engine Peugeot 406 2002.5 Service Manual

MAINTENANCE OF YOUR 40631
2.2 litre 16V turbo diesel HDI
engine
1
Power steering reservoir.
2 Coolant reservoir. 3
Windscreen and headlamp
wash reservoir.
4 Battery.
5 Air filter. 6
Brake and clutch fluid reservoir.
7 Engine oil filler cap.
8 Dipstick.
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29072002
CHECKING THE LEVELS
Engine
Checking the oil level
Check the level regularly and top up
between changes. Maximum con
sumption is 0.5 litres per 600 miles
(1 000 km).
The oil level should be checked with
the vehicle level and the engine cold.There are two marks on
the dipstick:
A= maximum
B = minimum
Oil change: according to the manu
facturer's servicing schedule.
Dipstick. Never fill past the maxi mum mark A.
Oil level gauge on the instrument panel.
Viscosity selection
In all cases, the oil selected must
meet the manufacturer's require
ments.
MAINTENANCE OF YOUR 406
32
Oil filter
Change the filter regularly according
to the servicing schedule.
Used oil
Prevent used oil from coming into
prolonged contact with the skin.
Do not dispose of used oil into drains
or onto the ground.
To maintain the reliability of engines
and emission control systems, the
use of additives in the engine oil is
prohibited.
Brakes and clutch
Checking the brake and clutch
fluid level:
The level should always be above
the DANGER mark on the reser
voir.
If the level drops substantially, con tact a PEUGEOT dealer imme
diately.
Fluid change
must be carried out according to the manufacturer's servicing
schedule.
use fluids approved by the manu facturer, which fulfil DOT 4 stan
dards. Cooling system
Use the fluid approved by the manu
facturer.
When the engine is warm, the tem
perature of the coolant is controlled
by the engine fan. Because this fan
can operate with the ignition key
removed and because the cooling
system is pressurised, wait for at
least one hour after the engine has
stopped before carrying out any
work.
In the event of a breakdown and to
avoid any risk of burns, slacken the
cap to the first notch to release the
pressure. When the pressure has
dropped, remove the cap and top up
the level.

29072002
MAINTENANCE OF YOUR 40633
Only use products
approved by Automobiles
PEUGEOT.
To ensure best perfor
mance from components as
important as the power steering
and the braking system,
PEUGEOT selects and offers
quite specific products.
Power steering reservoir
Open the reservoir with the engine
cold. The level should always be
above the MINI mark, close to the
MAXI mark.
Windscreen and headlamp
wash reservoir
For best quality cleaning and for your
safety, we recommend that you use
products approved by PEUGEOT
(capacity 4.5 litres or 9 litres with
headlamp wash).
Battery
At the start of winter, have your bat
tery checked by a PEUGEOT dealer.
Air filter
Regular replacement of the filter ele
ment is essential. If you drive in
very dusty conditions, change it
twice as often. Brake pads
Brake pad wear depends on the
style of driving, in particular for vehi
cles that are used in town, for short
journeys. It may be necessary to
check the thickness of the pads even
between services.
Handbrake
Where the handbrake travel is too
great or there is a reduction in the
performance of the system, the
handbrake should be adjusted, even
between services.
Have the system checked by a
PEUGEOT dealer.
Manual gearbox
This does not need an oil change.
Check the level according to the
manufacturer's servicing schedule.
Automatic autoadaptive
gearbox
This does not need an oil change.
Have the level checked by a
PEUGEOT dealer according to the
manufacturer's servicing schedule.

29072002
MAINTENANCE OF YOUR 40633
Only use products
approved by Automobiles
PEUGEOT.
To ensure best perfor
mance from components as
important as the power steering
and the braking system,
PEUGEOT selects and offers
quite specific products.
Power steering reservoir
Open the reservoir with the engine
cold. The level should always be
above the MINI mark, close to the
MAXI mark.
Windscreen and headlamp
wash reservoir
For best quality cleaning and for your
safety, we recommend that you use
products approved by PEUGEOT
(capacity 4.5 litres or 9 litres with
headlamp wash).
Battery
At the start of winter, have your bat
tery checked by a PEUGEOT dealer.
Air filter
Regular replacement of the filter ele
ment is essential. If you drive in
very dusty conditions, change it
twice as often. Brake pads
Brake pad wear depends on the
style of driving, in particular for vehi
cles that are used in town, for short
journeys. It may be necessary to
check the thickness of the pads even
between services.
Handbrake
Where the handbrake travel is too
great or there is a reduction in the
performance of the system, the
handbrake should be adjusted, even
between services.
Have the system checked by a
PEUGEOT dealer.
Manual gearbox
This does not need an oil change.
Check the level according to the
manufacturer's servicing schedule.
Automatic autoadaptive
gearbox
This does not need an oil change.
Have the level checked by a
PEUGEOT dealer according to the
manufacturer's servicing schedule.

29-07-2002
PETROL / LPG DUALFUEL VERSION167
Puncture
Insulated storage compartment
This is located in the boot and con
tains:
the temporary tyre repair cans 1
(your 406 LPG does not have a
spare wheel),
the adaptors 2 necessary for
filling the LPG tank in some
countries,
the towing eye 3.
Fuses
The LPG functions are protected
by the two fuses Ain the fuse box
located in the engine compartment.
Using the repair cans
(Refer to the directions on the cans
also)
if possible, remove the object
which caused the puncture,
rotate the wheel so that the valve is in the same position as the
figures 2 or 10 on a clock,
shake the cans vigorously before use. In very cold weather, warm
the cans between your hands for
few minutes,
hold the valve with one hand and with the other press the injection
nozzle on the can firmly onto the
valve, holding it straight,
maintain the pressure firmly for one minute, carry out the same operation with
the second can, then drive imme
diately, at a moderate speed , to
the nearest garage.
The cans enable you to carry out
a temporary repair.
After use, the tyre must be
changed.
As the cans are pressurized, they
must not be exposed to a temper
ature above 50°C.
Store them away from heat in the
insulated storage compartment.

29072002
CHANGING A FUSE
The fuse boxes are under the fascia
and in the engine compartment.
Fascia fuse box
Turn the three screws a quarter turn
with a coin.
Pull at Aand tilt the cover to access
the fuses. Removing and changing a fuse
Before changing a fuse you must find out the cause of the fa
ult and have it put
right. The fuse numbers are indicated on the fuse box.
Use the special pliers Aattached to the box.
Always change a faulty fuse for one of the same rating.
Correct Incorrect Pliers A
Remove the fascia panel lower trim to access the builtin systems in terface.
Fuse no
. Rating Functions
A 20 A Locking/Unlocking, Deadlocking.
B 10 A Rear fog lamps.
.
C 40 A Demisting the mirrors.
D 15 A Rear screen wiper.
E 30 A Electric windows.
F15 A Supply to instrument panel
Display Audio equipment
Satellite navigation system
Air conditioning.
MAINTENANCE OF YOUR 406 41

29072002
Engine compartment fuses
Fuse box
To access the fuse box in the engine
compartment (beside the battery),
unclip the cover.
Carefully close the cover when
you have finished.The electrical system of
your vehicle is designed
to operate with standard
or optional equipment.
Before installing other electrical
equipment or accessories on your
vehicle, contact a PEUGEOT
dealer.
Some electrical accessories or
the way in which they are fitted
can have damaging effects on the
operation of your vehicle; the
electronic control circuits, the
audio circuit and the battery
charging circuit.
PEUGEOT will not accept respon
sibility for the cost incurred in
repairing your vehicle or for recti
fying the malfunctions resulting
from the installation of acces
sories not supplied and not rec
ommended by PEUGEOT and not
installed in accordance with its
instructions, in particular where
the equipment in question con
sumes more than 10 mil
liamperes. *The maxifuses provide addition
al protection for the electrical sys
tems. All work must be carried out
by a PEUGEOT dealer.
Fuse N° Rating Functions
1* 10 A Reversing lights– Double injection relay Oil
temperature Oil level Air conditioning compressor.
2* 15 AFuel pump, canister solenoid valve.
3* 10 AControl unit.
4* 10 AEngine control unit and automatic gearbox.
5 10 A Particulate Emission Filter control unit Rear
windscreen relay.
6 15 AFront fog lamps.
7 20 AHeadlamp wash.
8* 20 A Direct petrol injection engine control unit Clutch pedal.
9* 15 ALefthand dipped beam lights.
10* 15 A Righthand dipped beam lights
MAINTENANCE OF YOUR 406
44

29-07-2002
PETROL / LPG DUALFUEL VERSION167
Puncture
Insulated storage compartment
This is located in the boot and con
tains:
the temporary tyre repair cans 1
(your 406 LPG does not have a
spare wheel),
the adaptors 2 necessary for
filling the LPG tank in some
countries,
the towing eye 3.
Fuses
The LPG functions are protected
by the two fuses Ain the fuse box
located in the engine compartment.
Using the repair cans
(Refer to the directions on the cans
also)
if possible, remove the object
which caused the puncture,
rotate the wheel so that the valve is in the same position as the
figures 2 or 10 on a clock,
shake the cans vigorously before use. In very cold weather, warm
the cans between your hands for
few minutes,
hold the valve with one hand and with the other press the injection
nozzle on the can firmly onto the
valve, holding it straight,
maintain the pressure firmly for one minute, carry out the same operation with
the second can, then drive imme
diately, at a moderate speed , to
the nearest garage.
The cans enable you to carry out
a temporary repair.
After use, the tyre must be
changed.
As the cans are pressurized, they
must not be exposed to a temper
ature above 50°C.
Store them away from heat in the
insulated storage compartment.

29072002
CHANGING A FUSE
The fuse boxes are under the fascia
and in the engine compartment.
Fascia fuse box
Turn the three screws a quarter turn
with a coin.
Pull at Aand tilt the cover to access
the fuses. Removing and changing a fuse
Before changing a fuse you must find out the cause of the fa
ult and have it put
right. The fuse numbers are indicated on the fuse box.
Use the special pliers Aattached to the box.
Always change a faulty fuse for one of the same rating.
Correct Incorrect Pliers A
Remove the fascia panel lower trim to access the builtin systems in terface.
Fuse no
. Rating Functions
A 20 A Locking/Unlocking, Deadlocking.
B 10 A Rear fog lamps.
.
C 40 A Demisting the mirrors.
D 15 A Rear screen wiper.
E 30 A Electric windows.
F15 A Supply to instrument panel
Display Audio equipment
Satellite navigation system
Air conditioning.
MAINTENANCE OF YOUR 406 41

29072002
BATTERY
To charge the battery using a battery charger:
Disconnect the battery,
Follow the instructions for use given by the battery charger manufacturer,
Reconnect starting with the negative (–) terminal,
Check that the terminals and connectors are clean. If they are covered with sul
phate (white or greenish deposit), disconnect them and clean t hem.
To start the vehicle from another battery:
Connect the red cable to the positive (+) terminals of the tw o batteries,
Connect one end of the green or black cable to the negat ive (–) terminal of the
slave battery,
Connect the other end of the green or black cable to an e arth point on the bro
ken down vehicle, as far as possible from the battery,
Operate the starter, let the engine run.
Wait for the engine to return to idle, then disconnect th e cables.
Never disconnect a terminal when the engine is running.
Never charge a battery without first disconnecting the terminal s.
Close the sunroof before disconnecting the battery. If it does not
operate normally following reconnection of the battery, you must
reinitialise it by turning the control to the maximum tilt po sition and pressing
it for a few seconds.
After every reconnection of the battery, switch on the igniti on and wait
1 minute before starting to allow the electronic systems to be initialised. If
slight difficulties are experienced after this, please contact a PEUGEOT
dealer. It is advisable to disconnect the battery if the vehicle
is not to be used for a period of more than one month.Economy mode
With the engine switched off and the
ignition key in the "running" or
"accessories" position for about half
an hour, certain electrical equipment
(displays, instrument panel, warning
lights, courtesy lights, electric win
dows, wipers etc.) will switch off
automatically to avoid draining the
battery.
Once the electrical equipment goes
into economy mode, it is necessary
to start the engine to enable the
equipment to work again.
MAINTENANCE OF YOUR 406
46