Peugeot 406 Petrol & Diesel 1999-2004 Full Service & Repair Manual

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🏷️ Basic Information Identification Make: Peugeot Model: 406 Years Covered: 1999, 2000, 2001, 2002, 2003, 2004 Codes Vehicle Platform: PSA EW/ES, XU/XUD, PRV V6 👋 Introduction Market Position Segment: Mid-size family car, Executive car Competitive Analysis Key Competitors: Ford Mondeo, Opel/Vauxhall Vectra, Volkswagen Passat, Renault Laguna, Toyota Avensis, Honda Accord. Key Features Design Philosophy: Known for its stylish Pininfarina-designed exterior, comfortable ride, and strong safety features for its era. Offered a range of efficient petrol and advanced common-rail diesel engines. Manual Advantage: Provides comprehensive factory-level repair and maintenance information, enabling owners to perform a wide range of tasks and diagnostics, saving on dealership labor costs. 📋 Manual Details Coverage Areas Engine Variants Covered: Petrol (1.6L, 1.8L, 2.0L, 2.2L, 3.0L V6), Diesel (1.9L, 2.0L HDi, 2.2L HDi) Page Count Estimated Pages: Hundreds (precise number not specified, but described as very detailed) Manual Type Type: Full Service & Repair Workshop Manual Language Language: English (implied by product description) Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine mechanicals (cylinder head, block, pistons, crankshaft, camshafts), Fuel system (injection, ignition, carburetion for older variants if applicable), Exhaust system, Cooling system, Lubrication system, Turbocharging (where applicable). Transmission: Manual and Automatic transmissions (operation, repair, fluid changes, component overhaul). Chassis: Suspension (front and rear), Steering system (power steering, steering rack, column), Brakes (hydraulic system, ABS, discs, pads, lines, parking brake), Wheels and tires. Electrical: Wiring diagrams, Battery, Charging system (alternator, starter), Lighting (headlights, taillights, interior), Fuses and relays, Ignition system, Instrument panel, Horn, Wiper and washer system, Power windows, Central locking. Bodywork: Exterior body panels, Doors, Hood, Trunk, Bumpers, Glass, Seals, Interior trim, Seats, Upholstery, Body repair procedures (minor dent repair, panel replacement - likely not extensive structural welding). Climate Control: Air conditioning system (refrigerant, compressor, evaporator, condenser, controls), Heating system. Emission Control: Catalytic converter operation, oxygen sensors, EGR valve diagnosis and replacement (where fitted). Cooling System: Radiator, thermostat, water pump, heater matrix, fan operation, coolant types and bleeding procedures. Exhaust System: Manifold, catalytic converter, mufflers, pipes, lambda sensors. Procedures Included Maintenance: Scheduled maintenance (oil changes, filter replacements, spark plugs, timing belt/chain inspection/replacement), Fluid level checks and top-ups, Brake pad/disc replacement, Tire rotation, Battery testing. Troubleshooting: Diagnostic procedures for common faults, symptom-based troubleshooting guides, diagnostic trouble codes (DTCs) interpretation (likely for OBD-II systems). Repair: Step-by-step repair instructions for major components and systems, engine rebuild procedures (e.g., head gasket replacement, piston ring replacement), transmission overhaul, suspension component replacement, brake system repair, electrical component replacement. Installation: Procedures for replacing major parts and assemblies (e.g., clutch replacement, starter motor replacement, alternator replacement). Diagnostics: Comprehensive diagnostic procedures, including fault code reading (for applicable systems), live data interpretation (if scan tool functionality is assumed to be known by the user), and component testing. Technical Depth Depth: Comprehensive (covers routine servicing to full engine and transmission rebuilds, detailed diagnostics). Diagrams And Photos: Hundreds of detailed photos and exploded diagrams illustrating disassembly, assembly, and component identification. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable (implied for PDF format, though not explicitly stated for the content) Compatibility: Compatible with Windows and MAC operating systems. Print Quality Print Capability: Printable (single page or entire manual) Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) Licensing Usage Rights: Lifetime usage, unlimited computers, no expiry ⚙️ Engine Specifications Primary Engine Petrol Engines: XU7JP (1.8L, 8v, 90-103hp), XU10J2 (2.0L, 8v, 110-115hp), XU10J4 (2.0L, 16v, 132-135hp), EW10J4 (2.0L, 16v, 136-143hp), EW12J4 (2.2L, 16v, 158hp), ES9J4S (3.0L V6, 24v, 194-207hp). Diesel Engines: XUD7TE (1.9L Turbo Diesel, 90hp), D8C (2.0L HDi, 90hp), RHY (2.0L HDi, 110hp), DW10ATED (2.0L HDi, 110hp), DW12TED4 (2.2L HDi, 136hp). Performance Hp Range: Approximately 90 hp to 207 hp, depending on engine variant. Torque Specs: Varies by engine; for example, 2.0 HDi (RHY) produces around 205 Nm @ 1750 rpm. Fuel System Injection Type: Multi-point Fuel Injection (MPI) for petrol, Common Rail Direct Injection (CRDi) for HDi diesel engines. Ignition System: Electronic Ignition (Distributorless Ignition System - DIS on many models). Engine Codes Example Petrol Engine Codes: XU5JP, XU7JP, XU10J2C, XU10J4R, EW10J4, EW12J4, ES9J4, ES9J4S. Example Diesel Engine Codes: XUD7TE, XUD9TE, RHY, DW10TD, DW10ATED, DW12TED4. 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Transmission (e.g., MA5, ML5C). Optional Transmission Type Optional: 4-speed Automatic Transmission (e.g., AL4). Features Automatic Features: Likely includes a 'Sport' mode or 'Snow' mode for altered gear shift points. Fluid Specs Manual Transmission Fluid: Typically GL-4 or GL-5 specification, viscosity grade SAE 75W-80 or 75W-90. Specific part numbers for PSA-approved fluids are available in the manual. Automatic Transmission Fluid: ESSO LT 71141 or equivalent (often Dexron III compatible, but specific is recommended). Fluid capacity approximately 5-6 liters for a drain and refill. 📐 Dimensions Exterior Length: Approx. 4635 mm (Saloon/Sedan), 4757 mm (Estate/SW). Width: Approx. 1740 mm. Height: Approx. 1410 mm (Saloon), 1490 mm (Estate). Weights Curb...

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Sku: 214547

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Tags: 1999 2000 2001 2002 2003 2004 406 Car Cars Peugeot

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Description

🏷️ Basic Information

Identification

Make:

Peugeot

Model:

Years Covered:

1999, 2000, 2001, 2002, 2003, 2004

Codes

Vehicle Platform:

PSA EW/ES, XU/XUD, PRV V6

👋 Introduction

Market Position

Segment:

Mid-size family car, Executive car

Competitive Analysis

Key Competitors:

Ford Mondeo, Opel/Vauxhall Vectra, Volkswagen Passat, Renault Laguna, Toyota Avensis, Honda Accord.

Key Features

Design Philosophy:

Known for its stylish Pininfarina-designed exterior, comfortable ride, and strong safety features for its era. Offered a range of efficient petrol and advanced common-rail diesel engines.

Manual Advantage:

Provides comprehensive factory-level repair and maintenance information, enabling owners to perform a wide range of tasks and diagnostics, saving on dealership labor costs.

📋 Manual Details

Coverage Areas

Engine Variants Covered:

Petrol (1.6L, 1.8L, 2.0L, 2.2L, 3.0L V6), Diesel (1.9L, 2.0L HDi, 2.2L HDi)

Page Count

Estimated Pages:

Hundreds (precise number not specified, but described as very detailed)

Manual Type

Type:

Full Service & Repair Workshop Manual

Language

Language:

English (implied by product description)

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanicals (cylinder head, block, pistons, crankshaft, camshafts), Fuel system (injection, ignition, carburetion for older variants if applicable), Exhaust system, Cooling system, Lubrication system, Turbocharging (where applicable).

Transmission:

Manual and Automatic transmissions (operation, repair, fluid changes, component overhaul).

Chassis:

Suspension (front and rear), Steering system (power steering, steering rack, column), Brakes (hydraulic system, ABS, discs, pads, lines, parking brake), Wheels and tires.

Electrical:

Wiring diagrams, Battery, Charging system (alternator, starter), Lighting (headlights, taillights, interior), Fuses and relays, Ignition system, Instrument panel, Horn, Wiper and washer system, Power windows, Central locking.

Bodywork:

Exterior body panels, Doors, Hood, Trunk, Bumpers, Glass, Seals, Interior trim, Seats, Upholstery, Body repair procedures (minor dent repair, panel replacement - likely not extensive structural welding).

Climate Control:

Air conditioning system (refrigerant, compressor, evaporator, condenser, controls), Heating system.

Emission Control:

Catalytic converter operation, oxygen sensors, EGR valve diagnosis and replacement (where fitted).

Cooling System:

Radiator, thermostat, water pump, heater matrix, fan operation, coolant types and bleeding procedures.

Exhaust System:

Manifold, catalytic converter, mufflers, pipes, lambda sensors.

Procedures Included

Maintenance:

Scheduled maintenance (oil changes, filter replacements, spark plugs, timing belt/chain inspection/replacement), Fluid level checks and top-ups, Brake pad/disc replacement, Tire rotation, Battery testing.

Troubleshooting:

Diagnostic procedures for common faults, symptom-based troubleshooting guides, diagnostic trouble codes (DTCs) interpretation (likely for OBD-II systems).

Repair:

Step-by-step repair instructions for major components and systems, engine rebuild procedures (e.g., head gasket replacement, piston ring replacement), transmission overhaul, suspension component replacement, brake system repair, electrical component replacement.

Installation:

Procedures for replacing major parts and assemblies (e.g., clutch replacement, starter motor replacement, alternator replacement).

Diagnostics:

Comprehensive diagnostic procedures, including fault code reading (for applicable systems), live data interpretation (if scan tool functionality is assumed to be known by the user), and component testing.

Technical Depth

Depth:

Comprehensive (covers routine servicing to full engine and transmission rebuilds, detailed diagnostics).

Diagrams And Photos:

Hundreds of detailed photos and exploded diagrams illustrating disassembly, assembly, and component identification.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable (implied for PDF format, though not explicitly stated for the content)

Compatibility:

Compatible with Windows and MAC operating systems.

Print Quality

Print Capability:

Printable (single page or entire manual)

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

Licensing

Usage Rights:

Lifetime usage, unlimited computers, no expiry

⚙️ Engine Specifications

Primary Engine

Petrol Engines:

XU7JP (1.8L, 8v, 90-103hp), XU10J2 (2.0L, 8v, 110-115hp), XU10J4 (2.0L, 16v, 132-135hp), EW10J4 (2.0L, 16v, 136-143hp), EW12J4 (2.2L, 16v, 158hp), ES9J4S (3.0L V6, 24v, 194-207hp).

Diesel Engines:

XUD7TE (1.9L Turbo Diesel, 90hp), D8C (2.0L HDi, 90hp), RHY (2.0L HDi, 110hp), DW10ATED (2.0L HDi, 110hp), DW12TED4 (2.2L HDi, 136hp).

Performance

Hp Range:

Approximately 90 hp to 207 hp, depending on engine variant.

Torque Specs:

Varies by engine; for example, 2.0 HDi (RHY) produces around 205 Nm @ 1750 rpm.

Fuel System

Injection Type:

Multi-point Fuel Injection (MPI) for petrol, Common Rail Direct Injection (CRDi) for HDi diesel engines.

Ignition System:

Electronic Ignition (Distributorless Ignition System - DIS on many models).

Engine Codes

Example Petrol Engine Codes:

XU5JP, XU7JP, XU10J2C, XU10J4R, EW10J4, EW12J4, ES9J4, ES9J4S.

Example Diesel Engine Codes:

XUD7TE, XUD9TE, RHY, DW10TD, DW10ATED, DW12TED4.

🔧 Transmission

Standard

Transmission Type Standard:

5-speed Manual Transmission (e.g., MA5, ML5C).

Optional

Transmission Type Optional:

4-speed Automatic Transmission (e.g., AL4).

Features

Automatic Features:

Likely includes a 'Sport' mode or 'Snow' mode for altered gear shift points.

Fluid Specs

Manual Transmission Fluid:

Typically GL-4 or GL-5 specification, viscosity grade SAE 75W-80 or 75W-90. Specific part numbers for PSA-approved fluids are available in the manual.

Automatic Transmission Fluid:

ESSO LT 71141 or equivalent (often Dexron III compatible, but specific is recommended). Fluid capacity approximately 5-6 liters for a drain and refill.

📐 Dimensions

Exterior

Length:

Approx. 4635 mm (Saloon/Sedan), 4757 mm (Estate/SW).

Width:

Approx. 1740 mm.

Height:

Approx. 1410 mm (Saloon), 1490 mm (Estate).

Weights

Curb Weight:

Ranges from approx. 1300 kg to 1550 kg depending on engine and specification.

Cargo

Boot Capacity:

Approx. 490 liters (Saloon), 510 liters (Estate with seats up).

🛡️ Safety Features

Ratings

Euro Ncap Rating:

Likely achieved a 4-star Euro NCAP rating in its original testing for adult occupant protection, reflecting good safety for its time. Specific rating may vary slightly by test year.

Active Features

Active Safety:

Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD), Traction Control (ASR on some models), Cruise Control.

Passive Features

Passive Safety:

Front airbags, Side airbags (optional on some trims), Seatbelt pre-tensioners, Crumple zones, Reinforced safety cell.

💡 Technology Features

Infotainment

Infotainment Systems:

Factory fitted radio/cassette or CD players, optional navigation system on later models. Basic climate controls, often manual or single-zone climate control.

Driver Assistance

Assistance Features:

Cruise control, parking sensors (rear, optional), ABS, optional ASR (traction control).

Connectivity

Connectivity Features:

Limited by modern standards. Typically includes radio, CD player, and optional external CD changer. No Bluetooth or USB connectivity as standard on most models of this era.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 10,000 to 15,000 miles (15,000 to 20,000 km) or 12 months, whichever comes first. Long-life synthetic oil may extend this. Consult manual for specific engine/oil type.

Timing Belt Replacement:

Crucial for many petrol and some diesel engines. Intervals vary but are commonly around 60,000 to 80,000 miles (100,000 to 120,000 km) or 5-6 years. The manual will specify the exact interval for each engine code and recommend replacing associated components like tensioners and water pump.

Fluid Specifications

Coolant Type:

PSA specific coolant (e.g., GLOF-4850 or equivalent) which is typically an organic acid technology (OAT) type, often orange or pink. Capacity approximately 7-8 liters.

Brake Fluid Type:

DOT 4.

Power Steering Fluid:

Typically PSA hydraulic fluid or equivalent (often synthetic ATF is NOT recommended). Consult manual for specific type. Capacity around 1-1.2 liters.

Engine Oil Specifications:

Dependent on engine. Petrol typically 5W-30 or 10W-40 meeting ACEA A3/B3 or API SJ/SL specifications. HDi diesels often require 5W-30 or 5W-40 low-SAPS oil meeting ACEA C3 or specific PSA standards (e.g., B71 2290). Manual will list exact PSA approval codes.

Known Issues

Common Petrol Issues:

Coil pack failure, ignition module issues, crankshaft/camshaft sensor failures, thermostat housing leaks, exhaust manifold cracks (especially on 2.0L 16v), EGR valve issues (especially on later petrols). The 2.0L HDi can suffer from turbo actuator issues or turbocharger failure if oil changes are neglected.

Common Diesel Issues:

Fuel injector seal leaks, turbocharger issues (especially if oil starvation occurs), glow plug failures, DPF issues (on later models not typically in this range, but worth noting for common diesel wear), dual-mass flywheel failure on manuals.

General Issues:

Front suspension wear (wishbone bushes, drop links), rear suspension self-levelling spheres (on some models) can leak, ABS sensor failures, air conditioning compressor clutch failure, electrical gremlins (water ingress into ECUs or connectors), automatic gearbox (AL4) can be prone to overheating or hydraulic issues.

Filter Part Numbers

Oil Filter Example:

Part numbers vary by engine and manufacturer (e.g., Purflux L302, Fram PH7114A for some variants). Manual provides specific OE and equivalent part numbers.

📚 Vehicle History

Brand Heritage

Peugeot History:

Peugeot, a French automotive manufacturer founded in 1810, has a long history of producing robust and stylish vehicles, often with a focus on ride comfort and handling. The 400 series has historically been Peugeot's mid-size offering.

Model Evolution

406 Generation Info:

The Peugeot 406 succeeded the 405 and was produced from 1995 to 2004 (with this manual covering the facelifted Phase 2 models from 1999 onwards). It was available as a saloon, estate (wagon), and a coupé variant (designed by Pininfarina).

Production

Production Plants:

Primarily manufactured in Sochaux, France, and also in Ryton-on-Dunsmore, United Kingdom, for the UK market.

🏆 Awards & Recognition

Recognitions

Industry Awards:

While specific major awards for the 406 sedan/estate might be less prominent than the Coupe (which received considerable acclaim for its styling), it was generally well-regarded in its class for comfort, refinement, and value, often appearing on 'best buy' lists in automotive publications of the time.