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PEUGEOT 206 T1 1998-2008 Factory Workshop Repair Manual

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🏷️ Basic Information Identification Make: Peugeot Model: 206 T1 Production Years: 1998-2008 Platform: PF1 Codes Chassis Code: T1 👋 Introduction Market Position Segment: Supermini / Compact Car Target Audience: Young drivers, urban commuters, small families Competitive Analysis Key Competitors: Ford Fiesta, Volkswagen Golf (older generations), Renault Clio, Opel/Vauxhall Corsa Key Features Design: Distinctive 'smiley face' front end, compact and agile handling, spacious interior for its size Powertrain Options: Wide range of petrol and diesel engines, catering to various efficiency and performance needs 📋 Manual Details Coverage Areas Manual Type: Factory Workshop Service Repair Manual Language: English Format: HTML Internet Requirement: Required Printable: Selected pages or whole manual Illustration Style: Pictures and Diagrams, Exploded Views Coverage Scope: Repairs, Maintenance, Servicing 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul procedures, component diagnostics, assembly/disassembly Lubrication System: Oil pump, oil filter, oil passages, oil pressure checks, oil type recommendations Cooling System: Radiator, coolant pump, thermostat, fan, hoses, coolant specifications, pressure testing Fuel System: Fuel injectors, fuel pump, fuel filter, fuel pressure, fuel system diagnostics, ECU control Exhaust System: Exhaust manifold, catalytic converter, mufflers, pipes, oxygen sensors, mounting Emission Control: EVAP system, EGR system, PCV system, emissions testing, component function Ignition System: Spark plugs, ignition coils, distributor (if applicable), timing, diagnostics Charging Starting System: Alternator, starter motor, battery, wiring diagrams, testing procedures Turbo Charging System: Turbocharger components, wastegate, intercooler, boost pressure control, diagnostics Clutch System: Clutch disc, pressure plate, release bearing, hydraulic system, bleeding procedures Manual Transmission: Gearbox overhaul, component replacement, fluid specifications, shift mechanism Automatic Transmission: Transmission types (e.g., AL4), hydraulic control, torque converter, fluid type, diagnostics Driveshaft: CV joints, driveshafts, mounting, balancing Suspension System: Front and rear suspension, control arms, bushings, shock absorbers, springs, alignment Variable Damping Suspension: Electronic suspension control, sensor diagnostics, component replacement Axle System: Front and rear axles, differentials, wheel bearings Steering System: Steering rack, tie rods, steering knuckles, geometry, alignment Power Steering: Hydraulic pump, fluid type, steering assist system, diagnostics Brakes System: Disc brakes, brake pads, calipers, brake fluid, bleeding procedures, parking brake ABS Traction Control: ABS modulator, wheel speed sensors, ABS ECU, system diagnostics, calibration Steering Wheel Column: Steering wheel removal, column components, airbag system safety precautions Electrical System: Comprehensive wiring diagrams, component testing, fuses, relays, lighting, accessories Driver Information: Instrument cluster, warning lights, trip computer, diagnostic codes (OBD-II) Cruise Control System: System components, operation, diagnostics, switch functionality Anti Theft System: Immobilizer, central locking, alarm system, key programming Horns Lock: Horn operation, door locks, central locking system actuators Entertainment System: Radio, CD player, speaker system, antenna, wiring Bodywork System: Body panel repair, chassis straightening, door mechanisms, tailgate, bonnet Lighting System: Headlights, taillights, interior lights, fog lights, bulb types, aiming Interior Exterior: Trim panels, upholstery, exterior trim, badging, seals HVAC System: Air conditioning, heating, ventilation, blower motor, refrigerant system, cabin filter Body Accessories: Bumpers, spoilers, mudguards, tow bar, roof rack preparation Seats Fascia Sun Roof: Seat adjustment, fascia panel removal, sunroof mechanisms, interior lighting Wiper Washer: Wiper motor, blades, washer pump, fluid reservoir, linkage Procedures Included Diagnostic Procedures: Troubleshooting charts, symptom-based diagnostics, DTC interpretation Maintenance Procedures: Scheduled maintenance, fluid changes, filter replacements, inspections Repair Procedures: Detailed step-by-step instructions for component replacement and repair Overhaul Procedures: Complete engine, transmission, and component rebuild instructions Installation Procedures: Installation of new or replacement components Technical Depth Depth Level: Factory-level diagnostic and repair procedures Diagnostic Tools: Reference to specific diagnostic tools and software (e.g., Diagbox, Lexia) Technical Specifications: Torque values, clearances, tolerances, electrical specifications 📊 Manual Specifications File Format File Type: HTML File Size: Varies depending on the specific download package Print Quality Print Ability: High (selected pages or whole manual) Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine List: EW10J4 (2.0L Petrol I4), DW10 (2.0L Diesel I4), D4D (1.0L Petrol I4), DW8 (1.9L Diesel I4), TU5JP4 (1.6L Petrol I4), TU1JP (1.1L Petrol I4), TU3JP (1.4L Petrol I4), TU5JP (1.6L Petrol I4), DV4 HDi (1.4L Diesel I4) Performance Ew10J4 Hp: Approximately 136-138 hp (depending on variant) Ew10J4 Torque: Approximately 192 Nm (142 lb-ft) Tu5Jp4 Hp: Approximately 109-110 hp Tu5Jp4 Torque: Approximately 147 Nm (108 lb-ft) Fuel System Injection Type: Multi-point fuel injection (MPI), Common Rail Diesel Injection (CRDi) for HDi engines Ignition Type: Spark Ignition (Petrol), Compression Ignition (Diesel) 🔧 Transmission Standard Manual Gearbox Options: 5-speed manual (e.g., BE4, MA5) Optional Automatic Gearbox Options: 4-speed automatic (e.g., AL4 - often found on 1.6L and some 2.0L models) Features Clutch Type: Hydraulically operated single dry plate clutch 📐 Dimensions Exterior Length Mm: Approx. 3929 Width Mm: Approx. 1673 Height Mm: Approx. 1427 Wheelbase Mm: Approx. 2444 Weights Kerb Weight Kg: Approx. 1050-1150 (depending on engine and trim) 🛡️ Safety Features Ratings Euro Ncap Rating: 4 Stars (achieved during its initial release period) Active Features ABS: Standard on many later models and higher trims;...
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Sku: 213379
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PEUGEOT 206 T1 1998-2008 Factory Workshop Repair Manual
🏷️ Basic Information
Identification
Make:
Peugeot
Model:
206 T1
Production Years:
1998-2008
Platform:
PF1
Codes
Chassis Code:
T1
👋 Introduction
Market Position
Segment:
Supermini / Compact Car
Target Audience:
Young drivers, urban commuters, small families
Competitive Analysis
Key Competitors:
Ford Fiesta, Volkswagen Golf (older generations), Renault Clio, Opel/Vauxhall Corsa
Key Features
Design:
Distinctive 'smiley face' front end, compact and agile handling, spacious interior for its size
Powertrain Options:
Wide range of petrol and diesel engines, catering to various efficiency and performance needs
📋 Manual Details
Coverage Areas
Manual Type:
Factory Workshop Service Repair Manual
Language:
English
Format:
HTML
Internet Requirement:
Required
Printable:
Selected pages or whole manual
Illustration Style:
Pictures and Diagrams, Exploded Views
Coverage Scope:
Repairs, Maintenance, Servicing
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul procedures, component diagnostics, assembly/disassembly
Lubrication System:
Oil pump, oil filter, oil passages, oil pressure checks, oil type recommendations
Cooling System:
Radiator, coolant pump, thermostat, fan, hoses, coolant specifications, pressure testing
Fuel System:
Fuel injectors, fuel pump, fuel filter, fuel pressure, fuel system diagnostics, ECU control
Exhaust System:
Exhaust manifold, catalytic converter, mufflers, pipes, oxygen sensors, mounting
Emission Control:
EVAP system, EGR system, PCV system, emissions testing, component function
Ignition System:
Spark plugs, ignition coils, distributor (if applicable), timing, diagnostics
Charging Starting System:
Alternator, starter motor, battery, wiring diagrams, testing procedures
Turbo Charging System:
Turbocharger components, wastegate, intercooler, boost pressure control, diagnostics
Clutch System:
Clutch disc, pressure plate, release bearing, hydraulic system, bleeding procedures
Manual Transmission:
Gearbox overhaul, component replacement, fluid specifications, shift mechanism
Automatic Transmission:
Transmission types (e.g., AL4), hydraulic control, torque converter, fluid type, diagnostics
Driveshaft:
CV joints, driveshafts, mounting, balancing
Suspension System:
Front and rear suspension, control arms, bushings, shock absorbers, springs, alignment
Variable Damping Suspension:
Electronic suspension control, sensor diagnostics, component replacement
Axle System:
Front and rear axles, differentials, wheel bearings
Steering System:
Steering rack, tie rods, steering knuckles, geometry, alignment
Power Steering:
Hydraulic pump, fluid type, steering assist system, diagnostics
Brakes System:
Disc brakes, brake pads, calipers, brake fluid, bleeding procedures, parking brake
ABS Traction Control:
ABS modulator, wheel speed sensors, ABS ECU, system diagnostics, calibration
Steering Wheel Column:
Steering wheel removal, column components, airbag system safety precautions
Electrical System:
Comprehensive wiring diagrams, component testing, fuses, relays, lighting, accessories
Driver Information:
Instrument cluster, warning lights, trip computer, diagnostic codes (OBD-II)
Cruise Control System:
System components, operation, diagnostics, switch functionality
Anti Theft System:
Immobilizer, central locking, alarm system, key programming
Horns Lock:
Horn operation, door locks, central locking system actuators
Entertainment System:
Radio, CD player, speaker system, antenna, wiring
Bodywork System:
Body panel repair, chassis straightening, door mechanisms, tailgate, bonnet
Lighting System:
Headlights, taillights, interior lights, fog lights, bulb types, aiming
Interior Exterior:
Trim panels, upholstery, exterior trim, badging, seals
HVAC System:
Air conditioning, heating, ventilation, blower motor, refrigerant system, cabin filter
Body Accessories:
Bumpers, spoilers, mudguards, tow bar, roof rack preparation
Seats Fascia Sun Roof:
Seat adjustment, fascia panel removal, sunroof mechanisms, interior lighting
Wiper Washer:
Wiper motor, blades, washer pump, fluid reservoir, linkage
Procedures Included
Diagnostic Procedures:
Troubleshooting charts, symptom-based diagnostics, DTC interpretation
Maintenance Procedures:
Scheduled maintenance, fluid changes, filter replacements, inspections
Repair Procedures:
Detailed step-by-step instructions for component replacement and repair
Overhaul Procedures:
Complete engine, transmission, and component rebuild instructions
Installation Procedures:
Installation of new or replacement components
Technical Depth
Depth Level:
Factory-level diagnostic and repair procedures
Diagnostic Tools:
Reference to specific diagnostic tools and software (e.g., Diagbox, Lexia)
Technical Specifications:
Torque values, clearances, tolerances, electrical specifications
📊 Manual Specifications
File Format
File Type:
HTML
File Size:
Varies depending on the specific download package
Print Quality
Print Ability:
High (selected pages or whole manual)
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine List:
EW10J4 (2.0L Petrol I4), DW10 (2.0L Diesel I4), D4D (1.0L Petrol I4), DW8 (1.9L Diesel I4), TU5JP4 (1.6L Petrol I4), TU1JP (1.1L Petrol I4), TU3JP (1.4L Petrol I4), TU5JP (1.6L Petrol I4), DV4 HDi (1.4L Diesel I4)
Performance
Ew10J4 Hp:
Approximately 136-138 hp (depending on variant)
Ew10J4 Torque:
Approximately 192 Nm (142 lb-ft)
Tu5Jp4 Hp:
Approximately 109-110 hp
Tu5Jp4 Torque:
Approximately 147 Nm (108 lb-ft)
Fuel System
Injection Type:
Multi-point fuel injection (MPI), Common Rail Diesel Injection (CRDi) for HDi engines
Ignition Type:
Spark Ignition (Petrol), Compression Ignition (Diesel)
🔧 Transmission
Standard
Manual Gearbox Options:
5-speed manual (e.g., BE4, MA5)
Optional
Automatic Gearbox Options:
4-speed automatic (e.g., AL4 - often found on 1.6L and some 2.0L models)
Features
Clutch Type:
Hydraulically operated single dry plate clutch
📐 Dimensions
Exterior
Length Mm:
Approx. 3929
Width Mm:
Approx. 1673
Height Mm:
Approx. 1427
Wheelbase Mm:
Approx. 2444
Weights
Kerb Weight Kg:
Approx. 1050-1150 (depending on engine and trim)
🛡️ Safety Features
Ratings
Euro Ncap Rating:
4 Stars (achieved during its initial release period)
Active Features
ABS:
Standard on many later models and higher trims; optional on earlier ones
Esp Traction Control:
Optional on certain higher-specification models
Passive Features
Airbags:
Driver and passenger airbags standard; side airbags optional on some variants
Seatbelts:
Pre-tensioned seatbelts with force limiters
💡 Technology Features
Infotainment
Head Unit Features:
AM/FM Radio, CD Player, often with steering wheel controls on higher trims
Driver Assistance
Parking Sensors:
Optional rear parking sensors on some models
Connectivity
Bluetooth:
Limited or no factory Bluetooth on earlier models; aftermarket solutions common
🔧 Maintenance
Service Intervals
Oil Change Interval Petrol:
Typically every 15,000 km or 1 year (whichever comes first)
Oil Change Interval Diesel:
Typically every 20,000 km or 1 year (whichever comes first), or as per DPF regeneration needs
Timing Belt Replacement Tu Engines:
Around 90,000 km or 5 years (critical for these engines)
Timing Belt Replacement Ew Engines:
Around 120,000 km or 5 years (critical for these engines)
Fluid Specifications
Engine Oil Petrol:
ACEA A3/B4 or A5/B5, API SL/SM, Viscosity: 5W-30 or 5W-40 (check manual for specific engine requirements)
Engine Oil Diesel:
ACEA B4 or C3 (for DPF models), API CF/CG-4, Viscosity: 5W-40 or 10W-40 (check manual for specific engine requirements)
Coolant Type:
Peugeot/PSA Approved Antifreeze (e.g., GVL 151 G11 or G12 equivalent, usually purple or blue/green)
Brake Fluid Type:
DOT 4
Transmission Oil Manual:
SAE 75W-80 GL-4
Transmission Oil Automatic:
ATF LT 71141 (for AL4 transmission)
Known Issues
Common Problems:
Rear axle beam failure (torsion bar wear), ignition coil failure, electric window regulators, ABS sensor issues, catalytic converter failures on some models, clutch slave cylinder issues
📚 Vehicle History
Brand Heritage
Parent Company:
PSA Peugeot Citroën
Model Evolution
Generation:
First Generation Peugeot 206 (introduced 1998)
Facelifts:
Received minor updates and facelifts throughout its production run, most notably in 2003/2004
Production
Manufacturing Locations:
Primarily France (Mulhouse), also produced in other PSA plants globally
🏆 Awards & Recognition
Recognitions
Design Awards:
Often praised for its stylish and modern design upon launch
Ratings
Reliability Perception:
Mixed; generally reliable with proper maintenance, but some specific components are known weak points
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