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PEUGEOT 806 2.2I 16V 2002 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Peugeot Model: 806 Year: 2002 Engine Variant: 2.2i 16V Codes Chassis Code: Type 814 Engine Code Prefix: EW12 👋 Introduction Market Position Vehicle Segment: Large MPV (Multi-Purpose Vehicle) Competitive Analysis Key Competitors: Renault Espace, Chrysler Voyager, Ford Galaxy, Volkswagen Sharan Key Features Unique Selling Points: Versatile seating configurations, spacious interior, shared platform with Fiat Ulysse and Lancia Zeta Manual Purpose Target Audience: DIY enthusiasts, independent repair shops, professional mechanics Manual Value Benefit To Owner: Empowers owners to perform maintenance and repairs, saving time and money, and ensuring correct procedures are followed. 📋 Manual Details Coverage Areas Scope: Comprehensive service, maintenance, and repair Page Count Estimated Pages: High (typically 1000+ for full service manuals) Manual Type Type: Full Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system Drivetrain: Manual and Automatic Transmission, clutch, drive axles, differential Chassis: Suspension (front and rear), steering system, braking system (ABS, EBD), wheel alignment Electrical: Battery, charging system, starting system, lighting, instrumentation, body electrical (power windows, locks, mirrors), ECU diagnostics, airbags, CAN bus systems Body: Body panels, doors, interior trim, glass, seals, heating, ventilation, and air conditioning (HVAC) Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and top-ups, belt and hose inspection Repair: Component removal and installation, detailed repair procedures for all major systems, gasket and seal replacement Troubleshooting: Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides, fault code interpretation Diagnostics: Engine management system diagnostics, ABS diagnostics, airbag system diagnostics, use of diagnostic tools (OBD-II) Body Repair: Panel replacement, door alignment, bumper repair, glass replacement, rust prevention and repair guidance. HVAC Repair: Refrigerant handling, component replacement (compressor, evaporator, condenser), blower motor, control panel diagnostics. Wheel Tire Suspension: Wheel bearing replacement, suspension component torque specifications, shock absorber replacement, spring replacement, wheel alignment procedures. Interior Trim: Removal and installation of seats, door panels, dashboard components, headliner, carpet. Technical Depth Depth: In-depth technical information, from basic maintenance to complete engine and transmission rebuilds, including torque specifications, clearances, and assembly sequences 📊 Manual Specifications File Format Compatibility: Adobe PDF Reader Compression Requirements: WinZip or compatible utility Print Quality Printability: Full Printable Zoom Functionality: Zoom IN/OUT enabled Binding Type Binding: Digital (PDF download) Paper Type Paper Quality: N/A (Digital format allows for on-demand printing) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-cylinder, naturally aspirated Displacement: 2179 cc (2.2 Liters) Bore X Stroke: 85.7 mm x 96 mm Compression Ratio: 10.8:1 Valve Train: DOHC (Dual Overhead Camshafts), 4 valves per cylinder Performance Horsepower: 158 hp (116 kW) @ 6000 rpm Torque: 217 Nm (160 lb-ft) @ 3900 rpm Fuel System Fuel Delivery: Multi-point Electronic Fuel Injection (MPI) Fuel Type: Unleaded gasoline (Octane rating 95 recommended) Cooling System Coolant Type: Antifreeze/coolant (e.g., PSA S71 2103 standard) Lubrication System Oil Capacity: Approx. 5.5 Liters (with filter) Recommended Oil Grade: SAE 5W-40 or 5W-30 (meeting PSA B71 2296 or ACEA A3/B4 specifications) 🔧 Transmission Standard Transmission Type: 5-speed Manual Transmission Optional Transmission Type: 4-speed Automatic Transmission (AL4) Features Clutch Type: Hydraulically operated single dry plate clutch Transmission Fluid Manual: API GL-4, SAE 75W-90 synthetic gear oil Transmission Fluid Automatic: ATF (Automatic Transmission Fluid) meeting PSA S71 2104 specification (e.g., Mobil ATF LT 71141) 📐 Dimensions Exterior Length: Approx. 4.46 m Width: Approx. 1.84 m Height: Approx. 1.76 m Wheelbase: Approx. 2.82 m Weights Curb Weight: Approx. 1600 - 1700 kg (depending on configuration) Gross Vehicle Weight Rating: Approx. 2300 - 2450 kg Cargo Luggage Capacity: Highly variable with seating configurations, up to approx. 2800 liters with all seats removed 🛡️ Safety Features Ratings Euro Ncap Rating: Not explicitly detailed for this specific year and model, but generally aimed for family safety. Earlier models had 3-4 stars. Active Features Braking System: Front ventilated discs, rear solid discs; ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution) Traction Control: Optional (ASR - Anti-Slip Regulation) Passive Features Airbags: Driver and front passenger airbags, optional side airbags Seatbelts: 3-point inertia reel seatbelts with pretensioners for all seats Child Safety: ISOFIX child seat anchor points 💡 Technology Features Infotainment Audio System: Factory fitted radio/CD player with steering wheel controls, optional CD changer. Driver Assistance Cruise Control: Available on higher trim levels Parking Sensors: Optional rear parking sensors Connectivity Diagnostic Interface: OBD-II compliant (SAE J1962 connector) 🔧 Maintenance Service Intervals Oil Change Interval: 15,000 km or 1 year, whichever comes first (or per manufacturer recommendation based on driving conditions) Timing Belt Replacement: 90,000 km or 5 years (critical for EW engines) Air Filter Replacement: 30,000 km or 2 years Spark Plug Replacement: 60,000 km (for platinum or iridium type spark plugs, check specific type) Fluid Specifications Brake Fluid: DOT 4 Power Steering Fluid: PSA S71 2290 compliant fluid (e.g., Total Fluide ATX) Known...
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PEUGEOT 806 2.2I 16V 2002 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Peugeot
Model:
806
Year:
2002
Engine Variant:
2.2i 16V
Codes
Chassis Code:
Type 814
Engine Code Prefix:
EW12
👋 Introduction
Market Position
Vehicle Segment:
Large MPV (Multi-Purpose Vehicle)
Competitive Analysis
Key Competitors:
Renault Espace, Chrysler Voyager, Ford Galaxy, Volkswagen Sharan
Key Features
Unique Selling Points:
Versatile seating configurations, spacious interior, shared platform with Fiat Ulysse and Lancia Zeta
Manual Purpose
Target Audience:
DIY enthusiasts, independent repair shops, professional mechanics
Manual Value
Benefit To Owner:
Empowers owners to perform maintenance and repairs, saving time and money, and ensuring correct procedures are followed.
📋 Manual Details
Coverage Areas
Scope:
Comprehensive service, maintenance, and repair
Page Count
Estimated Pages:
High (typically 1000+ for full service manuals)
Manual Type
Type:
Full Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system
Drivetrain:
Manual and Automatic Transmission, clutch, drive axles, differential
Chassis:
Suspension (front and rear), steering system, braking system (ABS, EBD), wheel alignment
Electrical:
Battery, charging system, starting system, lighting, instrumentation, body electrical (power windows, locks, mirrors), ECU diagnostics, airbags, CAN bus systems
Body:
Body panels, doors, interior trim, glass, seals, heating, ventilation, and air conditioning (HVAC)
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and top-ups, belt and hose inspection
Repair:
Component removal and installation, detailed repair procedures for all major systems, gasket and seal replacement
Troubleshooting:
Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides, fault code interpretation
Diagnostics:
Engine management system diagnostics, ABS diagnostics, airbag system diagnostics, use of diagnostic tools (OBD-II)
Body Repair:
Panel replacement, door alignment, bumper repair, glass replacement, rust prevention and repair guidance.
HVAC Repair:
Refrigerant handling, component replacement (compressor, evaporator, condenser), blower motor, control panel diagnostics.
Wheel Tire Suspension:
Wheel bearing replacement, suspension component torque specifications, shock absorber replacement, spring replacement, wheel alignment procedures.
Interior Trim:
Removal and installation of seats, door panels, dashboard components, headliner, carpet.
Technical Depth
Depth:
In-depth technical information, from basic maintenance to complete engine and transmission rebuilds, including torque specifications, clearances, and assembly sequences
📊 Manual Specifications
File Format
Compatibility:
Adobe PDF Reader
Compression Requirements:
WinZip or compatible utility
Print Quality
Printability:
Full Printable
Zoom Functionality:
Zoom IN/OUT enabled
Binding Type
Binding:
Digital (PDF download)
Paper Type
Paper Quality:
N/A (Digital format allows for on-demand printing)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-cylinder, naturally aspirated
Displacement:
2179 cc (2.2 Liters)
Bore X Stroke:
85.7 mm x 96 mm
Compression Ratio:
10.8:1
Valve Train:
DOHC (Dual Overhead Camshafts), 4 valves per cylinder
Performance
Horsepower:
158 hp (116 kW) @ 6000 rpm
Torque:
217 Nm (160 lb-ft) @ 3900 rpm
Fuel System
Fuel Delivery:
Multi-point Electronic Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline (Octane rating 95 recommended)
Cooling System
Coolant Type:
Antifreeze/coolant (e.g., PSA S71 2103 standard)
Lubrication System
Oil Capacity:
Approx. 5.5 Liters (with filter)
Recommended Oil Grade:
SAE 5W-40 or 5W-30 (meeting PSA B71 2296 or ACEA A3/B4 specifications)
🔧 Transmission
Standard
Transmission Type:
5-speed Manual Transmission
Optional
Transmission Type:
4-speed Automatic Transmission (AL4)
Features
Clutch Type:
Hydraulically operated single dry plate clutch
Transmission Fluid Manual:
API GL-4, SAE 75W-90 synthetic gear oil
Transmission Fluid Automatic:
ATF (Automatic Transmission Fluid) meeting PSA S71 2104 specification (e.g., Mobil ATF LT 71141)
📐 Dimensions
Exterior
Length:
Approx. 4.46 m
Width:
Approx. 1.84 m
Height:
Approx. 1.76 m
Wheelbase:
Approx. 2.82 m
Weights
Curb Weight:
Approx. 1600 - 1700 kg (depending on configuration)
Gross Vehicle Weight Rating:
Approx. 2300 - 2450 kg
Cargo
Luggage Capacity:
Highly variable with seating configurations, up to approx. 2800 liters with all seats removed
🛡️ Safety Features
Ratings
Euro Ncap Rating:
Not explicitly detailed for this specific year and model, but generally aimed for family safety. Earlier models had 3-4 stars.
Active Features
Braking System:
Front ventilated discs, rear solid discs; ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution)
Traction Control:
Optional (ASR - Anti-Slip Regulation)
Passive Features
Airbags:
Driver and front passenger airbags, optional side airbags
Seatbelts:
3-point inertia reel seatbelts with pretensioners for all seats
Child Safety:
ISOFIX child seat anchor points
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/CD player with steering wheel controls, optional CD changer.
Driver Assistance
Cruise Control:
Available on higher trim levels
Parking Sensors:
Optional rear parking sensors
Connectivity
Diagnostic Interface:
OBD-II compliant (SAE J1962 connector)
🔧 Maintenance
Service Intervals
Oil Change Interval:
15,000 km or 1 year, whichever comes first (or per manufacturer recommendation based on driving conditions)
Timing Belt Replacement:
90,000 km or 5 years (critical for EW engines)
Air Filter Replacement:
30,000 km or 2 years
Spark Plug Replacement:
60,000 km (for platinum or iridium type spark plugs, check specific type)
Fluid Specifications
Brake Fluid:
DOT 4
Power Steering Fluid:
PSA S71 2290 compliant fluid (e.g., Total Fluide ATX)
Known Issues
Engine:
Potential for oil leaks from gaskets, occasional issues with the electronic throttle body, pre-catalytic converter failure.
Transmission:
Automatic transmission (AL4) can be prone to solenoid issues and needing regular fluid changes to prevent wear.
Electrical:
Intermittent faults in body control modules, issues with power window regulators, sometimes alarm system glitches.
Suspension:
Wear in front suspension bushings and ball joints, rear axle bearing wear can occur.
📚 Vehicle History
Brand Heritage
Brand Focus:
Peugeot, a French automobile manufacturer with a long history of innovation and diverse vehicle offerings.
Model Evolution
Platform Sharing:
Based on the Sevel European platform, shared with Fiat Ulysse and Lancia Zeta. Also related to the Citroën Synergie.
Production
Production Period:
1994-2002 (First Generation)
Manufacturing Location:
France (often at the Sevel Nord plant)
🏆 Awards & Recognition
Recognitions
Market Reputation:
Generally well-regarded for its practicality and spaciousness as an MPV, although sometimes criticized for driving dynamics compared to rivals.
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