacement 2.2L: 2230 cc Power 2.2L: 160 PS (158 hp / 118 kW) at 6000 rpm Torque 2.2L: 220 Nm (162 lb-ft) at 3900 rpm Primary Engine Diesel Engine Codes: DW12 TED4 (2.2 HDi) Displacement Diesel: 2179 cc Power Diesel: 136 PS (134 hp / 100 kW) at 4000 rpm Torque Diesel: 310 Nm (229 lb-ft) at 2000 rpm Fuel System Petrol: Multi-point Fuel Injection (MPI) Diesel: Common Rail Direct Injection (CRDi) with Turbocharger and Intercooler 🔧 Transmission Standard Transmission Petrol 2.0L: 5-speed Manual (BE4) Petrol 2.2L: 5-speed Manual (ML5C) Diesel 2.2 Hdi: 5-speed Manual (ML5C) Optional Transmission Petrol 2.0L: 4-speed Automatic (AL4 - DPO) Petrol 2.2L: 4-speed Automatic (AL4 - DPO) Diesel 2.2 Hdi: 4-speed Automatic (AL4 - DPO) Features Al4 Drivetrain: Electronically controlled automatic transmission with Sport and Snow modes. 📐 Dimensions Exterior Length: Approx. 4870 mm (191.7 in) Width: Approx. 1830 mm (72.0 in) Height: Approx. 1450 mm (57.1 in) Wheelbase Wheelbase: Approx. 2800 mm (110.2 in) Weights Curb Weight Range: Approx. 1500-1650 kg (3307-3638 lbs) depending on engine and equipment. 🛡️ Safety Features Ratings Euroncap Rating: 4 Stars (2002) Active Features ABS: Standard Anti-lock Braking System Esp: Optional Electronic Stability Program (ESP) on some models. Passive Features Airbags: Multiple airbags including front, side, and curtain...
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Peugeot 607 2000-2010 Full Service & Repair Manual
🏷️ Basic Information
Identification
Make:
Peugeot
Model:
607
Model Years Covered:
2000-2010
👋 Introduction
Market Position
Vehicle Segment:
Executive/Luxury Sedan
Brand Perception:
Peugeot's flagship model during its production run, aimed at comfort, refinement, and advanced features for its time.
Competitive Analysis
Competitors:
Competed with other European executive sedans such as the BMW 5 Series, Mercedes-Benz E-Class, Audi A6, and the Citroën C6.
Key Features
Design:
Distinctive styling, often praised for its elegant and aerodynamic lines. Interior focused on high-quality materials and driver comfort.
Technology Early Adoption:
Featured advanced technologies for its era, including sophisticated electronic control units, premium audio systems, and often a powerful diesel engine option.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Repair Workshop Manual
Coverage Scope:
Full Service, Repair, and Troubleshooting
Format
File Format:
PDF Download
Accessibility:
Instant download, usable on multiple devices (computer, tablet, smartphone)
Printability:
Printable (single pages or entire manual)
Licensing
Usage License:
Lifetime use, no expiry, no renewal fees
Version Type:
Full, unrestricted version
Language
Language:
English (assumed based on product description)
Compatibility
Operating Systems:
Windows and macOS compatible
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed overhaul, repair, and diagnostic procedures for all engine variants (e.g., 2.0L EW10 J4, 2.2L EW12 J4, 2.2L HDi Diesel DW12 TED4/TED4-4).
Engine Management:
Ignition system, fuel injection system (Bosch Motronic, Siemens, etc.), emission control systems, sensor diagnostics, ECU testing and replacement.
Transmission Manual:
Repair and overhaul of manual gearboxes (e.g., BE4, ML5C), clutch system, linkage adjustments.
Transmission Automatic:
Service, repair, and diagnostic procedures for automatic transmissions (e.g., AL4 - DPO), torque converter, valve body, electronic control.
Braking System:
Front and rear brake component replacement (discs, pads, calipers), ABS/ESP system diagnostics and repair, hydraulic system bleeding.
Suspension Steering:
Front and rear suspension component replacement (struts, shocks, bushings, ball joints), power steering system repair, wheel alignment procedures.
Electrical System:
Wiring diagrams, battery, charging system (alternator, starter), lighting systems, auxiliary electrical components, fuse and relay identification.
Body Interior:
Body panel removal and installation, interior trim components, seating systems, door mechanisms, HVAC system service, climate control diagnostics.
Body Exterior:
Bumpers, fenders, hood, trunk lid, glass replacement, mirror assemblies, paint and corrosion protection.
Comfort Convenience:
Power windows, power locks, central locking system, sunroof operation, seat adjustment systems, parking sensors, cruise control.
Safety Systems
Airbag System:
Airbag module replacement, SRS system diagnostics, seat belt pre-tensioners, crash sensor location and replacement.
Procedures Included
Scheduled Maintenance:
Detailed service intervals for oil changes, filter replacements, brake fluid flush, coolant replacement, spark plug replacement, timing belt/chain inspection/replacement.
Troubleshooting:
Systematic diagnostic flowcharts and common fault finding procedures for engine performance issues, electrical faults, HVAC problems, and more.
Repair Overhaul:
Step-by-step instructions for component replacement, engine rebuilding, transmission overhauling, suspension and brake system repairs.
Diagnostics:
Information on diagnostic trouble codes (DTCs), sensor data interpretation, and using diagnostic tools (e.g., Peugeot Planet System - PPS).
Specifications Data:
Torque specifications for all fasteners, fluid capacities and types, component clearances, electrical resistance values, and battery specifications.
Technical Depth
Detail Level:
Comprehensive, suitable for professional mechanics and advanced DIY enthusiasts. Includes detailed exploded diagrams and high-resolution photos.
📊 Manual Specifications
File Characteristics
File Quality:
High-resolution digital format, ensuring clarity of diagrams and text.
Searchability:
Likely text-searchable PDF (common for modern digital manuals), allowing quick access to specific topics.
Physical Attributes
Binding Type:
Not applicable (downloadable PDF)
Paper Type:
Not applicable (downloadable PDF)
⚙️ Engine Specifications
Primary Engine Petrol
Engine Codes:
EW10 J4 (2.0L), EW12 J4 (2.2L)
Displacement 2.0L:
1997 cc
Power 2.0L:
136 PS (134 hp / 100 kW) at 6000 rpm
Torque 2.0L:
190 Nm (140 lb-ft) at 4100 rpm
Displacement 2.2L:
2230 cc
Power 2.2L:
160 PS (158 hp / 118 kW) at 6000 rpm
Torque 2.2L:
220 Nm (162 lb-ft) at 3900 rpm
Primary Engine Diesel
Engine Codes:
DW12 TED4 (2.2 HDi)
Displacement Diesel:
2179 cc
Power Diesel:
136 PS (134 hp / 100 kW) at 4000 rpm
Torque Diesel:
310 Nm (229 lb-ft) at 2000 rpm
Fuel System
Petrol:
Multi-point Fuel Injection (MPI)
Diesel:
Common Rail Direct Injection (CRDi) with Turbocharger and Intercooler
🔧 Transmission
Standard Transmission
Petrol 2.0L:
5-speed Manual (BE4)
Petrol 2.2L:
5-speed Manual (ML5C)
Diesel 2.2 Hdi:
5-speed Manual (ML5C)
Optional Transmission
Petrol 2.0L:
4-speed Automatic (AL4 - DPO)
Petrol 2.2L:
4-speed Automatic (AL4 - DPO)
Diesel 2.2 Hdi:
4-speed Automatic (AL4 - DPO)
Features
Al4 Drivetrain:
Electronically controlled automatic transmission with Sport and Snow modes.
📐 Dimensions
Exterior
Length:
Approx. 4870 mm (191.7 in)
Width:
Approx. 1830 mm (72.0 in)
Height:
Approx. 1450 mm (57.1 in)
Wheelbase
Wheelbase:
Approx. 2800 mm (110.2 in)
Weights
Curb Weight Range:
Approx. 1500-1650 kg (3307-3638 lbs) depending on engine and equipment.
🛡️ Safety Features
Ratings
Euroncap Rating:
4 Stars (2002)
Active Features
ABS:
Standard Anti-lock Braking System
Esp:
Optional Electronic Stability Program (ESP) on some models.
Passive Features
Airbags:
Multiple airbags including front, side, and curtain airbags.
Seatbelts:
Pre-tensioning seatbelts with force limiters.
💡 Technology Features
Infotainment
Audio System:
Premium JBL or Clarion audio systems, often with CD player, radio, and steering wheel controls. Some models featured navigation systems.
Driver Assistance
Parking Sensors:
Front and rear parking sensors were optional or standard on higher trims.
Cruise Control:
Standard or optional cruise control and speed limiter functions.
Connectivity
Can Bus:
Utilizes a CAN (Controller Area Network) bus system for communication between various electronic control units, impacting diagnostics.
Comfort Features
Seats:
Electric adjustment for front seats, often with memory function for the driver's seat. Heated seats were an option.
🔧 Maintenance
Service Intervals
Oil Change Petrol:
Every 15,000 km or 12 months (whichever comes first), subject to driving conditions. Refer to manual for specific oil grades.
Oil Change Diesel:
Every 20,000 km or 12 months (whichever comes first), subject to driving conditions. Diesel Particulate Filter (DPF) considerations are crucial.
Timing Belt Petrol:
For EW series engines, typically 120,000 km or 6 years. Critical to verify with the manual due to potential for severe damage if it breaks.
Timing Belt Diesel:
DW12 HDi engines use a timing belt. Interval typically 180,000 km or 8 years. Includes tensioners and idler pulleys.
Fluid Specifications
Engine Oil Petrol 2.0L:
SAE 5W-40, API SL/CF or ACEA A3/B4 (check specific oil manufacturer approvals).
Engine Oil Petrol 2.2L:
SAE 5W-40, API SL/CF or ACEA A3/B4 (check specific oil manufacturer approvals).
Engine Oil Diesel 2.2 Hdi:
SAE 5W-30 Low SAPS, API CF/CI-4 or ACEA C3 (essential for DPF systems). Check specific PSA approvals (e.g., B71 2290).
Coolant:
Peugeot/Citroën (PSA) approved antifreeze/coolant concentrate, typically a long-life silicate-free formulation. Mix 50/50 with distilled water. (e.g., Total Glacelf Auto Supra).
Brake Fluid:
DOT 4 (refer to manual for specific type, e.g., DOT 4 LV for lower viscosity).
Transmission Fluid Manual:
API GL-4, SAE 75W-80 synthetic gear oil (e.g., PSA B71 2330 specification).
Transmission Fluid Automatic Al4:
LT 71141 or equivalent (specific automatic transmission fluid). Critical to use correct fluid to avoid damage.
Known Issues
Electrical Gremlins:
Can suffer from intermittent electrical faults, often related to body control modules, door wiring harnesses, or CAN bus communication.
Hdi Dpf:
Diesel models with Diesel Particulate Filters (DPF) can experience clogging if regeneration cycles are not completed, especially with short journeys. Manual provides DPF service procedures.
Al4 Automatic Transmission:
Known for potential issues with the valve body, solenoid packs, and fluid degradation, leading to harsh shifting or limp-home mode. Proper fluid changes and diagnostics are key.
Suspension Components:
Wear on front suspension components like wishbone bushings and ball joints can lead to noise and poor handling. Strut top mounts can also fail.
Climate Control Actuators:
HVAC system can experience issues with blend door actuators, leading to incorrect temperature or air direction.
📚 Vehicle History
Brand Heritage
Peugeot Luxury Sedans:
Peugeot has a long history of producing large executive sedans, following models like the Peugeot 505 and 605.
Model Evolution
Generation 1 Codename:
Type D81/D82
Introduction Year:
1999 (Paris Motor Show), launched in 2000.
Facelift:
Minor facelift occurred around 2004, with subtle styling updates and technology improvements.
Production
Production End Year:
2010
Manufacturing Location:
Sochaux, France
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