Manual sections
Wiring diagrams- Battery
- Body
- Bodywork
- Braking
- Comfort and convenience
- Dashboard
- Electrical harnesses
- Engine
- Equipment
- Front anti -roll bar
- Front axle
- Front seats
- Front section
- Front shock absorbers
- Gearbox assembly
- General points
- General points about the vehicle
- Glovebox
- Instrument panel
- Instruments and controls
- Mechanical
- Power unit
- Pre-heating
- Protections and doors
- Re-assembling
- Rear axle
- Rear doors
- Rear section
- Rear shock absorbers
- Roof panel
- Side structure
- Steering
- Suspension
- Transmission
- Washing and wiping
Repair manual
Engine Peugeot 806 I
Step-by-step instructions on "Engine" for Peugeot 806 I (1994–1998). Pick an article — removal, installation, adjustment and diagnostics with illustrations.
Crankshaft
- Removing - refitting: ancillary drive belt (air conditioning) (XU10J2)
- Removing - refitting ancillary drive belt (XU10J2TE, XU10J2, 2.1 TD, 1.9 TD)
- Removing - refitting ancillary drive belt (XU10J4R)
- Data: half shells (EW10J4)
- Data conrods (EW10J4)
- Identification - data crankshaft (EW10J4)
- Data: conrods
- Data: crankshaft
- Data: pistons - piston rings
- Checks - removing - refitting - adjustment: balance shafts (EW12J4)
- Removing - refitting: ancillary drive belt (power assisted steering - air conditioning - XU10J2CTE engine) (XU10J4R)
- Data - identification liners
- Identification - data: pistons - piston rings
- Identification - data: crankshaft
- Identification - data: half shells
- Modification: reciprocating gear
- Data - identification conrods
- Check liner protrusion
- Check crankshaft pulley
- Assembly connecting rods - pistons
- Removing - refitting: ancillary drive belt (power assisted steering) (DW10ATED)
- Removing - refitting: ancillary drive belt (1.9 TD, 2.1 TD)
- Removing - refitting: ancillary drive belt (EW10J4)
- Removing - refitting: ancillary drive belt (DW10ATED4, DW10ATED)
Lubrication
- 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)
- Recommendations: lubricants — variant 3
- Check oil pressure (EW10J4, DW10ATED4)
- Check: oil pressure (With oil pressure switch)
- Check: oil pressure (Without oil pressure switch)
- Replace: engine oil filter cartridge
- Suction draining (engine)
- Assembly: new engine oil filter cartridge
- Data: cooling system
- Replace: engine oil filter cartridge (EW7J4, DW10ATED, DW10TED, EW12J4, EW10J4)
- Replace: engine oil filter cartridge — variant 2
- Replacement: engine oil filter cartridge (EW7J4, EW10J4, EW12J4, DW10ATED, DW10TED)
- Modification: Lubrication kit
- Maintenance: recommended ingredients, year 2006
Engine block
- Sealing: cylinder block - lower cover
- Data - identification cylinder block
- Identification - data: cylinder block
- Data cylinder block (EW10J4)
- 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
Timing gear
- Identification - data - tightening torques: camshaft (EW10J4)
- Adjustment: air gap (cylinder reference sensor) (DW10ATED)
- Data - identification camshafts
- Data: camshafts
- Standard replacement
- Timing check camshaft chain (DW10ATED4)
- Check end of compression pressures
- Check end of compression pressures — variant 2
- Removing - refitting: timing belt (XU10J2TE, XU10J2)
- Removing - refitting: timing belt (1.9 TD)
- Removing - refitting camshaft (XU10J2TE, XU10J2)
- Removing - refitting: timing belt (XU10J2TE)
- Removing - refitting: timing belt (2.1 TD)
- Removing - refitting: accessories belt dynamic tensioner
- Removing - refitting: timing belt (XU10J4R)
- Removing - refitting camshaft (XU10J4R)
- Removal - refitting: timing belt (first assembly) (EW10J4)
- Removing - refitting: timing covers (DW10ATED, DW10TED)
- Removal - refitting: timing covers (DW10ATED, DW10TED)
- Removing - refitting camshaft (DW10ATED)
- Removing - refitting camshaft (1.9 TD)
- Removing - refitting: timing belt (DW10ATED)
- Removing - refitting: timing belt (DW10ATED4)
- Removing - refitting camshaft (DW10ATED4)
- Removing - refitting: timing belt (second assembly) (EW10J4)
- Removing - refitting: camshaft (EW10J4)
- Modification: removal of the crankshaft pulley bolt (DW10BTED, DW10TED, DW10ATED4, DW10ATED)
- Presentation - use: D-TEK de LEYBOLD refrigerant leak detector (part number 9776.X9)
- Presentation - use: D-TEK de LEYBOLD refrigerant leak detector (Part No. 9776.X9)
Cylinder head
- Data: cylinder head gasket (DW10ATED)
- Modification: control of the "Swirl" butterflies (DW10ATED4)
- Modification: cylinder head
- Refitting: cylinder head
- Data valves and valve springs (EW10J4)
- Data valve guides - valve seats (EW10J4)
- Modification: cylinder head gasket
- Identification - data - tightening torques: cylinder head (EW10J4)
- Data - identification valve guides
- Identification, data, tightening torque(s): cylinder head
- Identification - data: cylinder head gasket
- Identification - data: cylinder head bolts
- Data - identification valves
- Data - identification valve springs
- Data - identification valve seats
- Data: valves
- Data: valve seats
- Data: valve springs
- Data: abutment washer - valve spring
- Identification - data: cylinder head gasket (DW10ATED, DW10ATED4)
- Identification: cylinder head bolt
- Identification: cylinder head bolts
- Identification: cylinder head bolt — variant 2
- Identification: cylinder head bolts — variant 2
- Identification: cylinder head bolts — variant 3
- Identification: cylinder head bolts — variant 4
- Identification: cylinder head bolts — variant 5
- Removing - refitting: cylinder head (2.1 TD)
- Removing - refitting: cylinder head (XU10J4R) (XU10J4R)
- Removing - refitting cylinder head (1.9 TD)
- Removing - refitting cylinder head (XU7JP)
- Removing - refitting: cylinder head (DW10ATED)
- Removing - refitting cylinder head cover (EW10J4)
- Removing - refitting: cylinder head cover (DW10ATED4)
- Removing - refitting: cylinder head (DW10ATED4)
- Removing - refitting: cylinder head (EW10J4)
- Stripping - re-assembling: cylinder head (XU10J2, XU7JP, XU10J2TE)
- Stripping - re-assembling: 16 valve cylinder head (XU10J4R)
- Overhaul: cylinder head
- Overhaul cylinder head (EW10J4)
- Modification: XU5JP, XU7JP engines (XU7JP)
- Modification: XU5, XU7 engine (XU7JP)
- Data: timing gear
- Checks and adjustments valve clearances
- Checks and adjustments: valve clearances (1.9 TD)
- Adjustment: valve clearances (8 valve engine(s)) (XU7JP, XU10J2TE, XU10J2)
Cooling system
- Maintenance: fluids recommendation
- Identification: components
- : - plug - expansion chamber
- Data cooling system (2.1 TD, 1.9 TD)
- Removing - refitting coolant pump (XU10J2TE, XU10J2)
- Removing - refitting PSA rapid connection (XU10J2, XU10J4R, XU10J2TE)
- Removing - refitting radiator (XU10J2TE, XU10J2)
- Removing - refitting: coolant pump
- Removing - refitting: coolant pump — variant 2
- Removing - refitting: coolant pump — variant 3
- Drain and refill - refilling - bleeding: cooling system
- Application: tooling
- Schematic diagram: coolant thermostat
- Check: coolant thermistor function
- Check: coolant thermistor function — variant 2
- Coolant temperature sensor check
- Coolant temperature sensor check — variant 2
- Check: purge canister solenoid valve function
- Check: purge canister solenoid valve function — variant 2
- Data: air conditioning systems
- Drain and refill - refilling: refrigerant circuit
- Modification: new coolant
Air and fuel supply
- Removing - refitting: diesel filter assembly
- Recommended tools
- Checks: idling - emission control
- Checks: idling - emission control — variant 2
- Checks: idling - emission control — variant 3
- Checks: idling - emission control — variant 4
- Adjustment accelerator cable (XU10J2TE, XU10J2)
- Removing - refitting fuel filler flap finisher
- Removing - refitting fuel filler neck (XU10J2, XU10J2TE)
- Removal-fitting fuel gauge tank unit - fuel pump (XU10J2, XU10J2TE)
- Removing - refitting fuel tank (XU10J2, XU10J2TE)
- Removing - refitting: fuel system click-on connectors
- Removing - refitting: fuel filter (DW10ATED)
- Replacement: stop electrovalve - transponder module (mechanical or semi-electronic pump BOSCH)
- Replacement: stop solenoid valve - transponder module (mechanical or semi-electronic pump BOSCH)
- Replacement: stop electrovalve - coded anti-start module (mechanical or semi-electronic pump BOSCH - metal screening)
- Replacement: stop solenoid valve - coded anti-start module (mechanical or semi-electronic pump BOSCH - metal screening)
- Replacement: stop electrovalve - transponder module (mechanical or semi-electronic pump LUCAS)
- Replacement: stop solenoid valve - transponder module (mechanical or semi-electronic pump LUCAS)
- Removing - refitting fuel filter (DW10ATED4)
- Replacement: diesel fuel filter
- Replace fuel filler flap electric locking unit
- Check: ignition advance
- Check: ignition advance — variant 2
- Conditions for working on the diesel circuit (DW10ATED, DW10BTED, DW10TED)
- Conditions for working on the diesel circuit (DW10ATED, DW10TED, DW10BTED)
Exhaust
Emission control
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
Turbocharging
- Check: function turbo (RHZ engine) (DW10ATED)
- Check: operation turbo (RHZ engine) (DW10ATED)
- Removing - refitting turbocharger (XU10J2, XU10J2TE)
- Removing - refitting intercooler (XU10J2TE, XU10J2)
- Removing - refitting: turbocharger (1.9 TD, 2.1 TD)
- Removing - refitting turbocharger (DW10ATED)
- Removing - refitting turbocharger (DW10ATED4)
- New special tools