Peugeot 406 1999-2002 Service Manual/Repair Manual
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🏷️ Basic Information Identification Make: Peugeot Model: 406 Year Range Covered: 1999-2002 Codes Chassis Codes: 8B (Saloon), 8E (Estate/Wagon), 8C (Coupe) 👋 Introduction Market Position Vehicle Segment: The Peugeot 406 was positioned as a popular mid-size family car, competing in a segment with strong offerings from other European manufacturers like Volkswagen, Ford, and Opel/Vauxhall, as well as Japanese brands. Competitive Analysis Key Competitors: Volkswagen Passat, Ford Mondeo, Opel Vectra, Renault Laguna, Citroën Xantia, BMW 3 Series (E46). Key Features Design And Comfort: Known for its elegant Pininfarina-designed styling (especially the Coupe), comfortable ride, and spacious interior, particularly the saloon and estate variants. Engine Options: Offered a range of petrol and diesel engines, including the renowned EW/DW family of diesel engines known for their economy and durability. Manual Advantage: This service manual provides detailed, expert-level guidance, empowering owners and independent mechanics to perform a wide range of maintenance and repair tasks, potentially saving significant costs compared to dealership servicing. 📋 Manual Details Coverage Areas General Coverage: Comprehensive repair, maintenance, and troubleshooting for all major systems. Page Count Estimated Page Count: Likely extensive, given the breadth of topics listed, often exceeding 1000 pages in physical format. PDF format offers excellent navigability regardless of raw page count. Manual Type Type: Service Manual / Repair Manual Language Language: Assumed English based on product description and keywords. Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed procedures for engine disassembly, assembly, inspection, and repair. Covers cylinder head, block, pistons, crankshaft, camshafts, valve train. Engine Control System: Diagnosis and repair of engine management systems, including sensors (Camshaft Position Sensor, Knock Sensor), actuators, and ECU troubleshooting. Fuel System: Maintenance and repair of fuel delivery, injection (Fuel Injector), fuel pump, fuel tank, and emission control systems (Charcoal Canister). Cooling System: Repair and maintenance of radiator, water pump, thermostat, cooling fan system, and coolant specifications. Ignition System: Details on spark plugs, coils, and ignition timing adjustments. Exhaust System: Information on exhaust pipes, mufflers, and emission control systems. Transmission Manual: Repair and maintenance of Manual Transaxle System, including clutch components (Clutch Unit, Clutch Master Cylinder, Clutch Release Cylinder), gears, and shafts. Transmission Automatic: Repair and maintenance of Automatic Transaxle System, including torque converter, valve body, and electronic controls. Drive Shafts And Axles: Service for front drive shafts and related components, including differential oil seals. Suspension Front: Detailed repair and alignment procedures for Front Suspension System, including control arms, springs, and shock absorbers. Front Wheel Alignment specifications included. Suspension Rear: Detailed repair and alignment procedures for Rear Suspension System, including coil springs, shock absorbers, and axle beam. Rear Wheel Alignment specifications included. Steering System: Repair and maintenance of steering column, power steering systems, and steering sensors. Brakes System: Comprehensive coverage of Brake System, including master cylinder, booster, calipers, pads, discs, and brake fluid specifications. Wheels And Tires: Information on wheel and tire systems, including specifications and potential replacement procedures. Electrical System Charging: Diagnosis and repair of the charging system, including the generator assembly. Electrical System Starting: Troubleshooting and repair of the starting system, including the starter motor and switch. Lighting System: Repair and maintenance of headlamps, tail lamps (Rear Combination Lamp Assy), and interior lighting. Instrument Panel And Gauges: Information on the instrument panel, combination meter, and related warning systems (Seat Belt Warning System). Audio Visual System: Basic information on the radio receiver assembly and associated components. Climate Control System: Repair and maintenance of the Air Conditioning System, including blower, heater, and refrigerant. Power Accessories: Service for power windows, power door locks, and power mirrors. Safety Restraint System: Detailed information on the Supplemental Restraint System (SRS), including airbags (Front Seat Airbag Assy, Side Air Bag Sensor Assy, Curtain Shield Air Bag Assy, Passenger Air Bag Assy) and related sensors. Body And Chassis: Procedures for body repair, including door glass weatherstrips, bumpers, and exterior mouldings. Wiper And Washer System: Maintenance and repair of wiper and washer systems, including motors and rubber blades. Procedures Included Routine Maintenance: Covers routine services like oil changes, filter replacements, and fluid checks. Troubleshooting: Extensive diagnostic procedures and symptom-based troubleshooting guides for various systems. Component Replacement: Step-by-step instructions for replacing major components and smaller parts. Wiring Diagrams: Includes detailed wiring diagrams for electrical systems, crucial for diagnostics and repairs. Technical Depth Depth: Extremely high. Covers everything from basic maintenance to complete engine and transmission rebuilds, advanced electrical diagnostics, and bodywork. 📊 Manual Specifications File Format Digital Features: PDF format allows for easy navigation, searching, zooming, and printing of specific pages or entire sections. Print Quality Printability: Designed to be printable, allowing users to create hard copies of specific sections or the entire manual as needed. Binding Type Digital Binding: N/A (digital format) Paper Type Digital Paper: N/A (digital format) ⚙️ Engine Specifications Primary Engine Engine Variants Covered: Likely covers common engines for the 1999-2002 period,...
The Peugeot 406 was positioned as a popular mid-size family car, competing in a segment with strong offerings from other European manufacturers like Volkswagen, Ford, and Opel/Vauxhall, as well as Japanese brands.
Competitive Analysis
Key Competitors:
Volkswagen Passat, Ford Mondeo, Opel Vectra, Renault Laguna, Citroën Xantia, BMW 3 Series (E46).
Key Features
Design And Comfort:
Known for its elegant Pininfarina-designed styling (especially the Coupe), comfortable ride, and spacious interior, particularly the saloon and estate variants.
Engine Options:
Offered a range of petrol and diesel engines, including the renowned EW/DW family of diesel engines known for their economy and durability.
Manual Advantage:
This service manual provides detailed, expert-level guidance, empowering owners and independent mechanics to perform a wide range of maintenance and repair tasks, potentially saving significant costs compared to dealership servicing.
📋 Manual Details
Coverage Areas
General Coverage:
Comprehensive repair, maintenance, and troubleshooting for all major systems.
Page Count
Estimated Page Count:
Likely extensive, given the breadth of topics listed, often exceeding 1000 pages in physical format. PDF format offers excellent navigability regardless of raw page count.
Manual Type
Type:
Service Manual / Repair Manual
Language
Language:
Assumed English based on product description and keywords.
Format
Digital Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed procedures for engine disassembly, assembly, inspection, and repair. Covers cylinder head, block, pistons, crankshaft, camshafts, valve train.
Engine Control System:
Diagnosis and repair of engine management systems, including sensors (Camshaft Position Sensor, Knock Sensor), actuators, and ECU troubleshooting.
Fuel System:
Maintenance and repair of fuel delivery, injection (Fuel Injector), fuel pump, fuel tank, and emission control systems (Charcoal Canister).
Cooling System:
Repair and maintenance of radiator, water pump, thermostat, cooling fan system, and coolant specifications.
Ignition System:
Details on spark plugs, coils, and ignition timing adjustments.
Exhaust System:
Information on exhaust pipes, mufflers, and emission control systems.
Transmission Manual:
Repair and maintenance of Manual Transaxle System, including clutch components (Clutch Unit, Clutch Master Cylinder, Clutch Release Cylinder), gears, and shafts.
Transmission Automatic:
Repair and maintenance of Automatic Transaxle System, including torque converter, valve body, and electronic controls.
Drive Shafts And Axles:
Service for front drive shafts and related components, including differential oil seals.
Suspension Front:
Detailed repair and alignment procedures for Front Suspension System, including control arms, springs, and shock absorbers. Front Wheel Alignment specifications included.
Suspension Rear:
Detailed repair and alignment procedures for Rear Suspension System, including coil springs, shock absorbers, and axle beam. Rear Wheel Alignment specifications included.
Steering System:
Repair and maintenance of steering column, power steering systems, and steering sensors.
Brakes System:
Comprehensive coverage of Brake System, including master cylinder, booster, calipers, pads, discs, and brake fluid specifications.
Wheels And Tires:
Information on wheel and tire systems, including specifications and potential replacement procedures.
Electrical System Charging:
Diagnosis and repair of the charging system, including the generator assembly.
Electrical System Starting:
Troubleshooting and repair of the starting system, including the starter motor and switch.
Lighting System:
Repair and maintenance of headlamps, tail lamps (Rear Combination Lamp Assy), and interior lighting.
Instrument Panel And Gauges:
Information on the instrument panel, combination meter, and related warning systems (Seat Belt Warning System).
Audio Visual System:
Basic information on the radio receiver assembly and associated components.
Climate Control System:
Repair and maintenance of the Air Conditioning System, including blower, heater, and refrigerant.
Power Accessories:
Service for power windows, power door locks, and power mirrors.
Safety Restraint System:
Detailed information on the Supplemental Restraint System (SRS), including airbags (Front Seat Airbag Assy, Side Air Bag Sensor Assy, Curtain Shield Air Bag Assy, Passenger Air Bag Assy) and related sensors.
Body And Chassis:
Procedures for body repair, including door glass weatherstrips, bumpers, and exterior mouldings.
Wiper And Washer System:
Maintenance and repair of wiper and washer systems, including motors and rubber blades.
Procedures Included
Routine Maintenance:
Covers routine services like oil changes, filter replacements, and fluid checks.
Troubleshooting:
Extensive diagnostic procedures and symptom-based troubleshooting guides for various systems.
Component Replacement:
Step-by-step instructions for replacing major components and smaller parts.
Wiring Diagrams:
Includes detailed wiring diagrams for electrical systems, crucial for diagnostics and repairs.
Technical Depth
Depth:
Extremely high. Covers everything from basic maintenance to complete engine and transmission rebuilds, advanced electrical diagnostics, and bodywork.
📊 Manual Specifications
File Format
Digital Features:
PDF format allows for easy navigation, searching, zooming, and printing of specific pages or entire sections.
Print Quality
Printability:
Designed to be printable, allowing users to create hard copies of specific sections or the entire manual as needed.
Binding Type
Digital Binding:
N/A (digital format)
Paper Type
Digital Paper:
N/A (digital format)
⚙️ Engine Specifications
Primary Engine
Engine Variants Covered:
Likely covers common engines for the 1999-2002 period, including petrol (e.g., XU7 JP4 1.8L, XU10 J4R 2.0L, EW10 J4 2.0L HPi) and diesel (e.g., XUD7 TE 1.9L Turbo Diesel, DW8 1.9L Diesel, DW10 TD 2.0L HDi).
Performance
Horsepower And Torque:
Specific figures vary by engine. For example, a 2.0L petrol engine might produce around 136-138 hp, while a 2.0L HDi diesel could offer around 90-110 hp. Torque figures would also vary accordingly.
Fuel System
Injection Type:
Petrol engines typically feature multi-point fuel injection (MPI). Diesel engines utilize direct injection, with common rail injection (HDi) becoming prevalent in later models of this generation.
🔧 Transmission
Standard
Manual Transmission:
A 5-speed manual transaxle was standard on most variants.
Optional
Automatic Transmission:
A 4-speed automatic transaxle was generally available as an option on many petrol models.
Features
Clutch System:
Hydraulically actuated clutch system for both manual and automatic transmissions (torque converter).
📐 Dimensions
Exterior
Body Styles:
Available as a 4-door Saloon (8B), 5-door Estate/Wagon (8E), and 2-door Coupe (8C).
Weights
Curb Weight:
Curb weight varied by body style and engine, typically ranging from approximately 1250 kg to 1500 kg.
🛡️ Safety Features
Ratings
Euro Ncap Performance:
The Peugeot 406 generally received good safety ratings for its time, with Euro NCAP testing indicating solid performance in frontal and side impacts. Specific ratings would vary by test year and configuration.
Passive Features
Airbags And Seatbelts:
Standard fitment of front airbags, with side and curtain airbags becoming available or standard on higher trims and later models. Three-point seatbelts with pre-tensioners were standard.
Active Features
ABS And Traction Control:
Anti-lock Braking System (ABS) was typically standard. Traction control (ASR) was an optional feature on some models.
💡 Technology Features
Infotainment
Audio System:
Early models featured basic radio/cassette players, with CD players becoming more common. Higher trims could include multi-speaker systems and optional navigation.
Driver Assistance
Cruise Control:
Cruise control was available on many models, especially those with higher engine displacements or as part of premium trim packages.
Connectivity
Remote Central Locking:
Remote central locking and alarm systems were standard or optional on most vehicles.
🔧 Maintenance
Service Intervals
Oil And Filter Change:
Typically every 10,000-15,000 miles (15,000-20,000 km) or annually, whichever comes first, depending on engine type and driving conditions. Diesel engines, especially HDi, might have slightly different recommendations.
Fluid Specifications
Engine Oil:
Varies by engine. Commonly used specifications include PSA B71 2294 (semi-synthetic) or PSA B71 2296 (fully synthetic) for petrol, and specific low-SAPS oils for HDi diesel engines (e.g., PSA B71 2290).
Coolant:
Peugeot recommends a long-life coolant, typically a mix of distilled water and Type D (green) or Type A (blue) antifreeze concentrate, meeting PSA specifications.
Brake Fluid:
DOT 4 brake fluid is typically specified.
Transmission Fluid Manual:
API GL-5 specification gear oil, such as 75W-80 or 75W-90, depending on the specific transaxle type.
Transmission Fluid Automatic:
ATF (Automatic Transmission Fluid) meeting PSA specifications, often a Dexron III equivalent or specific Peugeot type.
Known Issues
Common Problems:
Potential issues include suspension wear (especially front wishbone bushes), ABS sensor faults, swirl flap issues on HDi engines, and occasional electrical gremlins. Timing belt replacement is a critical maintenance item for petrol engines.
📚 Vehicle History
Brand Heritage
Peugeot Legacy:
Peugeot has a long history of producing well-engineered and stylish vehicles, with the 40X series being a cornerstone of its executive and family car offerings.
Model Evolution
Generations:
The 406 was the successor to the Peugeot 405 and was produced from 1995 to 2004, with the 1999-2002 period representing a significant facelift (Series 2) that introduced styling updates and improved engines.
Production
Manufacturing Locations:
Primarily manufactured in France (Sochaux) and also assembled in other countries via CKD kits.
🏆 Awards & Recognition
Recognitions
European Car Of The Year:
While the 406 itself did not win European Car of the Year, its predecessor (405) and successor (407) were highly regarded, and the 406 was often praised for its design and refinement.
Ratings
Owner Satisfaction:
Generally received good reviews for comfort and driving dynamics. Reliability was considered average to good, with specific engine variants and common issues noted.
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