Description
Factory Peugeot 406 Workshop Manual (1995-2004)
This is the same Peugeot Service Box dealer software used by authorized Peugeot workshops across the US and worldwide to service and diagnose the 406 in every body style – saloon, estate, and coupe – through all Phase 1 and Phase 2 production years.
Powertrain & Drive Coverage
| Component | Variants Covered |
|---|---|
| Petrol | 1.6L XU5, 1.8L XU7 / EW7, 2.0L XU10, 2.0L EW10, 2.0L EW10 Turbo, 2.2L EW12, 3.0L ES9 V6 |
| Diesel | 1.9L, 1.9L Turbo, 2.0L DW10 HDi, 2.1L Turbo, 2.2L DW12 HDi |
| Transmissions | 5-speed manual (BE3, ML5), 4-speed automatic (AL4), 6-speed manual (V6 models) |
| Drive | FWD |
| Model Years | 1995-2004 (Phase 1 & Phase 2) |
| Badge Twins | N/A |
Common 406 Repairs Covered
| System | Procedures |
|---|---|
| AL4 Automatic Transmission | Solenoid replacement, pressure regulation valve service, fluid specification and change intervals to address common jerky shifting faults |
| HDi Fuel System | Common rail high-pressure pump removal, injector coding, DPF regeneration procedures for DW10 and DW12 units |
| BSI (Built-in Systems Interface) | Multiplex network diagnostics, BSI initialization after battery disconnect, CAN-bus fault finding |
| Suspension & Steering | Front lower arm bush replacement, power steering rack seal kit procedures, wheel alignment data for all variants |
Format & Delivery
Dealer software (Peugeot Service Box, VMware Player Virtual Machine) – this is NOT a PDF. Compatible with Windows 11, 10, 8, 7, Vista, XP, Mac, and Linux. Instant download; lifetime re-downloads.
Frequently Asked Questions
Why does the AL4 automatic transmission shift harshly on my 406?
The AL4 (DP0) gearbox fitted to many 406 models is well known for developing harsh or jerky gear changes as the pressure regulation valve and solenoids wear. This software includes the full factory service sequence for disassembly, solenoid replacement, and the correct ATF specification – critical steps for restoring smooth operation without a full transmission replacement.
Which chassis codes and body styles does this software cover?
Coverage spans both D8 and D9 chassis codes across the complete 406 range: the 4-door saloon, 5-door estate (Break), and 2-door coupe. Both Phase 1 (1995-1999) and the facelifted Phase 2 (1999-2004) are fully included across all trim grades including LX, GLX, SV, ST, and Executive.
Are full wiring diagrams and BSI diagnostics included?
Yes. The software delivers color-coded interactive wiring schematics for every 406 variant, covering engine management, ABS, climate control, central locking, the BSI multiplex module, and CAN-bus networks. Component locator functions identify connector positions and ground points exactly as used by Peugeot dealer technicians.
What format is the manual?
This is NOT a PDF – it is the OEM Peugeot Service Box dealer software delivered as a VMware Player Virtual Machine image. It runs on Windows, Mac, and Linux and provides searchable databases, interactive diagrams, and integrated diagnostic flowcharts identical to authorized Peugeot workshop tooling.
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