Peugeot 106 Petrol & Diesel 1991-2001 Full Service & Repair Manual
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🏷️ Basic Information Identification Make: Peugeot Model: 106 Codes Chassis Codes: Axel, Type 1A 👋 Introduction Market Position Positioning: A comprehensive resource for owners and independent workshops maintaining the popular Peugeot 106 model. Competitive Analysis Value Proposition: Provides professional-level repair and maintenance data, equivalent to factory manuals, at a fraction of the cost and with permanent digital access. Key Features Feature Set: Detailed step-by-step procedures, extensive photographic and diagrammatic support, lifetime digital access, cross-platform compatibility. Professional Standard: Designed for use by professional mechanics and technicians, ensuring a high level of detail and accuracy. 📋 Manual Details Coverage Areas Model Years: 1991-2001 Engine Types: Petrol and Diesel Page Count Estimated Pages: Hundreds of pages (specific number not provided, but described as 'very detailed' and 'hundreds of pages') Manual Type Type: Full Service & Repair Workshop Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Powertrain: Engine, Fuel System, Exhaust System, Ignition System, Cooling System Drivetrain: Transmission (Manual and possibly Automatic depending on variant), Clutch, Driveshafts, Differentials Chassis: Suspension (Front and Rear), Steering System, Brakes (Front and Rear Discs/Drums), Wheels and Tires Electrical: Battery, Charging System, Starting System, Lighting System, Ignition and Engine Management Electronics, Instrumentation, Wipers and Washers, Audio System Wiring Body: Body Panels, Doors, Windows, Seats, Interior Trim, Exterior Trim, Bumpers, Glass Climate Control: Heating system functionality, ventilation, and air conditioning (if fitted as an option). Procedures for component diagnosis and refrigerant handling (where applicable). Body Electrical: Includes wiring diagrams for lighting, power windows (if equipped), central locking, interior lights, and dashboard warning lights. Procedures Included Maintenance: Scheduled Servicing, Oil Changes, Filter Replacements, Spark Plug Replacement, Fluid Checks and Top-ups, Brake Pad Replacement, Belt Replacement Repair: Engine Overhaul, Transmission Rebuild, Suspension Component Replacement, Brake System Repair, Electrical Component Diagnosis and Replacement, Body Panel Repair and Replacement Troubleshooting: Diagnostic procedures for engine performance issues, electrical faults, braking problems, and other common malfunctions. Wheel Alignment: Specifications for wheel alignment (caster, camber, toe) for front and rear axles, essential for tire wear and handling. Procedures for adjustment. Technical Depth Depth: Professional-grade, covering everything from basic servicing to complex component overhauls and diagnostics, with step-by-step instructions. Visual Aid Detail: Hundreds of detailed photos and exploded diagrams. Diagnostic Tools: While the manual is PDF-based, it details procedures that would typically be performed using standard hand tools and basic automotive diagnostic equipment. Advanced ECU diagnostics would refer to specific diagnostic codes (OBD-I or early OBD-II depending on year/market) and their interpretation. 📊 Manual Specifications File Format Compatibility: Compatible with all Windows and MAC computers. Searchability: Likely offers searchable text functionality within the PDF, enabling quick access to specific topics. Print Quality Printability: Printable (single pages or entire manual). Binding Type Binding: Not applicable (digital download). Paper Type Paper Type: Not applicable (digital download). Licensing Usage Rights: Unlimited use on multiple computers for life. No expiry or renewal fees. ⚙️ Engine Specifications Primary Engine Petrol Variants: Likely includes 1.0 litre (TU9), 1.1 litre (TU1), 1.3 litre (TU2 J2), 1.4 litre (TU3), 1.6 litre (TU5 J4, including GTI variants). Specific engine codes (e.g., KHY for 1.1) are detailed within the manual. Diesel Variants: Likely includes 1.4 litre (TUD3) and 1.5 litre (TUD5) diesel engines. Specific engine codes (e.g., K9A for 1.5D) are detailed within the manual. Engine Designation System: Peugeot utilizes a consistent engine designation system, often indicating displacement and valve count (e.g., TU1 for 1.1L, TU5J4 for 1.6L with 4 valves per cylinder). The manual will explain these. Performance Power Output Range: Ranges from approx. 45 hp (1.0 petrol) to 120 hp (1.6 16v GTI). Specific figures per engine detailed. Torque Range: Varies significantly by engine, e.g., around 70 Nm for 1.0L to over 150 Nm for 1.6 16v. Specific figures per engine detailed. Fuel System Petrol Injection: Likely covers single-point injection (SPI) and multi-point injection (MPI) systems, including electronic fuel injection (EFI) and engine control units (ECUs). Diesel Injection: Covers indirect injection diesel systems, likely with mechanical fuel pumps and injectors. 🔧 Transmission Standard Manual Gearbox: Typically a 5-speed manual transmission (e.g., BE gearbox family). Detailed procedures for clutch replacement, gearbox overhaul, and gear linkage adjustment. Optional Automatic Gearbox: Some models may have featured a 3-speed automatic transmission. Coverage for this transmission type would be detailed if applicable to the specified years/variants. Features Clutch Type: Hydraulically operated dry single-plate clutch. Procedures for inspection, replacement, and hydraulic system bleeding. 📐 Dimensions Exterior Overall Length: Approx. 3,600 mm (early models), may vary slightly with facelifts. Specific dimensions documented. Overall Width: Approx. 1,600 mm. Specific dimensions documented. Wheelbase: Approx. 2,385 mm. Specific dimensions documented. Weights Kerb Weight Range: Ranges from approx. 800 kg to 950 kg depending on engine and specification. Specific weights documented. 🛡️ Safety Features Ratings Euro Ncap Score: Euro NCAP testing began later in the 106's lifecycle, with earlier models not typically...
Heating system functionality, ventilation, and air conditioning (if fitted as an option). Procedures for component diagnosis and refrigerant handling (where applicable).
Body Electrical:
Includes wiring diagrams for lighting, power windows (if equipped), central locking, interior lights, and dashboard warning lights.
Procedures Included
Maintenance:
Scheduled Servicing, Oil Changes, Filter Replacements, Spark Plug Replacement, Fluid Checks and Top-ups, Brake Pad Replacement, Belt Replacement
Repair:
Engine Overhaul, Transmission Rebuild, Suspension Component Replacement, Brake System Repair, Electrical Component Diagnosis and Replacement, Body Panel Repair and Replacement
Troubleshooting:
Diagnostic procedures for engine performance issues, electrical faults, braking problems, and other common malfunctions.
Wheel Alignment:
Specifications for wheel alignment (caster, camber, toe) for front and rear axles, essential for tire wear and handling. Procedures for adjustment.
Technical Depth
Depth:
Professional-grade, covering everything from basic servicing to complex component overhauls and diagnostics, with step-by-step instructions.
Visual Aid Detail:
Hundreds of detailed photos and exploded diagrams.
Diagnostic Tools:
While the manual is PDF-based, it details procedures that would typically be performed using standard hand tools and basic automotive diagnostic equipment. Advanced ECU diagnostics would refer to specific diagnostic codes (OBD-I or early OBD-II depending on year/market) and their interpretation.
📊 Manual Specifications
File Format
Compatibility:
Compatible with all Windows and MAC computers.
Searchability:
Likely offers searchable text functionality within the PDF, enabling quick access to specific topics.
Print Quality
Printability:
Printable (single pages or entire manual).
Binding Type
Binding:
Not applicable (digital download).
Paper Type
Paper Type:
Not applicable (digital download).
Licensing
Usage Rights:
Unlimited use on multiple computers for life. No expiry or renewal fees.
⚙️ Engine Specifications
Primary Engine
Petrol Variants:
Likely includes 1.0 litre (TU9), 1.1 litre (TU1), 1.3 litre (TU2 J2), 1.4 litre (TU3), 1.6 litre (TU5 J4, including GTI variants). Specific engine codes (e.g., KHY for 1.1) are detailed within the manual.
Diesel Variants:
Likely includes 1.4 litre (TUD3) and 1.5 litre (TUD5) diesel engines. Specific engine codes (e.g., K9A for 1.5D) are detailed within the manual.
Engine Designation System:
Peugeot utilizes a consistent engine designation system, often indicating displacement and valve count (e.g., TU1 for 1.1L, TU5J4 for 1.6L with 4 valves per cylinder). The manual will explain these.
Performance
Power Output Range:
Ranges from approx. 45 hp (1.0 petrol) to 120 hp (1.6 16v GTI). Specific figures per engine detailed.
Torque Range:
Varies significantly by engine, e.g., around 70 Nm for 1.0L to over 150 Nm for 1.6 16v. Specific figures per engine detailed.
Fuel System
Petrol Injection:
Likely covers single-point injection (SPI) and multi-point injection (MPI) systems, including electronic fuel injection (EFI) and engine control units (ECUs).
Diesel Injection:
Covers indirect injection diesel systems, likely with mechanical fuel pumps and injectors.
🔧 Transmission
Standard
Manual Gearbox:
Typically a 5-speed manual transmission (e.g., BE gearbox family). Detailed procedures for clutch replacement, gearbox overhaul, and gear linkage adjustment.
Optional
Automatic Gearbox:
Some models may have featured a 3-speed automatic transmission. Coverage for this transmission type would be detailed if applicable to the specified years/variants.
Features
Clutch Type:
Hydraulically operated dry single-plate clutch. Procedures for inspection, replacement, and hydraulic system bleeding.
📐 Dimensions
Exterior
Overall Length:
Approx. 3,600 mm (early models), may vary slightly with facelifts. Specific dimensions documented.
Overall Width:
Approx. 1,600 mm. Specific dimensions documented.
Wheelbase:
Approx. 2,385 mm. Specific dimensions documented.
Weights
Kerb Weight Range:
Ranges from approx. 800 kg to 950 kg depending on engine and specification. Specific weights documented.
🛡️ Safety Features
Ratings
Euro Ncap Score:
Euro NCAP testing began later in the 106's lifecycle, with earlier models not typically having standardized NCAP scores. Later models may have achieved 3 stars. Specific crashworthiness data provided.
Active Features
ABS:
Anti-lock Braking System (ABS) was an optional extra on many variants, and standard on some later performance models. System diagnostics and repair covered.
Passive Features
Airbags:
Driver-side airbag became available and standard on some later models. Passenger airbags were rarer. Installation and diagnostic procedures covered.
Seatbelts:
Front and rear seatbelts. Procedures for inspection and replacement of components.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette players, with provisions for CD changers on later models. Manual covers wiring, speaker replacement, and head unit removal/installation.
Driver Assistance
Parking Sensors:
Not typically fitted as standard or widely available on this model.
Connectivity
Bluetooth:
Not available from the factory on this model. Aftermarket solutions would be covered by general electrical principles within the manual.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000 km or 12 months, whichever comes first. Specific intervals for petrol and diesel variants will be detailed in the manual.
Major Service Intervals:
Timing belt replacement is critical, typically every 80,000 km or 5 years. Spark plug replacement varies by engine type (e.g., every 40,000 km for standard, longer for platinum/iridium). Detailed schedules provided.
Fluid Specifications
Engine Oil Type:
Varies by engine. Commonly SAE 10W-40 or 5W-40 synthetic for petrol, and 15W-40 or 10W-40 semi-synthetic for diesel. Specific API/ACEA specifications are crucial and detailed in the manual.
Coolant Type:
Ethylene glycol based antifreeze with corrosion inhibitors. Typically purple or pink (G12/G12+ equivalent, or specific PSA coolant specification). Manual will specify capacity and type.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid. Regular replacement (e.g., every 2 years) is recommended due to moisture absorption. Manual will specify type and capacity.
Gearbox Oil:
API GL-4 manual transmission fluid. Viscosity grade (e.g., 75W-80 or 75W-90) depends on temperature. Manual specifies exact type and capacity.
Known Issues
Common Problems:
Rear axle beam suspension wear (torsion bar bearings), electrical gremlins (especially early models), heater matrix leaks, clutch slave cylinder failure, catalytic converter issues, minor rust around wheel arches and sills.
Brake Wear:
Rear drum brakes on some variants can be prone to sticking if not serviced regularly. Manual will cover brake drum and shoe inspection/replacement procedures.
📚 Vehicle History
Brand Heritage
Peugeot Heritage:
Peugeot has a long history of producing small, agile, and economical hatchbacks, building on the legacy of models like the 205 and 104.
Model Evolution
Generation Overview:
The Peugeot 106 was launched in 1991 as a successor to the 105 and was sold alongside the more upmarket Saxo. It received facelifts in 1996 and 2000, introducing updated styling, engines, and features.
Production
Production Period:
1991 - 2003 (though this manual covers up to 2001, with later models having minor updates).
Manufacturing Locations:
Primarily manufactured in France.
🏆 Awards & Recognition
Recognitions
Model Accolades:
While specific awards for the 106 are less publicized than its predecessor (205), it was widely praised for its handling, driving dynamics, and value for money, especially in its GTI variants, often winning 'supermini' or 'hot hatch' comparison tests in automotive publications of the era.