PEUGEOT 406 Petrol Diesel Workshop Repair Manual All 1999-2002 ModelS COVERED

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🏷️ Basic Information Identification Make: Peugeot Model: 406 Model Years Covered By Manual: 1999, 2000, 2001, 2002 Engine Types Covered By Manual: Petrol, Diesel Codes Manual Product Name: PEUGEOT 406 Petrol Diesel Workshop Repair Manual All 1999-2002 ModelS COVERED Manual Format Identifier: Instant Download PDF 👋 Introduction Market Position Vehicle Segment: Mid-size family car, often considered a strong contender in its class for comfort and practicality. Competitive Analysis Key Competitors 1999-2002: Ford Mondeo, Vauxhall Vectra (Opel Vectra), Volkswagen Passat, Renault Laguna, Mazda 626. Key Features Vehicle Strengths As Per Era: Known for comfortable ride, refined handling (especially with Hydractive suspension), spacious interior, and attractive styling (especially the coupe). Manual Advantage: Provides the comprehensive technical data needed for independent repair and maintenance, saving costs on dealership servicing. 📋 Manual Details Coverage Areas Manual Scope: Comprehensive workshop service and repair Specific Models Included: All Peugeot 406 variants from 1999-2002, including saloon, estate (break), and coupe body styles. Page Count Estimated Page Count: Varies by engine/specification, typically 2000+ pages for a full set Manual Type Manual Classification: Workshop Repair Manual / Service Manual Language Language: English Format Download Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed overhaul, diagnosis, and repair for petrol and diesel engines, including cylinder head, crankshaft, pistons, connecting rods, timing systems (belts/chains), oil pump, and lubrication systems. Engine Management: Fuel injection systems (MPI, Common Rail Diesel), ignition systems, emission control systems (catalytic converter, EGR), engine control units (ECU) diagnosis and wiring. Transmission Manual: Repair and overhaul of manual gearboxes, clutch system, linkage adjustment, and gearbox fluid specifications. Transmission Automatic: Diagnosis, maintenance, and repair of automatic transmission systems, including torque converter, valve body, hydraulic control, and transmission fluid specifications. Suspension Steering: Front and rear suspension component replacement (struts, shocks, springs, wishbones, bushings), steering system overhaul, power steering system, wheel alignment specifications. Brakes: Front and rear brake system repair (discs, pads, calipers), hydraulic system bleeding, ABS (Anti-lock Braking System) diagnosis and components, parking brake system. Electrical Systems: Full electrical system diagrams, wiring schematics, starter motor, alternator, battery, lighting systems, interior and exterior electrics, fuse and relay identification. Bodywork Chassis: Body panel removal and installation, interior trim, door mechanisms, glass replacement, chassis component repair, corrosion protection. Heating Ventilation Air Conditioning: HVAC system diagnosis, refrigerant handling, component replacement (compressor, condenser, evaporator), climate control systems. Body Electrical Features: Power windows, central locking, mirrors, seats, sunroof operation and repair. Procedures Included Routine Maintenance: Oil and filter changes, air filter replacement, spark plug replacement, fuel filter replacement, coolant checks and changes. Major Repairs: Engine rebuilds, gearbox overhauls, suspension component replacement, brake caliper/master cylinder replacement, timing belt/chain replacement. Diagnostics Troubleshooting: Step-by-step troubleshooting guides for common faults, electrical system fault finding using wiring diagrams, engine performance issues. Component Replacement: Detailed instructions for replacing virtually all mechanical and electrical components. Adjustments: Clutch adjustment, handbrake adjustment, steering wheel alignment checks. Technical Depth Depth Of Information: Detailed, from basic checks to full engine and transmission rebuilds. Includes factory specifications and tolerances. Diagnostic Capabilities: Covers both mechanical diagnosis and electrical system fault finding, including guidance on using diagnostic tools. Diagrams Illustrations: Includes exploded views, wiring diagrams, and step-by-step illustrations for clarity. 📊 Manual Specifications File Format PDF Version Compatibility: Compatible with all modern PDF readers and operating systems (PC & Mac: 95, 98, 2000, NT, XP, Vista, Windows 7 & 8 Etc). Print Quality Printability: High-resolution PDF, designed for clear printing of individual pages or sections. Binding Type Delivery Method: Digital Download (no physical binding) Paper Type Digital Equivalent: Digital PDF format, equivalent to high-quality workshop manual paper. ⚙️ Engine Specifications Primary Engine Petrol Common Petrol Engines: 1.8L (XU7JP / LFY), 2.0L (XU10J4 / RFN/RFN1), 2.0L Turbo (ES9J4S / ES9A), 3.0L V6 (ES9J4 / ES9J4S). Primary Engine Diesel Common Diesel Engines: 1.9L TD (XUD9TE / DHY), 2.0L HDi (DW10TD / RHY), 2.2L HDi (DW12TED4 / 4HX). Performance Example 2.0 Hdi Performance: Approx. 90-110 PS (depending on variant), significant torque for cruising. Example V6 Performance: Approx. 190-207 PS, smooth power delivery, refined engine note. Fuel System Petrol Fuel Delivery: Multi-point fuel injection (MPI), electronic fuel management. Diesel Fuel Delivery: Turbocharged Direct Injection (TDI), High-Pressure Common Rail (HDi). 🔧 Transmission Standard Standard Transmission Type: 5-speed manual gearbox. Optional Optional Transmission Type: 4-speed automatic transmission (AL4 for many models, ZF 4HP20 for V6). Features Automatic Transmission Features: Often featured 'Sport' and 'Snow' modes for altered shift characteristics. 📐 Dimensions Exterior Typical Saloon Length: Approx. 4600 mm Typical Estate Length: Approx. 4750 mm Interior Cabin Space Comment: Generous passenger space, particularly for rear occupants. Excellent for its class. Cargo Typical Saloon Boot Capacity: Approx. 445 litres Typical Estate Boot Capacity: Approx. 510 litres (seats up), expandable significantly with seats folded. Weights Kerb Weight Range: Approx. 1300 kg to 1600 kg, depending on engine and equipment. 🛡️ Safety Features Ratings Euro Ncap Rating Era: 4-star Euro...

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Description

🏷️ Basic Information

Identification

Make:

Peugeot

Model:

Model Years Covered By Manual:

1999, 2000, 2001, 2002

Engine Types Covered By Manual:

Petrol, Diesel

Codes

Manual Product Name:

PEUGEOT 406 Petrol Diesel Workshop Repair Manual All 1999-2002 ModelS COVERED

Manual Format Identifier:

Instant Download PDF

👋 Introduction

Market Position

Vehicle Segment:

Mid-size family car, often considered a strong contender in its class for comfort and practicality.

Competitive Analysis

Key Competitors 1999-2002:

Ford Mondeo, Vauxhall Vectra (Opel Vectra), Volkswagen Passat, Renault Laguna, Mazda 626.

Key Features

Vehicle Strengths As Per Era:

Known for comfortable ride, refined handling (especially with Hydractive suspension), spacious interior, and attractive styling (especially the coupe).

Manual Advantage:

Provides the comprehensive technical data needed for independent repair and maintenance, saving costs on dealership servicing.

📋 Manual Details

Coverage Areas

Manual Scope:

Comprehensive workshop service and repair

Specific Models Included:

All Peugeot 406 variants from 1999-2002, including saloon, estate (break), and coupe body styles.

Page Count

Estimated Page Count:

Varies by engine/specification, typically 2000+ pages for a full set

Manual Type

Manual Classification:

Workshop Repair Manual / Service Manual

Language

Language:

English

Format

Download Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed overhaul, diagnosis, and repair for petrol and diesel engines, including cylinder head, crankshaft, pistons, connecting rods, timing systems (belts/chains), oil pump, and lubrication systems.

Engine Management:

Fuel injection systems (MPI, Common Rail Diesel), ignition systems, emission control systems (catalytic converter, EGR), engine control units (ECU) diagnosis and wiring.

Transmission Manual:

Repair and overhaul of manual gearboxes, clutch system, linkage adjustment, and gearbox fluid specifications.

Transmission Automatic:

Diagnosis, maintenance, and repair of automatic transmission systems, including torque converter, valve body, hydraulic control, and transmission fluid specifications.

Suspension Steering:

Front and rear suspension component replacement (struts, shocks, springs, wishbones, bushings), steering system overhaul, power steering system, wheel alignment specifications.

Brakes:

Front and rear brake system repair (discs, pads, calipers), hydraulic system bleeding, ABS (Anti-lock Braking System) diagnosis and components, parking brake system.

Electrical Systems:

Full electrical system diagrams, wiring schematics, starter motor, alternator, battery, lighting systems, interior and exterior electrics, fuse and relay identification.

Bodywork Chassis:

Body panel removal and installation, interior trim, door mechanisms, glass replacement, chassis component repair, corrosion protection.

Heating Ventilation Air Conditioning:

HVAC system diagnosis, refrigerant handling, component replacement (compressor, condenser, evaporator), climate control systems.

Body Electrical Features:

Power windows, central locking, mirrors, seats, sunroof operation and repair.

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter replacement, spark plug replacement, fuel filter replacement, coolant checks and changes.

Major Repairs:

Engine rebuilds, gearbox overhauls, suspension component replacement, brake caliper/master cylinder replacement, timing belt/chain replacement.

Diagnostics Troubleshooting:

Step-by-step troubleshooting guides for common faults, electrical system fault finding using wiring diagrams, engine performance issues.

Component Replacement:

Detailed instructions for replacing virtually all mechanical and electrical components.

Adjustments:

Clutch adjustment, handbrake adjustment, steering wheel alignment checks.

Technical Depth

Depth Of Information:

Detailed, from basic checks to full engine and transmission rebuilds. Includes factory specifications and tolerances.

Diagnostic Capabilities:

Covers both mechanical diagnosis and electrical system fault finding, including guidance on using diagnostic tools.

Diagrams Illustrations:

Includes exploded views, wiring diagrams, and step-by-step illustrations for clarity.

📊 Manual Specifications

File Format

PDF Version Compatibility:

Compatible with all modern PDF readers and operating systems (PC & Mac: 95, 98, 2000, NT, XP, Vista, Windows 7 & 8 Etc).

Print Quality

Printability:

High-resolution PDF, designed for clear printing of individual pages or sections.

Binding Type

Delivery Method:

Digital Download (no physical binding)

Paper Type

Digital Equivalent:

Digital PDF format, equivalent to high-quality workshop manual paper.

⚙️ Engine Specifications

Primary Engine Petrol

Common Petrol Engines:

1.8L (XU7JP / LFY), 2.0L (XU10J4 / RFN/RFN1), 2.0L Turbo (ES9J4S / ES9A), 3.0L V6 (ES9J4 / ES9J4S).

Primary Engine Diesel

Common Diesel Engines:

1.9L TD (XUD9TE / DHY), 2.0L HDi (DW10TD / RHY), 2.2L HDi (DW12TED4 / 4HX).

Performance

Example 2.0 Hdi Performance:

Approx. 90-110 PS (depending on variant), significant torque for cruising.

Example V6 Performance:

Approx. 190-207 PS, smooth power delivery, refined engine note.

Fuel System

Petrol Fuel Delivery:

Multi-point fuel injection (MPI), electronic fuel management.

Diesel Fuel Delivery:

Turbocharged Direct Injection (TDI), High-Pressure Common Rail (HDi).

🔧 Transmission

Standard

Standard Transmission Type:

5-speed manual gearbox.

Optional

Optional Transmission Type:

4-speed automatic transmission (AL4 for many models, ZF 4HP20 for V6).

Features

Automatic Transmission Features:

Often featured 'Sport' and 'Snow' modes for altered shift characteristics.

📐 Dimensions

Exterior

Typical Saloon Length:

Approx. 4600 mm

Typical Estate Length:

Approx. 4750 mm

Interior

Cabin Space Comment:

Generous passenger space, particularly for rear occupants. Excellent for its class.

Cargo

Typical Saloon Boot Capacity:

Approx. 445 litres

Typical Estate Boot Capacity:

Approx. 510 litres (seats up), expandable significantly with seats folded.

Weights

Kerb Weight Range:

Approx. 1300 kg to 1600 kg, depending on engine and equipment.

🛡️ Safety Features

Ratings

Euro Ncap Rating Era:

4-star Euro NCAP for frontal impact (early models tested, later updates likely maintained or improved).

Active Features

Standard Active Safety:

Anti-lock Braking System (ABS), power-assisted steering.

Optional Active Safety:

Electronic Stability Program (ESP) on some higher-spec models.

Passive Features

Standard Passive Safety:

Driver and front passenger airbags, side airbags (optional/standard on higher trims), three-point seatbelts with pre-tensioners.

Chassis Safety Features:

Collapsible steering column, impact-absorbing crumple zones.

💡 Technology Features

Infotainment

Standard Audio System:

RDS radio cassette player or CD player with 4-6 speakers. Higher trims might have upgraded Clarion or JBL systems.

Navigation System:

Optional factory-fitted satellite navigation system available on higher trims, often with a monochrome or color screen.

Driver Assistance

Cruise Control:

Available on many models, particularly with automatic transmission or higher engine specifications.

Parking Sensors:

Optional rear parking sensors available on later models.

Connectivity

Original Connectivity:

Basic connectivity, primarily through the audio system. No integrated Bluetooth or USB ports on most models of this era.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 10,000-15,000 miles or 12 months, whichever comes first (check manual for specific engine).

Timing Belt Replacement:

Critical. Usually 70,000-90,000 miles or 5-7 years for petrol engines. HDi diesel engines have timing chains or belts with different intervals; consult manual.

Fluid Specifications

Engine Oil Viscosity Petrol:

Commonly 5W-40 or 10W-40 (e.g., Total Quartz 7000/9000), API SN or ACEA A3/B4.

Engine Oil Viscosity Diesel:

Commonly 5W-40 or 10W-40 (e.g., Total Quartz 7000/9000), API SN or ACEA A3/B4/C3 for HDi models.

Coolant Type:

Ethylene glycol based antifreeze, typically purple or pink (e.g., Total Glysantin G33 or equivalent).

Automatic Transmission Fluid:

Specific ATF, e.g., for AL4: LT 71141; for ZF 4HP20: ZF LifeguardFluid 5 or equivalent.

Known Issues

Common Fault 1:

Electrical gremlins (e.g., instrument cluster issues, central locking problems) due to aging wiring or connectors.

Common Fault 2:

Suspension component wear (e.g., ball joints, wishbone bushings) leading to knocking sounds or poor handling.

Common Fault 3:

HDi diesel engine specific issues: turbocharger problems, injector seal leaks, swirl flap issues on some variants.

Common Fault 4:

Air conditioning system leaks or compressor failure.

Common Fault 5:

Automatic transmission (AL4) can be prone to solenoid issues or overheating if not serviced correctly.

📚 Vehicle History

Brand Heritage

Peugeot Positioning:

Peugeot has a long history of producing well-engineered and comfortable family cars, often with a focus on driving dynamics and ride quality.

Model Evolution

406 Generation Context:

The 406 succeeded the 405 and was a significant step forward in design, technology, and refinement. It was available in saloon, estate, and a Pininfarina-designed coupe body style.

Production

Production Years For 406:

1995–2004 (with facelift in 1999).

Manufacturing Locations:

Primarily France (Sochaux), with some assembly in other European countries.

🏆 Awards & Recognition

Recognitions

Industry Reviews Era:

The Peugeot 406 generally received positive reviews for its ride comfort, handling, and refinement, often praised for its value for money compared to German rivals.

Specific Awards Mention:

While specific major awards for the 1999-2002 facelifted models aren't as prominently documented as earlier versions, the 406 range consistently performed well in automotive press comparisons.

Ratings

Reliability Perception:

Reliability can be mixed, with some models proving robust while others are subject to specific electrical or mechanical issues as detailed in maintenance section. Proactive maintenance is key.