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Peugeot 406 1999-2002 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Peugeot Model: 406 Year: 1999-2002 Codes Chassis Code: 8B (Saloon/Sedan), 8E (Estate/Station Wagon), 8C (Coupe) 👋 Introduction Market Position Target Audience: DIY enthusiasts, independent repair shops, and Peugeot 406 owners seeking to perform maintenance and repairs. Competitive Analysis Differentiation: This manual is presented as the 'SAME manual used in the local service/repair shop' and an 'Original Peugeot Workshop Service Repair Manual,' implying a higher level of accuracy and completeness compared to generic guides. Key Features Benefits: Saves money on repair bills, empowers owners to perform self-maintenance, provides professional-level diagnostic and repair information, includes diagrams and detailed instructions. 📋 Manual Details Coverage Areas Vehicles Covered: All Peugeot 406 models, engines, trim levels, and transmission types manufactured between 1999 and 2002. Page Count Estimated Pages: Hundreds (specific count not provided, but described as a 'Complete Informational Book' with 'hundreds of pages'). Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine service/repair, transmission service/repair, fuel injection/fuel system, emission system, engine control system, differential/drive, axle. Chassis And Suspension: Brake system, suspension, steering, chassis/body. Electrical And Accessories: Electrical system, wiring diagram, restraint system, interior, heating/air conditioning. Procedures Included Routine Maintenance: General maintenance, periodic lubrication, fluid checks and changes, filter replacements, tune-ups. Diagnostic And Repair: Troubleshooting, diagnostic procedures, detailed repair procedures, disassembly, assembly, cleaning, reinstallation. Specialized Areas: Electrical system diagnostics and repair, wiring diagrams for troubleshooting. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to advanced diagnostics and repair, as used by professional technicians. 📊 Manual Specifications File Format Format: PDF Searchable: Implied by PDF format, though direct confirmation of OCR is not stated. Print Quality Printability: Full Printable Zoom Capability: YES (Zoom IN/OUT) Binding Type Binding: N/A (Digital PDF download) Paper Type Paper: N/A (Digital PDF download) ⚙️ Engine Specifications Primary Engine Engine Variants: The manual covers 'All Models/Engines'. Specific engines likely include the EW/DW series (e.g., EW10 J4 2.0L 16V, DW10 TD/HD 2.0L HDi) and potentially earlier XU/ES series engines (e.g., XU10 J2 TE 2.0L Turbo), and gasoline variants like the XFU 2.0L (ES9 J4 3.0L V6 for Coupe models). Performance Horsepower Torque: Detailed specifications for various engine variants are expected within the manual, including horsepower and torque figures, RPM ranges, and performance curves. Fuel System Injection Type: Likely covers both multi-point fuel injection (MPI) for gasoline engines and common rail direct injection (CRDi) for HDi diesel engines. 🔧 Transmission Standard Manual Gearboxes: Likely covers 5-speed manual transmissions (e.g., BE series). Optional Automatic Gearboxes: Likely covers AL4 automatic transmissions (also known as DP0 in some markets). Features Transmission Controls: Information on gear linkage, clutch system, and automatic transmission control modules. 📐 Dimensions Exterior Body Styles: Saloon/Sedan (8B), Estate/Station Wagon (8E), Coupe (8C). Interior Seating Capacity: Typically 5 occupants. Cargo Boot Space: Specifications for boot capacity for saloon and coupe models, and cargo volume for the estate model would be detailed. Weights Curb Weight: Weight specifications will vary by engine and body style, detailed in the manual. 🛡️ Safety Features Ratings Euro Ncap: The Peugeot 406 received a 4-star Euro NCAP rating for adult occupant protection in its initial tests (though these were before the 1999-2002 models). Active Features Braking Systems: ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), optional Brake Assist. Passive Features Restraint Systems: Front airbags, side airbags (optional on some models), pre-tensioned seatbelts, ISOFIX child seat anchor points. 💡 Technology Features Infotainment Audio System: Factory fitted radio/cassette or CD players with speakers. Advanced models might include steering wheel controls and a multi-function display. Driver Assistance Cruise Control: Available on higher trim levels, especially with automatic transmissions. Connectivity Climate Control: Manual or automatic climate control systems with air conditioning. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 10,000 miles (16,000 km) or 12 months for gasoline, and 12,500 miles (20,000 km) or 12 months for HDi diesel, depending on driving conditions. Consult the manual for specific intervals. Fluid Specifications Engine Oil: Likely requires synthetic or semi-synthetic engine oil meeting API SJ/SL or ACEA A3/B3/B4 specifications. Viscosity grades such as 5W-40 or 10W-40 are common. Specific grade depends on engine type and climate. Refer to manual for precise API/ACEA and viscosity requirements. Coolant: Typically requires a long-life organic acid technology (OAT) coolant, typically purple or pink, mixed 50/50 with distilled water. Refer to manual for specific Peugeot or PSA group approved coolant type and concentration. Brake Fluid: DOT 3 or DOT 4 brake fluid is standard. Replacement every 2 years is recommended. Refer to manual for exact specification. Transmission Fluid Manual: Gearbox oil specification typically based on API GL-4 or GL-5, with a viscosity of 75W-80 or 75W-90. Refer to manual for precise specification and capacity. Transmission Fluid Automatic: Specific ATF (Automatic Transmission Fluid) is required for the AL4 transmission, likely a low-viscosity fluid like LT...
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Peugeot 406 1999-2002 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Peugeot
Model:
406
Year:
1999-2002
Codes
Chassis Code:
8B (Saloon/Sedan), 8E (Estate/Station Wagon), 8C (Coupe)
👋 Introduction
Market Position
Target Audience:
DIY enthusiasts, independent repair shops, and Peugeot 406 owners seeking to perform maintenance and repairs.
Competitive Analysis
Differentiation:
This manual is presented as the 'SAME manual used in the local service/repair shop' and an 'Original Peugeot Workshop Service Repair Manual,' implying a higher level of accuracy and completeness compared to generic guides.
Key Features
Benefits:
Saves money on repair bills, empowers owners to perform self-maintenance, provides professional-level diagnostic and repair information, includes diagrams and detailed instructions.
📋 Manual Details
Coverage Areas
Vehicles Covered:
All Peugeot 406 models, engines, trim levels, and transmission types manufactured between 1999 and 2002.
Page Count
Estimated Pages:
Hundreds (specific count not provided, but described as a 'Complete Informational Book' with 'hundreds of pages').
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine service/repair, transmission service/repair, fuel injection/fuel system, emission system, engine control system, differential/drive, axle.
Chassis And Suspension:
Brake system, suspension, steering, chassis/body.
Electrical And Accessories:
Electrical system, wiring diagram, restraint system, interior, heating/air conditioning.
Procedures Included
Routine Maintenance:
General maintenance, periodic lubrication, fluid checks and changes, filter replacements, tune-ups.
Diagnostic And Repair:
Troubleshooting, diagnostic procedures, detailed repair procedures, disassembly, assembly, cleaning, reinstallation.
Specialized Areas:
Electrical system diagnostics and repair, wiring diagrams for troubleshooting.
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to advanced diagnostics and repair, as used by professional technicians.
📊 Manual Specifications
File Format
Format:
PDF
Searchable:
Implied by PDF format, though direct confirmation of OCR is not stated.
Print Quality
Printability:
Full Printable
Zoom Capability:
YES (Zoom IN/OUT)
Binding Type
Binding:
N/A (Digital PDF download)
Paper Type
Paper:
N/A (Digital PDF download)
⚙️ Engine Specifications
Primary Engine
Engine Variants:
The manual covers 'All Models/Engines'. Specific engines likely include the EW/DW series (e.g., EW10 J4 2.0L 16V, DW10 TD/HD 2.0L HDi) and potentially earlier XU/ES series engines (e.g., XU10 J2 TE 2.0L Turbo), and gasoline variants like the XFU 2.0L (ES9 J4 3.0L V6 for Coupe models).
Performance
Horsepower Torque:
Detailed specifications for various engine variants are expected within the manual, including horsepower and torque figures, RPM ranges, and performance curves.
Fuel System
Injection Type:
Likely covers both multi-point fuel injection (MPI) for gasoline engines and common rail direct injection (CRDi) for HDi diesel engines.
🔧 Transmission
Standard
Manual Gearboxes:
Likely covers 5-speed manual transmissions (e.g., BE series).
Optional
Automatic Gearboxes:
Likely covers AL4 automatic transmissions (also known as DP0 in some markets).
Features
Transmission Controls:
Information on gear linkage, clutch system, and automatic transmission control modules.
📐 Dimensions
Exterior
Body Styles:
Saloon/Sedan (8B), Estate/Station Wagon (8E), Coupe (8C).
Interior
Seating Capacity:
Typically 5 occupants.
Cargo
Boot Space:
Specifications for boot capacity for saloon and coupe models, and cargo volume for the estate model would be detailed.
Weights
Curb Weight:
Weight specifications will vary by engine and body style, detailed in the manual.
🛡️ Safety Features
Ratings
Euro Ncap:
The Peugeot 406 received a 4-star Euro NCAP rating for adult occupant protection in its initial tests (though these were before the 1999-2002 models).
Active Features
Braking Systems:
ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), optional Brake Assist.
Passive Features
Restraint Systems:
Front airbags, side airbags (optional on some models), pre-tensioned seatbelts, ISOFIX child seat anchor points.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette or CD players with speakers. Advanced models might include steering wheel controls and a multi-function display.
Driver Assistance
Cruise Control:
Available on higher trim levels, especially with automatic transmissions.
Connectivity
Climate Control:
Manual or automatic climate control systems with air conditioning.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 10,000 miles (16,000 km) or 12 months for gasoline, and 12,500 miles (20,000 km) or 12 months for HDi diesel, depending on driving conditions. Consult the manual for specific intervals.
Fluid Specifications
Engine Oil:
Likely requires synthetic or semi-synthetic engine oil meeting API SJ/SL or ACEA A3/B3/B4 specifications. Viscosity grades such as 5W-40 or 10W-40 are common. Specific grade depends on engine type and climate. Refer to manual for precise API/ACEA and viscosity requirements.
Coolant:
Typically requires a long-life organic acid technology (OAT) coolant, typically purple or pink, mixed 50/50 with distilled water. Refer to manual for specific Peugeot or PSA group approved coolant type and concentration.
Brake Fluid:
DOT 3 or DOT 4 brake fluid is standard. Replacement every 2 years is recommended. Refer to manual for exact specification.
Transmission Fluid Manual:
Gearbox oil specification typically based on API GL-4 or GL-5, with a viscosity of 75W-80 or 75W-90. Refer to manual for precise specification and capacity.
Transmission Fluid Automatic:
Specific ATF (Automatic Transmission Fluid) is required for the AL4 transmission, likely a low-viscosity fluid like LT 71141 or equivalent. Refer to manual for exact specification and capacity.
Known Issues
Common Problems:
Examples include sagging rear suspension (due to worn bushes), electrical issues (e.g., central locking, window regulators), HDI diesel engine glow plug issues, and early generation common rail fuel system wear. The manual would provide diagnostic and repair steps for these.
📚 Vehicle History
Brand Heritage
Peugeot History:
Peugeot is a French automobile manufacturer with a long history dating back to 1810, known for producing reliable and stylish vehicles.
Model Evolution
406 Development:
The Peugeot 406 was launched in 1995 as the successor to the Peugeot 405. The 1999-2002 period covers the facelifted ('Phase 2') version, which introduced updated styling, improved engines, and enhanced features.
Production
Manufacturing Locations:
Primarily manufactured in France (Sochaux, Rennes) and also assembled in other countries through CKD kits.
🏆 Awards & Recognition
Recognitions
Industry Awards:
While specific awards for the 1999-2002 facelift model aren't widely publicized, the Peugeot 406 was generally well-received for its ride quality, comfort, and styling, often winning praise from automotive journalists.
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