2003 Peugeot 607 160 – Workshop Service & Repair Manual

A common issue reported by owners of the 2003 Peugeot 607 160 is difficulty starting the engine when it's warm. This problem may be due to various factors, including fuel pressure issues, ignition problems, or sensor malfunctions.

Step-by-Step Solution:

Check the Fuel Pressure:

Inspect the Fuel Pump: Make sure the fuel pump is functioning properly. Listen for a humming sound from the fuel tank when the ignition is turned on.

Test the Fuel Pressure: Use a fuel pressure gauge to check if the pressure meets the specifications outlined in the manual. Low pressure may indicate a failing fuel pump or clogged fuel filter.

Examine the Ignition System:

Spark Plugs and Wires: Inspect spark plugs for wear or carbon buildup and replace if necessary. Check spark plug wires for any visible damage.

Ignition Coil: Test the ignition coil for proper function using a multimeter. Replace if it shows signs of failure.

Evaluate the Engine Sensors:

Coolant Temperature Sensor: A faulty sensor might give incorrect temperature readings, affecting starting conditions. Test and replace if needed.

Crankshaft Position Sensor: This sensor is crucial for engine timing. Inspect it for faults and replace if it's not functioning properly.

Inspect the Battery and Connections:

Battery Health: Check the battery voltage and charge. A weak battery can struggle to provide enough power to start a warm engine.

Connections and Terminals: Ensure all connections are clean and tight. Corroded terminals can impede electrical flow.

Consider the Starter Motor:

Starter Inspection: If the starter motor is sluggish or unresponsive, it might need replacement or repair.

Our 2003 Peugeot 607 160 Workshop Service & Repair Manual (PDF) provides detailed procedures for diagnosing and resolving starting issues, ensuring your vehicle runs smoothly even when warm.

Electrical problems are not uncommon in older vehicles like the 2003 Peugeot 607 160. These may manifest as flickering lights, malfunctioning dashboard components, or blown fuses.

Step-by-Step Solution:

Check Fuses and Relays:

Fuse Box Inspection: Locate the fuse box under the dashboard or in the engine compartment. Refer to the manual for fuse identification and replace any blown fuses.

Relay Testing: Use a multimeter to test relays for continuity. Replace any faulty relays to restore proper function.

Inspect Wiring and Connectors:

Wiring Harness: Visually inspect the wiring harness for damage, fraying, or corrosion. Repair or replace any damaged sections.

Connector Check: Ensure all connectors are clean and securely fastened. Loose or corroded connectors can cause intermittent electrical failures.

Evaluate the Battery and Charging System:

Alternator Check: Test the alternator output to ensure it’s charging the battery correctly. A failing alternator may cause electrical components to act erratically.

Battery Health: As mentioned earlier, ensure the battery is in good condition and capable of holding a charge.

Inspect the Grounds:

Ground Connections: Ensure all ground connections are clean and tightly secured. A poor ground can lead to numerous electrical issues.

Check Lighting Components:

Bulb Replacement: If lights are flickering or not working, check the bulbs and replace them if burned out.

Switches and Controls: Test light switches and controls to ensure they are working properly.

The 2003 Peugeot 607 160 Workshop Service & Repair Manual includes comprehensive diagrams and troubleshooting steps for electrical systems, helping you identify and resolve issues effectively.

Experiencing poor fuel economy can be frustrating and costly. It can be caused by various factors, such as incorrect tire pressure, clogged air filters, or engine tuning problems.

Step-by-Step Solution:

Check Tire Pressure:

Tire Inflation: Ensure all tires are inflated to the recommended PSI. Under-inflated tires can lead to increased fuel consumption.

Tire Alignment: Misaligned tires cause drag and reduce efficiency. Have a professional check the alignment if needed.

Inspect Air Filters:

Air Filter Replacement: A clogged air filter restricts airflow, affecting combustion efficiency. Replace the air filter if it appears dirty or clogged.

Evaluate Engine Performance:

Fuel Injector Cleaning: Dirty fuel injectors can cause uneven fuel delivery. Consider using a fuel injector cleaner or have them professionally cleaned.

Spark Plug Inspection: As mentioned earlier, check spark plugs for wear and replace them if necessary.

Assess Driving Habits:

Smooth Acceleration: Avoid rapid acceleration and braking, as these behaviors increase fuel consumption.

Optimal Speed: Drive at a consistent speed and use cruise control on highways when possible to improve fuel efficiency.

Consider ECU Reprogramming:

ECU Update: A reprogrammed Engine Control Unit (ECU) may improve fuel efficiency by optimizing engine performance settings.

Our manual provides in-depth guidance on enhancing your 2003 Peugeot 607 160's fuel economy, from maintenance tips to performance tweaks.

Overheating can lead to serious engine damage if not addressed promptly. Common causes include coolant leaks, radiator blockages, or a malfunctioning thermostat.

Step-by-Step Solution:

Check Coolant Levels:

Coolant Inspection: Ensure the coolant level is between the minimum and maximum marks. Top up with the correct coolant type if needed.

Look for Leaks: Inspect hoses, the radiator, and the coolant reservoir for signs of leaks or damage.

Inspect the Radiator:

Radiator Condition: Ensure the radiator is not blocked by debris or dirt. Clean it if necessary.

Radiator Cap: Check the radiator cap for wear or damage. A faulty cap can affect the pressure in the cooling system.

Evaluate the Thermostat:

Thermostat Function: A stuck thermostat may prevent coolant from flowing properly. Replace it if it's not opening or closing as it should.

Check the Water Pump:

Water Pump Inspection: Ensure the water pump is circulating coolant effectively. Listen for unusual noises that may indicate a failing pump.

Examine the Fan System:

Cooling Fan: Make sure the cooling fan operates when the engine reaches operating temperature. Test the fan motor and related wiring if necessary.

Avoid engine damage by following our detailed instructions for troubleshooting overheating problems in your 2003 Peugeot 607 160.

Unusual vibrations during driving can result from tire imbalances, suspension issues, or drivetrain problems.

Step-by-Step Solution:

Inspect Tires and Wheels:

Tire Balancing: Have your tires balanced to eliminate vibrations caused by uneven weight distribution.

Wheel Alignment: Ensure wheels are properly aligned, as misalignment can lead to vibrations.

Check Suspension Components:

Suspension Inspection: Inspect shock absorbers, struts, and bushings for wear or damage. Replace any faulty components.

Steering System: Evaluate the steering system for looseness or damage. Tighten or replace parts as necessary.

Examine the Drivetrain:

Drivetrain Inspection: Inspect driveshafts and CV joints for damage or wear. Replace any parts showing signs of failure.

Transmission Mounts: Check transmission mounts for wear. Damaged mounts can cause vibrations.

Evaluate Brake Components:

Brake Inspection: Warped brake rotors can cause vibrations when braking. Have them machined or replaced if necessary.

Caliper Functionality: Ensure calipers are working smoothly and not causing brake drag.

Consider Engine Mounts:

Engine Mounts Check: Inspect engine mounts for wear or damage. Replace any mounts that fail to secure the engine properly.

Our 2003 Peugeot 607 160 Workshop Service & Repair Manual offers expert guidance to diagnose and fix vibration issues,