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Peugeot 806 2.2 HDi 2002 Service Repair Manual

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🏷️ Basic Information Identification Make: Peugeot Model: 806 Year: 2002 Engine Variant: 2.2 HDi (with particle filter) Codes Engine Code: DW12TED4 👋 Introduction Market Position Segment: Large MPV (Multi-Purpose Vehicle) Target Audience: Families, individuals requiring flexible passenger and cargo space. Competitive Analysis Key Competitors: Renault Espace, Ford Galaxy, Volkswagen Sharan, Seat Alhambra. Key Features Design: Distinctive styling, spacious and versatile interior with multiple seating configurations. Powertrain: Known for its torquey and relatively efficient 2.2 HDi diesel engine. Practicality: Emphasis on passenger comfort, safety, and modular interior for various carrying needs. 📋 Manual Details Coverage Areas Coverage: All Models/Engines/Trim/Transmissions Types of the Peugeot 806 2.2 HDi (With particle filter) 2002 Page Count Page Count: Not specified, but described as 'complete' and 'intact' Manual Type Type: Factory Service Repair Workshop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, inspection, repair, timing belt, cylinder head, pistons, crankshaft, connecting rods, lubrication system, cooling system, fuel system (HDi injection), exhaust system, turbocharger. Engine Management: ECU diagnostics, sensor data, actuators, glow plug system, particulate filter (DPF) system, emissions control. Transmission: Manual and automatic transmission repair, clutch, gearbox, drive shafts, fluid specifications, troubleshooting. Brakes: Hydraulic system, disc brakes (front and rear), ABS, EBD, brake pad and rotor replacement, bleeding procedure, parking brake. Suspension And Steering: Front and rear suspension components, shock absorbers, springs, control arms, wheel alignment, power steering system, steering rack and pump. Electrical System: Wiring diagrams, battery, alternator, starter motor, lighting system, fuses, relays, power windows, central locking, climate control, instrument cluster, diagnostic connectors. Body And Chassis: Body panel repair, door mechanisms, glass replacement, interior trim, structural components, anti-corrosion treatment. Heating Ventilation Air Conditioning HVAC: HVAC system operation, refrigerant handling, component replacement (compressor, condenser, evaporator), troubleshooting. Procedures Included Maintenance: Regular service schedules, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement (if applicable), brake inspections. Troubleshooting: Diagnostic procedures for common and uncommon faults, fault code interpretation, symptom-based troubleshooting guides. Repair: Step-by-step repair instructions for all major vehicle systems, including component removal, installation, and adjustment. Overhaul: Complete engine and transmission overhaul procedures, including disassembly, cleaning, inspection, measuring, and reassembly. Diagnostics: Detailed diagnostic trees and procedures for identifying and rectifying faults using onboard diagnostic (OBD) systems and specialized tools. Technical Depth Depth: Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic information. 📊 Manual Specifications File Format Format: PDF Print Quality Printability: Printable without any restriction Binding Type Binding: Digital Download (PDF) Paper Type Paper Type: N/A (Digital) Requirements Software Requirements: Adobe PDF Reader ⚙️ Engine Specifications Primary Engine Engine Type: Turbocharged Direct Injection Diesel (HDi) Displacement: 2179 cc Bore X Stroke: 85 mm x 96 mm Compression Ratio: 18.1:1 Power Output: 130 PS (96 kW) @ 4000 rpm (approx.) Torque Output: 317 Nm (234 lb-ft) @ 2000 rpm (approx.) Performance Top Speed: 183 km/h (approx.) Acceleration 0 100 Kmh: 11.1 seconds (approx.) Fuel System Fuel Type: Diesel Injection System: Common Rail Direct Injection (CRDi) Emission Control: Diesel Particulate Filter (DPF) 🔧 Transmission Standard Type: 5-speed Manual Optional Type: 4-speed Automatic (likely available on some trims) Features Fluid Type Manual: API GL-4/GL-5 specification, SAE 75W-80 or 75W-90 synthetic gear oil (refer to manual for exact specification) Fluid Type Automatic: Dexron III or equivalent (refer to manual for exact specification) 📐 Dimensions Exterior Length: 4730 mm Width: 1800 mm Height: 1735 mm Wheelbase: 2820 mm Weights Kerb Weight: 1700 kg (approx.) Gross Vehicle Weight: 2350 kg (approx.) Cargo Luggage Capacity Seats Up: 440 litres (approx.) Luggage Capacity Seats Down: 1900 litres (approx.) 🛡️ Safety Features Ratings Euro Ncap Rating: 4 Stars (for the Peugeot 806 generation, specific rating for 2002 may vary) Active Features ABS: Anti-lock Braking System Ebd: Electronic Brakeforce Distribution Traction Control: ASR (Antipatinage) may be available depending on trim Passive Features Airbags: Driver, front passenger, and side airbags (depending on trim level) Seatbelts: 3-point seatbelts with pretensioners and force limiters for all seats Child Seat Anchors: ISOFIX anchorage points 💡 Technology Features Infotainment Head Unit: Factory fitted radio/cassette or CD player with steering wheel controls (optional). Navigation: Optional satellite navigation system may have been available on higher trims. Driver Assistance Cruise Control: Available on some models. Parking Sensors: Rear parking sensors may have been an option. Connectivity Climate Control: Manual or automatic climate control with air conditioning. 🔧 Maintenance Service Intervals Oil Change: Typically every 15,000 km or 1 year, whichever comes first. Refer to the manual for precise interval based on driving conditions. Air Filter Replacement: Every 30,000 km or 2 years. Fuel Filter Replacement: Every 30,000 km or 2 years for diesel. Timing Belt Replacement: Critical: 120,000 km or 10 years, whichever comes first. Failure can cause severe engine damage. Fluid Specifications Engine Oil Type: Fully synthetic 5W-40 or 5W-30 Low SAPS engine oil...
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Peugeot 806 2.2 HDi 2002 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Peugeot
Model:
806
Year:
2002
Engine Variant:
2.2 HDi (with particle filter)
Codes
Engine Code:
DW12TED4
👋 Introduction
Market Position
Segment:
Large MPV (Multi-Purpose Vehicle)
Target Audience:
Families, individuals requiring flexible passenger and cargo space.
Competitive Analysis
Key Competitors:
Renault Espace, Ford Galaxy, Volkswagen Sharan, Seat Alhambra.
Key Features
Design:
Distinctive styling, spacious and versatile interior with multiple seating configurations.
Powertrain:
Known for its torquey and relatively efficient 2.2 HDi diesel engine.
Practicality:
Emphasis on passenger comfort, safety, and modular interior for various carrying needs.
📋 Manual Details
Coverage Areas
Coverage:
All Models/Engines/Trim/Transmissions Types of the Peugeot 806 2.2 HDi (With particle filter) 2002
Page Count
Page Count:
Not specified, but described as 'complete' and 'intact'
Manual Type
Type:
Factory Service Repair Workshop Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, inspection, repair, timing belt, cylinder head, pistons, crankshaft, connecting rods, lubrication system, cooling system, fuel system (HDi injection), exhaust system, turbocharger.
Engine Management:
ECU diagnostics, sensor data, actuators, glow plug system, particulate filter (DPF) system, emissions control.
Transmission:
Manual and automatic transmission repair, clutch, gearbox, drive shafts, fluid specifications, troubleshooting.
Brakes:
Hydraulic system, disc brakes (front and rear), ABS, EBD, brake pad and rotor replacement, bleeding procedure, parking brake.
Suspension And Steering:
Front and rear suspension components, shock absorbers, springs, control arms, wheel alignment, power steering system, steering rack and pump.
Electrical System:
Wiring diagrams, battery, alternator, starter motor, lighting system, fuses, relays, power windows, central locking, climate control, instrument cluster, diagnostic connectors.
Body And Chassis:
Body panel repair, door mechanisms, glass replacement, interior trim, structural components, anti-corrosion treatment.
Heating Ventilation Air Conditioning HVAC:
HVAC system operation, refrigerant handling, component replacement (compressor, condenser, evaporator), troubleshooting.
Procedures Included
Maintenance:
Regular service schedules, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement (if applicable), brake inspections.
Troubleshooting:
Diagnostic procedures for common and uncommon faults, fault code interpretation, symptom-based troubleshooting guides.
Repair:
Step-by-step repair instructions for all major vehicle systems, including component removal, installation, and adjustment.
Overhaul:
Complete engine and transmission overhaul procedures, including disassembly, cleaning, inspection, measuring, and reassembly.
Diagnostics:
Detailed diagnostic trees and procedures for identifying and rectifying faults using onboard diagnostic (OBD) systems and specialized tools.
Technical Depth
Depth:
Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic information.
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Printability:
Printable without any restriction
Binding Type
Binding:
Digital Download (PDF)
Paper Type
Paper Type:
N/A (Digital)
Requirements
Software Requirements:
Adobe PDF Reader
⚙️ Engine Specifications
Primary Engine
Engine Type:
Turbocharged Direct Injection Diesel (HDi)
Displacement:
2179 cc
Bore X Stroke:
85 mm x 96 mm
Compression Ratio:
18.1:1
Power Output:
130 PS (96 kW) @ 4000 rpm (approx.)
Torque Output:
317 Nm (234 lb-ft) @ 2000 rpm (approx.)
Performance
Top Speed:
183 km/h (approx.)
Acceleration 0 100 Kmh:
11.1 seconds (approx.)
Fuel System
Fuel Type:
Diesel
Injection System:
Common Rail Direct Injection (CRDi)
Emission Control:
Diesel Particulate Filter (DPF)
🔧 Transmission
Standard
Type:
5-speed Manual
Optional
Type:
4-speed Automatic (likely available on some trims)
Features
Fluid Type Manual:
API GL-4/GL-5 specification, SAE 75W-80 or 75W-90 synthetic gear oil (refer to manual for exact specification)
Fluid Type Automatic:
Dexron III or equivalent (refer to manual for exact specification)
📐 Dimensions
Exterior
Length:
4730 mm
Width:
1800 mm
Height:
1735 mm
Wheelbase:
2820 mm
Weights
Kerb Weight:
1700 kg (approx.)
Gross Vehicle Weight:
2350 kg (approx.)
Cargo
Luggage Capacity Seats Up:
440 litres (approx.)
Luggage Capacity Seats Down:
1900 litres (approx.)
🛡️ Safety Features
Ratings
Euro Ncap Rating:
4 Stars (for the Peugeot 806 generation, specific rating for 2002 may vary)
Active Features
ABS:
Anti-lock Braking System
Ebd:
Electronic Brakeforce Distribution
Traction Control:
ASR (Antipatinage) may be available depending on trim
Passive Features
Airbags:
Driver, front passenger, and side airbags (depending on trim level)
Seatbelts:
3-point seatbelts with pretensioners and force limiters for all seats
Child Seat Anchors:
ISOFIX anchorage points
💡 Technology Features
Infotainment
Head Unit:
Factory fitted radio/cassette or CD player with steering wheel controls (optional).
Navigation:
Optional satellite navigation system may have been available on higher trims.
Driver Assistance
Cruise Control:
Available on some models.
Parking Sensors:
Rear parking sensors may have been an option.
Connectivity
Climate Control:
Manual or automatic climate control with air conditioning.
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 15,000 km or 1 year, whichever comes first. Refer to the manual for precise interval based on driving conditions.
Air Filter Replacement:
Every 30,000 km or 2 years.
Fuel Filter Replacement:
Every 30,000 km or 2 years for diesel.
Timing Belt Replacement:
Critical: 120,000 km or 10 years, whichever comes first. Failure can cause severe engine damage.
Fluid Specifications
Engine Oil Type:
Fully synthetic 5W-40 or 5W-30 Low SAPS engine oil meeting ACEA C3 or C2 specifications (due to DPF). Refer to manual for exact Peugeot approval (e.g., PSA B71 2294 or PSA B71 2297).
Coolant Type:
Organic Acid Technology (OAT) coolant, long-life, typically blue or pink, pre-diluted or concentrate. Peugeot part number: 9730 07 or equivalent.
Brake Fluid Type:
DOT 4
Known Issues
Egr Valve Clogging:
Common in diesel engines, leading to reduced performance and increased emissions. Requires cleaning or replacement.
Dpf Regeneration Issues:
Short-distance driving can lead to DPF clogging if regeneration cycles are not completed. Manual regeneration or cleaning might be needed.
Turbocharger Wear:
Can occur with age and mileage, leading to loss of power and excessive smoke. Regular oil changes are crucial.
Window Regulator Failure:
Common wear item on power windows, especially for sliding rear doors.
Electrical Gremlins:
As with many vehicles of this era, intermittent electrical issues can arise, often related to wiring harnesses or module faults.
📚 Vehicle History
Brand Heritage
Manufacturer:
Peugeot is a French automotive manufacturer with a long history dating back to 1810, known for its diverse range of passenger cars, commercial vehicles, and historically, bicycles and motorcycles.
Model Evolution
Generation:
The Peugeot 806 is part of the first generation (Type 8B), a joint venture product with Fiat, Lancia, and Citroën/Talbot, resulting in the Fiat Ulysse, Lancia Zeta, Citroën Evasion, and Peugeot 806. The 2002 model represents a mid-life update or specific year variant.
Production
Production Period:
1994-2002 (for the first generation)
Production Location
Manufacturing Plant:
Sevel Nord plant in Hordain, France (jointly operated by PSA Peugeot Citroën and Fiat).
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