Peugeot 406 Complete Workshop Service Repair Manual 1996 1997 1998

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🏷️ Basic Information Identification Make: Peugeot Model: 406 Model Generation: First Generation (Type D9) Year: 1996, 1997, 1998 Codes Chassis Code: D9 👋 Introduction Market Position Market Segment: Mid-size family car, competing in the European executive car segment. Competitive Analysis Key Competitors: Ford Mondeo, Opel/Vauxhall Vectra, Renault Laguna, Volkswagen Passat, BMW 3 Series (E36/E46), Audi A4 (B5). Key Features Vehicle Strengths: Comfortable ride, spacious interior, elegant styling (especially Pininfarina-designed coupe/cabriolet), strong diesel engines, good handling. Manual Value Proposition Cost Savings: Enables DIY repairs, saving significant labor costs at dealerships or independent garages. Manual Utility Ease Of Use: Step-by-step instructions and pictures make complex tasks manageable for DIY enthusiasts. 📋 Manual Details Coverage Areas Manual Coverage Scope: All Models, All Engines, All Trim Levels, All Transmission Types Page Count Estimated Page Count: Comprehensive (exact number not specified but implied to be extensive) Manual Type Manual Type: Workshop Service Repair Manual Language Language: English (implied by product description) Format Format: Downloadable Digital Format (PDF compatible) 📖 Manual Coverage Systems Covered Engine Systems: Engine Overhaul, Engine Mechanicals, Lubrication System, Cooling System, Fuel System (Petrol & Diesel), Ignition System, Emission Control Systems, Engine Management Systems (ECU), Turbocharging (if applicable) Transmission Systems: Manual Transmission Overhaul & Repair, Automatic Transmission Overhaul & Repair, Clutch System, Drive Shafts & Axles Suspension Steering Braking: Front Suspension, Rear Suspension, Steering System, Brake System (Front & Rear, ABS), Parking Brake Electrical Systems: Wiring Diagrams, Battery, Charging System (Alternator), Starting System, Lighting System, Instrumentation, Central Locking, Power Windows, Wipers & Washers, Horn, Audio System, Air Conditioning System (if applicable), SRS (Airbag) System Bodywork Chassis: Body & Frame Repair, Exterior Panels, Doors, Hinges, Locks, Interior Trim, Seating, Glass & Seals, Bumpers, Corrosion Protection Procedures Included Maintenance Procedures: Routine Servicing, Oil Changes, Filter Replacements, Spark Plug Replacement, Belt Replacement, Brake Pad/Disc Replacement, Tire Rotation, Fluid Level Checks & Top-ups, Scheduled Maintenance Intervals Repair Procedures: Engine Component Replacement (e.g., pistons, rings, bearings), Cylinder Head Overhaul, Transmission Rebuild, Suspension Component Replacement, Brake Caliper Overhaul, Electrical Component Diagnosis & Replacement, Body Panel Repair & Replacement Troubleshooting Diagnostics: Systematic Diagnostic Flowcharts, Fault Code Interpretation (if applicable), Symptom-based Troubleshooting Guides, Component Testing Procedures Technical Information: Torque Specifications, Tightening Sequences, Component Clearances, Electrical Schematics, Diagnostic Trouble Codes (DTCs), Special Tool Requirements Technical Depth Depth Of Coverage: Comprehensive: From basic maintenance to full engine and transmission rebuilds, including detailed diagnostic procedures and wiring diagrams. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Print Quality Print Quality: High Quality (suitable for printing individual pages or the entire manual) Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Format) Software Requirements Required Software: Adobe Reader (or compatible PDF viewer) Accessibility Device Compatibility: All PC & MAC Computers, Tablets, Smartphones ⚙️ Engine Specifications Primary Engine Petrol Engine Code Example: XU7JP (1.8L), XU10J4 (2.0L 16V, GTi/Mi16), ES9J4 (3.0L V6) Primary Engine Diesel Engine Code Example: XUD7TE (1.9L TD), DW10ATED (2.0L HDi) Performance 1.8L Horsepower: Approx. 90-103 hp Torque: Approx. 145-153 Nm Performance 2.0L Horsepower: Approx. 115-135 hp (16V GTi/Mi16) Torque: Approx. 170-185 Nm Performance 3.0L V6 Horsepower: Approx. 190-194 hp Torque: Approx. 270-275 Nm Performance 1.9L Td Horsepower: Approx. 90 hp Torque: Approx. 180 Nm Performance 2.0L Hdi Horsepower: Approx. 90 hp Torque: Approx. 205 Nm Fuel System Injection Type Petrol: Multi-point Fuel Injection (MPI) / Electronic Fuel Injection (EFI) Injection Type Diesel: Indirect Injection (IDI) Turbo Diesel / Common Rail Direct Injection (CRDi - HDi) Cylinder Count Engine Configurations: Inline 4-cylinder, V6 🔧 Transmission Standard Transmission Manual Gearbox Options: 5-speed manual Optional Transmission Automatic Gearbox Options: 4-speed automatic (e.g., AL4) Features Clutch Type: Dry single-plate, hydraulically operated diaphragm spring clutch Gear Ratio Info: Specific ratios provided for each engine/transmission combination within the manual. 📐 Dimensions Exterior Dimensions Sedan Length: Approx. 4615 mm Width: Approx. 1742 mm Height: Approx. 1403 mm Interior Dimensions Cabin Space: Known for generous cabin space, particularly rear legroom, for its class. Cargo Dimensions Boot Capacity Sedan: Approx. 530 liters Weights Curb Weight Range: Approx. 1300 kg to 1550 kg (depending on engine and specification) 🛡️ Safety Features Ratings Euro Ncap Rating: 3-star (early models) to 4-star (later models with improved side impact protection and airbags). Active Features ABS: Anti-lock Braking System (standard on many models, optional on some base trims) Traction Control: ASR (Anti-Slip Regulation) available on some higher-spec models. Passive Features Airbags: Driver and front passenger airbags standard; side airbags available on higher trims. Seatbelts: Pre-tensioned seatbelts with force limiters. 💡 Technology Features Infotainment Audio System: Factory fitted radio/cassette or CD player, with options for CD changer integration. Navigation: Optional factory fitted navigation system (RT2 or similar) on higher trim levels. Driver Assistance Cruise Control: Available on higher trim levels and with specific engine options. Parking Sensors: Rarely fitted as standard, likely an aftermarket addition. Connectivity Phone Integration: Optional integrated Bluetooth...

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Description

🏷️ Basic Information

Identification

Make:

Peugeot

Model:

Model Generation:

First Generation (Type D9)

Year:

1996, 1997, 1998

Codes

Chassis Code:

👋 Introduction

Market Position

Market Segment:

Mid-size family car, competing in the European executive car segment.

Competitive Analysis

Key Competitors:

Ford Mondeo, Opel/Vauxhall Vectra, Renault Laguna, Volkswagen Passat, BMW 3 Series (E36/E46), Audi A4 (B5).

Key Features

Vehicle Strengths:

Comfortable ride, spacious interior, elegant styling (especially Pininfarina-designed coupe/cabriolet), strong diesel engines, good handling.

Manual Value Proposition

Cost Savings:

Enables DIY repairs, saving significant labor costs at dealerships or independent garages.

Manual Utility

Ease Of Use:

Step-by-step instructions and pictures make complex tasks manageable for DIY enthusiasts.

📋 Manual Details

Coverage Areas

Manual Coverage Scope:

All Models, All Engines, All Trim Levels, All Transmission Types

Page Count

Estimated Page Count:

Comprehensive (exact number not specified but implied to be extensive)

Manual Type

Manual Type:

Workshop Service Repair Manual

Language

Language:

English (implied by product description)

Format

Format:

Downloadable Digital Format (PDF compatible)

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine Overhaul, Engine Mechanicals, Lubrication System, Cooling System, Fuel System (Petrol & Diesel), Ignition System, Emission Control Systems, Engine Management Systems (ECU), Turbocharging (if applicable)

Transmission Systems:

Manual Transmission Overhaul & Repair, Automatic Transmission Overhaul & Repair, Clutch System, Drive Shafts & Axles

Suspension Steering Braking:

Front Suspension, Rear Suspension, Steering System, Brake System (Front & Rear, ABS), Parking Brake

Electrical Systems:

Wiring Diagrams, Battery, Charging System (Alternator), Starting System, Lighting System, Instrumentation, Central Locking, Power Windows, Wipers & Washers, Horn, Audio System, Air Conditioning System (if applicable), SRS (Airbag) System

Bodywork Chassis:

Body & Frame Repair, Exterior Panels, Doors, Hinges, Locks, Interior Trim, Seating, Glass & Seals, Bumpers, Corrosion Protection

Procedures Included

Maintenance Procedures:

Routine Servicing, Oil Changes, Filter Replacements, Spark Plug Replacement, Belt Replacement, Brake Pad/Disc Replacement, Tire Rotation, Fluid Level Checks & Top-ups, Scheduled Maintenance Intervals

Repair Procedures:

Engine Component Replacement (e.g., pistons, rings, bearings), Cylinder Head Overhaul, Transmission Rebuild, Suspension Component Replacement, Brake Caliper Overhaul, Electrical Component Diagnosis & Replacement, Body Panel Repair & Replacement

Troubleshooting Diagnostics:

Systematic Diagnostic Flowcharts, Fault Code Interpretation (if applicable), Symptom-based Troubleshooting Guides, Component Testing Procedures

Technical Information:

Torque Specifications, Tightening Sequences, Component Clearances, Electrical Schematics, Diagnostic Trouble Codes (DTCs), Special Tool Requirements

Technical Depth

Depth Of Coverage:

Comprehensive: From basic maintenance to full engine and transmission rebuilds, including detailed diagnostic procedures and wiring diagrams.

📊 Manual Specifications

File Format

File Format:

PDF (Portable Document Format)

Print Quality

Print Quality:

High Quality (suitable for printing individual pages or the entire manual)

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Format)

Software Requirements

Required Software:

Adobe Reader (or compatible PDF viewer)

Accessibility

Device Compatibility:

All PC & MAC Computers, Tablets, Smartphones

⚙️ Engine Specifications

Primary Engine Petrol

Engine Code Example:

XU7JP (1.8L), XU10J4 (2.0L 16V, GTi/Mi16), ES9J4 (3.0L V6)

Primary Engine Diesel

Engine Code Example:

XUD7TE (1.9L TD), DW10ATED (2.0L HDi)

Performance 1.8L

Horsepower:

Approx. 90-103 hp

Torque:

Approx. 145-153 Nm

Performance 2.0L

Horsepower:

Approx. 115-135 hp (16V GTi/Mi16)

Torque:

Approx. 170-185 Nm

Performance 3.0L V6

Horsepower:

Approx. 190-194 hp

Torque:

Approx. 270-275 Nm

Performance 1.9L Td

Horsepower:

Approx. 90 hp

Torque:

Approx. 180 Nm

Performance 2.0L Hdi

Horsepower:

Approx. 90 hp

Torque:

Approx. 205 Nm

Fuel System

Injection Type Petrol:

Multi-point Fuel Injection (MPI) / Electronic Fuel Injection (EFI)

Injection Type Diesel:

Indirect Injection (IDI) Turbo Diesel / Common Rail Direct Injection (CRDi - HDi)

Cylinder Count

Engine Configurations:

Inline 4-cylinder, V6

🔧 Transmission

Standard Transmission

Manual Gearbox Options:

5-speed manual

Optional Transmission

Automatic Gearbox Options:

4-speed automatic (e.g., AL4)

Features

Clutch Type:

Dry single-plate, hydraulically operated diaphragm spring clutch

Gear Ratio Info:

Specific ratios provided for each engine/transmission combination within the manual.

📐 Dimensions

Exterior Dimensions Sedan

Length:

Approx. 4615 mm

Width:

Approx. 1742 mm

Height:

Approx. 1403 mm

Interior Dimensions

Cabin Space:

Known for generous cabin space, particularly rear legroom, for its class.

Cargo Dimensions

Boot Capacity Sedan:

Approx. 530 liters

Weights

Curb Weight Range:

Approx. 1300 kg to 1550 kg (depending on engine and specification)

🛡️ Safety Features

Ratings

Euro Ncap Rating:

3-star (early models) to 4-star (later models with improved side impact protection and airbags).

Active Features

Anti-lock Braking System (standard on many models, optional on some base trims)

Traction Control:

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

Passive Features

Airbags:

Driver and front passenger airbags standard; side airbags available on higher trims.

Seatbelts:

Pre-tensioned seatbelts with force limiters.

💡 Technology Features

Infotainment

Audio System:

Factory fitted radio/cassette or CD player, with options for CD changer integration.

Navigation:

Optional factory fitted navigation system (RT2 or similar) on higher trim levels.

Driver Assistance

Cruise Control:

Available on higher trim levels and with specific engine options.

Parking Sensors:

Rarely fitted as standard, likely an aftermarket addition.

Connectivity

Phone Integration:

Optional integrated Bluetooth hands-free kits on later models.

🔧 Maintenance

Service Intervals Oil

Engine Oil Change Interval:

Typically 10,000-15,000 km or 1 year, whichever comes first (depending on engine type and oil used).

Service Intervals Filters

Oil Filter Replacement:

With every oil change.

Air Filter Replacement:

Every 20,000-30,000 km.

Fuel Filter Replacement Petrol:

Every 40,000-60,000 km.

Fuel Filter Replacement Diesel:

Every 20,000-40,000 km (critical for HDi).

Service Intervals Timing Belt

Timing Belt Replacement Interval Petrol Xu:

Every 80,000-120,000 km or 5-7 years (interference engine, critical).

Timing Belt Replacement Interval Diesel Xud:

Every 80,000-100,000 km or 5 years (interference engine, critical).

Timing Belt Replacement Interval Hdi Dw10:

Every 120,000-160,000 km or 6-10 years (critical).

Fluid Specifications

Engine Oil Type Petrol:

API SL/SJ, ACEA A3/B3 or A3/B4, SAE 10W-40 or 5W-40 (refer to manual for specific grades).

Engine Oil Type Diesel:

API CG-4/CH-4, ACEA B3/B4, SAE 10W-40 or 5W-40 (refer to manual for specific grades).

Coolant Type:

Glysantin G30 or equivalent (purple/pink OAT coolant) or G11 (blue/green Si-OAT) - Check manual for specific vehicle fill.

Brake Fluid Type:

DOT 4

Transmission Fluid Manual:

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

Transmission Fluid Automatic:

ATF LT 71141 (for AL4 transmission) or equivalent.

Known Issues

Common Faults Electrical:

Premature failure of body control module (BCM), interior light issues, central locking faults, window regulator failures.

Common Faults Engine:

Oil leaks (especially from rear main seal and rocker cover), thermostat housing leaks, ignition coil pack failure (petrol), injector issues (HDi).

Common Faults Suspension Steering:

Front wishbone bush wear, rear axle bearing wear, power steering leaks.

Common Faults Transmission:

Wear in manual gearbox synchros, hydraulic leaks in clutch actuation, early AL4 automatic gearbox solenoid failures/control issues.

Common Faults Brakes:

ABS sensor failures, sticking handbrake mechanism.

Common Faults Exhaust System:

Corrosion and failure of exhaust sections, catalytic converter issues.

📚 Vehicle History

Brand Heritage

Peugeot History:

Peugeot has a long history dating back to the late 19th century, known for producing well-engineered and stylish vehicles.

Model Evolution

406 Predecessor:

Peugeot 405

406 Successor:

Peugeot 407

Production Period

Production Years:

1995–2004 (Europe)

Production Locations

Manufacturing Plants:

Sochaux, France; Ryton-on-Dunsmore, England; El Palomar, Argentina; Wuhan, China (Dongfeng Peugeot-Citroën).

🏆 Awards & Recognition

Recognitions

Previous Awards:

The Peugeot 406 was well-received by the automotive press upon its launch, praised for its comfort, style, and value, though specific major awards for the 1996-1998 period are not prominently cited as category winners.