Peugeot 406 1996 Service Repair Manual

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🏷️ Basic Information Identification Make: Peugeot Model: 406 Year: 1996 Codes Chassis Code: 8B (Saloon), 8E (Estate/SW), 8C (Coupe) Engine Codes: XU7JP (1.8L 8v), XU10J2 (2.0L 8v), XU10J4R (2.0L 16v), ES9J4 (3.0L V6 24v), D8A/D9B (1.9L TD), DHX/DHY (2.1L TD) 👋 Introduction Market Position Segment: Family car, executive car Competitive Analysis Competitors: Ford Mondeo, Opel/Vauxhall Vectra, Volkswagen Passat, Renault Laguna, Fiat Croma, BMW 3 Series (E36), Mercedes-Benz C-Class (W202). Key Features Design: Penned by Italian designer Pininfarina, known for its elegant and flowing lines, and excellent aerodynamics. Ride Comfort: Renowned for its exceptional ride comfort and sophisticated handling, often praised as class-leading in its segment. Engines: Offered with a range of reliable PSA XU and ES petrol engines, and robust Indenor diesel and turbodiesel units. Body Styles: Available as a saloon (sedan), hatchback (5-door), estate (wagon/SW), and coupe. 📋 Manual Details Coverage Areas Engine: Yes Transmission: Yes Brakes: Yes Suspension: Yes Steering: Yes Electrical System: Yes Body And Chassis: Yes Climate Control: Yes Fuel System: Yes Exhaust System: Yes Cooling System: Yes Lighting: Yes Comfort And Interior: Yes Safety Systems: Yes Diagnosis And Troubleshooting: Yes Page Count Estimated Pages: Extensive (typical factory service manual, ~2000+ pages) Manual Type Type: Service and Repair Manual (Factory Equivalent) Language Language: English Format File Format: PDF Delivery: Instant Download Requirements Software Requirements: Adobe PDF Reader, WinZip Compatibility Operating Systems: All Versions of Windows & Mac 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, component removal/installation, lubrication, cooling, fuel, exhaust systems. Engine Performance: Ignition timing, fuel injection (Motronic, Bosch systems), emissions control. Transmission Manual: Clutch, gearbox disassembly/assembly, shift mechanisms, fluid specifications. Transmission Automatic: Component identification, hydraulic circuits, electronic control, fluid specifications, servicing. Brakes Hydraulic: Master cylinder, brake lines, calipers, wheel cylinders, bleeding procedures, fluid specifications. Brakes Antilock: ABS modulator, wheel speed sensors, diagnosis and troubleshooting. Suspension Front: MacPherson struts, wishbones, anti-roll bar, bearings, servicing. Suspension Rear: Multi-link independent suspension (all models), shock absorbers, springs, bushings, alignment. Steering: Power steering system, rack and pinion, steering column, universal joints. Electrical Charging: Alternator, regulator, battery specifications, testing. Electrical Starting: Starter motor, ignition switch, battery testing. Electrical Lighting Interior Exterior: Headlights, taillights, interior illumination, bulb types, wiring diagrams. Electrical Instruments Gauges: Speedometer, tachometer, fuel gauge, warning lights, instrument cluster. Electrical Comfort Features: Power windows, central locking, mirrors, seats, sunroofs. Electrical Accessories: Wipers, washers, horn, radio, cigarette lighter. Body Exterior: Door mechanisms, hood, trunk, bumpers, exterior trim, glass replacement. Body Interior: Seat removal/installation, dashboard, trim panels, headliner. Climate Control HVAC: Heater core, A/C compressor, refrigerant, blower motor, control panel. Fuel System Injection: Fuel pump, injectors, fuel pressure regulator, fuel filter, fuel tank. Emission Control: Catalytic converter, oxygen sensors, EVAP system. Safety Airbags: Airbag module, SRS system components, diagnostic procedures. Safety Seatbelts: Seatbelt mechanisms, pretensioners. Procedures Included Maintenance: Scheduled maintenance (oil changes, filter replacements, fluid checks, belt inspection/replacement), tune-ups. Repair: Component disassembly, repair, reassembly, and adjustment for all major systems. Troubleshooting: Diagnostic charts, symptom-to-cause analysis, common problem resolution. Wiring Diagrams: Comprehensive electrical schematics for all circuits and systems. Specifications: Tightening torques, clearances, fluid capacities, component dimensions, electrical values. Illustrations Diagrams: Detailed diagrams, exploded views, and photographs to aid in understanding procedures. Diagnostic Codes: OBD-II diagnostic trouble codes (DTCs) and their meanings. Technical Depth Depth: Professional technician level, covering everything from basic maintenance to complex component overhauls and diagnostics. 📊 Manual Specifications File Format Quality: High-resolution PDF, suitable for zooming and detailed viewing. Print Quality Printability: Full Printable Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Petrol Options: 1.8L (1761cc) XU7JP (8v), 2.0L (1998cc) XU10J2 (8v), 2.0L (1998cc) XU10J4R (16v), 3.0L (2946cc) ES9J4 (V6, 24v). Diesel Options: 1.9L (1905cc) XD Turbo Diesel (D8A/D9B), 2.1L (2088cc) XD Turbo Diesel (DHX/DHY). Performance 2.0L 16V (Xu10J4R) Power: Approx. 135 PS (133 hp; 99 kW) 2.0L 16V (Xu10J4R) Torque: Approx. 187 Nm (138 lb-ft) 3.0L V6 (Es9J4) Power: Approx. 194 PS (191 hp; 143 kW) 3.0L V6 (Es9J4) Torque: Approx. 267 Nm (197 lb-ft) Fuel System Injection Type: Multi-point fuel injection (MPI) for petrol engines, direct injection for diesel engines. Fuel Type: Unleaded Petrol (RON 95 recommended), Diesel. 🔧 Transmission Standard Manual Gearbox: 5-speed manual transmission. Optional Automatic Gearbox: 4-speed automatic transmission (ZF 4HP18 / AL4 PFA). Features Transmission Control: Cable-operated manual clutch, hydraulic clutch operation for some models. Electronic control for automatic transmissions. 📐 Dimensions Exterior Length: Saloon: Approx. 4675 mm (184.1 in) Width: Approx. 1740 mm (68.5 in) Height: Saloon: Approx. 1410 mm (55.5 in) Wheelbase: Approx. 2700 mm (106.3 in) Weights Kerb Weight: Varies by engine and body style, typically from 1250 kg to 1550 kg. 🛡️ Safety Features Ratings Euro Ncap: Euro NCAP (original testing protocols) - Likely achieved 3 or 4 stars based on contemporary standards. Active Features Braking System: ABS (Anti-lock Braking System) available on higher trims and later models,...

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Sku: 213130

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Product variants

Description

🏷️ Basic Information

Identification

Make:

Peugeot

Model:

Year:

Codes

Chassis Code:

8B (Saloon), 8E (Estate/SW), 8C (Coupe)

Engine Codes:

XU7JP (1.8L 8v), XU10J2 (2.0L 8v), XU10J4R (2.0L 16v), ES9J4 (3.0L V6 24v), D8A/D9B (1.9L TD), DHX/DHY (2.1L TD)

👋 Introduction

Market Position

Segment:

Family car, executive car

Competitive Analysis

Competitors:

Ford Mondeo, Opel/Vauxhall Vectra, Volkswagen Passat, Renault Laguna, Fiat Croma, BMW 3 Series (E36), Mercedes-Benz C-Class (W202).

Key Features

Design:

Penned by Italian designer Pininfarina, known for its elegant and flowing lines, and excellent aerodynamics.

Ride Comfort:

Renowned for its exceptional ride comfort and sophisticated handling, often praised as class-leading in its segment.

Engines:

Offered with a range of reliable PSA XU and ES petrol engines, and robust Indenor diesel and turbodiesel units.

Body Styles:

Available as a saloon (sedan), hatchback (5-door), estate (wagon/SW), and coupe.

📋 Manual Details

Coverage Areas

Engine:

Transmission:

Brakes:

Suspension:

Steering:

Electrical System:

Body And Chassis:

Climate Control:

Fuel System:

Exhaust System:

Cooling System:

Lighting:

Comfort And Interior:

Safety Systems:

Diagnosis And Troubleshooting:

Page Count

Estimated Pages:

Extensive (typical factory service manual, ~2000+ pages)

Manual Type

Type:

Service and Repair Manual (Factory Equivalent)

Language

Language:

English

Format

File Format:

Delivery:

Instant Download

Requirements

Software Requirements:

Adobe PDF Reader, WinZip

Compatibility

Operating Systems:

All Versions of Windows & Mac

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, component removal/installation, lubrication, cooling, fuel, exhaust systems.

Engine Performance:

Ignition timing, fuel injection (Motronic, Bosch systems), emissions control.

Transmission Manual:

Clutch, gearbox disassembly/assembly, shift mechanisms, fluid specifications.

Transmission Automatic:

Component identification, hydraulic circuits, electronic control, fluid specifications, servicing.

Brakes Hydraulic:

Master cylinder, brake lines, calipers, wheel cylinders, bleeding procedures, fluid specifications.

Brakes Antilock:

ABS modulator, wheel speed sensors, diagnosis and troubleshooting.

Suspension Front:

MacPherson struts, wishbones, anti-roll bar, bearings, servicing.

Suspension Rear:

Multi-link independent suspension (all models), shock absorbers, springs, bushings, alignment.

Steering:

Power steering system, rack and pinion, steering column, universal joints.

Electrical Charging:

Alternator, regulator, battery specifications, testing.

Electrical Starting:

Starter motor, ignition switch, battery testing.

Electrical Lighting Interior Exterior:

Headlights, taillights, interior illumination, bulb types, wiring diagrams.

Electrical Instruments Gauges:

Speedometer, tachometer, fuel gauge, warning lights, instrument cluster.

Electrical Comfort Features:

Power windows, central locking, mirrors, seats, sunroofs.

Electrical Accessories:

Wipers, washers, horn, radio, cigarette lighter.

Body Exterior:

Door mechanisms, hood, trunk, bumpers, exterior trim, glass replacement.

Body Interior:

Seat removal/installation, dashboard, trim panels, headliner.

Climate Control HVAC:

Heater core, A/C compressor, refrigerant, blower motor, control panel.

Fuel System Injection:

Fuel pump, injectors, fuel pressure regulator, fuel filter, fuel tank.

Emission Control:

Catalytic converter, oxygen sensors, EVAP system.

Safety Airbags:

Airbag module, SRS system components, diagnostic procedures.

Safety Seatbelts:

Seatbelt mechanisms, pretensioners.

Procedures Included

Maintenance:

Scheduled maintenance (oil changes, filter replacements, fluid checks, belt inspection/replacement), tune-ups.

Repair:

Component disassembly, repair, reassembly, and adjustment for all major systems.

Troubleshooting:

Diagnostic charts, symptom-to-cause analysis, common problem resolution.

Wiring Diagrams:

Comprehensive electrical schematics for all circuits and systems.

Specifications:

Tightening torques, clearances, fluid capacities, component dimensions, electrical values.

Illustrations Diagrams:

Detailed diagrams, exploded views, and photographs to aid in understanding procedures.

Diagnostic Codes:

OBD-II diagnostic trouble codes (DTCs) and their meanings.

Technical Depth

Depth:

Professional technician level, covering everything from basic maintenance to complex component overhauls and diagnostics.

📊 Manual Specifications

File Format

Quality:

High-resolution PDF, suitable for zooming and detailed viewing.

Print Quality

Printability:

Full Printable

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Petrol Options:

1.8L (1761cc) XU7JP (8v), 2.0L (1998cc) XU10J2 (8v), 2.0L (1998cc) XU10J4R (16v), 3.0L (2946cc) ES9J4 (V6, 24v).

Diesel Options:

1.9L (1905cc) XD Turbo Diesel (D8A/D9B), 2.1L (2088cc) XD Turbo Diesel (DHX/DHY).

Performance

2.0L 16V (Xu10J4R) Power:

Approx. 135 PS (133 hp; 99 kW)

2.0L 16V (Xu10J4R) Torque:

Approx. 187 Nm (138 lb-ft)

3.0L V6 (Es9J4) Power:

Approx. 194 PS (191 hp; 143 kW)

3.0L V6 (Es9J4) Torque:

Approx. 267 Nm (197 lb-ft)

Fuel System

Injection Type:

Multi-point fuel injection (MPI) for petrol engines, direct injection for diesel engines.

Fuel Type:

Unleaded Petrol (RON 95 recommended), Diesel.

🔧 Transmission

Standard

Manual Gearbox:

5-speed manual transmission.

Optional

Automatic Gearbox:

4-speed automatic transmission (ZF 4HP18 / AL4 PFA).

Features

Transmission Control:

Cable-operated manual clutch, hydraulic clutch operation for some models. Electronic control for automatic transmissions.

📐 Dimensions

Exterior

Length:

Saloon: Approx. 4675 mm (184.1 in)

Width:

Approx. 1740 mm (68.5 in)

Height:

Saloon: Approx. 1410 mm (55.5 in)

Wheelbase:

Approx. 2700 mm (106.3 in)

Weights

Kerb Weight:

Varies by engine and body style, typically from 1250 kg to 1550 kg.

🛡️ Safety Features

Ratings

Euro Ncap:

Euro NCAP (original testing protocols) - Likely achieved 3 or 4 stars based on contemporary standards.

Active Features

Braking System:

ABS (Anti-lock Braking System) available on higher trims and later models, EBD (Electronic Brakeforce Distribution) on some variants.

Traction Control:

ASR (Anti-Slip Regulation) available on some higher-spec models.

Passive Features

Airbags:

Driver and front passenger airbags standard on most models. Side airbags optional on some trims.

Seatbelts:

Three-point seatbelts with pre-tensioners for front occupants, three-point rear seatbelts.

Chassis Strength:

Designed with crumple zones and a rigid passenger cell for enhanced crash protection.

💡 Technology Features

Infotainment

Audio System:

Factory fitted radio/cassette or CD player, often with steering wheel mounted controls on higher trims. Speaker configurations vary.

Driver Assistance

Cruise Control:

Available as an option on many models.

Connectivity

Communication Systems:

Optional mobile phone integration available on some higher trim levels.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 15,000 km (9,300 miles) or 12 months, whichever comes first (synthetic oil recommended).

Timing Belt Replacement:

Every 80,000 - 120,000 km (50,000 - 75,000 miles) or 5 years, depending on engine and usage. Crucial for interference engines.

Fluid Specifications

Engine Oil Petrol:

API SJ or higher, ACEA A3/B3 or A3/B4. Viscosity: 5W-40 or 10W-40 (check owner's manual for specific recommendations based on climate).

Engine Oil Diesel:

API CG-4 or higher, ACEA B3/B4. Viscosity: 5W-40 or 10W-40.

Coolant:

Antifreeze/coolant concentrate (typically ethylene glycol based) mixed with distilled water in a 50:50 ratio. Use PSA approved coolant.

Brake Fluid:

DOT 4 synthetic brake fluid.

Power Steering Fluid:

PSA Specific Hydraulic Fluid (typically mineral oil based) or equivalent Dexterity fluid. Refer to manual for exact specification.

Manual Transmission Fluid:

API GL-4, SAE 75W-80 or 75W-90 synthetic gear oil.

Automatic Transmission Fluid:

Specific ATF fluid as per manufacturer recommendation (e.g., LT 71141 for ZF 4HP18, or equivalent for AL4).

Known Issues

Suspension Wear:

Front suspension components (ball joints, wishbone bushings) and rear multi-link bushings can wear prematurely, leading to knocking noises and poor handling.

Electrical Gremlins:

Minor electrical issues can occur, such as central locking faults, instrument cluster problems, or indicator failures due to aging wiring or poor connections.

Engine Mounts:

Engine and gearbox mounts can degrade over time, resulting in increased vibration and noise entering the cabin.

Cooling System Leaks:

Plastic coolant expansion tanks can become brittle and crack, leading to coolant leaks. Radiator leaks are also possible.

Diesel Glow Plugs:

Glow plugs on diesel models can fail, causing hard starting in cold weather.

Exhaust Manifold Cracks:

Cast iron exhaust manifolds on some petrol engines can develop cracks, leading to exhaust leaks and a ticking noise.

📚 Vehicle History

Brand Heritage

Heritage:

Peugeot has a long history dating back to the 19th century, known for producing robust and innovative vehicles, particularly in the medium to large family car segments.

Model Evolution

Predecessor:

Peugeot 405.

Successor:

Peugeot 407.

Production

Production Years:

1995 - 2004 (with a facelift in 2000).

Manufacturing Locations:

Primarily manufactured in France (Sochaux), with some production in other countries.

🏆 Awards & Recognition

Recognitions

Design Award:

The Peugeot 406 Coupe was designed by Pininfarina and received critical acclaim for its aesthetic appeal, often cited as one of the most beautiful cars of its era.