Peugeot 406 Petrol & Diesel Complete Workshop Service Repair Manual 1999 2000 2001 2002 2003 2004
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🏷️ Basic Information Identification Make: Peugeot Model: 406 Model Years Covered: 1999, 2000, 2001, 2002, 2003, 2004 Codes Chassis Codes: 8B (Saloon), 8E (Estate/Break), 8C (Coupe) 👋 Introduction Market Position Target Audience: DIY mechanics, independent repair shops, and Peugeot 406 owners seeking to perform their own maintenance and repairs. Competitive Analysis Value Proposition: Offers significant cost savings compared to dealership servicing by enabling users to perform a wide range of tasks themselves. Key Features Accessibility: Instant email delivery upon payment, user-friendly digital format accessible on multiple devices. Ease Of Use: Features step-by-step instructions and accompanying pictures to simplify complex repair procedures. 📋 Manual Details Coverage Areas Global Coverage: Yes, covers all models, engines, trims, and transmissions for the specified years. Page Count Estimated Pages: Likely over 1000 pages, typical for comprehensive workshop manuals covering multiple engine variants and body styles. Manual Type Type: Complete Workshop Service Repair Manual Language Language: English (Assumed based on product description and common practice for downloadable manuals). Format Format: Downloadable Digital File (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanicals (petrol & diesel), fuel systems, ignition, exhaust, cooling, lubrication, engine management systems. Transmission: Manual and Automatic Transmission servicing, repair, overhaul, clutch, differential, driveshafts. Chassis: Suspension (front & rear), steering system, brakes (front & rear, ABS), wheel alignment. Electrical: Wiring diagrams, lighting, charging system, starting system, ignition, dashboard instruments, body electricals, HVAC controls, infotainment system. Bodywork: Body and chassis repair, panel replacement, doors, windows, locks, interior trim, body sealing, corrosion protection. Procedures Included Maintenance: Oil changes, filter replacements, spark plug replacement, brake fluid changes, coolant flushes, belt inspections/replacements. Repair: Engine rebuilds, head gasket replacement, transmission overhaul, brake caliper replacement, suspension component renewal, electrical component diagnosis and replacement. Diagnostics: Troubleshooting guides, fault code interpretation (if applicable to the era), component testing procedures. Troubleshooting: Step-by-step diagnostic trees for common problems related to engine performance, starting, electrical issues, and more. Technical Depth Depth: Comprehensive, covering everything from basic routine maintenance to detailed component removal, repair, and reassembly. Includes diagnostic procedures and specifications. 📊 Manual Specifications File Format Compatibility: Compatible with all PC and MAC computers, tablets, and smartphones with Adobe Reader. Print Quality Printability: Printable in full or in part, allowing users to create physical copies of specific sections. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Petrol Engines: 1.6L EW7, 1.8L EW7, 2.0L EW10, 2.2L EW11, 3.0L ES9 V6. (Specific engine codes like XU7JP, XU7JP4, XU10J2, XU10J4, XU10J4R, RFN, RFS, RFR, ES9J4, ES9J4S are covered). Diesel Engines: 1.9L DW8, 1.9L DW8B, 2.0L DW10, 2.1L XUD11BTE. (Specific engine codes like DHY, DHW, RHX, RHY, RHZ, RGX, P8C are covered). Performance Horsepower Range: Approximately 90 hp (1.9D) to 207 hp (3.0 V6). Torque Range: Approximately 150 Nm (1.9D) to 287 Nm (3.0 V6). Fuel System Petrol Injection: Multi-point fuel injection (MPI) and Sequential Electronic Fuel Injection (SEFI) depending on engine variant. Diesel Injection: Direct injection (DI) and Common Rail Direct Injection (CRDI) for later models. Engine Management ECU Coverage: Covers various Engine Control Units (ECUs) and their functions, including diagnostic protocols of the era. 🔧 Transmission Standard Manual Gearboxes: 5-speed manual gearboxes (e.g., MA5, ML5) and 6-speed manual gearboxes for some performance variants. Optional Automatic Gearboxes: 4-speed automatic transmissions (e.g., AL4/DP0) and later 5-speed automatics for V6 models. Features Clutch Systems: Hydraulically actuated clutch systems, including slave and master cylinder replacement. 📐 Dimensions Exterior Body Styles: Saloon (Berline), Estate (Break/SW), Coupe. Length Approx: 4620 mm (Saloon), 4720 mm (Estate), 4615 mm (Coupe). Width Approx: 1740 mm. Height Approx: 1420 mm (Saloon), 1480 mm (Estate), 1350 mm (Coupe). Weights Kerb Weight Range: Approx. 1300 kg to 1600 kg depending on engine and body style. 🛡️ Safety Features Ratings Euro Ncap Early Results: Achieved 4 stars in Euro NCAP frontal impact tests for the saloon variant (early assessment during its production run). Active Features Braking Systems: Anti-lock Braking System (ABS) standard on most models, Electronic Brake Force Distribution (EBD), Brake Assist (BA). Passive Features Airbags: Front airbags, side airbags, and curtain airbags on higher trims. Seatbelts: Pre-tensioning seatbelts with force limiters, ISOFIX child seat anchor points. 💡 Technology Features Infotainment Radio Cd Player: Factory fitted Clarion or Philips radio/CD players with steering wheel controls on many models. Navigation: Optional factory fitted navigation systems (RT2 or similar) available on higher trim levels. Driver Assistance Cruise Control: Available on many models, providing comfort for long-distance driving. Parking Sensors: Rear parking sensors became more common in later production years. Connectivity OBD Ii Port: Standard OBD-II diagnostic port for fault code reading, essential for modern diagnostics. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 10,000 - 15,000 miles or 12 months, depending on engine type and oil specification used. Timing Belt Interval: Petrol engines: 70,000 - 80,000 miles or 5 years. Diesel engines (DW8, DW10):...
Engine rebuilds, head gasket replacement, transmission overhaul, brake caliper replacement, suspension component renewal, electrical component diagnosis and replacement.
Diagnostics:
Troubleshooting guides, fault code interpretation (if applicable to the era), component testing procedures.
Troubleshooting:
Step-by-step diagnostic trees for common problems related to engine performance, starting, electrical issues, and more.
Technical Depth
Depth:
Comprehensive, covering everything from basic routine maintenance to detailed component removal, repair, and reassembly. Includes diagnostic procedures and specifications.
📊 Manual Specifications
File Format
Compatibility:
Compatible with all PC and MAC computers, tablets, and smartphones with Adobe Reader.
Print Quality
Printability:
Printable in full or in part, allowing users to create physical copies of specific sections.
Multi-point fuel injection (MPI) and Sequential Electronic Fuel Injection (SEFI) depending on engine variant.
Diesel Injection:
Direct injection (DI) and Common Rail Direct Injection (CRDI) for later models.
Engine Management
ECU Coverage:
Covers various Engine Control Units (ECUs) and their functions, including diagnostic protocols of the era.
🔧 Transmission
Standard
Manual Gearboxes:
5-speed manual gearboxes (e.g., MA5, ML5) and 6-speed manual gearboxes for some performance variants.
Optional
Automatic Gearboxes:
4-speed automatic transmissions (e.g., AL4/DP0) and later 5-speed automatics for V6 models.
Features
Clutch Systems:
Hydraulically actuated clutch systems, including slave and master cylinder replacement.
📐 Dimensions
Exterior
Body Styles:
Saloon (Berline), Estate (Break/SW), Coupe.
Length Approx:
4620 mm (Saloon), 4720 mm (Estate), 4615 mm (Coupe).
Width Approx:
1740 mm.
Height Approx:
1420 mm (Saloon), 1480 mm (Estate), 1350 mm (Coupe).
Weights
Kerb Weight Range:
Approx. 1300 kg to 1600 kg depending on engine and body style.
🛡️ Safety Features
Ratings
Euro Ncap Early Results:
Achieved 4 stars in Euro NCAP frontal impact tests for the saloon variant (early assessment during its production run).
Active Features
Braking Systems:
Anti-lock Braking System (ABS) standard on most models, Electronic Brake Force Distribution (EBD), Brake Assist (BA).
Passive Features
Airbags:
Front airbags, side airbags, and curtain airbags on higher trims.
Seatbelts:
Pre-tensioning seatbelts with force limiters, ISOFIX child seat anchor points.
💡 Technology Features
Infotainment
Radio Cd Player:
Factory fitted Clarion or Philips radio/CD players with steering wheel controls on many models.
Navigation:
Optional factory fitted navigation systems (RT2 or similar) available on higher trim levels.
Driver Assistance
Cruise Control:
Available on many models, providing comfort for long-distance driving.
Parking Sensors:
Rear parking sensors became more common in later production years.
Connectivity
OBD Ii Port:
Standard OBD-II diagnostic port for fault code reading, essential for modern diagnostics.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 10,000 - 15,000 miles or 12 months, depending on engine type and oil specification used.
Timing Belt Interval:
Petrol engines: 70,000 - 80,000 miles or 5 years. Diesel engines (DW8, DW10): 70,000 - 80,000 miles or 5 years. (Crucial to follow for belt-driven engines).
Fluid Specifications
Engine Oil Grade:
Varies by engine. Common grades include 10W-40, 5W-40, 5W-30 (fully synthetic) meeting ACEA A3/B3 or A3/B4 specifications.
Coolant Specification:
OAT (Organic Acid Technology) type, typically purple or orange, antifreeze/coolant mixture.
Brake Fluid Specification:
DOT 4.
Transmission Fluid Manual:
API GL-4 or GL-5, SAE 75W-90 or 75W-80 synthetic gear oil (specifics vary).
Transmission Fluid Automatic:
LF/LT 71141 or equivalent automatic transmission fluid (ATF), specific to the AL4 gearbox.
Known Issues
Suspension Wear:
Front suspension components (wishbone bushes, drop links) and rear axle bushes are common wear items due to the multi-link setup.
Electrical Gremlins:
Intermittent faults with body control modules, window regulators, and dashboard warning lights can occur.
Engine Management Petrol:
Coil pack failures, lambda sensor issues, and thermostat failures on 2.0L EW10 engines.
Engine Management Diesel:
Injectors (especially on DW10 HDi), glow plug issues, and EGR valve problems.
Cooling System:
Plastic radiator end tanks can crack, and heater matrix leaks can occur.
Exhaust System:
Catalytic converter failure and exhaust manifold cracks are not uncommon, especially on diesel models.
📚 Vehicle History
Brand Heritage
Peugeot Legacy:
Peugeot has a long history of producing well-engineered and comfortable family cars, with the 406 continuing this tradition.
Model Evolution
Generation Development:
The 406 was designed by Pininfarina, succeeding the Peugeot 405. It was known for its ride comfort and handling, particularly with the advanced multi-link rear suspension on many models.
Production
Production Years:
1995-2004.
Manufacturing Locations:
Primarily Sochaux, France, and also produced under license in other countries.
🏆 Awards & Recognition
Recognitions
European Car Of The Year:
While not a winner, the Peugeot 406 was a strong contender in its class and was well-regarded for its design and comfort.
Platform Sharing:
Shared its platform with the Citroën Xantia, known for its advanced hydractive suspension system, though the 406 predominantly used conventional suspension.
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