PEUGEOT 806 2.0 HDI (WITHOUT PARTICLE FILTER) 2002 SRM

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🏷️ Basic Information Identification Make: Peugeot Model: 806 Year: 2002 Engine Variant: 2.0 HDI (Without Particle Filter) Vehicle Type: MPV (Multi-Purpose Vehicle) Codes Engine Code Prefix: DW10 👋 Introduction Market Position Segment: Large MPV / Family Minivan Target Audience: Families, individuals requiring versatile passenger and cargo space Competitive Analysis Key Competitors: Renault Espace, Chrysler Voyager, Ford Galaxy, Volkswagen Sharan, Seat Alhambra Key Features Design: Cab-forward design, spacious interior, flexible seating configurations Engine Options: Emphasis on the 2.0 HDI diesel engine, known for its balance of power and fuel economy in this segment Practicality: Sliding rear doors, ample cargo space, often with removable seats for maximum flexibility 📋 Manual Details Coverage Areas Primary Coverage: Mechanical, Electrical, Bodywork, Maintenance, Troubleshooting, Repair Specific Systems: Engine, Fuel System, Cooling System, Lubrication System, Exhaust System, Ignition System, Clutch, Gearbox, Driveshafts, Suspension, Steering, Brakes, Electrical System, Body Panels, Interior Trim, HVAC, Safety Systems Page Count Estimated Pages: High (Detailed Professional Manual - Exact count not provided but implied extensive coverage) Manual Type Type: Service and Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine disassembly, assembly, component specifications, cylinder head, crankshaft, pistons, connecting rods, timing system, valve train Fuel System: Injection system, fuel pump, injectors, fuel lines, pressure regulation, diagnostic procedures Cooling System: Radiator, water pump, thermostat, coolant specifications, hoses, fan operation Lubrication System: Oil pump, oil filter, oil specifications, lubrication passages Exhaust System: Muffler, catalytic converter (where applicable for non-DPF models), exhaust pipes, mounting, emissions control (basic) Transmission Manual: Gearbox operation, removal, installation, internal components, clutch operation, fluid specifications Transmission Automatic: If equipped, likely includes operation, removal, installation, fluid specifications, and basic troubleshooting Suspension Front: MacPherson struts, control arms, anti-roll bar, bushings, replacement procedures, alignment specifications Suspension Rear: Torsion beam or independent setup (model dependent), shock absorbers, springs, bushings, replacement procedures Steering System: Power steering pump, steering rack, tie rods, steering column, fluid specifications, alignment Braking System: Disc brakes (front and rear), ABS system, brake pads, brake discs, brake fluid, lines, calipers, master cylinder, bleeding procedures Electrical System Lighting: Headlights, taillights, interior lighting, bulb types, wiring diagrams Electrical System Charging: Alternator, battery, charging circuit diagnostics Electrical System Starting: Starter motor, ignition switch, starting circuit diagnostics Electrical System Body: Power windows, power locks, mirrors, wipers, horn, central locking, fuse box locations and functions Bodywork Exterior: Door removal/installation, hood, tailgate, bumpers, fenders, glass replacement, panel alignment Bodywork Interior: Seat removal, dashboard disassembly, trim panel replacement, carpeting HVAC System: Air conditioning, heating, ventilation, refrigerant types, component replacement, troubleshooting Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-ups, spark plug replacement (if applicable), belt inspection/replacement Scheduled Maintenance: Brake service, suspension checks, fluid flushes, timing belt replacement intervals Troubleshooting: Diagnostic charts, symptom-based troubleshooting, fault code interpretation (where applicable) Repair Procedures: Step-by-step instructions for component removal, repair, and reinstallation Diagnostic Procedures: Testing procedures for various systems, using specialized tools and multimeters Component Replacement: Detailed instructions for replacing common wear items and major components Technical Depth Depth: Comprehensive (from basic maintenance to complete engine and transmission rebuilds) Diagrams Illustrations: High-quality exploded views, wiring diagrams, system schematics Information Type: Manufacturer specifications, tolerances, torque values, diagnostic trouble codes (DTCs) 📊 Manual Specifications File Format Format: PDF Searchability: Likely text-searchable for ease of use Print Quality Printability: Full Printable Zoom Functionality: YES (Allows for detailed viewing of diagrams) Binding Type Type: Digital Download (PDF) Paper Type Media: Digital PDF (No physical paper) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-cylinder Diesel Engine Code: DW10ATED (likely the variant without particle filter) Displacement: 1997 cc Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 17.3:1 (Typical for DW10 engines) Valvetrain: DOHC, 4 valves per cylinder Performance Horsepower: Approximately 109-110 PS (80-81 kW) at 4000 rpm Torque: Approximately 250-265 Nm (184-195 lb-ft) at 1750-2000 rpm Fuel System Injection Type: Common Rail Direct Injection (CRDi) Turbocharger: Variable Geometry Turbocharger (VGT) Fuel Type: Diesel Fluid Capacity Engine Oil Capacity: Approximately 5.5 - 6.0 liters (with filter change) Coolant Capacity: Approximately 8.0 - 8.5 liters 🔧 Transmission Standard Type: 5-Speed Manual Transmission Optional Type: 4-Speed Automatic Transmission (AL4 likely) Features Clutch: Hydraulically operated, single dry plate Fluid Specifications Manual Gearbox Oil: API GL-4, SAE 75W-80 (e.g., PSA specification LW 1564) Automatic Gearbox Oil: LT 71141 or equivalent (e.g., ATF SP-III) 📐 Dimensions Exterior Length: Approx. 4,455 mm Width: Approx. 1,746 mm (excluding mirrors) Height: Approx. 1,723 mm Wheelbase: Approx. 2,703 mm Front Track: Approx. 1,488 mm Rear Track: Approx. 1,510 mm Weights Curb Weight: Approx. 1,600 - 1,750 kg (depending on configuration) Gross Vehicle Weight Rating: Approx. 2,300 - 2,400 kg Towing Capacity Braked: Approx. 1,500 kg Towing Capacity Unbraked: Approx. 750 kg Cargo Cargo Volume Min: Approx. 330 liters (with all seats in place) Cargo Volume Max: Approx. 1900 - 2500 liters (with rear seats removed/folded)...

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Sku: 215230

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Tags: 2002 806 806 2.0 HDI (WITHOUT PARTICLE FILTER) Car Cars Peugeot

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Description

🏷️ Basic Information

Identification

Make:

Peugeot

Model:

Year:

Engine Variant:

2.0 HDI (Without Particle Filter)

Vehicle Type:

MPV (Multi-Purpose Vehicle)

Codes

Engine Code Prefix:

👋 Introduction

Market Position

Segment:

Large MPV / Family Minivan

Target Audience:

Families, individuals requiring versatile passenger and cargo space

Competitive Analysis

Key Competitors:

Renault Espace, Chrysler Voyager, Ford Galaxy, Volkswagen Sharan, Seat Alhambra

Key Features

Design:

Cab-forward design, spacious interior, flexible seating configurations

Engine Options:

Emphasis on the 2.0 HDI diesel engine, known for its balance of power and fuel economy in this segment

Practicality:

Sliding rear doors, ample cargo space, often with removable seats for maximum flexibility

📋 Manual Details

Coverage Areas

Primary Coverage:

Mechanical, Electrical, Bodywork, Maintenance, Troubleshooting, Repair

Specific Systems:

Engine, Fuel System, Cooling System, Lubrication System, Exhaust System, Ignition System, Clutch, Gearbox, Driveshafts, Suspension, Steering, Brakes, Electrical System, Body Panels, Interior Trim, HVAC, Safety Systems

Page Count

Estimated Pages:

High (Detailed Professional Manual - Exact count not provided but implied extensive coverage)

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine disassembly, assembly, component specifications, cylinder head, crankshaft, pistons, connecting rods, timing system, valve train

Fuel System:

Injection system, fuel pump, injectors, fuel lines, pressure regulation, diagnostic procedures

Cooling System:

Radiator, water pump, thermostat, coolant specifications, hoses, fan operation

Lubrication System:

Oil pump, oil filter, oil specifications, lubrication passages

Exhaust System:

Muffler, catalytic converter (where applicable for non-DPF models), exhaust pipes, mounting, emissions control (basic)

Transmission Manual:

Gearbox operation, removal, installation, internal components, clutch operation, fluid specifications

Transmission Automatic:

If equipped, likely includes operation, removal, installation, fluid specifications, and basic troubleshooting

Suspension Front:

MacPherson struts, control arms, anti-roll bar, bushings, replacement procedures, alignment specifications

Suspension Rear:

Torsion beam or independent setup (model dependent), shock absorbers, springs, bushings, replacement procedures

Steering System:

Power steering pump, steering rack, tie rods, steering column, fluid specifications, alignment

Braking System:

Disc brakes (front and rear), ABS system, brake pads, brake discs, brake fluid, lines, calipers, master cylinder, bleeding procedures

Electrical System Lighting:

Headlights, taillights, interior lighting, bulb types, wiring diagrams

Electrical System Charging:

Alternator, battery, charging circuit diagnostics

Electrical System Starting:

Starter motor, ignition switch, starting circuit diagnostics

Electrical System Body:

Power windows, power locks, mirrors, wipers, horn, central locking, fuse box locations and functions

Bodywork Exterior:

Door removal/installation, hood, tailgate, bumpers, fenders, glass replacement, panel alignment

Bodywork Interior:

Seat removal, dashboard disassembly, trim panel replacement, carpeting

HVAC System:

Air conditioning, heating, ventilation, refrigerant types, component replacement, troubleshooting

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-ups, spark plug replacement (if applicable), belt inspection/replacement

Scheduled Maintenance:

Brake service, suspension checks, fluid flushes, timing belt replacement intervals

Troubleshooting:

Diagnostic charts, symptom-based troubleshooting, fault code interpretation (where applicable)

Repair Procedures:

Step-by-step instructions for component removal, repair, and reinstallation

Diagnostic Procedures:

Testing procedures for various systems, using specialized tools and multimeters

Component Replacement:

Detailed instructions for replacing common wear items and major components

Technical Depth

Depth:

Comprehensive (from basic maintenance to complete engine and transmission rebuilds)

Diagrams Illustrations:

High-quality exploded views, wiring diagrams, system schematics

Information Type:

Manufacturer specifications, tolerances, torque values, diagnostic trouble codes (DTCs)

📊 Manual Specifications

File Format

Format:

Searchability:

Likely text-searchable for ease of use

Print Quality

Printability:

Full Printable

Zoom Functionality:

YES (Allows for detailed viewing of diagrams)

Binding Type

Type:

Digital Download (PDF)

Paper Type

Media:

Digital PDF (No physical paper)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline 4-cylinder Diesel

Engine Code:

DW10ATED (likely the variant without particle filter)

Displacement:

1997 cc

Bore X Stroke:

85.0 mm x 88.0 mm

Compression Ratio:

17.3:1 (Typical for DW10 engines)

Valvetrain:

DOHC, 4 valves per cylinder

Performance

Horsepower:

Approximately 109-110 PS (80-81 kW) at 4000 rpm

Torque:

Approximately 250-265 Nm (184-195 lb-ft) at 1750-2000 rpm

Fuel System

Injection Type:

Common Rail Direct Injection (CRDi)

Turbocharger:

Variable Geometry Turbocharger (VGT)

Fuel Type:

Diesel

Fluid Capacity

Engine Oil Capacity:

Approximately 5.5 - 6.0 liters (with filter change)

Coolant Capacity:

Approximately 8.0 - 8.5 liters

🔧 Transmission

Standard

Type:

5-Speed Manual Transmission

Optional

Type:

4-Speed Automatic Transmission (AL4 likely)

Features

Clutch:

Hydraulically operated, single dry plate

Fluid Specifications

Manual Gearbox Oil:

API GL-4, SAE 75W-80 (e.g., PSA specification LW 1564)

Automatic Gearbox Oil:

LT 71141 or equivalent (e.g., ATF SP-III)

📐 Dimensions

Exterior

Length:

Approx. 4,455 mm

Width:

Approx. 1,746 mm (excluding mirrors)

Height:

Approx. 1,723 mm

Wheelbase:

Approx. 2,703 mm

Front Track:

Approx. 1,488 mm

Rear Track:

Approx. 1,510 mm

Weights

Curb Weight:

Approx. 1,600 - 1,750 kg (depending on configuration)

Gross Vehicle Weight Rating:

Approx. 2,300 - 2,400 kg

Towing Capacity Braked:

Approx. 1,500 kg

Towing Capacity Unbraked:

Approx. 750 kg

Cargo

Cargo Volume Min:

Approx. 330 liters (with all seats in place)

Cargo Volume Max:

Approx. 1900 - 2500 liters (with rear seats removed/folded)

🛡️ Safety Features

Ratings

Euro Ncap Rating:

4 Stars (for the 806 model generally, specific year may vary slightly)

Active Features

Standard

Electronic Brake-force Distribution (likely standard)

Emergency Brake Assist:

Optional/Standard depending on trim

Passive Features

Airbags Front:

Driver and Front Passenger Airbags (Standard)

Airbags Side:

Optional or Standard on higher trims

Seatbelts:

3-point seatbelts with pretensioners for all occupants

Child Seat Anchors:

ISOFIX mounting points (typically on rear outer seats)

💡 Technology Features

Infotainment

Audio System:

Factory fitted radio/CD player with speaker system. Steering wheel mounted audio controls often available.

Navigation:

Optional satellite navigation system may be available on higher trims.

Driver Assistance

Cruise Control:

Often available as an option or standard on higher trim levels.

Parking Sensors:

Rear parking sensors may be an option.

Connectivity

Auxiliary Input:

Less common in 2002 models, but some later units might have had an AUX input for external audio devices.

🔧 Maintenance

Service Intervals

Oil Change:

Typically every 20,000 km or 1 year, whichever comes first (consult manual for specific conditions).

Air Filter Replacement:

Every 40,000 km or 2 years.

Fuel Filter Replacement:

Every 40,000 km or 2 years for diesel.

Timing Belt Replacement:

Crucial: Typically every 120,000 km or 5-6 years. This is a critical maintenance item for the DW10 engine, and failure can cause catastrophic engine damage.

Coolant Flush:

Every 4 years or 60,000 km.

Fluid Specifications

Engine Oil Specification:

ACEA B3/B4, API CF or CH-4. Viscosity: 5W-40 or 10W-40, synthetic or semi-synthetic.

Brake Fluid:

DOT 4

Power Steering Fluid:

LHM Plus or equivalent (confirm specific PSA fluid specification)

Known Issues

E Grinding Noise From Rear:

Often due to worn rear wheel bearings or suspension bushings.

Engine Performance Issues:

Can be related to EWS (Engine Immobiliser) faults, fuel pressure regulator, or turbocharger issues. Clogged EGR valve also common.

Electrical Gremlins:

Common in older PSA vehicles, can affect various systems due to aging wiring or module failures. The BSI (Body Side Interface) can be a source of issues.

Automatic Transmission Problems:

The AL4 automatic gearbox is known for potential issues with solenoid blocks, valve bodies, and torque converters if not maintained properly or if overheating occurs.

Interior Trim Wear:

Soft-touch plastics and fabric can show wear over time. Door seals can degrade leading to wind noise.

📚 Vehicle History

Brand Heritage

Manufacturer:

Peugeot, a French automotive manufacturer with a long history dating back to 1810 (initially as a coffee mill manufacturer, automotive production began in 1891).

Model Evolution

Generation:

The Peugeot 806 is part of the Eurovan family, a collaborative project between PSA Peugeot Citroën and Fiat Auto. It shared its platform with the Citroën Evasion, Fiat Ulysse, and Lancia Zeta. The 806 was launched in 1994 and received a facelift in 2002, making this manual relevant for the post-facelift model.

Production

Production Period:

1994-2002 (Pre-facelift), 2002-2004 (Facelift)

Manufacturing Location:

Italy (as part of the Eurovan collaboration, produced by Sevel)

🏆 Awards & Recognition

Recognitions

European Mpv Of The Year:

While the 806 itself might not have won a specific award in 2002, its collaborative platform (Eurovan) was a significant development in the MPV market, and Peugeot's vehicles generally receive recognition for practicality and design.