PEUGEOT 306 Service Repair Manual 93-02

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🏷️ Basic Information Identification Make: Peugeot Model: 306 Production Years Covered: 1993-2002 Codes Body Styles: Hatchback (3-door, 5-door), Saloon (4-door), Estate (5-door), Convertible (2-door) Chassis Codes: Type 7D 👋 Introduction Market Position Vehicle Segment: Compact family car (supermini/small family car class) Target Audience: Affordable and practical transportation, appealing to families and individuals seeking a reliable daily driver. Competitive Analysis Key Competitors: Ford Escort/Focus, Volkswagen Golf, Opel/Vauxhall Astra, Renault Mégane, Fiat Bravo/Brava, Honda Civic. Competitive Advantages: Known for its comfortable ride, stylish design (especially the PH1 generation), good handling, and wide range of engine options. Often offered good value for money. Key Features Design Philosophy: Emphasized driver comfort, sophisticated interior packaging, and a blend of performance and economy. Platform Sharing: Shared underpinnings and some components with other PSA Group vehicles, facilitating parts availability and manufacturing efficiency. 📋 Manual Details Coverage Areas Regions Covered: Primarily Europe, but relevant for global markets due to common engineering principles. Page Count Page Count: Hundreds (exact number not specified, implies a comprehensive volume) Manual Type Manual Type: Service and Repair Manual Language Language: English (standard for international manuals, though original may vary) Format Format: PDF 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical (including cylinder head, block, crankshaft, pistons, connecting rods), fuel injection and delivery (petrol and diesel), ignition system, cooling system, lubrication system, exhaust system, emissions control. Transmission Systems: Manual transmission (gearbox internals, clutch operation, linkage), automatic transmission (torque converter, planetary gearsets, hydraulic controls), final drive and differentials. Suspension And Steering: Front and rear suspension (struts, shock absorbers, springs, control arms, anti-roll bars), power steering system, steering rack, column, wheel alignment specifications. Braking Systems: Hydraulic brake system (master cylinder, brake lines, calipers, wheel cylinders), ABS system (components, operation, troubleshooting), parking brake. Electrical Systems: Wiring diagrams, battery, starter motor, alternator, lighting (headlights, taillights, interior), fuses and relays, instrument panel, switches, power windows, central locking, basic ECU functions. Body And Chassis: Body panel removal and installation, door mechanisms, interior trim, glass replacement, corrosion prevention, jacking points, structural components. Heating Ventilation And Air Conditioning: HVAC system operation, components (compressor, condenser, evaporator), refrigerant handling, dashboard vents, cabin filter replacement. Procedures Included Maintenance Procedures: Oil changes, filter replacements, spark plug replacement, coolant flushes, brake fluid changes, air filter replacement, belt inspections and replacement. Repair Procedures: Engine overhaul, transmission rebuild, clutch replacement, suspension component replacement, brake caliper overhaul, steering rack replacement, alternator/starter replacement, body panel repair. Troubleshooting: Diagnostic fault finding for engine, transmission, braking, electrical, and HVAC systems; common problems and their solutions. Rebuilding And Refurbishment: Detailed steps for dismantling, inspecting, and reassembling major mechanical components. Restoration Guidance: Implied through comprehensive repair and refurbishment sections, providing a basis for restoration projects. Technical Depth Depth Of Information: Comprehensive, covering basic maintenance to complex component rebuilds and diagnostics. Diagnostic Capabilities: Includes diagnostic procedures and potential troubleshooting steps, likely referencing specific fault codes or symptom-based diagnostics. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Searchability: Likely text-searchable if professionally created PDF, allowing for quick access to specific topics. Print Quality Printability: Designed to be printable, allowing users to create physical copies for workshop use. Binding Type Binding Type: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Families: Primarily PSA XU and EW (petrol) and XUD (diesel) engines. Engine Families Petrol Engine Variants: 1.1L (TU series, less common in 306), 1.4L (XU5JP, XU5M), 1.6L (XU7JP, XU7M), 1.8L (XU7PB, XU7), 2.0L (XU10J2, XU10J4 - including GTi-6/Rallye variants). Later models may feature EW series engines (1.6, 2.0). Specific codes like LFX (1.8 16v) and RFY (2.0 GTi-6) are important. Diesel Engine Variants: 1.9L naturally aspirated (XUD7TE), 1.9L turbodiesel (XUD7TE, XUD9TE), 2.0L HDi turbodiesel (DW10TD). Direct injection (Di) and indirect injection (TDi) variants exist. Performance Horsepower Range: Approximately 60 hp (1.1L) to 167 hp (2.0L GTi-6/Rallye). Torque Range: Varies significantly by engine, e.g., 1.4L petrol around 110-115 Nm, 2.0L HDi around 205 Nm. Fuel System Fuel Delivery Petrol: Electronic Fuel Injection (MPI - Multi-Point Injection). Fuel Delivery Diesel: Rotary or inline injection pumps for older XUD diesels; Common Rail Injection (HDI). Ignition System: Distributorless Ignition System (DIS) or traditional distributor with coil pack depending on year and engine. 🔧 Transmission Standard Standard Transmission: 5-speed manual transmission (e.g., BE3, MA5). Optional Optional Transmission: 4-speed automatic transmission (e.g., AL4). Features Clutch Type: Hydraulically actuated dry single-plate clutch. Gear Ratios: Specific gear ratios would be detailed in the manual for each transmission variant and engine combination. 📐 Dimensions Exterior Length Approx: Hatchback: ~4030 mm, Estate: ~4215 mm, Saloon: ~4215 mm, Convertible: ~4005 mm Width Approx: ~1690-1710 mm Height Approx: ~1390-1430 mm (Hatchback), ~1440-1460 mm (Estate) Weights Curb Weight Range: ~1050 kg to ~1350 kg depending on engine and body style. 🛡️ Safety Features Ratings Euro Ncap Rating: Early Euro NCAP tests (if applicable for the covered years)...

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Tags: 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 306 Car Cars Peugeot

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Description

🏷️ Basic Information

Identification

Make:

Peugeot

Model:

Production Years Covered:

1993-2002

Codes

Body Styles:

Hatchback (3-door, 5-door), Saloon (4-door), Estate (5-door), Convertible (2-door)

Chassis Codes:

Type 7D

👋 Introduction

Market Position

Vehicle Segment:

Compact family car (supermini/small family car class)

Target Audience:

Affordable and practical transportation, appealing to families and individuals seeking a reliable daily driver.

Competitive Analysis

Key Competitors:

Ford Escort/Focus, Volkswagen Golf, Opel/Vauxhall Astra, Renault Mégane, Fiat Bravo/Brava, Honda Civic.

Competitive Advantages:

Known for its comfortable ride, stylish design (especially the PH1 generation), good handling, and wide range of engine options. Often offered good value for money.

Key Features

Design Philosophy:

Emphasized driver comfort, sophisticated interior packaging, and a blend of performance and economy.

Platform Sharing:

Shared underpinnings and some components with other PSA Group vehicles, facilitating parts availability and manufacturing efficiency.

📋 Manual Details

Coverage Areas

Regions Covered:

Primarily Europe, but relevant for global markets due to common engineering principles.

Page Count

Page Count:

Hundreds (exact number not specified, implies a comprehensive volume)

Manual Type

Manual Type:

Service and Repair Manual

Language

Language:

English (standard for international manuals, though original may vary)

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine mechanical (including cylinder head, block, crankshaft, pistons, connecting rods), fuel injection and delivery (petrol and diesel), ignition system, cooling system, lubrication system, exhaust system, emissions control.

Transmission Systems:

Manual transmission (gearbox internals, clutch operation, linkage), automatic transmission (torque converter, planetary gearsets, hydraulic controls), final drive and differentials.

Suspension And Steering:

Front and rear suspension (struts, shock absorbers, springs, control arms, anti-roll bars), power steering system, steering rack, column, wheel alignment specifications.

Braking Systems:

Hydraulic brake system (master cylinder, brake lines, calipers, wheel cylinders), ABS system (components, operation, troubleshooting), parking brake.

Electrical Systems:

Wiring diagrams, battery, starter motor, alternator, lighting (headlights, taillights, interior), fuses and relays, instrument panel, switches, power windows, central locking, basic ECU functions.

Body And Chassis:

Body panel removal and installation, door mechanisms, interior trim, glass replacement, corrosion prevention, jacking points, structural components.

Heating Ventilation And Air Conditioning:

HVAC system operation, components (compressor, condenser, evaporator), refrigerant handling, dashboard vents, cabin filter replacement.

Procedures Included

Maintenance Procedures:

Oil changes, filter replacements, spark plug replacement, coolant flushes, brake fluid changes, air filter replacement, belt inspections and replacement.

Repair Procedures:

Engine overhaul, transmission rebuild, clutch replacement, suspension component replacement, brake caliper overhaul, steering rack replacement, alternator/starter replacement, body panel repair.

Troubleshooting:

Diagnostic fault finding for engine, transmission, braking, electrical, and HVAC systems; common problems and their solutions.

Rebuilding And Refurbishment:

Detailed steps for dismantling, inspecting, and reassembling major mechanical components.

Restoration Guidance:

Implied through comprehensive repair and refurbishment sections, providing a basis for restoration projects.

Technical Depth

Depth Of Information:

Comprehensive, covering basic maintenance to complex component rebuilds and diagnostics.

Diagnostic Capabilities:

Includes diagnostic procedures and potential troubleshooting steps, likely referencing specific fault codes or symptom-based diagnostics.

📊 Manual Specifications

File Format

File Format:

PDF (Portable Document Format)

Searchability:

Likely text-searchable if professionally created PDF, allowing for quick access to specific topics.

Print Quality

Printability:

Designed to be printable, allowing users to create physical copies for workshop use.

Binding Type

Binding Type:

N/A (Digital PDF format)

Paper Type

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Families:

Primarily PSA XU and EW (petrol) and XUD (diesel) engines.

Engine Families

Petrol Engine Variants:

1.1L (TU series, less common in 306), 1.4L (XU5JP, XU5M), 1.6L (XU7JP, XU7M), 1.8L (XU7PB, XU7), 2.0L (XU10J2, XU10J4 - including GTi-6/Rallye variants). Later models may feature EW series engines (1.6, 2.0). Specific codes like LFX (1.8 16v) and RFY (2.0 GTi-6) are important.

Diesel Engine Variants:

1.9L naturally aspirated (XUD7TE), 1.9L turbodiesel (XUD7TE, XUD9TE), 2.0L HDi turbodiesel (DW10TD). Direct injection (Di) and indirect injection (TDi) variants exist.

Performance

Horsepower Range:

Approximately 60 hp (1.1L) to 167 hp (2.0L GTi-6/Rallye).

Torque Range:

Varies significantly by engine, e.g., 1.4L petrol around 110-115 Nm, 2.0L HDi around 205 Nm.

Fuel System

Fuel Delivery Petrol:

Electronic Fuel Injection (MPI - Multi-Point Injection).

Fuel Delivery Diesel:

Rotary or inline injection pumps for older XUD diesels; Common Rail Injection (HDI).

Ignition System:

Distributorless Ignition System (DIS) or traditional distributor with coil pack depending on year and engine.

🔧 Transmission

Standard

Standard Transmission:

5-speed manual transmission (e.g., BE3, MA5).

Optional

Optional Transmission:

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

Features

Clutch Type:

Hydraulically actuated dry single-plate clutch.

Gear Ratios:

Specific gear ratios would be detailed in the manual for each transmission variant and engine combination.

📐 Dimensions

Exterior

Length Approx:

Hatchback: ~4030 mm, Estate: ~4215 mm, Saloon: ~4215 mm, Convertible: ~4005 mm

Width Approx:

~1690-1710 mm

Height Approx:

~1390-1430 mm (Hatchback), ~1440-1460 mm (Estate)

Weights

Curb Weight Range:

~1050 kg to ~1350 kg depending on engine and body style.

🛡️ Safety Features

Ratings

Euro Ncap Rating:

Early Euro NCAP tests (if applicable for the covered years) would be relevant. The 306 generally performed moderately for its era, with improvements in later models. Specific ratings would need verification for the exact year.

Active Features

Active Safety Features:

Anti-lock Braking System (ABS) - often optional or standard on higher trims. Power assisted braking.

Passive Features

Passive Safety Features:

Front airbags (driver and passenger - often optional or standard on later models), seatbelt pre-tensioners, reinforced safety cell, side impact protection beams.

💡 Technology Features

Infotainment

Audio System:

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

Driver Assistance

Driver Assistance Systems:

Limited by modern standards. ABS was the primary advanced system. Some models might have had basic trip computers.

Connectivity

Connectivity Features:

Basic connectivity, primarily through the audio system. No Bluetooth or USB as standard.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 6,000 - 10,000 miles (10,000 - 16,000 km) or 12 months, depending on engine type and oil used. Refer to manual for specific engine/oil recommendation.

Timing Belt Replacement:

Crucial for interference engines (most XU and EW petrols, XUD diesels). Generally every 60,000 - 80,000 miles (100,000 - 120,000 km) or 5 years. Failure can cause catastrophic engine damage.

Fluid Specifications

Engine Oil Type:

Depends on engine. Common specifications include: PSA Grade 4 (10W-40, 15W-50) for older XU/XUD, and various API SL/SM or ACEA A3/B3/B4 specifications for later EW engines. Refer to manual for exact grade and viscosity.

Coolant Type:

Ethylene glycol-based antifreeze, typically a blue or purple/pink long-life coolant. PSA specific coolant types might be recommended. Capacity approx. 7-8 liters.

Brake Fluid Type:

DOT 4 brake fluid.

Transmission Fluid Manual:

GL-4 specification gear oil, typically 75W-80 or 75W-90. Capacity around 2.2 - 2.5 liters.

Transmission Fluid Automatic:

Specific ATF fluid (e.g., LT 71141 for AL4) - critical to use the correct type. Capacity around 5-6 liters for a full change.

Known Issues

Common Faults:

Rear axle beam pivot bearings wear out, causing alignment issues and a knocking noise. Suspension drop links, ball joints, and bushes can wear. Electrical gremlins (window motors, central locking) are not uncommon. Radiator fan issues. Clutch slave cylinder leaks. Engine management issues on some petrol variants.

Hdi Engine Issues:

Glow plug issues, turbo wear, injector sealing problems, some variants can suffer from oil pump drive wear.

Petrol Engine Issues:

Uneven idling (throttle body issues), oil leaks, potential for head gasket failure on higher mileage engines, ignition coil pack failures.

📚 Vehicle History

Brand Heritage

Peugeot Legacy:

Peugeot has a long history of producing well-handling and comfortable small to medium family cars, building on the success of models like the 205 and 309.

Model Evolution

Generation Details:

The 306 replaced the 309. It underwent two major facelifts: Phase 1 (1993-1997) characterized by sharp styling, and Phase 2 (1997-2002) with a softer, more rounded front end and revised interior. The convertible was introduced later.

Production

Manufacturing Locations:

Primarily manufactured in France (e.g., Aulnay-sous-Bois, Mulhouse) and the UK (Ryton-on-Dunsmore).

🏆 Awards & Recognition

Recognitions

Industry Accolades:

While specific awards for the 306 aren't prominently recalled as headline wins, it was generally well-received by the motoring press for its handling and ride quality, often praised in group tests against its contemporaries.

Ratings

Customer Satisfaction:

Customer satisfaction varied; while praised for driving dynamics, reliability issues in certain areas (like the rear axle) affected its perception compared to some rivals.