Manual sections
Wiring diagrams- Battery
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- Bodywork
- Braking
- Comfort and convenience
- Confort
- Current generation
- Dashboard
- Driver information
- Electrical harnesses
- Engine
- Equipment
- Front anti -roll bar
- Front axle
- Front door trim
- Front doors
- Front seats
- Front section
- Front shock absorbers
- Gearbox assembly
- General points
- General points about the vehicle
- Glovebox
- Instrument panel
- Instruments and controls
- Lighting - signalling
- Mechanical
- Power unit
- Pre-heating
- Protections and doors
- Re-assembling
- Rear axle
- Rear parcel tray
- Rear seats
- Rear section
- Rear shock absorbers
- Roof panel
- Side structure
- Starting
- Steering
- Suspension
- Transmission
- Washing and wiping
Repair manual
Engine Peugeot 406 I
Step-by-step instructions on "Engine" for Peugeot 406 I (1995–2003). Pick an article — removal, installation, adjustment and diagnostics with illustrations.
Timing gear
- Removing - refitting ancillary drive belt (ES9J4)
- Data: camshaft (ES9J4S, ES9J4)
- Modification: timing belt tensioner roller
- Modification: timing belt tensioner roller — variant 2
- Removing - refitting: timing belt, assembly of camshaft pulleys mounting by 3 bolts (XU7JP4)
- Removal - refitting: timing belt, assembly of camshaft pulleys mounting by 3 bolts (XU7JP4)
- Removing - refitting: timing belt, assembly of camshaft pulleys mounting by 1 bolts (XU7JP4)
- Removal - refitting: timing belt, assembly of camshaft pulleys mounting by 1 bolts (XU7JP4)
- Identification - data - tightening torques: camshaft (EW10D, EW10J4, EW7J4)
- Adjustment: air gap (cylinder reference sensor) (DW10ATED, DW10TD)
- Data - identification camshafts
- Standard replacement
- Data - identification camshafts (ES9J4)
- Check setting the valve timing (ES9J4)
- Identification - data - tightening torques: timing gear (ES9J4S)
- Data: camshafts
- Identification - data - tightening torques timing gear (DW12TED4)
- Removing - refitting: timing belt (XU10J2TE)
- Identification - data - tightening torques: timing gear (EW7J4, EW10J4)
- Data: camshaft (EW12J4)
- Removing - refitting camshafts (ES9J4)
- Removing - refitting camshaft (XU10J4R, XU7JP4)
- Check end of compression pressures
- Removing - refitting: timing belt (XU10J4R, XU7JP4)
- Check end of compression pressures — variant 2
- Removing - refitting: timing belt (XU7JB)
- Removing - refitting: timing belt
- Removing - refitting: timing belt — variant 2
- Removing - refitting: camshaft (XU7JB, XU5JP, XU7JP, XU7JP4, XU10J4R)
- Removal - refitting: timing belt (first assembly) (EW10J4)
- Removing - refitting: accessories belt dynamic tensioner
- Removing - refitting: camshaft (EW10J4)
- Removing - refitting: timing covers (DW10TD, DW12TED4, DW10ATED)
- Removal - refitting: timing covers (DW10TD, DW12TED4, DW10ATED)
- Removing - refitting camshaft (XUD9TE)
- Removing - refitting: camshaft (EW12J4)
- Removing - refitting: variable timing camshaft hub (EW12J4)
- Removing - refitting: timing belt (first assembly) (EW12J4)
- Removing - refitting: timing belt (XU5JP, XU7JP)
- Removing - refitting camshaft
- Removing - refitting: timing belt — variant 3
- Removing - refitting: timing belt (XUD9TE)
- Removing - refitting: solenoid valve VTC (Variable Timing Camshaft) (ES9J4S)
- Presentation - use: D-TEK de LEYBOLD refrigerant leak detector (part number 9776.X9)
- Removing - refitting: Variable Timing Camshaft (VTC) (ES9J4S)
- Presentation - use: D-TEK de LEYBOLD refrigerant leak detector (Part No. 9776.X9)
- Removing - refitting: timing belt — variant 4
- Removing - refitting: camshafts (ES9J4S)
- Removing - refitting: camshaft (EW7J4)
- Removing - refitting: timing belt (first assembly) (EW7J4)
- Removing - refitting: timing belt (with the engine removed) (DW12TED4)
- Removing - refitting camshaft (with the engine removed) (DW12TED4)
- Removing - refitting: timing belt (first assembly) (EW10D)
- Removing - refitting: timing belt (second assembly) (DW10TD, DW10ATED)
- Removing - refitting: timing belt (second assembly) (EW10D)
- Removing - refitting: timing belt (second assembly) (EW7J4)
- Removing - refitting: timing belt (second assembly) (EW10J4)
- Removing - refitting: timing belt (second assembly) (EW12J4)
- Removing - refitting: solenoid valve VTC (Variable Timing Camshaft) (EW12J4)
- Modification: removal of the crankshaft pulley bolt (DW10ATED, DW10TD, DW12TED4)
- Modification: timing gear (EW10J4)
- Modification: timing gear (DW10ATED, DW10TD)
- Modification: crankshaft gear (timing gear) - EW7 - EW12 - EW10 engines (not EW10J4S)
- Removing - refitting: ancillary drive belt (ES9J4) — variant 2
Lubrication
- Removing - refitting: lower cover (DW12TED4)
- Capacity of units
- Recommendations lubricants
- Recommendations: lubricants — variant 2
- General: lubrication
- Capacity: engine oil
- Recommendations: oils for petrol engines
- Recommended engine oils (DIESEL)
- Data - tightening torques: lubrication (engine)
- Check oil pressure (EW10D, EW7J4, EW12J4, EW10J4)
- Recommendations: lubricants — variant 3
- Check: oil pressure (With oil pressure switch)
- Check: oil pressure (Without oil pressure switch)
- Removing - refitting: oil pump (ES9J4S)
- Removing - refitting oil pump (with the engine removed) (DW12TED4)
- Replace: engine oil filter cartridge
- Suction draining (engine)
- Modification: oil filter gauze (ES9J4)
- Removing - refitting coolant/oil heat exchanger (engine) (ES9J4S)
- Assembly: new engine oil filter cartridge
- Data: cooling system
- Replace: engine oil filter cartridge (EW7J4, DW10ATED, DW12TED4, DW10TD, EW12J4, EW10J4, XU7JP, XU7JB, XU10J4R, XU7JP4, XU5JP)
- Replace: engine oil filter cartridge
- Replacement: engine oil filter cartridge (XU5JP, XU7JP4, XU10J4R, XU7JB, XU7JP, EW7J4, EW10J4, EW12J4, DW10TD, DW12TED4, DW10ATED)
- Modification: Lubrication kit
- Maintenance: recommended ingredients, year 2006
Ignition
- Pressurising the fuel system
- Pressurising the fuel system — variant 2
- Injection-ignition: BOSCH MP7.0
- Injection-ignition: BOSCH MP7.0 — variant 2
- Help in diagnosis
- Help in diagnosis — variant 2
- Check: ignition advance
- Check: ignition advance — variant 2
- Check high voltage present
- Check high voltage present — variant 2
- Check high voltage present — variant 3
- Check high voltage present — variant 4
- Check high voltage present — variant 5
- Check high voltage present — variant 6
- Foot Off/Foot Down recognition
- Foot Off/Foot Down recognition — variant 2
- Injection-ignition wiring diagram: injection ignition
- Injection-ignition wiring diagram: injection ignition — variant 2
Engine block
- Sealing: cylinder block - lower cover
- Data: cylinder block (ES9J4S)
- Data - identification cylinder block
- Identification - data: cylinder block
- Data: cylinder block (EW12J4)
- Data cylinder block (EW7J4, EW10D, EW10J4)
- Identification - data cylinder block (DW12TED4)
- Check: diesel high pressure monitoring function
- Check: diesel high pressure monitoring function — variant 2
- Check: sensor supply function (accelerator pedal sensor, inlet pressure sensor, fuel pressure sensor, cylinder reference sensor)
- Check: sensor supply function (accelerator pedal sensor, inlet pressure sensor, fuel pressure sensor — variant 2
Crankshaft
- Removing - refitting ancillary drive belt (ES9J4S)
- Removing - refitting ancillary drive belt (2.1 TD, XU5JP, XU7JB, XUD9TE, XU7JP, XU10J2TE)
- Removing - refitting ancillary drive belt (XU7JP4, XU10J4R)
- Data: conrods andhalf shells (ES9J4, ES9J4S)
- Data: crankshaft and bearing half-shells (ES9J4, ES9J4S)
- Data: pistons - little ends - piston rings (ES9J4S, ES9J4)
- Identification - data: crankshaft and bearing half-shells (DW12TED4)
- Data: half shells (EW7J4, EW10D, EW10J4)
- Data conrods (EW7J4, EW10D, EW10J4)
- Identification - data crankshaft (EW7J4, EW10D, EW10J4)
- Data: conrods
- Data: crankshaft
- Removing - refitting: ancillary drive belt (power assisted steering - air conditioning - XU10J2CTE engine) (XU10J2TE, XU7JB, XU5JP, XU7JP, XU7JP4)
- Removing - refitting lip seals (ES9J4)
- Data: pistons - piston rings (DW10ATED)
- Identification - data: crankshaft (EW12J4)
- Checks - removing - refitting - adjustment: balance shafts (EW12J4)
- Dismantling - refitting: conrods - pistons (ES9J4S)
- Matching: main shell bearings (ES9J4S, ES9J4)
- Removing - refitting: ancillary drive belt (DW12TED4)
- Modification: reciprocating gear
- Removing - refitting ancillary drive belt (EW7J4)
- Data - identification liners
- Identification - data: pistons - piston rings
- Data - identification conrods (ES9J4)
- Identification - data: crankshaft
- Identification - data: half shells
- Data - identification pistons - piston rings (ES9J4)
- Data - identification conrods
- Modification: lubrication system (XU10J4R)
- Data - identification pistons - piston rings (ES9J4S)
- Identification - data - tightening torques crankshaft - bearing shells (DW12TED4)
- Removing - refitting: ancillary drive belt (2.1 TD)
- Identification balance shafts (DW12TED4)
- Data conrods - connecting shells (DW12TED4)
- Identification - data pistons-gudgeon pins-rings (DW12TED4)
- Data: conrods (EW12J4)
- Data: half shells (EW12J4)
- Identification - data: pistons - piston rings - the piston shaft (EW12J4)
- Check liner protrusion
- Check crankshaft pulley
- Matching: bearing shells
- Assembly connecting rods - pistons
- Removing - refitting: counterbalance shaft (DW12TED4)
- Removing - refitting: ancillary drive belt (power assisted steering)
- Removing - refitting: ancillary drive belt (EW12J4, EW10J4)
- Removing - refitting: ancillary drive belt (ES9J4S) — variant 2
- Removing - refitting: ancillary drive belt (DW10ATED, DW10TD)
Cylinder head
- Data: valve seats and guides (ES9J4S, ES9J4)
- Data: valves and valve springs (ES9J4, ES9J4S)
- Data: cylinder head (ES9J4S, ES9J4)
- Data: cylinder head gasket (ES9J4, ES9J4S)
- Data: cylinder head bolts (ES9J4, ES9J4S)
- Identification - data - tightening torques: cylinder head (EW12J4)
- Modification: cylinder head
- Data: cylinder head gasket (DW10ATED)
- Stripping-assembling: cylinder head (ES9J4S and ES9A engine) (ES9J4S)
- Refitting: cylinder head
- Modification: cylinder head gasket
- Refitting cylinder head (ES9J4)
- Identification, data, tightening torque(s): cylinder head
- Identification - data - tightening torques: cylinder head (ES9J4S)
- Data valves and valve springs (EW7J4, EW10D, EW10J4)
- Data valve guides - valve seats (EW7J4, EW10D, EW10J4)
- Identification - data - tightening torques: cylinder head (EW10D, EW7J4, EW10J4)
- Data - identification valve guides
- Data - identification cylinder heads
- Identification - data: cylinder head gasket
- Identification - data: cylinder head bolts
- Data - identification valves
- Data - identification valve springs
- Data - identification valve seats
- Data - identification valve guides (ES9J4)
- Data - identification cylinder head gasket (ES9J4)
- Data cylinder head (ES9J4)
- Data valve seats (ES9J4)
- Data: valves
- Identification: cylinder head bolt
- Data: valve seats
- Data: valve springs
- Identification: cylinder head bolts
- Data: abutment washer - valve spring
- Identification: cylinder head bolt — variant 2
- Identification: cylinder head bolts — variant 2
- Identification - data: cylinder head gasket (DW10ATED, DW10TD)
- Identification - data cylinder head (DW12TED4)
- Identification: cylinder head bolts — variant 3
- Identification: cylinder head bolts — variant 4
- Data valves and valve springs (DW12TED4)
- Identification: cylinder head bolts — variant 5
- Data valve seats and guides (DW12TED4)
- Identification - data: cylinder head (EW12J4)
- Removing - refitting cylinder head (XUD9TE)
- Data: seats - valve guides (EW12J4)
- Data: cylinder head gasket (EW12J4)
- Data: cylinder head bolts - cylinder head tightening (EW12J4)
- Removing - refitting cylinder head (XU7JB)
- Removing - refitting cylinder head (XU5JP)
- Removing - refitting cylinder head (XU10J4R, XU7JP4)
- Removing - refitting: cylinder head (ES9J4)
- Removing - refitting: cylinder head (EW10J4)
- Removing - refitting cylinder head (XU7JP)
- Removing - refitting: cylinder head (EW7J4)
- Removing - refitting: cylinder head (DW10ATED)
- Modification: XU5JP, XU7JP engines (XU5JP, XU7JP)
- Removing - refitting: cylinder head (DW10TD)
- Removing - refitting cylinder head cover (EW7J4, EW10D, EW10J4)
- Modification: XU5, XU7 engine (XU5JP, XU7JP, XU7JP4)
- Data: timing gear
- Removing - refitting: cylinder head (EW12J4)
- Stripping - re-assembling: cylinder head (XU7JB, XU7JP, XU5JP)
- Checks and adjustments valve clearances (XU7JB, XU5JP, XU7JP, XU10J4R, XU7JP4)
- Checks and adjustments: valve clearances
- Stripping - re-assembling: 16 valve cylinder head (XU7JP4, XU10J4R)
- Cylinder head overhaul (ES9J4)
- Overhaul: cylinder head
- Stripping - re-assembling: cylinder head (EW12J4)
- Overhaul cylinder head (EW7J4, EW10D, EW10J4)
- Data: valves and valve springs (EW12J4)
- Adjustment: valve clearances (8 valve engine(s)) (XU7JB, XU7JP, XU5JP)
Cooling system
- Maintenance: fluids recommendation
- Wheels and tyres
- Cooling system data
- Capacity: cooling system
- Removing - refitting: coolant pump (ES9J4S)
- Removing - refitting thermostat (ES9J4S, ES9J4)
- Identification: components
- Removing - refitting: coolant pump (DW10TD, DW10ATED)
- Removing - refitting radiator
- Removing - refitting: coolant pump (EW12J4, EW10J4, EW10D)
- Removing - refitting radiator (XU5JP, XU7JP, XU7JB, XU10J4R, XU7JP4)
- Drain and refill - refilling - bleeding: cooling system
- Removing - refitting radiator (XU10J2TE)
- Removing - refitting fan (cooling system) (DW10ATED, DW12TED4)
- Check: coolant thermistor function
- Removing - refitting radiator (ES9J4)
- Check: coolant thermistor function — variant 2
- Removing - refitting coolant pump (ES9J4)
- Coolant temperature sensor check
- Coolant temperature sensor check — variant 2
- Application: tooling
- Data: air conditioning systems
- Drain and refill - refilling: refrigerant circuit
- Schematic diagram: coolant thermostat
- Modification: new coolant
- Check: purge canister solenoid valve function
- Check: purge canister solenoid valve function — variant 2
- Service action
- Service action — variant 2
Air and fuel supply
- Presentation: engine (XU7JB)
- Removing - refitting: diesel filter assembly (DW10TD)
- Recommended tools
- Filling device
- Filling device — variant 2
- LPG (Liquid Petroleum Gas) tank
- LPG (Liquid Petroleum Gas) tank — variant 2
- Operation of the multi-valve
- Operation of the multi-valve — variant 2
- Operation of the components secured to the cylindrical tank
- Operation of the components secured to the cylindrical tank — variant 2
- Presentation: gas injection system (XU7JP4)
- Removing - refitting: fuel gauge sender unit
- Checks: idling - emission control
- Checks: idling - emission control — variant 2
- Removing - refitting fuel tank
- Checks: idling - emission control — variant 3
- Removing - refitting: fuel filter (DW10TD, DW10ATED)
- Replacement: stop electrovalve - transponder module (mechanical or semi-electronic pump LUCAS)
- Checks: idling - emission control — variant 4
- Replacement: stop solenoid valve - transponder module (mechanical or semi-electronic pump LUCAS)
- Removing - refitting fuel filter (EW10J4, ES9J4S, EW12J4)
- Removing - refitting: lower manifold (ES9J4S)
- Removing - refitting fuel filter (XU5JP, XU7JB, XU10J4R, XU7JP, XU7JP4)
- Removing - refitting inlet manifold (ES9J4)
- Removing - refitting fuel filler neck (DW12TED4)
- Removing - refitting gauge mechanism (XU7JP4)
- Removing - refitting: intake air distributor (EW12J4)
- Removing - refitting LPG tank (XU7JP4)
- Drain and refill - refilling: fuel tank (XU10J4R, XU5JP, XU7JP, EW7J4, EW12J4, EW10J4, EW10D, XU7JP4, ES9J4, ES9J4S)
- Removing - refitting: inlet manifold (ES9J4S)
- Removing - refitting distributor valve (XU7JP4)
- Removal-fitting electrovalves - filter (XU7JP4)
- Check: fuel additive circuit
- Removing - refitting: fuel system click-on connectors
- Removing - refitting: additive reservoir (DW12TED4, DW10ATED)
- Removing - refitting: additive injector (DW12TED4, DW10ATED)
- Replacement: stop electrovalve - transponder module (mechanical or semi-electronic pump BOSCH)
- Refilling: additive reservoir (DW12TED4, DW10ATED)
- Replacement: stop solenoid valve - transponder module (mechanical or semi-electronic pump BOSCH)
- Modification: particle filter additive
- Replacement: stop electrovalve - coded anti-start module (mechanical or semi-electronic pump BOSCH - metal screening)
- Removing - refitting: fuel tank (DW12TED4)
- Replacement: stop solenoid valve - coded anti-start module (mechanical or semi-electronic pump BOSCH - metal screening)
- Change in routing of the fuel filler cap opening control cable
- Charging procedure: starting batteries
- Conditions for working on the diesel circuit
- Replacement: diesel fuel filter
- Conditions for working on the diesel circuit — variant 2
- Drain and refill LPG tank (XU7JP4)
- Check: ignition advance
- Check: ignition advance — variant 2
Emission control
- Name: emission control standards
- Removing - refitting EGR valve (DW10ATED, DW10TD)
- Reference: emission control standards
- Operations to be carried out on the particulate emission filter with 80 000 Km (EOLYS DPX42 additive) or with 120 000 Km (EOLYS 176 additive) or when the system is clogged (DW10ATED, DW12TED4)
- Modification: oxygen sensor
- Removing - refitting EGR valve (DW10ATED)
- Modification: particle filter additive - frequency of service operations (DW10ATED, DW12TED4)
- Modification - discontinuation of the EGR cooler (DW12TED4)
- Modification: discontinuation of the air mixer (DW10ATED)
- Frequency of service operations
Turbocharging
- Check: function turbo (RHZ engine) (DW10ATED)
- Check: operation turbo (RHZ engine) (DW10ATED)
- Removing - refitting turbocharger (DW10TD, DW10ATED)
- Removing - refitting turbocharger (engine(s) XUD9 with front air exchanger + XUD11BTE engine)
- Removing - refitting turbocharger (XU10J2TE)
- Removing - refitting turbocharger (DW10ATED)
- New special tools
Exhaust
- Identification of tightening torques exhaust (EW10D)
- Removing - refitting exhaust front manifold (ES9J4S)
- Removing - refitting: pre-catalysers (ES9J4S)
- Removing - refitting exhaust rear manifold (ES9J4S)
- Removing - refitting exhaust manifold (EW12J4)
- Removing - refitting: particle filter (DW12TED4, DW10ATED)
- Removing - refitting exhaust manifold (EW10D)
- Presentation: particle filter (OS2)