🏷️ Basic Information

Make:

Peugeot

Model:

406

Year:

1996-1997

Platform:

PSA EW/ES platform (shared with Citroën Xantia, XM, and some aspects with XJ X300/X308)

👋 Introduction

Segment:

Mid-size Family Car (often classified as a lower-medium or executive car)

Key Competitors:

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

Design Philosophy:

Emphasized comfort, ride quality, and distinctive styling (particularly the Coupe by Pininfarina).

Platform Sharing:

Utilized the advanced PSA EW/ES platform, contributing to excellent handling and ride comfort, similar to its Citroën counterparts.

📋 Manual Details

Geographical Coverage:

Global (primarily European market focus)

Model Variants Covered:

Sedan, Estate (Break/SW), Coupe

Estimated Page Count:

Large (up to 5 GB estimated file size suggests extensive coverage)

Manual Type:

Service and Repair Manual (Workshop Manual)

Language:

English

Delivery Format:

Digital Download (PDF, ZIP, RAR, EXE)

📖 Manual Coverage

Powertrain:

Engine Mechanical (including Cylinder Head, Cylinder Block, Crankshaft, Pistons, Connecting Rods), Fuel System (Fuel Pump, Injectors, Fuel Tank), Cooling System, Exhaust System, Ignition System, Emissions Control Systems, Lubrication System

Transmission:

Manual Transaxle System, Automatic Transaxle System, Clutch System (Clutch Master Cylinder, Clutch Release Cylinder, Clutch Pedal)

Chassis:

Front Suspension System, Rear Suspension System, Steering System, Brake System (Brake Master Cylinder, Brake Booster, Brake Actuator), Wheel and Tire System, Drive Shafts

Electrical:

Charging System (Generator), Starting System (Starter Assy), Lighting System (Headlamps, Tail Lamps, Interior Lights), Instrument Panel, Combination Meter, Audio & Visual System, Power Window Control System, Power Door Lock Control System, Wiper and Washer System, Horn System, Supplemental Restraint System (Airbag System)

Body:

Body Repair, Exterior Components (Bumpers, Doors, Hood, Trunk, Glass), Interior Components (Seats, Roof Headlining, Instrument Panel)

Maintenance:

Scheduled Maintenance, Fluid Changes (Engine Oil, Transmission Fluid, Coolant, Brake Fluid), Filter Replacements, Belt Inspections and Replacements

Troubleshooting:

Diagnostic Procedures, Fault Code Interpretation (where applicable), Symptom-Based Troubleshooting for all major systems

Repair:

Component Removal and Installation, Engine Rebuilding, Transmission Overhaul, Suspension and Steering Component Replacement, Brake System Repairs, Electrical Component Diagnosis and Repair, Body Panel Repair and Replacement

Diagnostics:

Engine Control System Diagnostics, ABS Diagnostics, Airbag System Diagnostics, Transmission Control Diagnostics

Wiring Diagrams:

Includes detailed wiring diagrams for electrical systems, aiding in diagnosis and repair of electrical faults.

Explod Views:

Features exploded views of components for easier identification and assembly/disassembly guidance.

Depth:

Comprehensive: Covers everything from basic fluid checks and component replacement to in-depth engine and transmission overhauls, electrical system diagnostics, and bodywork. Includes detailed diagrams and specifications for professional-level repairs.

Torque Specifications:

Provides specific torque values for all critical fasteners, essential for correct assembly and component integrity.

Special Tools:

Lists any specialized tools required for specific repair procedures.

📊 Manual Specifications

Primary Format:

PDF

Compression:

May be provided in ZIP or RAR format for larger files.

Printability:

High Quality, Printable on any computer and printer.

Binding:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

PDF Reader:

Requires a PDF Reader (e.g., Adobe Acrobat Reader)

Unzipping Software:

Requires unzipping software (e.g., WinZip, WinRAR) if delivered in compressed format.

⚙️ Engine Specifications

Engine Options 1996-1997:

Petrol: XU7JP (1.8L), XU10J2Z/L3 (2.0L), XU10J4R (2.0L 16V), ES9J4 (3.0L V6); Diesel: XUD7TE (1.9L TD), DW8 (2.0L HDi - introduced later in the generation, but potential for early models depending on market)

Typical Power Output 2.0L Petrol:

Approx. 132-135 PS (97-99 kW)

Typical Power Output 3.0L V6:

Approx. 190-194 PS (140-143 kW)

Typical Torque 2.0L Petrol:

Approx. 180-187 Nm

Fuel Injection Type:

Multi-point Fuel Injection (MPi) for petrol engines, Direct Injection for HDi diesel engines.

Common Petrol Engine Codes:

XU7JP, XU10J2, XU10J4R, ES9J4

Common Diesel Engine Codes:

XUD7TE, DW8

🔧 Transmission

Manual Transmission Availability:

Standard on most petrol and diesel models.

Automatic Transmission Availability:

Optional on many petrol engines, notably the 2.0L and 3.0L V6.

Automatic Transmission Type:

AL4 (4-speed automatic with electronic control) was common on later models, earlier might use AW-30.

Manual Transmission Type:

Typically 5-speed manual transaxles.

📐 Dimensions

Sedan Length:

Approx. 4,605 mm (181.3 in)

Estate Length:

Approx. 4,705 mm (185.2 in)

Coupe Length:

Approx. 4,677 mm (184.1 in)

Kerb Weight Range:

Approx. 1300-1550 kg (depending on engine and body style)

🛡️ Safety Features

Euro Ncap Rating:

Euro NCAP: 4 stars (for 1997 testing, early rating system)

Standard Safety Features:

Driver and Passenger Airbags (standard on most models), ABS (Anti-lock Braking System), Seatbelt Pre-tensioners.

Optional Safety Features:

Side Airbags (later models), Cruise Control.

💡 Technology Features

Audio System:

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

Display Technology:

Basic monochrome LCD for trip computer and audio information, analog gauges for speed, RPM, fuel, and temperature.

Cruise Control:

Available as an option on many models.

Parking Assistance:

Not typically available for this generation.

Connectivity Features:

Limited to basic audio inputs; no integrated Bluetooth or USB for this era.

🔧 Maintenance

Oil Change Interval:

Typically 10,000 - 15,000 km (6,000 - 9,000 miles) or annually, whichever comes first, depending on oil type and driving conditions. Consult manual for specific intervals.

Timing Belt Replacement:

Crucial for XU and early EW engines: Typically every 80,000 - 120,000 km (50,000 - 75,000 miles) or 5-6 years. Failure can cause catastrophic engine damage.

Engine Oil Type:

Varies by engine. Common specifications include ACEA A3/B3 or A3/B4, API SJ or SL. Viscosity grades like 5W-40, 10W-40, or 10W-50 depending on climate and engine. Refer to manual for exact specifications.

Coolant Type:

Ethylene Glycol based coolant, typically OAT (Organic Acid Technology) type, often Peugeot/Citroën specific. Pre-mixed or concentrate. Consult manual for exact type and 50/50 mix ratio.

Brake Fluid Type:

DOT 4 is commonly specified.

Transmission Fluid Manual:

API GL-5, SAE 75W-80 or 75W-90 gear oil.

Transmission Fluid Automatic:

Specific ATF fluid for the AL4 or AW-30 transmission. Refer to manual for exact part number and capacity.

Common Problems Engine:

Head gasket failures (especially on older XU engines), oil leaks from crank seals, timing belt tensioner failure, ignition coil issues (on later petrol variants).

Common Problems Transmission:

Automatic transmission (AL4) 'intelligence' issues, clutch wear on manual transmissions, gearbox oil leaks.

Common Problems Suspension Steering:

Wear in front suspension bushings and drop links, rear axle beam bearing wear (leading to negative camber), power steering pump leaks.

Common Problems Electrical:

Window regulator failures, central locking issues, dashboard warning light illumination (various causes), sensor failures (ABS, engine management).

📚 Vehicle History

Peugeot History:

Peugeot, a historic French automotive manufacturer, known for its dynamic handling and often avant-garde design.

406 Generation:

Second generation of the Peugeot 400-series, replacing the Peugeot 405. Known for its significant improvements in comfort and refinement.

Facelift:

A significant facelift occurred in 1999, introducing revised styling, improved engines (including HDi), and enhanced features, but this manual covers the pre-facelift models.

Production Years:

1995-2004 (with facelift in 1999)

Manufacturing Sites:

Primarily France (Sochaux), also assembled in other countries under license.

🏆 Awards & Recognition

Notable Awards:

Peugeot 406 Coupe (designed by Pininfarina) widely praised for its styling and often considered one of the most beautiful modern cars.