PEUGEOT 406 Petrol & Diesel Digital Workshop Repair Manual 1999-2002
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🏷️ Basic Information Identification Make: Peugeot Model: 406 Product Type: Digital Workshop Repair Manual Codes Product Identifier: PEUGEOT 406 Petrol & Diesel Digital Workshop Repair Manual 1999-2002 👋 Introduction Market Position Target Audience: Peugeot 406 owners, independent repair shops, professional mechanics Competitive Analysis Value Proposition: Significant savings on service and repair costs compared to dealership maintenance Key Features Accessibility: Easy to use, printable for offline reference, no advanced computer skills required Durability: Avoids wear and tear issues associated with physical manuals Information Source: Contains the same information used by professional technicians 📋 Manual Details Coverage Areas Vehicle Years Covered: 1999, 2000, 2001, 2002 Engine Types Covered: Petrol and Diesel variants Page Count Estimated Page Count: Comprehensive (Exact count not specified, but described as 'everything you will ever need') Manual Type Type: Workshop Repair Manual Language Language: English Format Digital Format: Digital (Downloadable) 📖 Manual Coverage Systems Covered Engine: Diagnosis, repair, rebuilding of all petrol and diesel engines Fuel System: Fuel injection, carburetion (if applicable), fuel pump, lines, and filters Cooling System: Radiator, water pump, thermostat, hoses, fan assembly Ignition System: Spark plugs, coils, distributors, electronic ignition control Exhaust System: Manifolds, catalytic converters, mufflers, pipes Transmission: Manual and automatic transmission repair, overhaul, fluid service Drivetrain: Clutch, driveshafts, CV joints, differentials Suspension: Front and rear suspension components, shock absorbers, springs, bushings Steering: Power steering system, rack and pinion, steering column Brakes: Brake system diagnosis, repair, hydraulic components, ABS Electrical System: Wiring diagrams, component testing, charging system, starting system Bodywork: Body panel repair, alignment, glass replacement Interior: Trim, upholstery, dashboard components HVAC: Heating, ventilation, and air conditioning system service and repair Electronics: ECU diagnostics, sensors, actuators, lighting systems Procedures Included Maintenance: Oil changes, filter replacements, fluid checks, tune-ups, scheduled servicing Troubleshooting: Diagnostic procedures, fault finding, common problem resolution Repair: Step-by-step instructions for all major and minor repairs Rebuild: Complete engine and transmission rebuilding procedures Restoration: Procedures for refurbishing and restoring components Diagnosis: Detailed diagnostic charts and procedures for all systems Technical Depth Depth Of Coverage: A-Z comprehensive coverage, suitable for professional technicians and DIY mechanics Diagnostic Level: Advanced diagnostic procedures and troubleshooting guidance Repair Level: Detailed step-by-step repair instructions for all components and systems 📊 Manual Specifications File Format Compatibility: Windows 95, 98, 98SE, 2000, NT, ME, XP, Vista, Windows 7, All Mac computers Print Quality Visuals: High-quality photos, illustrations, and diagrams Binding Type Binding: Not applicable (Digital format) Paper Type Paper Quality: Not applicable (Digital format, printable pages) ⚙️ Engine Specifications Primary Engine Engine Variants List: Covers multiple petrol and diesel engines used in the 406 model during these years (specific engine codes would require manual lookup, e.g., XU series diesel, EW series petrol) Performance Typical Hp Range: Varies by engine, e.g., 1.8L petrol (approx. 110-118 hp), 2.0L petrol (approx. 135-145 hp), 2.0L HDi diesel (approx. 90-110 hp), 2.1L TD diesel (approx. 110 hp), 2.2L petrol (approx. 160 hp) Typical Torque Range: Varies by engine, e.g., 2.0 HDi (approx. 205 Nm), 2.0L petrol (approx. 190 Nm) Fuel System Injection Type Petrol: Multi-point fuel injection (MPI) Injection Type Diesel: Direct injection (HDi), Indirect injection (older TD variants) 🔧 Transmission Standard Standard Transmission Type: Manual transmission (e.g., 5-speed) Optional Optional Transmission Type: Automatic transmission (e.g., 4-speed or 5-speed depending on engine/year) Features Transmission Fluid Spec: Specific to transmission type and manufacturer's recommendation (e.g., PSA ATF LT 71141 for automatics, GL-4 for manuals) 📐 Dimensions Exterior Body Styles: Saloon (sedan), Estate (wagon), Coupe Weights Curb Weight Range: Approx. 1300 kg to 1550 kg depending on body style and engine Gross Vehicle Weight Rating: Typically around 1900 kg to 2100 kg 🛡️ Safety Features Ratings Euro Ncap Rating: 4 stars (for Saloon and Estate variants in early tests) Active Features ABS: Anti-lock Braking System (standard on most models) Traction Control: Available on higher specification models Passive Features Airbags: Front airbags, optional side airbags Seatbelts: Pre-tensioned seatbelts with force limiters 💡 Technology Features Infotainment Audio System: Factory fitted radio/CD players, steering wheel audio controls on higher trims. Driver Assistance Cruise Control: Available on many models. Parking Sensors: Optional rear parking sensors on later models. Connectivity Phone Integration: Optional Bluetooth hands-free kits on some later facelift models. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 10,000 miles (16,000 km) or 1 year, depending on engine oil type and driving conditions (refer to manual for specifics) Timing Belt Replacement: Crucial for many engine variants, typically around 70,000-80,000 miles or 5-7 years (manual will specify exact interval and engine variants) Air Filter Replacement: Recommended every 20,000-30,000 miles or as needed based on driving environment Coolant Replacement: Typically every 2-4 years or a specific mileage Fluid Specifications Engine Oil Specification: e.g., 5W-30, 5W-40, 10W-40 API SL/CF or ACEA A3/B3/B4 (specific grade depends on engine and climate, consult manual) Coolant Specification: Peugeot/PSA approved long-life coolant (often blue or green, ethylene glycol based)...
Diagnostic procedures, fault finding, common problem resolution
Repair:
Step-by-step instructions for all major and minor repairs
Rebuild:
Complete engine and transmission rebuilding procedures
Restoration:
Procedures for refurbishing and restoring components
Diagnosis:
Detailed diagnostic charts and procedures for all systems
Technical Depth
Depth Of Coverage:
A-Z comprehensive coverage, suitable for professional technicians and DIY mechanics
Diagnostic Level:
Advanced diagnostic procedures and troubleshooting guidance
Repair Level:
Detailed step-by-step repair instructions for all components and systems
📊 Manual Specifications
File Format
Compatibility:
Windows 95, 98, 98SE, 2000, NT, ME, XP, Vista, Windows 7, All Mac computers
Print Quality
Visuals:
High-quality photos, illustrations, and diagrams
Binding Type
Binding:
Not applicable (Digital format)
Paper Type
Paper Quality:
Not applicable (Digital format, printable pages)
⚙️ Engine Specifications
Primary Engine
Engine Variants List:
Covers multiple petrol and diesel engines used in the 406 model during these years (specific engine codes would require manual lookup, e.g., XU series diesel, EW series petrol)
Performance
Typical Hp Range:
Varies by engine, e.g., 1.8L petrol (approx. 110-118 hp), 2.0L petrol (approx. 135-145 hp), 2.0L HDi diesel (approx. 90-110 hp), 2.1L TD diesel (approx. 110 hp), 2.2L petrol (approx. 160 hp)
Typical Torque Range:
Varies by engine, e.g., 2.0 HDi (approx. 205 Nm), 2.0L petrol (approx. 190 Nm)
Fuel System
Injection Type Petrol:
Multi-point fuel injection (MPI)
Injection Type Diesel:
Direct injection (HDi), Indirect injection (older TD variants)
🔧 Transmission
Standard
Standard Transmission Type:
Manual transmission (e.g., 5-speed)
Optional
Optional Transmission Type:
Automatic transmission (e.g., 4-speed or 5-speed depending on engine/year)
Features
Transmission Fluid Spec:
Specific to transmission type and manufacturer's recommendation (e.g., PSA ATF LT 71141 for automatics, GL-4 for manuals)
📐 Dimensions
Exterior
Body Styles:
Saloon (sedan), Estate (wagon), Coupe
Weights
Curb Weight Range:
Approx. 1300 kg to 1550 kg depending on body style and engine
Gross Vehicle Weight Rating:
Typically around 1900 kg to 2100 kg
🛡️ Safety Features
Ratings
Euro Ncap Rating:
4 stars (for Saloon and Estate variants in early tests)
Active Features
ABS:
Anti-lock Braking System (standard on most models)
Optional Bluetooth hands-free kits on some later facelift models.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 10,000 miles (16,000 km) or 1 year, depending on engine oil type and driving conditions (refer to manual for specifics)
Timing Belt Replacement:
Crucial for many engine variants, typically around 70,000-80,000 miles or 5-7 years (manual will specify exact interval and engine variants)
Air Filter Replacement:
Recommended every 20,000-30,000 miles or as needed based on driving environment
Coolant Replacement:
Typically every 2-4 years or a specific mileage
Fluid Specifications
Engine Oil Specification:
e.g., 5W-30, 5W-40, 10W-40 API SL/CF or ACEA A3/B3/B4 (specific grade depends on engine and climate, consult manual)
Coolant Specification:
Peugeot/PSA approved long-life coolant (often blue or green, ethylene glycol based)
Brake Fluid Specification:
DOT 4
Known Issues
Common Problems:
Front suspension wear (wishbone bushes, drop links), rear axle beam bushes, electrical gremlins (e.g., central locking, window regulators), exhaust manifold cracks (petrol engines), injector seal leaks (HDi diesels), coolant leaks (especially from thermostat housing or hoses)
Diagnostic Tips:
Manual provides guidance on identifying and rectifying common faults.
📚 Vehicle History
Brand Heritage
Peugeot History:
Peugeot is one of the oldest automobile manufacturers, known for innovation and comfortable family cars.
Model Evolution
406 Generation:
Second generation of the Peugeot 406, succeeding the 405 and preceding the 407. Known for its stylish Pininfarina design.
Production
Production Period:
1995-2004 (with this manual covering the facelifted models from 1999)
Manufacturing Locations:
France (Sochaux), United Kingdom (Ryton-on-Dunsmore)
🏆 Awards & Recognition
Recognitions
Car Of The Year Awards:
The Peugeot 406 was highly regarded for its ride comfort and handling, often praised in contemporary automotive reviews.
Ratings
Reliability Reputation:
Mixed, with certain engine variants (like the HDi diesels) and build quality generally considered good, though electrical and suspension issues were not uncommon as the cars aged.
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