Vehicle Type:
Light Commercial Vehicle / Panel Van / Leisure Vehicle
Competitors:
Renault Express/Trafic, Peugeot Partner/Expert, Fiat Fiorino/Scudo, Ford Transit Connect/Courier
Strengths:
Robustness, Simplicity, Fuel Efficiency (Diesel), Versatility, Cost-Effectiveness
Powertrain:
Engine, Fuel System, Cooling System, Lubrication System, Exhaust System
Drivetrain:
Clutch, Manual Transmission, Driveshafts, Differential
Chassis:
Suspension (Front & Rear), Steering System, Brakes (Hydraulic & Parking)
Electrical:
Battery, Charging System, Starting System, Ignition System, Lighting, Instrumentation, Wipers, Horn, Accessories
Body:
Body Panels, Doors, Windows, Seats, Interior Trim, Exterior Trim, Paint
Maintenance:
Oil Changes, Filter Replacements, Fluid Top-ups, Spark Plug Replacement, Belt Inspection/Replacement
Troubleshooting:
Diagnostic Procedures, Fault Finding Charts, Symptom-based Diagnosis
Repair:
Engine Overhaul, Transmission Rebuild, Brake Caliper Replacement, Suspension Component Replacement, Electrical Component Repair
Installation:
Component Installation, Accessory Fitment (where applicable)
Depth:
Comprehensive (from basic maintenance to full engine/transmission overhauls)
Engine Type:
Naturally Aspirated Diesel
Displacement:
1.9 Liters (1868 cc)
Configuration:
Inline 4-Cylinder
Horsepower:
Approx. 60-70 PS (metric horsepower) at 4600 rpm (exact figures may vary slightly based on specific tune)
Torque:
Approx. 110-125 Nm at 2000-2500 rpm
Injection Type:
Indirect Injection (IDI) with Bosch VE Rotary Pump
Coolant Type:
Ethylene Glycol based antifreeze (e.g., PSA specification)
Oil Type:
API CG-4 or ACEA E2 (or equivalent) multi-grade diesel engine oil, e.g., 10W-40
Oil Capacity:
Approx. 5.0 - 5.5 Liters (including filter)
Transmission Type:
5-speed Manual
Optional Transmission:
None commonly documented for 1.9 D
Gear Ratios:
Specific ratios detailed in manual (e.g., 1st, 2nd, 3rd, 4th, 5th, Reverse)
Transmission Fluid:
GL-4 Gear Oil (e.g., SAE 75W-80 or 75W-90)
Euro Ncap Rating:
Not generally tested or rated for this period/segment (basic safety features)
Braking System:
Front Disc Brakes, Rear Drum Brakes (ABS optional on later models/higher trims, less common on 2004 1.9D)
Airbags:
Driver's airbag standard on most models; passenger airbag optional/less common.
Seatbelts:
Front 3-point inertia reel seatbelts, Rear (if fitted) lap or 3-point seatbelts
Oil Change Interval:
Typically 7,500 - 10,000 miles (12,000 - 15,000 km) or 12 months
Air Filter Interval:
Every 15,000 - 20,000 miles (24,000 - 32,000 km) or as needed
Fuel Filter Interval:
Every 20,000 - 30,000 miles (32,000 - 48,000 km)
Timing Belt Interval:
This engine (DW8) uses a timing *chain*, not a belt, eliminating periodic replacement. Maintenance involves checking tensioners if noise develops.
Coolant Capacity:
Approx. 7.5 Liters
Power Steering Fluid:
Typically ATF Dexron II/III or specified mineral oil (check manual for exact type)
Common Problems:
Glow plug failure, diesel injector issues, exhaust system corrosion, suspension wear (bushings, ball joints), minor electrical gremlins, potential for oil leaks from seals.
